JLG 510AJ Service Manual

Service and Maintenance Manual

Model
510AJ

P/N - 3121181

August, 2014

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

AGENERAL

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

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

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

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

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

BHYDRAULIC SYSTEM SAFETY

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

Relieve system pressure by cycling 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.

CMAINTENANCE

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

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

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

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

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

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

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

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

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
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.

3121181 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - January 24, 2003
Revised - March 12, 2003
Revised - September 20, 2005
Revised - March 16, 2007
Revised - October 10, 2007
Revised - January 5, 2011
Revised - August 20, 2014

A-2 – JLG Lift – 3121181

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

1.3 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.8 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.9 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.10 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.11 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3121181 – JLG Lift – i

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 3 - CHASSIS AND 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 Torque Hub (Machines built Before S/N 1300000064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Roll, Leak and Brake Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Housing-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Spindle-Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Output Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Spindle-Brake Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Housing-Spindle Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Integral Brake Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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

3.3 Torque Hub (Machines built After S/N 1300000064) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Main Disassembly for ”B” Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.4 Re-Aligning torque hub input coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.5 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

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

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3.6 Adjustment Procedure For Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3.7 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Lockout Cylinder Bleeding (Early Cylinders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Lockout Cylinder Bleeding (Ram Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3.8 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

ii – JLG Lift – 3121181

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3.9 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

3.10 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Replacing Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Cleaning Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

3.11 Deutz EMR 2 (S/N 1300000981 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

3.12 Perkins Engine General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Replacing the Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Engine Oil and Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Setting the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Speed Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

3.13 Engine Radiator Fill Procedure - Perkins & Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

3.14 DGC Diagnostic Support and Trouble Code Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

List of Abbreviations in this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

Fault Code Broadcast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

MIL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Diagnostic Calibration Configuration and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

Fault/Diagnostic Trouble Code Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

DBW Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

3.15 Diagnostic Trouble Code Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

DTC 117- ECT/CHT Low Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101

DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

DTC 122- TPS1 Signal Voltage Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

DTC 123- TPS1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

DTC 217- ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

DTC 219- RPM Higher Than Max Allowed Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110

DTC 336- Crank Signal Input Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

DTC 337- Loss of Crank Input Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

DTC 521- Oil Pressure Sender/Switch High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

DTC 524- Oil Pressure Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117

DTC 562- Battery Voltage (VBat) Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123

DTC 601- Microprocessor Failure - FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125

DTC 604- Microprocessor Failure - RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127

DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129

DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131

DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132

DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133

DTC 1613- Microprocessor Failure - RTI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

DTC 1614- Microprocessor Failure - RTI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

DTC 1615- Microprocessor Failure - A/D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

DTC 1616- Microprocessor Failure - interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

DTC 1625- CAN J1939 Shutdown Request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

3121181 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

DTC 1626- CAN J1939 Transmit (Tx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143

DTC 1627- CAN J1939 Receive (Rx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144

DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145

DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147

Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147

DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148

Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148

DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149

DTC 2112- Unable to Reach Higher TPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151

DTC 9999- Throttle Actuator Failsafe Spring Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152

DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153

SECTION 4 - BOOM AND PLATFORM

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

Remove Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Disassemble Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

Assemble Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Install Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3 Rotary Actuator

(S/N 1300006433 to Present)4-9

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS

5.1 O-Ring Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

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

Brush-On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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

Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Main Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

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

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Platform Level (Slave) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Jib Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Axle Lockout Cylinder (Outside Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Axle Lockout Cylinder (Inside Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5.3 Hydraulic Pump (Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Inspect Parts For Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Reverse Shaft Rotation of Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5.4 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Ports and Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Removal and Installation of FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

iv – JLG Lift – 3121181

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

Removal and Installation of FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Charge Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5.5 Hydraulic Component Start-Up Procedures and Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5.6 Pressure Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Telescope Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Platform Level Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Articulating Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Proportional Main Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Swing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

SECTION 6 - JLG CONTROL SYSTEM

6.1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.4 To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.5 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

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

6.8 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.9 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6.10 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Test from the Ground Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS

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

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

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

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

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

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

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

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

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

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

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

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

7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

3121181 – JLG Lift – v

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

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

1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

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

2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-2. Engine Operating Temperature Specifications - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3-1. Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Output Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5. Housing-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-6. Spindle Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-7. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-8. Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-9. Spindle Brake Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-10. Housing-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-11. Main Assembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-12. Main Assembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-13. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-14. Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-15. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-16. Assembly Drawing - With Integral Input Brake - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-17. Assembly Tools - Bearing Cone Pressing - “B” Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-18. Assembly Tools - Bearing Cone Pressing - “A” Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-19. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-20. Assembly Tools - Seal Pressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-21. Assembly Tools - Spacer - Brake Disc Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-22. Assembly Tools - Brake Retaining Ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-23. Cluster Gear Punch Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-24. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-25. Removing Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-26. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-27. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-28. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-29. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-30. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-31. Cylinder Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-32. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-33. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-34. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-35. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-36. Servo Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-37. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-38. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-39. Shaft and Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-40. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-41. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-42. Valve Plate and Rear Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-43. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-44. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-45. Plugs and Fittings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-46. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3-47. Chassis Torque Values - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-47. Chassis Torque Values - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

vi

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3-47. Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3-48. Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

3-49. Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

3-50. Swing Bearing Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3-51. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-52. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3-53. Auxiliary Pump - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3-54. Auxiliary Pump - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

3-54. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3-55. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3-56. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

3-57. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

3-58. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74

3-59. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

3-60. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3-61. EMR 2 Engine Plug Pin Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

3-62. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

3-63. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

3-64. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

3-65. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81

3-66. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82

3-67. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

3-68. Crankcase Breather - Perkins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

3-69. Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

3-70. Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3-71. Faults Page with Active Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

3-72. Faults Page with Historic Fault Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

3-73. Custom Fault Variable Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

3-74. Historic Fault Information Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

3-75. Snapshot Data Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

3-76. Flight Data Recorder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98

3-77. Clear Faults Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

3-78. Exhaust Venturi Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154

3-79. Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155

4-1. Location of Components - Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-2. Boom Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-3. Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4. Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-5. Rotator Assembly - Cutaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-6. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-7. Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-8. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-9. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

5-1. Hydraulic Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

5-5. Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Piston And Spacer Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-7. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-8. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-9. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-10. Piston And Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-11. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-12. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-13. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

3121181 – JLG Lift – vii

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-14. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-15. Main Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-16. Piston And Spacer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-17. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-18. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-19. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-20. Piston And Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-21. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-22. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-23. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-24. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-25. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-26. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-27. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-28. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-29. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-30. Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-31. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-32. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-33. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-34. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-35. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-36. Piston And Spacer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-37. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-38. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-39. Piston And Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-40. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-41. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-42. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-43. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-44. Platform Level (Slave) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-45. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-46. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-47. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-48. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-49. Piston And Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-50. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-51. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-52. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-53. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-54. Jib Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-55. Piston And Bushings Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-56. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-57. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-58. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-59. Piston And Bushings Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-60. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-61. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-62. Removing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-63. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-64. Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-65. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-66. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-67. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-68. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-69. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-70. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

. . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

viii

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-71. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-72. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-73. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-74. Axle Lockout Cylinder (Inside Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-75. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-76. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-77. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-78. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-79. Piston And Bushings Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-80. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-81. Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5-82. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-83. Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-84. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-85. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-86. Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-87. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-88. Charge Pump Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5-89. Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

5-90. Main Control Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-91. Platform Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5-91. Hydraulic Schematic - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-92. Hydraulic Schematic - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-93. Hydraulic Schematic - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

5-94. Hydraulic Schematic - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

5-95. Hydraulic Schematic - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

6-1. Hand-Held Analyzer (WANALYZER Controls and Display Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4. ADE Control System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-7. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-11. Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-12. Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-13. Analyzer Flow Chart, Version 6.X Software - Sheet 1of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-14. Analyzer Flow Chart, Version 6.X Software - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-15. Analyzer Flow Chart, Version 6.X Software - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-16. Analyzer Flow Chart, Version 6.X Software - Sheet 4of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-17. Analyzer Flow Chart, Version 6.X Software - Sheet 5of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-18. Analyzer Flow Chart, Version 6.X Software - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-19. System Test Flow Chart - Platform Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-20. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

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. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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

. . . . . . . . . . . . 6-21

3121181 – JLG Lift – ix

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-18. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-19. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-20. Electrical Schematic - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-21. Electrical Schematic - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-22. Electrical Schematic - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-23. Electrical Schematic - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-24. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-25. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-26. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-27. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-28. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-29. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-30. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 4 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-31. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1of 4 (RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-32. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 4 (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-33. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 4 (RH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-34. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7-35. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

x

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

1-3 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 Deutz F3M2011F/D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-5 Perkins 404C-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-6 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-7 Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-8 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-9 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-10 Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

1-12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-13 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-14 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-15 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-16 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-17 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-19 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-20 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

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

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

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

3-2 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-3 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-7 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3-8 Chassis Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-9 Chassis Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-10 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

3-11 Diagnostic Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

3-12 Historic Fault Information Interface Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97

5-1 Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-2 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

6-1 Machine Set-Up Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-2 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-3 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . . . . . . . . . . 6-30

6-4 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . . . . . . . . . . 6-34

6-5 Machine Configuration Programming Information Software Version P5.3 to P6.1. . . . . . . . . . . . . . . . . . . . . 6-38

6-6 Machine Configuration Programming Information Software Version P6.1 to Present . . . . . . . . . . . . . . . . . 6-43

6-7 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-8 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

6-9 Help Fault Codes, Displayed Faults, and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

3121181 – JLG Lift – xi

THIS PAGE INTENTIONALLY BLANK

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Table 1-1. Capacities

Fuel Tank 17 gallons (64.3 liters)
Hydraulic Tank 27 gallons (102 liters)

23.6 gal. (89 liters) to the Full line
on the sight gauge

1.2 TIRES

Table 1-2. Tires

Size Type Pressure Weight

12x16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg)
12x16.5 Foam-Filled N/A 328 lbs. (149 kg)
33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lbs. (61 kg)
33/1550x16.5 Foam-Filled N/A 395 lbs. (179 kg)
14 x 16.1 Pneumatic 40 lbs. (3 bar) 91.5 lbs. (41.5 kg)
14 x 16.1 Foam-Filled N/A 426 lbs. (193 kg)

1.3 ENGINE

NOTE: RPM Tolerances are ± 100.

