JLG 600SC-660SJC Service Manual

Service and Maintenance Manual

Model

600SC
600SJC
660SJC

3120794

April 9, 2002

ANSI

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tan n oc h s id e P a r k
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L .
Trapadella, 2
P. I . C a s t e l l b i s b a l S u r
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

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

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

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

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

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

B HYDRAULIC SYSTEM SAFETY

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

feed lines to system components can then be disconnected
with minimal fluid loss.

C MAINTENANCE

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

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

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

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

• OBSERVE AND OBEY ALL WARNINGS AND CAU­TIONS ON MACHINE AND IN SERVICEMANUAL.

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

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTED­DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

Relieve system pressure by cycling the applicable control
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure

3120794 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - January 25, 2000
Revised - July 28, 2000
Revised - April 9, 2002

A-2 – JLG Lift – 3120794

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH 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

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic System (Including Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Engine - Diesel (Liquid-Cooled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight approximately. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Height (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Length (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

1.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Deutz F4M1011F Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SECTION 2 - GENERAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3120794 – JLG Lift – i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

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

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

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

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

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

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

SECTION 3 - TURNTABLE

3.1 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Throttle Checks and Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

3.3 Swing Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Swing Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.5 Swing Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SECTION 4 - BOOM & PLATFORM

4.1 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

4.4 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

Three Month Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Five Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

Disassembly of Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

4.6 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.7 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.8 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.9 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.10 SUPERFLEX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

System Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

SUPERFLEX Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

SUPERFLEX Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Setup and Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

How to Perform the Normal-Active Tuning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

How to make Bench-Static Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

How To Troubleshoot the SUPERFLEX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

How to Troubleshoot the Digisensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Important Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Crawler Tracking Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Drive & Steer Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Superflex Inputs And Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

SECTION 5 - HYDRAULICS

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

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

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

5.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Solenoid Control Valve - Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder . . . . . . . . 5-1

Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

5.5 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Main Boom Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.6 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Main Relief, Steer, Swing and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Articulating Jib Boom (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.7 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5.8 Hydraulic Component Start-Up Procedures and recommendations . . . . . . . . . . . . . . . . . . . . . . .5-16

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION 6 - UNDERCARRIAGE

6.1 Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.2 Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.3 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Separate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4 Front Idler and Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Front Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Recoil Spring Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Recoil Spring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6.5 Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.6 Final Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.7 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.8 Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.9 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.10 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.11 Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6.12 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

Final Drive Oil - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Final Drive Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

6.13 Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

6.14 Towing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62

Towing the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Final Drive Sun Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

6.15 Track Adjustment - Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

Measuring Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Tightening the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Loosening the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Track Adjustment - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6.16 Undercarriage- Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64

SECTION 7 - SCHEMATICS

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

7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Lubrication Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

3-1. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2. Addco Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-3. Swing Torque Hub Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-4. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-5. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-6. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-7. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-8. Swing Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

4-1. Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-4. Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-5. Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-6. Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-7. Location of Components - Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-8. Boom Assembly Cutaway - S Models - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-9. Boom Assembly Cutaway - S Models - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-10. Boom Assembly Cutaway - S Models - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-11. Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-12. Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-13. Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-14. Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-15. Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-16. Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-17. Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-18. Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-20. Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-21. Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-22. Removing Setscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-23. Removing End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-19. Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-24. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-25. Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

3120794 – JLG Lift – v

TABLE OF CONTENTS (Continued)

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO.

4-26. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-27. SUPERFLEX Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-28. Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis. . . . . . . . . . . . . . . . . . .4-22

4-29. Controller Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-30. Calibration Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-31. Testing the SUPERFLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-32. Digisensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4-33. Typical SUPERFLEX System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

4-34. OPTIMIZER Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

5-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-5. Gar-Max Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-8. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-10. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-11. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-12. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-13. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-14. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-15. Articulating Jib Boom Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-18. Location of Components - Main Control Valve (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-19. Location of Components - Main Control Valve (Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

6-1. Undercarriage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2. Track Carrier Roller - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-3. Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-4. Track Roller - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-5. Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-6. Track Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-7. Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-8. Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-9. Recoil Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-10. Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-11. Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

6-12. Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43

6-13. Tooling (J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

6-14. Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-60

7-1. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3. Electrical Schematic - Deutz or Isuzu - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-4. Electrical Schematic - Deutz or Isuzu - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7-5. Hydraulic Schematic - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-6. Hydraulic Schematic - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7-7. Hydraulic Schematic - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-8. Hydraulic Schematic - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-9. Hydraulic Schematic w/GFT24 Drive - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-10. Hydraulic Schematic w/GFT24 Drive - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-11. Hydraulic Schematic w/GFT24 Drive - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-12. Hydraulic Schematic w/GFT24 Drive - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

vi – JLG Lift – 3120794

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

1-5 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-9 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

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

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

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

3-1 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4-1 Adjusting Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-2 Adjustment Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

4-3 Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

6-1 Track Carrier Roller Required Tools - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Track Carrier Roller Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-3 Track Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-4 Track Roller Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-5 Track Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-6 Track Required Tools - Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-7 Track Required Tools - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-8 Front Idler Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

6-9 Recoil Spring Required Tools - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-10 Recoil Spring Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

6-11 Track Adjuster Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

6-12 Final Drive Sprocket Required Tools - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

6-13 Final Drive Sprocket Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

6-14 Travel Motor Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

6-15 Travel Motor Required Tools - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-16 Travel Motor Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

6-17 Travel Motor Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

6-18 Final Drive Required Tools - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

6-19 Final Drive Required Tools - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-20 Final Drive Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50

6-21 Final Drive Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56

3120794 – JLG Lift – vii

TABLE OF CONTENTS (Continued)

This page left blank intentionally.

viii – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank

39 US. Gallons (147.6 l)

Hydraulic Oil Tank

31 U.S. Gallons (117.3 l) with 10% air space

Hydraulic System (Including Tank)

37.2 U.S. Gallons (140.8 l)

Engine Crankcase

Deutz F4M1011F Diesel w/Filter - 11 quarts (10.5 l)

1.2 COMPONENT DATA

Engine - Diesel (Liquid-Cooled)

Manufacturer/Model- Deutz F4M1011F.

Oil Capacity.

5 Quarts (4.5 l) Cooling System.

11 Quarts (10.5 l) w/Filter.

16 Quarts (15 l) Total Capacity.

Low RPM - 1800.

Swing System

Swing Motor Displacement - 4.62 cu. in. (75 cm3]).

Swing Brake - Automatic spring applied hydraulically
released disc brakes.

Swing Hub Ratio - 50:1.

Hydraulic Gear Pump. (at 1800 RPM)

7.9 GPM (29.90 lpm).

Pump Displacement - 1.02 cu. in. (16 cm3]).

Clockwise Rotation.

Auxiliary Power Pump

2.6 GPM (9.84 lpm) @ 1200 PSI. (82.7 BAR.

Pump Displacement - .244 cu. in. (14 cm3]).

DC Motor.

Clockwise Rotation.

Hydraulic Filter - In-line.

Return - Bypass Type.

10 Microns Absolute.

Charge.

10 Microns Absolute.

Hydraulic Strainers (In Tank).

High RPM - 2800.

Alternator - 60 Amp, belt drive.

Battery - 1000 Cold Cranking Amps, 210 Minutes
ReserveCapacity, 12 VDC.

Fuel Consumption.

Low RPM - 1.90 GPH (7.19 lph).

High RPM - 2.50 GPH (9.46 lph).

Horsepower - 65 @ 3000 RPM, full load.

Engine - Diesel. (Water-Cooled)

30 Microns.

3120794 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.3 PERFORMANCE DATA

Travel Speed

1.6 MPH (2.6 Km/hr.)

Travel Speed - Out of Transport

0.4 MPH (0.6 Km/hr.)

Gradeability.

55%

Turning Radius (Outside)

8 ft. (2.4 m)

Turning Radius (Inside)

0

Boom Elevation

600SC - +60 ft. 2 13/16 in. (18.36 m)

-6 ft. 1 11/16 in. (1.87 m)

600SCJ - +60 ft. 5 3/4 in. (18.43 m)

-9 ft. 9 3/16 in. (2.98 m)

660SCJ - +66 ft. 7 5/8 in. (20.31 m)

-11 ft. 5 1/4 in. (3.49 m)

Machine Weight approximately

Steel Track - 25,900 lbs. (11,748 kg)

Rubber Track - 26,860 lbs. (12,184 kg)

Machine Height (Stowed)

Steel Track - 8’4" (2.54 m)

Rubber Track - 8’6" (2.59 m)

Machine Length (Stowed)

35’ 6" (10.8 m)

Machine Width

8 ft. (2.4 m)

1.4 FUNCTION SPEEDS

Table 1-1. Function Speeds (In Seconds)

Function Speed

Lift Up 46-60

Lift Down 33-43

Swing Right & Left* 79-101

Telescope In 22-33

Telescope Out 50-67

Platform Rotate Right & Le ft** 16-25

Jib Up 22-34

Jib Down 16-26

Drive (Forward & Reverse) 85-90

Drive Out of Transport (Forward & Reverse) 80-85

*Max 10% Difference Betwe en Left & Right
**Max 15% Difference Betwe en Left & Right

Machine Orientation When Doing Speed Te st s

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

Record Time.