Table 1-3. 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 10 qt. (9.4 L)

Compression Ratio 19:1

Firing Order 1-3-4-2

Max. RPM 2800

Fuel Diesel
No. of Cylinders 3
Bore 3.7 in. (94 mm)
Stroke 4.4 in. (112 mm)
Displacement 142 cu. in. (2331 cm³)
Oil Capacity

cr a nk ca s e
co o le r
total capacity

Low RPM 1200
Mid RPM

Tower Lift, Upper Lift, Tele
Sw i ng , B a sk et L ev el , Ba sk e t
Rotate, Jib Lift

High RPM 2800

Fuel Diesel
No. of Cylinders 4
BHP 50 HP (37.3 kW )
Bore 3.3 in. (84 mm)
Stroke 3.9 in. (100 mm)
Firin g Orde r 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

Table 1-4. Deutz F3M2011F/D2011L03

6.3 quarts (6 L)

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

1800
1500

Table 1-5. Perkins 404C-22

1.4 SPECIFICATIONS AND PERFORMANCE DATA

Dimensional Data

Table 1-6. Dimensional Data

Overall Width 7.4 ft. (2.26 m)
Tailswing 0
Stowed Height 7.4 ft. (2.26 m)
Stowed Length 25.1 ft. (7.68 m)
Wheel base 7.67 ft. (2.34 m)

Tur nin g Ra diu s
6 .5 f t. ( 2. 0 m)
1 6. 4 ft . (5 . 0 m )

Track Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)

Ground Clearance 1.18 ft. (0.36 m)

6 .5 f t. ( 2. 0 m)

1 6. 4 ft . (5 . 0 m )

65.3 in. (1.66 m)

66.3 in. (1.69 m)

66.6 in. (1.69 m)

3121181 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Reach Specifications

Table 1-7. Reach Specifications

Max. Platform Height 51.8 ft. (15.81 m)
Max. Horizontal Reach 31.1 ft. (9.48 m)
Up & Over Height 24.08 ft. (7.34 m)

Jib Length 4.5 ft. (1.37 m)

Jib Angle 135° (+70°, -65°)

Chassis

Table 1-8. Chassis Specifications

Swing 357° non-continuous

Platform Capacity 500 lbs. (230 kg)

Rated Gradeability 40%
Max. Tire Load 7900 lb. (3583 kg)

Max. Ground Bearing Pressure

S td . T i re

Fl o ta t io n Ti r e

Axle Oscillation 8 in. (0.2 m)

Drive Speed 4.5 mph (7.2 kph)

System Voltage 12 Volts
Max. Hydraulic System Operating

Pressure
Gross Machine Weight 16,104 lbs. (7305 kg)

48 psi (3.37 kg/cm

36 psi (2.53 kg/cm

4500 psi

(310 bar)

1.5 FUNCTION SPEEDS

Table 1-9. Function Speeds (In Seconds)

Machine Orientation When Doing Speed Tests

Lift: Boom Retracted. Telescope Retracted. Lift Up, Record
Time, Lift Down, Record Time.

Swing: Boom at Full Elevation. Telescope Retracted. Swing the
Turntable to the end stop. Swing the Opposite Direction,
Record Time.

Te le sc o pe : Boom at Full Elevation; Telescope Retracted; Tele­scope Out, Record Time. Telescope In, Record Time.

Drive: Test to be done on a smooth level surface. Drive Select
Switch should be set at 2WD High Engine. Start approximately
25 ft. (7.62 m) from starting point so that the unit is at maxi­mum speed when starting the test. Results should be recorded
for a 200 ft. (60.96 m) course. Drive Forward, record time. Drive
Reverse, Record Time.

Drive (Above Horizontal): Test should be done on a smooth
level surface. Set Drive Select Switch to High Engine, High
Drive. The Platform Speed Knob should be selected out of the

2)

2)

creep speed. This verifies switches are working when boom is
above horizontal. Results should be recorded for a 50 ft.
course. Drive Forward, Record Time. Drive Reverse, Record
Time.

Platform Rotate: Platform level and completely rotated one
direction. Rotate the opposite direction, Record Time. Rotate
the other direction, Record Time.

Articulating Jib: Platform level and centered with the boom.
Start with the Jib down. Jib Up, Record Time. Jib Down, Record
Time.

Lower Lift: Upper Boom horizontal. Telescoped In. Lower Lift
Up, Record Time. Lower Lift Down, Record Time.

Function Speed

Main Lift Up 24-28
Main Lift Down 20-24
Swing Right & Left* 85-95
Telescope Out 18-22
Telescope In 12-16
Platform R otate Right & Left** 25-32
Jib Up 21-31
Jib Down 19-25
Lower Lift Up 30-38
Lower Lif t Down 22-28
Drive (4WD High Engine) 29-31

(4.5 MPH)

Drive above Horizontal
(50 ft.)

*Max 10% Difference Between Left & Right
**Max 15% Difference Between Left & Right

46-68

(0.75 - 0.50

MPH)

Test Notes

1. Start Stop watch with function, not controller or switch.

2. Drive test results reflect 12x16.5 tires.

3. All speed tests are run from the platform. Speeds do not
reflect ground control operation.

4. Platform speed knob control must be at full speed
(turned clockwise completely).

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

6. Some flow control functions may not work with the
speed knob clicked into creep position.

1-2 – JLG Lift – 3121181

1.6 TORQUE REQUIREMENTS 1.7 LUBRICATION

Table 1-13. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscos ity Ind ex 152

SECTION 1 - SPECIFICATIONS

Table 1-10. Torque Specification

Description Torque Va l ue Interval Hours

Wheel Lugs 170 ft. lbs.

(230 Nm)

Swing Bearing
(Loctite)

Starter Solenoid
Co n ta c t s
Co i l

Drive Hub to Axle 240 ft. lbs.

Drive Motor to Axle 120 ft. lbs.

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

Table 1-11. Engine Torque Requirements

Description

Cylin der Head Cover 6 8.5

Cyind er Head C over 6 8.5

Rocker Arm Adjust ment
Screw

Intake Manifold 6 8.5

240 ft. lbs.

(325 Nm)

95 in. lbs. (9.5 Nm)

40 in. lbs. (4 Nm)

(325 Nm)

(163 Nm)

Torque Va l u e

Ft. Lb.s

15 21

150

50/600*

As required

As required

As required

Torque Va l ue

Nm

Hydraulic Oil

Table 1-12. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

+0° to + 180° F

(-18° to +83° C)

+0° to + 210° F

(-18° to +99° C)

+50° to + 210° F

(+10° to +99° C

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 Industries rec­ommends Mobilfluid 424 hydraulic oil, with 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 DTE13.

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.

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

Air Intake Pipe 15 21

Exhaust Manifold

(F3M1011)

Exhaust Manifold

(F3M2011)

Pump Co upling (dry) 26.5 37

Pump Co upling

#242)

Oil Drain Plug 39 55

Oil Pan (sheet metal) 15 21

Oil Pan (cast) 22 31

Injection Line Attach­ment

Injection Valve Attach­ment

Lube Oil Fil ter Cartrid ge 19 27

3121181 – JLG Lift – 1-3

(Loctite

28.5 40

16 22

28.5 40

21 30

15 21

SECTION 1 - SPECIFICATIONS

Table 1-14. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscos ity Ind ex 140

Table 1-15. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Viscosity

at 0° C (32° F) 340 cSt (1600SUS)

at 40° C (104° F) 46 cSt (215SUS)

at 65° C (150° F) 22 cSt (106SUS)

Viscosity Index 170

Table 1-16. 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

Viscos ity Ind ex 153

Table 1-17. Quintolubric 888-46

Density

0.91 @ 15°C (59°F)

Pour Point

<-20°C (<-4°F)

Flash Point

275°C (527°F)

Fire Point

325°C (617°F)

Autoignition Temperature

450°C (842°F)

Viscosity

at 0° C (32°F) 360 cSt

at 20° C (68°F) 102 cSt

at 40° C (104°F) 46 cSt

at 100° C (212°F) 10 cSt

Viscosity Index 220

1-4 – JLG Lift – 3121181

SECTION 1 - SPECIFICATIONS

Figure 1-1. Operator Maintenance and Lubrication Diagram

2B

3

4

3

4

5

7,8

1

4

2A

6

4

9,10,11,12,13

1.8 OPERATOR MAINTENANCE

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

Operator Maintenance and Lubrication Diagram.

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

Table 1-18. 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-

2. A. Swing Bearing - Teeth

Lube Point(s) - Spray On
Capacity - A/R
Lube - OGL
Interval - Every 3 months or 150 hrs of operation
Comments - More frequent lubrication intervals may
be required

cation GL-5 or MIL-Spec MIL-L-2105

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.

B. End Bearings - Worm Gear*

Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hrs of operation
Comments - Remove grease fittings and install
plugs after greasing

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

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

at the same time.

3121181 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

*If necessary install grease fittings into worm gear
housing and grease bearings.

5. Hydraulic Return Filter

DO NOT OVER-GREASE END BEARINGS. OVER-GREASING
BEARINGS WILL BLOW OUTER SEAL IN HOUSING.