Swing: Boom at Full Elevation. Telescope Retracted.
Swing the Turntable off center and stop. Swing the oppo­site direction ana start the test wen the turntable is cen­tered up. This eliminates ramp up and down on the
controller affecting times.

Te l e sc o p e : Boom at Full Elevation; Telescope Retracted;
Telescope Out, Record Time. Telescope In, Record Time.

Trackin g : Test to be done on a gravelled level surface.
Position the machine driving at high speed at a reference
point. (No steer correction). Results should be 4 to 6
ft.(1.2 to 1.8 m) tracking error at 200 ft. (60.9 m).

Drive: Test should be done on a graveled level surface.
Drive select switch should be set at High Speed. Start
approx. 10 ft. from starting point so that the unit is at max­imum speed when starting the test. Results should be
recorded for a 200 ft. (60.9 m) course. Drive Forward,
Record Time. Drive Reverse, Record Time.

Drive (Out of Transport): Test should be done on a grav­eled level surface. Drive select switch should be set at
Low Engine, Low Drive (The platform speed knob control,
if equipped, could be selected to the creep speed to simu­late the boom above horizontal). Results should be
recorded for a 50 ft. (15.2 m) course. Drive Forward,
Record Time. Drive Reverse, Record Time.

1-2 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

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.

Te s t N ot e s

1. Stop watch should be started with the function, not
with the controller or switch.

2. All speed tests are run from the platform. These
speeds do not reflect the ground control operation.

3. The platform speed knob control must be at full
speed (turned clockwise completely).

4. Function speeds may vary due to cold, thick hydrau­lic oil. Test should be run with the oil temperature

above 100° F (38° C).

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

1.5 TORQUE REQUIREMENTS

Ta b le 1- 2. To r q u e R e q u i r em en ts

Description

Bearing To Chassis See Note 50/600*

Tor qu e Va lu e

(Dry)

Interval

Hours

1.6 LUBRICATION

Deutz F4M1011F Engine

Single Viscosity Oil (CD-SE, CD-SF).

When Outside Temperature is

Consistently

-20°F. t o + 2 5 °F. ( - 2 9 °C. to +4°C.) *10W

+5°F. t o + 5 0 °F. ( + 1 5 °C. to +10°C.) 20W-20

+40°F. t o + 8 5 °F. ( + 4°C. to +30°C.) 30

Above 75°F. ( 2 4 °C.) 40

Multi Viscosity Oil (CD-SE, CD-SF)

*This viscosity can be used at colder temperatures with
engine oil preheating.

When Outside

Temperature is

Consistently

-40°F. t o + 7 5 °F. ( - 4 0 °C. to
+24°C.)

-15°F. t o + 7 0 °F. ( - 2 6 °C. to
+21°C.)

-15°F. t o + 8 5 °F. ( - 2 6 °C. to
+30°C.)

Above -5°F. ( - 2 1 °C.) 15W-40

-5°F. t o +7 5 °F. ( - 21 °C. to
+24°C.)

*This viscosity can be used at colder temperatures with
engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity Number

*5W-30 (Synthetic)

10W-30

10W-40

15W-30

Bearing To Turntable See Note 50/600*

Wire Rope 15 ft.lbs.

(20 Nm)

M16 Travel motor
mounting bolts

M20 Final Drive
mounting bolts

M20 Track roller
mounting bolts

M24 Carrier roller
mounting bolts

*Check swing bearing bolts for security after first 50 hours
of operation and every 600 hours thereafter. (See para­graph on Swing Bearing in Section 2.)

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to
determine proper torque value.

175 ±30 ft.lbs.

(240±40 Nm)

390 ±50 ft.lbs.

(530±70 Nm)

340 ±44 ft.lbs.

(460±60 Nm)

600 ±70 ft.lbs.

(800±100 Nm)

150

As

required

As

required

As

required

As

required

NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C or

have properties of API classification CC/CD grades.

3120794 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Hydraulic Oil

Ta b l e 1 - 3 . H y dr au li c O il

HYDRAULIC SYSTEM

OPERATING

TEMPERATURE RANGE

+0° to +180° F (-18° C to

+83° C)

+0° F to +210° F (-18° C to

+99° C)

+50° F to +210° F (+10° C to

+210° 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, which has an SAE viscosity index of
152 .