3. Wheel Bearings (2WD Only)

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

4. 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.

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

6. Hydraulic Charge Filter

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

7. Hydraulic Tank

1-6 – JLG Lift – 3121181

SECTION 1 - SPECIFICATIONS

Lube Point(s) - Fill Cap
Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters)
to the Full line on the sight gauge
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.

8. Suction Strainers

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

9. Oil Change w/Filter - Caterpillar

Lube Point(s) - Fill Cap/Spin-on Element
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.

10. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts
(4.7 L) Cooler
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in
accordance with engine manual.

11. 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.

12. Fuel Filter - Caterpillar

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

13. Fuel Filter - Deutz

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

14. Fuel Filter - Perkins

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

3121181 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-2. Serial Number Locations

15. Air Filter

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

1.9 MAJOR COMPONENT WEIGHTS

Table 1-19. Component Weights

Component Pounds Kilograms

Engine Only 440 200

Upper Boom 1257 570

Frame (Bare) 2105 955

Turntable (Bare) 1533 695.5

1.10 PRESSURE SETTINGS

Table 1-20. Pressure Settings

SETTING PSI BAR

Bang-Bang Main Relief 3300 227.5

Steer 2500 172

Platform Level Up 2800 193

Platform Level Down 1800 124

Articulating Jib 1500 103

Proportional Main
Relief

Lift Down 1200 83

Swing 1700 117

3200 220

1.11 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.

1-8 – JLG Lift – 3121181

SECTION 1 - SPECIFICATIONS

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

3121181 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

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

1-10 – JLG Lift – 3121181

SECTION 1 - SPECIFICATIONS

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

3121181 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

1-12 – JLG Lift – 3121181

SECTION 1 - SPECIFICATIONS

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

3121181 – JLG Lift – 1-13

SECTION 1 - SPECIFICATIONS

NOTES:

1-14 – JLG Lift – 3121181

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.

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

Table 2-1. Inspection and Maintenance

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 Factory­Certified 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
Inspection and Preventative Maintenance Schedule for items
requiring inspection during performance of this inspection.
Reference 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.

Typ e F req uen cy

Primary

Responsibility

Service

Qualification

Reference

3121181 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Pre- Start I nspec­tion

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative

Maintenance

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

In service for 3 months or 150 hours,

whichever comes first; or

Out of service for a period of more than

3 months; or

Purchas ed 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

User or Operator User or Operator Operator and Safety Man-

ual

Owner, Dealer, or

User

Owner, Dealer, or

User

Owner, Dealer, or

User

Owner, Dealer, or

User

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.

Qualified JLG

Mechanic

Qualified JLG

Mechanic

Factory-Certified

Service Techni-

cian

Qualified JLG

Mechanic

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.

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.

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.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete

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.

2-2 – JLG Lift – 3121181

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.

SECTION 2 - GENERAL

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 races and balls (or rollers) are pitted,
scored, or burned.

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

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

Gaskets

Check holes in gaskets align with openings in 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 heat­treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Chart Sec­tion 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines, electrical wiring, and their
receptacles when disconnecting or removing them from the
unit. This will ensure 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 amount, type, and grade
of lubricant recommended in this manual at 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.

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 pump
to cavitate due to insufficient system warm-up or leaks
in pump supply (suction) lines.

2. Design and manufacturing tolerances of 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 components and gener­ally results in faulty operation. Every precaution must be
taken to keep hydraulic oil clean, including reserve oil in
storage. Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified
intervals required in the Lubrication Chart in Section 1.
Always examine filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which per­mits organic growth, resulting in oxidation or corrosion.
If this condition occurs, 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 required additives or be of com­parable viscosities. Good grade mineral oils, with viscos­ities suited to ambient temperatures in which the
machine is operating, are recommended for use.

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

due to the wear-in of meshing components.

3121181 – JLG Lift – 2-3

SECTION 2 - GENERAL

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° F (-26° C) is not recommended. If it is necessary to start
the system in a sub-zero environment, it will be necessary
to heat oil with a low density, 100 VAC heater to a mini­mum temperature of -15° F (-26° 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° F (-29° C).
However, use of this oil will give poor performance at
temperatures above 120° F (49° C). Systems using DTE
13 oil should not be operated at temperatures above
200° F (94° C) under any condition.

Changing Hydraulic Oil

1. Use of recommended crankcase or hydraulic oils elimi­nates need for changing oil on a regular basis. However,
filter elements must be changed after first 50 hours of
operation and every 300 hours thereafter. If it is neces­sary to change oil, use only oils meeting or exceeding
specifications in this manual. If unable to obtain the
same type of oil supplied with machine, consult local
supplier for assistance in selecting the proper equiva­lent. Avoid mixing petroleum and synthetic base oils.

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

3. While 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 machine back in
service.

Lubrication Specifications

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

Cylinder Drift Test

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

Platform Drift

Measure drift of 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 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

8 203.2 0.0038 0.10

9 228.6 0.0030 0.08

Measure drift at cylinder rod with a calibrated dial indicator.
Cylinder oil must be at ambient temperature and temperature
stabilized.

Max. Acceptable Drift

in 10 Minutes

Cylinder must have normal platform load applied.

If cylinder passes this test, it is acceptable.

NOTE: Information is based on 6 drops per minute cylinder leak-

age.

2-4 – JLG Lift – 3121181

SECTION 2 - GENERAL

2.4 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 joint during operation.

2. Filament wound bearings should be replaced if any of
the following is observed:

a. Frayed or separated fibers on liner surface.

b. Cracked or damaged liner backing.

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

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):

a. Detectable wear in bearing area.

b. Flaking, pealing, scoring, or scratches on pin surface.

c. Rusting of the pin in bearing area.

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

a. Blow out housing to remove all dirt and debris.

Bearings and bearing housings must be free of all
contamination.

b. Clean bearing and pins with a solvent to remove all

grease and oil. Filament wound bearings are a dry
joint and should not be lubricated.

c. Inspect pins to ensure they are free of burrs, nicks,

and scratches which would damage bearing during
installation and operation.

2.5 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 battery.

• Disconnect moment pin connection (where fitted)

• Ground only to structure being welded.

DO NOT DO THE FOLLOWING WHEN WELDING ON
JLG EQUIPMENT

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

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

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

3121181 – JLG Lift – 2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-

Delivery

or

Frequent

Inspection

2

3

Inspection

Annual

(Yearly)

4

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 a nd Pin Retain ers 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 1,2,3,13,14

Oil Coupling 9

Swing Drive System

Tur nta ble Loc k 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

Tor qu e Hu bs 11 11

Functions/Controls

Pre-Start

Inspection

9

9

9

9

9

1

Preventive

Maintenan

Wee kly

ce

Monthly
Preventive
Maintenan

ce

Every 2

Years

2-6 – JLG Lift – 3121181

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

SECTION 2 - GENERAL

Pre-

Delivery

or

Frequent

Inspection

2

3

Inspection

Annual

(Yearly)

4

Every 2

Years

AREA

Pre-Start

Inspection

1

Preventive
Maintenan

Wee kly

ce

Monthly
Preventive
Maintenan

ce

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

3121181 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-

Delivery

or

Frequent

Inspection

2

3

Inspection

Annual

(Yearly)

4

Every 2

AREA

Pre-Start

Inspection

1

Preventive

Maintenan

Wee kly

ce

Monthly
Preventive
Maintenan

ce

Capacity Decals Installed, Secure, Legible 21 21 21

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, 2 2

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Years

2-8 – JLG Lift – 3121181

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

SECTION 2 - GENERAL

AREA

Pre-Start

Inspection

1

Preventive
Maintenan

Wee kly

ce

Monthly
Preventive
Maintenan

ce

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 used

4

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

Per forman ce Code s:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off " position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill

Pre-

Delivery

or

Frequent

Inspection

2

3

Inspection

Annual

(Yearly)

4

Every 2

Years

3121181 – JLG Lift – 2-9

SECTION 2 - GENERAL

Figure 2-1. Engine Operating Temperature Specifications - Deutz

4150548 D

2-10 – JLG Lift – 3121181

SECTION 2 - GENERAL

AMBIE NT AIR

TEMP ERAT URE

Figure 2-2. Engine Operating Temperature Specifications - Perkins

4150548 D

3121181 – JLG Lift – 2-11

SECTION 2 - GENERAL

NOTES:

2-12 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

SECTION 3. CHASSIS AND 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 when
any cut, rip, or tear is discovered that exposes sidewall or tread
area cords, remove the JLG product from service immediately.
Arrangements must be made for replacement of tire or tire
assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recom­mends when any of the following are discovered, remove the
JLG product from service immediately. 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 ensure the damage
has not propagated beyond the allowable criteria.

Wheel Replacement

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

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

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

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 all tires are inflated to pressure recommended by JLG.
Due to size variations between tire brands, both tires on the
same axle should be the same.

1st Stage 2nd Stage 3rd Stage

40 ft-lb (55 Nm) 100 ft-lb (130 Nm) 170 ft-lb (255 Nm)

3. Torque wheel nuts after first 50 hours of operation and

3121181 – JLG Lift – 3-1

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

after each wheel removal. Check torque every 3 months
or 150 hours of operation.

SECTION 3 - CHASSIS AND TURNTABLE

3.2 TORQUE HUB (MACHINES BUILT BEFORE S/N

1300000064)

Roll, Leak and Brake Testing

Torque-Hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the unit's
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing
these tests.

NOTE: The brake must be released before performing the roll test.

This can be accomplished by either pressurizing the brake
using the Brake Leak Test procedure below or by tightening
the bolts into the piston through the end plate (See Brake
Disassembly Procedure)

NOTE: Bolts must be removed while performing brake release test

ROLL TEST

The purpose of the 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 constant
checker. If you feel more
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con­cerned if the gears in your unit seem to roll hard as long as
they roll with consistency

drag in the gears only at certain

.

force to the roll

The following steps describe how to tighten and torque 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. Crisscross around the bolt circle and tighten remaining
bolts.

4. Now use a torque wrench to apply the specified torque
to bolt "A".

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

LEAK TEST (MAIN UNIT)

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 leak checking fitting starts to fall after the unit has
been pressurized and allowed to equalize. Leaks most likely
occur at pipe plugs, main seal, or wherever o-rings or gaskets
are located. Exact location of a leak can usually be detected by
brushing a soap and water solution around the main seal and
where O-rings or gaskets meet on the exterior of the unit, then
checking for air bubbles. If a leak is detected in a seal, O-ring or
gasket, the part must be replaced, and unit rechecked. Leak
test at 10 psi for 20 minutes.

BRAKE TEST

Input Brake - 1,850 in-lb (208 Nm) Static,
225 psi (15.5 bar) Full Release
3000 psi (207 bar) maximum o-ring check.

If brake does not release at these pressure values, brake must
be inspected, repaired or replaced.

NOTE: Failure to perform this test may result in damaged or inef-

fective brake parts.

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure that the bolts are not tightened
beyond their specified torque.

3-2 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

6. Cover 14. Cover Bolts

9. Input Coupling 19. O-ring

10. Thrust Spacer

Figure 3-1. Main Disassembly Drawing 1

Main Disassembly

1. Perform Roll Check, Leak Check and Brake Check if appli­cable before disassembling the unit.

2. Drain oil from unit. Note condition and volume of oil.

3. Remove Input Coupling (9) from Spindle (1A) end of
unit.

4. Remove Cover Bolts (14) and remove Cover (6).

5. Remove O-ring (19) and Thrust Spacer (10) from Cover
(6).

6. Remove Input Sun Gear (17) from Input Carrier Sub­Assembly (3A).

7. Remove Input Carrier Sub-Assembly (3A) from Housing
(1E).

8. Remove Output Sun Gear (8) from Output Carrier Sub­Assembly (4A).

9. Remove Input Shaft (7) from Output Carrier Sub-Assem­bly (4A).

10. Remove Output Carrier Sub-Assembly (4A) from Hous­ing (1E).

3121181 – JLG Lift – 3-3

SECTION 3 - CHASSIS AND TURNTABLE

7. Input Shaft 17. Input Sun Gear

8. Output Sun Gear

Figure 3-2. Main Disassembly Drawing 2

3-4 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

3A. Carrier 3E. Planet Shaft

3B. Thrust Washers 3F. Planet Gear

3C. Needle Bearings

Figure 3-3. Input Carrier Disassembly

Input Carrier Disassembly

1. Place Carrier (3A) on a press with spline end up. Drive
Planet Shaft (3E) out of Carrier (3A).

2. Slide Planet Gear (3F) and two Thrust Washers (3B) out
of Carrier (3A).

3. Remove 14 needle Bearings (3C) from bore of Planet
Gear (3F).

4. Repeat steps 1 through 3 for two remaining planet
gears.

3121181 – JLG Lift – 3-5

SECTION 3 - CHASSIS AND TURNTABLE

4G. Roll Pin 4J. Thrust Washer 4B. Thrust Washers 4F. Planet Gear

4H. Thrust Washer 4K. Retaining Ring 4C. Needle Bearings

4I. Spring 4A. Carrier 4E. Planet Shaft

Figure 3-4. Output Carrier Disassembly

Output Carrier Disassembly

1. Using a small diameter punch, Drive Roll Pin (4G) which
holds Planet Shaft (4E) in Carrier (4A) into Planet Shaft
(4E) until it bottoms.

NOTE: Make sure Roll Pin has bottomed. Otherwise, damage to

carrier could occur when Planet Shaft is removed.

2. Remove Planet Shaft (4E) from Carrier (4A). Use a small
punch to remove Roll Pin (4G) from Planet Shaft (4E).

3. Slide Planet Gear (4F) and two Thrust Washers (4B) out
of Carrier (4A).

4. Remove 15 needle Bearings (4C) from bore of Planet
Gear (4F).

5. Repeat steps 1 through 4 for two remaining planet
gears.

6. Remove Thrust Washer (4H) from Carrier (4A).

7. Using retaining ring pliers, remove Retaining Ring (4K)
from Carrier (4A). Pull Thrust Washer (4J) and Spring (4I)
out of Carrier (4A).

3-6 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

1B. Seal 1D. Bearing Cone 1F. Bearing Spacer 1H. Wheel Stud

1C. Bearing Cups 1E. Housing 1G. Retaining Ring

Figure 3-5. Housing-Spindle Disassembly

Housing-Spindle Disassembly

1. Place unit on bench with Spindle (1A) end down.

EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN
THIS PROCEDURE.

2. Using retaining ring pliers, remove Retaining Ring (1G)
from groove in Spindle (1A).

3. Remove Bearing Spacer (1F) from top of Bearing Cone
(1D).

4. While supporting the unit on Housing (1E) flange, press
Spindle (1A) out of Housing (1E). The Seal (1B) and “B”

position Bearing Cone (1D) should come out of Housing
(1E) with Spindle (1A).

5. Remove “A” position Bearing Cone (1D) from Bearing
Cup (1D) in Housing (1E).

6. Lift Housing (1E) off of Spindle (1A).

7. If necessary, press Studs (1N) out of Housing (1E). Locate
Housing (1E) on Seal (1B) end.

8. Remove “B” position Bearing Cone (1D) from Spindle
(1A).

9. Remove Seal (1B) from the Spindle (1A).

10. Using a soft steel rod, knock both Bearing Cups (1C) out

of Housing (1E)

3121181 – JLG Lift – 3-7

SECTION 3 - CHASSIS AND TURNTABLE

1-A. Spindle 2-2. O-ring 2-5. Back-up Ring 2-8. Piston 2-11. Capscrew

12. Pressure Plug 2-3. Back-up Ring 2-6. Internal Circlip 2-9. Stator 2-12. Rotor

2-1. Internal Circlip 2-4. O-ring 2-7. End Plate 2-10. Spacer 2-13. Compression Spring

Figure 3-6. Spindle Brake Disassembly

Spindle-Brake Disassembly

NOTE: This procedure applies only to units with integral input

brake (2).

NOTE: For this procedure, use the Brake Assembly Drawing, which

will show the proper balloon numbers for the individual
brake components. In the following instructions, if the
number has a “-” between two numbers, it refers to the

Brake Assembly Drawing only and NOT the Torque Hub
Assembly Drawing.

NOTE: The Pressure Plug (12) requires a special tool for installa-

tion. It is not recommended to remove this plug unless it is
leaking. The plug is called a Koenig Expander. The installa­tion tool is not supplied by Fairfield manufacturing, but
can be supplied by the manufacturer of the Koenig

Expander, Sherex Industries, or one of their distributors.

3-8 – JLG Lift – 3121181

EYE PROTECTION MUST BE WORN WHILE PERFORMING THE STEPS 1-3 IN THIS
PROCEDURE.

SECTION 3 - CHASSIS AND TURNTABLE

NOTE: The last roller installed must be installed end wise. That is,

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

1. Compress the Compression Springs (2-13) by installing a
minimum of three M4 x 16mm Socket Head Cap Screws
(2-11) equally spaced through End Plate (2-7) and into
Piston (2-8) and tightening incrementally until spring
force has been taken off of the Retaining Ring (2-6).

2. Using a small pry bar or screwdriver, pry one end of the
Retaining Ring (2-6) out of the groove in Spindle (1A),
then, using pliers, pull Retaining Ring (2-6) the rest of
the way out of the groove.

3. Back Socket Head Cap Screws (2-11) incrementally out
of Piston (2-8) until spring force is relieved from the End
Plate (2-7).

4. Remove Socket Head Cap Screws (2-11) and End Plate
(2-7) from brake cavity in Spindle.

5. Remove Compression Springs (2-13) from Piston (2-8).

EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN
THIS PROCEDURE.

6. Using an air hose, slowly and carefully pressurize the
brake port in the Spindle (1A) until the Piston (2-8)
comes out of piston bore of Spindle (1A), Then pull the
Piston (2-8) the rest of the way out of the Spindle (1A) by
hand.

7. Remove Backup Rings (2-3) & (2-5) and O-rings (2-2) &
(2-4) from Piston (2-8).

8. Remove Rotors (2-12) and Stators (2-9) from Spindle
(1A).

EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN
THIS PROCEDURE.

9. Invert Spindle (1A) and, using retaining ring pliers,
remove Retaining Ring (2-1).

10. Remove Spacer (2-10) from Spindle.

Input Carrier Sub-Assembly

1. Apply a liberal coat of grease to the bore of one Input
Planet Gear (3F).

3. Set Carrier (3A) in an upright position.

4. Insert a Planet Shaft (3E) into the planet shaft hole in the
end of the Carrier (3A) opposite the splined end.

5. Place one Thrust Washer (3B) onto the end of Planet
Shaft (3E). Make sure the flat faces towards the inside of
the carrier and make sure the button fits in the pocket
inside the Carrier (3A).

6. Place one more Thrust Washer (3B) into the Carrier (3A).
Align the Thrust Washer (3B) in the same manner
described in Step 5.

NOTE: Some grease may need to be applied to the Thrust Washers

(3B) to hold them in place while installing the planet gear.
Instead of using grease, washers can be inserted from the
ID of the carrier for buttons to fit in pockets of the carrier.