NOTE: When temperatures remain below 20° F (-7 degrees

C), JLG Industries recommends the use of Mobil
DTE 13M.

Table 1-4. 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)

at 40° C 33cSt

at 100° C6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

Viscosity

Lubrication Specifications

Ta b le 1 - 5. Lubrication Specifications

KEY SPECIFICATIONS

MPG

EPGL

HO

EO

Multipurpose Grease having a mini­mum dripping point of 350° F. E xc e l ­lent water resistance and adhesive
qualities, and being of extreme pres­sure type.
(Timken OK 40 pounds minimum.)

Extreme Pressu re Gear Lube (oil)
meeting API service classification
GL-5 or MIL-Spec MIL-L-2105

Hydraulic Oil. API service classifica­tion GL-3, e.g. Mobilfluid 424.

Engine (crankcas e) Oil. Gas - API SF,
SH, SG class, MIL-L-2104. Diesel ­AP I C C /C D c la ss , M IL- L-2 10 4B /M IL­L-2104C.

NOTE: Refer to Lubrication Chart, for specific lubrication

procedures.

1.7 PRESSURE SETTINGS

Main Relief - 3000 PSI (206.85 Bar).

Upper Boom Lift Down - 1500 PSI (103.4 Bar).

Swing - 1700 PSI (117.2 Bar).

Platform Level Forward - 2800 PSI (193.06 Bar).

Backward - 1800 PSI (124.11 Bar).

Articulating Jib Boom Up - 1500 PSI (103 Bar).

Down - 1200 PSI (82.7 Bar).

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

1-4 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

1.8 CYLINDER SPECIFICATIONS

Table 1-6. Cylinder Specifications

DESRIPTON BORE STROKE ROD DIA.

600SJ 660SJ 600S 600SJ 660SJ 600S 600SJ 660SJ 600S

Lift 6.00

Telescope 3.5

Master 3.5

Slave Level 3.5

Lift (Articulating Jib
Boom)

(152.4)

(88.9)

(88.9)

(88.9)

(76.2)

3

6.00

(152.4)

3.5

(88.9)

3.5

(88.9)

3.5

(88.9)

3

(76.2)

6.00

(152.4)

3.5

(88.9)

3

(76.2)

3

(76.2)

N/A 25.5

44.6875
(1135.1)

143.1875
(3637)

13.0625
(331.8)

13.0625
(331.8)

(647.7)

44.6875

(1135.1)

168.4375
(4278.3)

13.0625
(331.8)

13.0625
(331.8)

25.5

(647.7)

44.6875
(1135.1)

177.75

(4514.9)

8.5

(215.9)

8.5

(215.9)

N/A 1.5

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

(38.1)

3

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

1.5

(38.1)

3

1.9 MAJOR COMPONENT WEIGHTS

Table 1-7. Major Component Weights

600SJ 660SJ 600S

LB.KG.LB.KG.LB.KG.

Platform Control Con sole 250 113 250 113 250 113

Platform Level Cylinder 602760274621

Main Boom (Includ es Lift Cyl., Rotator, and Support) 3483 1580 3783 1716 3527 1600

Turntable Complete (including engine) 7915 3590 9065 4112 7315 3318

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

N/A

3

1.10 CRITICAL STABILITY WEIGHTS

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

Table 1-8. Critical Stability Weights

600SJ 660SJ 600S

LB.KG.LB.KG.LB.KG.

Engine Ford 460 209 460 209 460 209

Platform 6 ft. (1.83 M ) 205 93 205 93 205 93

8 ft. (2.44 M) 230 105 230 105 230 105

3120794 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

1.11 SERIAL NUMBER LOCATIONS

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.

Figure 1-1. Serial Number Locations

1-6 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

This page left blank intentionally.

3120794 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Point Location

1-8 – JLG Lift – 3120794

Table 1-9. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

Components

Number/Type

Lube Points

Capacity Lube

Lubrication

Swing Bearing

1

Swing Drive Hub

2

Final Drive Hub

3

Hydraulic Return Filter

4

Hydraulic Charge Filter

5

Hydraulic Oil

6

Suction Strainers (in

7

tank)

2 Grease Fittings A/R MPG X Remote Access

Level/Fill Plug 17 oz. (1/2 Full) EPGL X Check level every 150 hrs/change 1200 hours

Level/Fill Plug 2.1 gal. (1/2 Full) EPGL X Check level every 150 hrs/change 1200 hours

N/A N/A N/A X Change after first 50 hrs. and eve ry 300 hrs.