7. Following the thrust washers, place Planet Gear (3F)
with needle rollers, into the Carrier (3A) between the
Thrust Washers (3B).

8. Push the Planet Shaft (3E) through the Planet Gear (3F)
and the other Thrust Washer (3B) until it touches the
other side of the Carrier (3A).

SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.

9. Press the Planet Shaft (3E) until it is pressed to the
appropriate depth.

NOTE: If planet shaft locating tooling is not available, press lightly

on Planet Shaft (3E) and make sure not to press Planet
Shaft (3E) through the small shoulder in Carrier (3A). This
shoulder is intended to keep the planet pin from working
loose in that direction during proper operation of the unit.
It is NOT intended to keep the planet pin from being
pressed through the carrier.

10. On the side of the Carrier (3A) where the Planet Shaft
(3E) was inserted, stake the Carrier (3A) in 3 places using
a punch and a hammer around the Planet Shaft (3E) to
assure the shaft stays in place during operation of the
unit.

11. Repeat Steps 1 through 10 for the installation of the two
remaining Planet Gears (3F).

2. Line the inside of the Planet Gear (3F) with 14 Needle
Rollers (3C).

3121181 – JLG Lift – 3-9

SECTION 3 - CHASSIS AND TURNTABLE

3A. Carrier 3E. Planet Shaft

3B. Thrust Washers 3F. Planet Gear

3C. Needle Bearings

Figure 3-7. Input Carrier Sub-Assembly

3-10 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Output Carrier Sub-Assembly

1. Place Spring (4I) into the deep counterbore of the Out­put Carrier (4A).

2. Place Washer (4J) on top of Spring (4I).

SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.

3. With Retaining Ring (4K) installed on snap ring pliers,
place on top of Washer (4J) and compress Spring (4I)
until Retaining Ring (4K) is seated completely in groove.

4. Apply a liberal coat of grease to the bore of one Output
Planet Gear (4F).

5. Line the inside of the Planet Gear (4F) with 15 Needle
Rollers (4C).

NOTE: The last roller installed must be installed end wise. That is,

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

6. Place Thrust Washer (4H) into the shallow counterbore
of the Output Carrier (4A).

7. Set Carrier (4A) in an upright position.

8. Insert a Planet Shaft (4E) into one of the planet shaft
holes on the Carrier (4A). The end of the planet shaft
that does NOT have the roll pin hole should be inserted
in the carrier FIRST.

9. Place one Thrust Washer (4B) onto the end of Planet
Shaft (4E). Make sure the flat faces towards the inside of
the carrier and make sure the button fits in the pocket
inside the Carrier (4A).

10. Following the thrust washer, place Planet Gear (4F) with
needle rollers, onto Planet Shaft (4E).

11. Following the planet gear, place one more Thrust
Washer (4B) onto Planet Shaft (4E). Align the Thrust
Washer (4B) in the same manner described in Step 6.

12. Now insert Planet Shaft (4E) through the opposite
planet shaft hole on Carrier (4A). Use an alignment
punch or similar tool to align the roll pin holes on Carrier
(4A) and Planet Shaft (4E).

SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.

13. Drive Roll Pin (4G) down into the aligned roll pin holes.
Pin should be flush with OD of carrier.

14. Repeat Steps 4,5, & 8-13 for the installation of the two
remaining Planet Gears (4F).

3121181 – JLG Lift – 3-11

SECTION 3 - CHASSIS AND TURNTABLE

4A. Output Carrier 4E. Planet Shaft 4H. Thrust Washer 4K. Retaining Ring

4B. Thrust Washer 4F. Planet Gear 4I. Spring

4C. Needle Rollers 4G. Roll Pin 4J. Washer

Figure 3-8. Input Carrier Sub-Assembly

3-12 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Spindle-Brake Sub-Assembly

NOTE: This procedure applies only to units with integral input

brake (2).

NOTE: For this procedure, use the Brake Assembly Drawing, which

will show the proper balloon numbers for individual brake
components. In the following instructions, if the number
has a “-” between two numbers, it refers to the Brake
Assembly Drawing only and NOT the Torque Hub Assembly
Drawing.

NOTE: The Pressure Plug (12) requires a special tool for installa-

tion. It is not recommended to remove this plug unless it is
leaking. The plug is called a Koenig Expander. The installa­tion tool is not supplied by Fairfield manufacturing, but
can be supplied by the manufacturer of the Koenig
Expander, Sherex Industries, or one of their distributors.

1. Install Pressure Plug (12) into Spindle (1A) using follow­ing procedure:

• Clean hole in spindle using appropriate Loctite spray

• Dip collar of plug in Loctite 290 or 680 (keep unplugged
portion of hole free of Loctite)

• Using appropriate tool, install plug flush with surface of
spindle

SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.

9. Grease the large O-Ring (2-2) and install in the large­diameter groove at the bottom of the Piston (2-8), on
top of the large Backup Ring (2-3).

10. Grease the small O-Ring (2-5) and install in the small­diameter groove near the top of the Piston (2-8). Make
sure the O-Ring is seated on the bottom of the groove.

11. Grease the small Backup Ring (2-4) and install in the
small-diameter groove near the top of the Piston (2-8),
on top of the small O-Ring (2-5).

NOTE: If piston comes pre-assembled with shipping bolts (2-11),

skip to Step 15.

12. Insert Piston (2-8) into Spindle (1A) until it contacts the
Stator (2-9).

13. Insert appropriate number of Springs (2-13) into Piston
(2-8) counterbore. Use brake spring chart below and a
bill of materials for your particular model number to
determine number of springs.

BRAKE

CODE

A 902337 12

B 902341 10

C 902342 8

D 902343 6

E 902345 9

BRAKE P/N

NUMBER

OF SPRINGS

2. Place Spindle (1A) such that the splined end is facing
down. Using appropriate tool (See back of manual),
install Retaining Ring (2-1) into the spindle groove
within the splines.

3. Place Washer (2-10) on top of Retaining Ring (2-1).

4. Place Stator (2-9) on top of Washer (2-10).

5. Place Rotor (2-12) on top of Stator (2-9).

6. Repeat steps 3 & 4 until there are a total of 8 Stators (2-9)
and 7 Rotors (2-12) installed.

7. Place Piston (2-8) such that the smaller O.D. end is facing
upward.

8. Grease the large Backup Ring (2-3) and install in the
large-diameter groove at the bottom of the Piston (2-8).

14. Place Pressure Plate (2-7) on top of Springs (2-13).

SAFETY GLASSES MUST BE WORN DURING THE NEXT TWO STEPS.

15. Using snap ring pliers, install Retaining Ring (2-6) into
groove in Spindle (1A) and on top of Pressure Plate (2-7).
Make sure that Retaining Ring (2-6) is seated properly in
the groove.

16. Remove Shipping Bolts (2-11) in brake pressure plate to
release springs in brake. Before removing bolts, use the
Coupling (9) (See Assembly Drawing at back of manual)
to center and align the Brake Rotors (2-12) with the Spin­dle (1A).

3121181 – JLG Lift – 3-13

SECTION 3 - CHASSIS AND TURNTABLE

1-A. Spindle 2-3. Back-up Ring 2-7. End Plate 2-11. Capscrew

12. Pressure Plug 2-4. O-ring 2-8. Piston 2-12. Rotor

2-1. Internal Circlip 2-5. Back-up Ring 2-9. Stator 2-13. Compression Spring

2-2. O-ring 2-6. Internal Circlip 2-10. Spacer

Figure 3-9. Spindle Brake Sub-Assembly

3-14 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Housing-Spindle Sub-Assembly

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

assembly.

SAFETY GLASSES MUST BE WORN DURING THE ENTIRE HOUSING-SPINDLE
SUBASSEMBLY.

1. Press Bearing Cup (1C), position A, into Housing (1E)
using appropriate pressing tool (See back of manual).

2. Turn Housing (1E) over and place into pressing base.
Press nine Studs (1H) into Housing (1E).

NOTE: Use enough pressure to press in studs. Don t use excessively

high pressure to press in studs or Housing may crack. Make
sure head of stud contacts face of flange on Housing.

NOTE: Spray a generous amount of oil on bearings during instal-

lation.

3. Press Bearing Cup (1C), position "B", into Housing (1E)
using “B” Bearing Cone pressing tool (see back of man­ual).

4. Place Bearing Cone (1D), into Bearing Cup (1C), position
"B".

5. Grease Seal (1B) lip and press seal into Housing (1E)
using seal pressing tool (see back of manual) until seal is
flush with end of Housing.

6. Turn Housing (1E) over and lower onto Spindle (1A).

7. Install Bearing Cone (1D) into Bearing Cup (1C), position
"A". and lightly press on Bearing Cup using the “A” Bear­ing Cone pressing tool (see back of manual) while rotat­ing Housing (1E) in both directions to seat bearings.

Integral Brake Check

1. Using appropriate fittings, connect hydraulic line from
hand pump to brake port.

2. Check brake is set by trying to rotate Input Shaft (7). This
can be accomplished by installing an appropriate tool
(any tool that can locate on splines of Input Coupling (9),
such as a mating splined shaft) into Input Coupling (9)

3. Bleed brake. Increase hydraulic pressure gradually while
trying to rotate input until brake just starts to release.
Note this pressure. Make sure pressure falls into the
appropriate range below.

BRAKE

CODE

A 902337 185-230

B 902341 155-192

C 902342 125-155

D 902343 93-115

E 902345 132-172

4. Increase pressure to 3,000 psi and hold for 30 seconds to

NOTE: Make sure brake re-engages when pressure is released.

NOTE: When done, make sure Input Coupling (9) is centered in

BRAKE P/N

check for leaks. Repair leaks if necessary.

Spindle (1A) to make installation of motor possible without
release of brake.

JUST RELEASE

PRESSURE RANGE (psi)

8. Place Bearing Spacer (1F) on top of Bearing Cone (1D).

9. Using retaining ring pliers, install Retaining Ring (1G)
into Spindle (1A) groove. Make sure ring is completely
seated in groove.

NOTE: Extra bearing pre-load caused by pressing “A” Bearing

Cone (1D) must be removed. This should be done by plac­ing a flat piece of steel or a pressing tool on end of spindle,
then lightly striking the tool with a piece of barstock. This
should be adequate to remove any additional bearing pre­load.

3121181 – JLG Lift – 3-15

SECTION 3 - CHASSIS AND TURNTABLE

1B. Seal 1D. Bearing Cone 1F. Bearing Spacer 1H. Wheel Stud

1C. Bearing Cups 1E. Housing 1G. Retaining Ring

Figure 3-10. Housing-Spindle Disassembly

3-16 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

7. Input Shaft 8. Output Sun Gear 17. Input Sun Gear

Figure 3-11. Main Assembly Drawing 1

Main Assembly

NOTE: All components should receive a generous amount of lubri-

cant oil as they are being assembled.

1. Place Housing-Spindle Sub-Assembly on bench with
Spindle (1A) side down.

2. Place Output Carrier Sub-Assembly into Housing (1E)
and onto Spindle (1A).

3. Insert larger diameter splined end of Input Shaft (7)
through bore of Output Carrier Sub Assembly (4A) until
shoulder of Input Shaft (7) contacts Thrust Washer (4J)
(See assembly drawing at back of manual).

4. With modified spline end facing up, place Output Sun
Gear (8) into mesh with planet gears from Output Carrier
Sub-Assembly (4A).

5. Place Input Carrier Sub-Assembly (3A) onto Output Sun
Gear (8) splines.

6. Grease O-Ring (19) and insert into groove in Cover Sub­Assembly (6).

7. Install Cover Sub-Assembly (6) onto Housing (1E) and
install twelve Bolts (14) into Cover (6). Torque bolts to
70-80 in-lbs.

8. Attach ID Tag (15) onto unit. If Cover has knobs as part of
the cover, peen top of each knob to form a head to hold
on the Tag. If cover has no such knobs, use drive screws.

9. Check disconnect, roll and leak check unit, leak check
brake, check brake release pressure.

3121181 – JLG Lift – 3-17

SECTION 3 - CHASSIS AND TURNTABLE

6. Cover 10. Thrust Spacer 19. O-ring

9. Input Coupling 14. Cover Bolts

Figure 3-12. Main Assembly Drawing 2

3-18 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-13. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2

3121181 – JLG Lift – 3-19

SECTION 3 - CHASSIS AND TURNTABLE

1A Spindle

1G Retaining Ring - Ext

12 Pressure Plug

16 O-ring Pipe Plug

1F Thrust Washer

1E Housing/Ring Gear

1N Stud

1C Tapered Bearing - Cup

1D Tapered Bearing - Cone

1B Lip Seal

3A Carrier

3F Planet Gear

3E Planet Shaft

3C Needle Bearing

3B Thrust Washer

4A Carrier

4F Planet Gear

4E Planet Shaft

4C Needle Bearing

4I Spring

4K Retaining Ring - Int

4G Roll Pin

4B Thrust Washer

4H Thrust Washer

4J Thrust Washer

17 Sun Gear

8Sun Gear

7Input Shaft

9Coupling

6 Cover Subassembly

10 Thrust Spacer

15 Id Plate

14 12 Pt Flange Bolt

19 O-ring

Figure 3-14. Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2

3-20 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-15. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2

3121181 – JLG Lift – 3-21

SECTION 3 - CHASSIS AND TURNTABLE

1A Spindle

2 Input Brake

1G Retaining Ring - Ext

12 Pressure Plug

16 O-ring Pipe Plug

1F Thrust Washer

1E Housing/Ring Gear

1N Stud

1C Tapered Bearing - Cup

1D Tapered Bearing - Cone

1B Lip Seal

3A Carrier

3F Planet Gear

3E Planet Shaft

3C Needle Bearing

3B Thrust Washer

4A Carrier

4F Planet Gear

4E Planet Shaft

4C Needle Bearing

4I Spring

4K Retaining Ring - Int

4G Roll Pin

4B Thrust Washer

4H Thrust Washer

4J Thrust Washer

17 Sun Gear

8Sun Gear

7Input Shaft

9 Coupling

6 Cover Subassembly

10 Thrust Spacer

15 Id Plate

14 12 Pt Flange Bolt

19 O-ring

Figure 3-16. Assembly Drawing - With Integral Input Brake - Sheet 2 of 2

3-22 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-17. Assembly Tools - Bearing Cone Pressing - “B” Bearing

3121181 – JLG Lift – 3-23

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-18. Assembly Tools - Bearing Cone Pressing - “A” Bearing

3-24 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-19. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings

3121181 – JLG Lift – 3-25

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-20. Assembly Tools - Seal Pressing

3-26 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-21. Assembly Tools - Spacer - Brake Disc Installation

3121181 – JLG Lift – 3-27

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-22. Assembly Tools - Brake Retaining Ring Installation

3-28 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

3.3 TORQUE HUB (MACHINES BUILT AFTER S/N

1300000064)

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.

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
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

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 to the roll

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 ensure that you do NOT tighten the bolts beyond their
indicated torque specification. Never
tighten shoulder bolts. Always
hand.

The following steps describe the proper procedure for tighten­ing and torquing bolts or socket head capscrews 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 impact wrench to

tighten all shoulder bolts by

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 sub­assembly (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).

11. Lift input shaft sub-assembly (7) out of middle of spindle
(1A), and stand input shaft (7A) on its splined end.

3121181 – JLG Lift – 3-29

SECTION 3 - CHASSIS AND TURNTABLE

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 O­RING.

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.

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 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.

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 counterbore with punch when you remove 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 nine studs (1N) out of stud holes in hub (1G).

10. At this point hub-spindle disassembly is complete.

Cover Disassembly

1. Remove 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).

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 needle rollers from cluster gears, discard

old needle rollers and use new ones during re-assembly.

1. Using a punch and hammer, drive roll pin (3G) into
planet shaft (3E).

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 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.

3-30 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

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.

Carrier Assembly

1. Apply grease to inside of one cluster gear (3F) and line
one half of cluster gear with 16 needle rollers (3C).

3. Line remaining half of cluster gear (3F) with 16 needle
rollers.

4. Set carrier housing (3A) on table, sideways. Insert a
planet shaft (3E), roll pin hole last, in one of planet shaft
holes from roll-pin-holed side of carrier housing (3A).

2. Place one spacer (3D) inside cluster gear (3F) so that it
rests on top of the needle rollers.

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.

3121181 – JLG Lift – 3-31

SECTION 3 - CHASSIS AND TURNTABLE

6. Following thrust washer, place cluster gear (3F), large
end toward roll pin hole in carrier housing, on planet
shaft (3E).

7. Following cluster gear, place one more thrust washer
(3B) on planet shaft (3E) through opposite planet shaft
hole in carrier housing (3A).

9. Drive roll pin (3G) down in aligned roll pin holes in car­rier housing (3A) and planet shaft (3E).

10. Repeat steps 1 thru 9 to assemble and install remaining
cluster gears.

11. At this point carrier sub-assembly is complete.

8. Use an alignment punch or similar tool to align roll pin
holes in carrier housing (3A) and planet shaft (3E).

3-32 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Cover Sub-Assembly

1. Using the disconnect rod, push O-ring (6F) in groove
inside cover cap (6B).

2. Place O-ring (6G) on cover cap (6B) so that it rests
against flange of cover cap.

4. Set cover (6A) on table, exterior side up. Place cover cap
(6B) on cover (6A), aligning pipe plug hole in cover cap
over pipe plug hole in cover.

5. Place two cover cap bolts (6C) in any two bolt hoes that
are 180° apart on cover cap (6B) and tighten bolts.

3. Insert disconnect rod (6E) in cover cap (6B).

6. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm)
of torque to both bolts (6C).

3121181 – JLG Lift – 3-33

SECTION 3 - CHASSIS AND TURNTABLE

7. With large end down, place disconnect cap (6D) on
cover cap (6B), aligning pipe plug hole in disconnect cap
over pipe plug hole in cover cap.

8. Place two remaining bolts (6C) in bolt holes in discon­nect cap (6D). Tighten bolts.

10. Apply a light coat of "Never-Seize" to pipe plug (6H) and
tighten it in pipe plug hole in cover (6A).

Hub-Spindle Sub-Assembly

NOTE: Make sure cup is square with counterbore before pressing.

1. Set hub (1G) on large end. Press bearing cup (1C) in
counterbore in small end of hub (1G).

9. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm)
of torque to both bolts (6C).

2. Press nine studs (1N) in stud holes in hub (1G).

3-34 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

3. Apply a light coat of "Never-Seize" to two pipe plugs (1J)
and tighten them into two pipe plug holes in side of
hub (1G).

NOTE: Make sure cup is square with counterbore before pressing.

4. Turn hub (1G) over onto its small end. Press bearing cup
(1E) in counterbore in deep end of hub (1G).

6. Press seal (1B) in small end of hub (1G).

7. Oil spindle, then lower hub (1G), small end down, onto
spindle (1A).

5. Set hub (1G) on its large end. Place bearing cone (1D) in
bearing cup (1C).

8. Press bearing cone (1F) on spindle (1A) in hub (1G).

3121181 – JLG Lift – 3-35

SECTION 3 - CHASSIS AND TURNTABLE

9. Place spacer (1H) on spindle (1A) in hub (1G).

NOTE: Make sure retaining ring is securely seated in groove.

10. Place retaining ring (1I) over 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 in hub counterbore (1G).

NOTE: O-ring may be stretched or pinched together to make it fit

counterbore.

2. Oil all exposed surfaces inside hub (1G).

11. At this point hub-spindle sub-assembly is complete.

Place internal gear (2) in hub (1G) so its internal splines
mesh with external splines of spindle (1A). Oil internal
gear (2).

3-36 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

3. Place thrust washer (11) around spindle (1A) so it rests
on bottom of internal gear (2).

4. Stand input shaft (7A) on its splined end. Place one
spacer (7D) on smooth end of input shaft (7A).

6. Place spacer (7D) on 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.

7. Using retaining ring pliers, insert retaining ring (7B) in
groove on input shaft (7A) by compressing spring and
spacers together.

5. Place one spring (7C) on smooth end of input shaft (7A).

8. With large splined end down, place input shaft sub­assembly (7) in spindle (1A).

3121181 – JLG Lift – 3-37

SECTION 3 - CHASSIS AND TURNTABLE

Figure 3-23. Cluster Gear Punch Marks

9. Place thrust spacer (9) on input shaft (7).

10. Set carrier sub-assembly (3) on a flat work surface so
large ends of cluster gears (3F) face up. Locate punch
marks on face of each cluster gear (3F) and position
them at 12 o’clock.

12. Place carrier sub assembly (3) and ring gear (4) together
into mesh with internal gear (2). Align "X" marked shoul­der bolt hole in ring gear (4) over one of the shoulder
bolt holes in the hub. Mark location of shoulder bolt
holes on outside of ring gear and hub.

NOTE: You may lift ring gear off hub to align shoulder bolt holes.

Ring gear and carrier are installed together only to keep
punch marks on the carrier in place.

13. With internal splines facing up (counterbore end facing
down), place input gear (8) into mesh with carrier sub­assembly (3).

11. With "X" marked side facing up, place ring gear (4)
around cluster gears (3F).

NOTE: This will hold punch marks in position while installing car-

rier into hub.

14. Oil all exposed surfaces inside hub (1G). Place thrust
washer (11) in counterbore in top of carrier.

3-38 – JLG Lift – 3121181

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING O-RING.

15. Set cover (6A) on table, interior side up. Grease O-ring (5)
and place it in counterbore around edge of cover (6A).

NOTE: O-ring may be stretched or pinched together to make it fit

counterbore.

SECTION 3 - CHASSIS AND TURNTABLE

18. Place shoulder bolts (13) in four shoulder bolt holes in
cover (6). Tighten by hand.

19. Place remaining 12 flat washers (16) on remaining bolt
holes in cover (6).

16. Place cover sub-assembly (6) on ring gear (4). Align pipe
plug holes according to alignment before disassembly.

17. Place four flat washers (16) on top of bolt holes in cover
sub-assembly.

20. Place 12 bolts in remaining bolt holes in cover (6) and
tighten.

3121181 – JLG Lift – 3-39

SECTION 3 - CHASSIS AND TURNTABLE

21. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm).
Torque bolts (12) 18 to 25 ft-lb (25 to 34 Nm).

22. Turn hub (1G) over on its side. Insert coupling (14) in the
end of spindle (1A).

24. Leak test unit at a pressure of 5 psi for 2 to 3 minutes.

25. At this point main assembly is complete.

23. Roll test unit in clockwise and counterclockwise direc­tions. Perform same number of turns in each direction as
the ratio of the unit. The ratio is last two digits of model
number on the unit’s ID tag.

3-40 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

Tool List

The following specialized tools are used to assemble this unit.
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: To improve tool life, tools may be carburized and hard-

ened. If this is done, tools must be ground on all surfaces
labeled with a "G" on the tool diagram.

1. T-118126 SEAL PRESSING TOOL for SEAL (1B).

3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E)

4. T-109691 ASSEMSLY PRESSING TOOL for CONE (1F)

2. T-138903 ASSEMBLY PRESSING TOOL for CUP (1C)

* These tools are for specific seals, cups or cones. There is a
specific tool for each cup and cone.

3121181 – JLG Lift – 3-41

SECTION 3 - CHASSIS AND TURNTABLE

Bias spring

Servo piston

Swashplate

Output

Shaft

Piston

Slipper

Cylinder
Block

Endcap

Shaft
Seal

Bearing

Minimum
Angle
Stop

Valv

e plate

Figure 3-24. Drive Motor Cross Section

1

2

3

1. Snap Ring

2. Support Washer

3. Shaft Seal

Figure 3-25. Removing Shaft Seal

3.4 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 hydraulic
power supply to brake port.

2. Pressurize brake release port 155 to 200 psi (10.6 to 13.8
bar) to release 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 drive motor on hub, then release hydraulic pres­sure at brake release port. Coupling will remain in posi­tion.

6. Disconnect the hydraulic power supply and reconnect
the line going into the brake release port.

The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.

Shaft Seal Replacement

REMOVAL

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

3.5 DRIVE MOTOR

Description

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.

Motors are spring biased to maximum displacement and
hydraulically shifted to minimum displacement. Minimum and
maximum displacement can be set with fixed internal stops.

2. Remove the support washer (2).

3. Carefully pry out shaft seal (3).

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

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

4. Discard seal.

3-42 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND 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. Shift Spool

13. Orifice Poppet

Figure 3-26. Loop Flushing Spool

INSPECT 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.

Loop Flushing Valve

REMOVAL

1. Using a 11/16 in internal hex wrench remove plug (1)
and (2).

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

6. Remove shift spool (12).

7. Remove orifice poppet (13).

INSPECT 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).

3121181 – JLG Lift – 3-43

SECTION 3 - CHASSIS AND TURNTABLE

Troubleshooting

Table 3-2. Excessive Noise and/or Vibration

Item Description Action

Check oil level in reservoir and oil
supply to the motor.

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

Fill the reservoir to the proper level and ensure that oil supply to the motor
is adequate and the lines are unobstructed.

Check for air in the system.

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.

Air trapped within the system lines, or the motor itself, could result in cavi­tation that would cause system noise.

A loose or incorrect shaft coupling will produce vibrations 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 properly aligned.

Replace hydraulic oil with appropriate fluid for operating conditions.

Fill the reservoir to the proper level.

Ensure that heat exchanger is receiving adequate air flow and that the
heat exchanger is in good operating condition. Repair or replace as n eces­sary.

Repair or replace any malfunctioning 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 signal 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 longer 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 orifices are installed in the motor and verify
that they are not obstructed. Clean or replace as necessary.

3-44 – JLG Lift – 3121181

Disassembly

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. Shift Spool

13. Orifice Poppet

Figure 3-27. Loop Flushing Spool

15

20161619171821

14

14. Lock Nut

15. O-ring Plug

16. Control Line Plug

17. Control Line Plug

18. Cavity Plug

19. Drain Plug

20. Drain Plug

21. Work Port Plug

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

NOTE: Removal of 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.

SECTION 3 - CHASSIS AND TURNTABLE

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).

3121181 – JLG Lift – 3-45

8. Remove all fittings from unit. Discard O-rings on 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 two­line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard O­rings.

SECTION 3 - CHASSIS AND TURNTABLE

24

22

23

22. Screw

23. End Cap

24. O-ring

Figure 3-29. End Cap

26

28

29

30

292725

25. Valve Plate

26. End Cap

27. O-ring

28. O-ring

29. Angle Stop

30. Servo Spring

Figure 3-30. Valve Plate & Rear Shaft Bearing

13. Using an 8 mm internal hex wrench, remove endcap
screws (22).

14. Remove endcap (23). Remove O-ring (24) from housing
or endcap.

When endcap screws are removed, pressure from servo
spring will cause endcap to bind on shaft. Press down on
portion of endcap covering servo piston and hold end­cap level while removing.

TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE PLATE.

15. Remove valve plate (25) and timing pin (26) from end­cap.

Each displacement has a unique valve plate. For identifi­cation, the last two digits of the valve plate part number
are stamped on its surface.

16. Remove and discard O-rings (27, 28).

17. Remove rear shaft bearing (29) from endcap with a bear­ing puller.

Bearing may be difficult to remove with a puller. Try this
as an alternative: Pack bearing cavity with heavy grease.
After shaft is removed, insert it into bearing cavity and
tap lightly with a soft mallet on the splined end. Grease
will force the bearing out. Use caution not to drive bear­ing past rear shaft journal as the bearing may become
trapped on shaft and damaged.

18. Remove minimum angle stop (29) and servo spring (30)
from the housing.

3-46 – JLG Lift – 3121181

19. Turn housing on its side and remove cylinder kit assem-

31

31. Cylinder Kit Assembly

Figure 3-31. Cylinder Kit

32

33

34

32. Snap Ring

33. Support Washer

34. Shaft Seal

Figure 3-32. Shaft Seal

38

37

36

35

35. Inner Snap Ring

36. Snap Ring

37. Bearing

38. Shaft

Figure 3-33. Shaft & Front Bearing

41

42

40

Lift here

39

43

39. Swashplate

40. Servo Piston

41. Piston Seal

42. O-ring

43. Journal Bearings

Figure 3-34. Swash Plate & Servo Piston

bly (31). Set assembly aside. Do not scratch the running
surface.

NOTE: Grooves on the surface of the cylinder kit identify its dis-

placement:

Table 3-5. Displacement Identifiers

SECTION 3 - CHASSIS AND TURNTABLE

21. To avoid damaging 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.

# of

Grooves

Frame L Frame K

12538

23045

335- -

22. Remove inner snap ring (35) and shaft/bearing assem­bly.

23. Remove snap-ring (36) retaining the shaft front bearing.
Pull bearing (37) off of the shaft (38).

20. Turn housing over and remove snap ring (32) retaining
shaft seal and support washer. Remove support washer
(33) and carefully pry out shaft seal (34). Discard seal.

3121181 – JLG Lift – 3-47

SECTION 3 - CHASSIS AND TURNTABLE

51

50

52

53

46

49

48

47

45

44

44. Piston

45. Slipper Retainer

46. Cylinder Block

47. Ball Guide

48. Holddown Pins

49. Retaining Ring

50. Block Spring Washer

51. Spiral Retaining Ring

52. Block Spring

53. Inner Block Spring Washer

Figure 3-35. Cylinder Kit Disassembly

Slipper

Maximum end play

M inimum
slipper fo ot
thick ness

24. Turn housing over and remove swashplate (39) by lifting
on the end opposite the servo lever.

25. Remove servo piston (40). Remove piston seal (41) and
O-ring (42) from servo piston. Discard seal and O-ring.

26. 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.

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.

29. Turn block over. Using a press, apply pressure on the
block spring washer (50) to compress the block spring.
Compress spring enough to safely remove the spiral
retaining ring (51). While maintaining pressure, unwind
spiral retaining ring (51). Carefully release pressure and
remove outer block spring washer (50), block spring
(52), and inner block spring washer (53) from cylinder
block.

Inspection

After disassembly, wash all parts (including 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.

NOTE: Most repairs do not require block spring removal. Perform

3-48 – JLG Lift – 3121181

27. 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.

28. Remove ball guide (47), hold-down pins (48), and retain­ing ring (49) from cylinder block.

this procedure only if you suspect problems with the block
spring.

PISTON

Inspect the pistons for damage and discoloration. Discolored
pistons may indicate excessive heat; do not reuse.

SLIPPERS

Inspect 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 slipper axial end­play. Replace any piston assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end-play
are given in the table below.

Table 3-6. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness

Piston/Slipper End Play

mm
(in.)

2.71

(0.11)

4.07

(0.16)

0.15

(0.006)

SECTION 3 - CHASSIS AND TURNTABLE

A

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

Slipper retainer

Ball guide

3.83 mm [0.151 in] min.

0.025 mm
[0.001 in]

0.0076 mm
[0.00030 in]

convex max

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.

BALL GUIDE AND SLIPPER RETAINER

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.

VALVE PLATE

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.

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.

3121181 – JLG Lift – 3-49

SECTION 3 - CHASSIS AND TURNTABLE

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]

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. Replace swashplate if the difference in
thickness from one side to the other exceeds specification.

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.

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.

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.

3-50 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

3

2

1

3

1. O-ring

2. Piston Seal

3. Servo Piston

Figure 3-36. Servo Piston

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 3-37. Cylinder Kit Assembly

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. Install inner block spring washer (4), block spring (5),
and outer washer (6) into 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.

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.

3121181 – JLG Lift – 3-51

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.

SECTION 3 - CHASSIS AND TURNTABLE

14

13

13

13. Journal Bearings

14. Swash Plate

Figure 3-38. Swash Plate and Journal Bearing

16

15

17

18

15. Front Shaft Bearing

16. Shaft

17. Snap Ring

18. Snap Ring

Figure 3-39. Shaft and Front Bearing

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.

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.

7. Install swashplate (14) in housing. Tilt 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 running surface of
the swashplate.

9. While holding swashplate in place, turn housing on its
side. Install shaft/bearing assembly into housing from
the flange end. Install snap-ring (18).

3-52 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

19

19. Cylinder Kit

Figure 3-40. Cylinder Kit Installation

20

21

20. Servo Spring

21. Minimum Angle Stop

Figure 3-41. Servo Spring and Minimum Angle Stop

232322

24

3

mm

[0.12 in]

2 mm

[0.08 in]

23

22

22. Rear Shaft Bearing

23. Timing Pin

24. Valve Plate

Figure 3-42. Valve Plate and Rear Bearing

10. Verify swashplate and bearings are properly seated.
Install cylinder kit (19) on shaft. Install with slippers fac­ing swashplate. Rock shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,
journal bearings, and servo piston are secure and prop­erly installed.

11. Lubricate and install servo spring (20), and minimum
angle stop (21) in housing bore.

12. Press rear shaft bearing (22) in endcap. Install bearing
with letters facing out. Press until bearing surface is 0.08
±0.01 in (2 ±0.25 mm) above endcap surface.

3121181 – JLG Lift – 3-53

13. Install timing pin (23) into its bore in endcap. Install pin
with groove facing toward or away from shaft. Press pin
until end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above
endcap surface.

14. Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.

SECTION 3 - CHASSIS AND TURNTABLE

26

25

8 mm
(47-61 Nm)

35-45 ft.lbs.

25. End Cap

26. Screw

Figure 3-43. End Cap

29

28

27

27. Shaft Seal

28. Seal Support Washer

29. Snap Ring

Figure 3-44. Shaft Seal

1/4 in

(45 Nm)

33 ft-lb

5/16 in

(85 Nm)

63 ft-lb

5/16in

(85 Nm) 63 ft-lb

1/4 in

(45 Nm)

33 ft-lb

9/16 in

(170 Nm)

125 ft-lb

3 mm

(2 to 3.4 Nm)

1.5 to 2.5 ft-lb

Figure 3-45. Plugs and Fittings Installation

NOTE: Improper assembly of internal components may prevent

endcap from seating properly.

15. Install endcap (25) on housing with endcap screws (26).
Check endcap will properly seat on housing without
interference. Ensure O-rings seat properly when install­ing endcap.

18. Cover shaft splines with an installation sleeve. Install
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).

19. Install remaining plugs and fittings to housing. Refer to
drawing below for wrench sizes and installation torques.

3-54 – JLG Lift – 3121181

16. Using an 8 mm internal hex wrench, tighten endcap
screws. Tighten screws in opposite corners slowly and
evenly to compress servo spring and properly seat the
endcap. Torque endcap screws 35-45 ft.lbs. (47-61 Nm).

17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, dis­assemble and check unit.

SECTION 3 - CHASSIS AND 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. Shift 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 3-46. Loop Flushing Spool

20. Install orifice poppet (30).

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 5/8" wrench torque plug (40) to 20 ft-lb (27 Nm).

26. Using 11/16" wrench, torque plugs (41 and 42) to 27 ft­lbs (37 Nm).

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 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 reservoir with recommended hydraulic fluid. Always
filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid.

2. Fill inlet line leading from pump to the reservoir. Check
inlet line for properly tightened fittings and be certain it
is free of restrictions and air leaks.

3. Fill pump and motor housing with clean hydraulic fluid.
Pour filtered oil directly in upper most case drain port.

4. To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.

5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres­sure gauge port of pump to monitor system pressure
during start up.

6. While watching pressure gauge, run engine at lowest
possible speed until system pressure builds to normal
levels (minimum 160 psi [11 bar]). Once system pressure
is established, increase to full operating speed. If system
pressure is not maintained, shut down the prime mover,
determine cause, and take corrective action.

7. Operate hydraulic system for at least fifteen minutes
under light load conditions.

8. Check and adjust control settings as necessary after
installation.

9. Shut down prime mover and remove pressure gauge.
Replace plug at charge pressure gauge port.

10. Check fluid level in reservoir; add clean filtered fluid if
necessary. The motor is now ready for operation.

3121181 – JLG Lift – 3-55

SECTION 3 - CHASSIS AND TURNTABLE

Table 3-8. Chassis Torque Values

Ft-Lbs. Nm

A 120 163

B 240 325

C 170 230

D 140 190

E 165 224

F 35 47

Figure 3-47. Chassis Torque Values - Sheet 1 of 2

This figure applies to machines built prior to S/N 1300003222

3-56 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE

E

ABC

D

Table 3-9. Chassis Torque Values

Item Ft-Lbs. Nm

A 120 163

B 240 325

C 170 230

D 85 115

E 165 224

Figure 3-47. Chassis Torque Values - Sheet 2 of 2

This figure applies to machines built S/N 1300003222 to Present

3121181 – JLG Lift – 3-57

SECTION 3 - CHASSIS AND TURNTABLE

1 . W as h er
2 . B r ac k et
3 . L o ck ou t Va lv e

Figure 3-47. Valve Adjustment

3.6 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" (7.9 ± 1.6
mm).

3.7 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST

Lockout Cylinder Bleeding (Early Cylinders)

NOTE: The following procedure is to be used on machines built

prior to S/N 1300003222.

ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN­TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING
PROCEDURE.

ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR
WHEELS ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.

1. Make sure machine is on a level surface.

2. Center boom over rear axle to make sure the cam valve
in the rotary coupling is depressed.

3. Place chocks under the tires to ensure the machine does
not move. Disable the machine brakes by disconnecting
the brake solenoid(s) on the brake valve.

4. Use suitable containers to catch any excess hydraulic
fluid. Place the containers under each lockout cylinder.

2. The ideal adjustment is 3/8" (9.5 mm). Do not push the
plunger in more that 3/8" (9.5 mm). The extra adjust­ment is needed for the turntable bearing play.

5. Open one bleeder screw at a time.

6. Start the engine, position drive control lever forward or
reverse.

7. Close bleeder screws when all air is dissipated (bled).

8. Reconnect the brake solenoid(s) and remove the wheel
chocks.

9. Perform oscillating axle lockout test.

10. If necessary, repeat steps 1 thru 7.

3-58 – JLG Lift – 3121181