N/A N/A N/A X Change after first 50 hrs. and eve ry 300 hrs.

Fill Cap 30.6 gal. Tank

32.7 gal. System

2 N/A N/A X Remove and clean at time of hydraulic oil

HO X Check level daily/change 1200 hours

thereafter or as indicated by Condition Indica­tor.

thereafter or as indicated by Condition Indica­tor.

change.

Engines

Oil Change w/ Filter -

8

Deutz

Fuel Filter - Deutz

9

Air Filter - Deutz

10

NOTES: KEY TO LUBRICANTS

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.

Fill Cap/Spin-on Element 11 Quarts Crankcase

Replaceab le Element N/A N/A X

Replaceabl e Element N/A N/A X Or as indicated b y Condition Indicat or.

**5 Quarts C ooler

** When changing oil in the Deutz oil cooled engine, drain both the crankcase and
the cooler. When refilling it is acceptable to overfill the crankcase (16 qts., capac­ity of both crankcase and cooler combined). Start engine, allow the engine to run
until the thermostat opens (approximately 221 degrees F) cooler will fill up within
minutes; shut down and wait for approximately two minutes. Check oil level, fill oil
to max mar king on th e dipstick.

EO X Check level daily/Change every 1000 hours

EPGL

or one year, whichever comes first. Adjust
final oil level by mark on dipstick.

EO

Engine Oil
Extreme Pressure Gear Lube

HO

Hydraulic F luid (Mobil #4 24 or equivalent )

MPG

Multi-Purpose Grease

3120794 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart

1-10 – JLG Lift – 3120794

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

increased as environment, severity and frequency of
usage requires.

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

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

3120794 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative
Maintenance

Prior to use each day ; or

At each Operator change .

Prior to each sa le, lease, or

rental delivery.

In service for 3 mo nths or 150 hours, which-

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as sp ecified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

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

Cleanliness

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

Primary

Responsibility

User or Operator User or Operato r Operator and S afety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Fa ctory-Certified

Owner, Dealer, or User Qualified JLG

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

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

Service

Qualification

Mechanic

Mechanic

Service Technician

Mechanic

Reference

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual

Components Removal and Installation

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

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

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

2-2 – JLG Lift – 3120794

SECTION 2 - GENERAL

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

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

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

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

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

Gaskets

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

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

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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

Lubrication and Servicing

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

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.

3120794 – JLG Lift – 2-3

SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

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

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

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

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

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

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

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

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

Changing Hydraulic Oil

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

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

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

Lubrication Specifications

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

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

NOTE: Start-up of hydraulic system with oil temperatures

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

2-4 – JLG Lift – 3120794

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

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

Platform Drift

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

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

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

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

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

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

ing.

d. Debris embedded in liner surface.

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

a. Detectable wear in the bearing area.

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

surface.

c. Rusting of the pin in the bearing area.

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

a. Housing should be blown out to remove all dirt

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

b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubri­cated.

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

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

3120794 – JLG Lift – 2-5

SECTION 2 - GENERAL

AREA

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

Boom Assembly

Boom Weldmen ts 1,2,4 1,2,4

Hose/Cable Carrie r Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retai ners 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 o r 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 Gea r 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System 1,2,14 1,2,3,13,14

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

Hood, Hood Props, Hood L atches 5 1,2,5

Chassis Assembly

Drive Motors 1,2 1,2

To r qu e H ub s 11 11

Functions/Controls

Platform Cont rols 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 Swit ches (Ground & Platform) 555

Function Limit or C utout Switch Systems 55

Capacity Indicator 5

Drive Brakes 5

9

9

9

9

9

2-6 – JLG Lift – 3120794

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Swing Brakes 5

Boom Synchronization/ Sequencing Systems 5

Manual Descent or Aux iliary Power 55

Power System

9

Engine Idle, Throttl e, and RPM 33

Engine Fluids (Oil, Cool ant, Fuel) 11 9,11 11 11

Air/Fuel Filter 1,7 7 7

Exhaust Syste m 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 Cyli nders 1,9,7 2 1,2,9 1,2,9

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

Hydraulic Hoses, Li nes, 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, S witches, Lights, Horn 15,23

General

Operators and Safety Manuals in Stora ge Box 21 21 21

ANSI and EMI Manuals/Handbooks Install ed 21

Capacity Decals Ins talled, Secure, Legible 21 21 21

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

Walk-Around Inspection Perform ed 21

Annual Machine Inspec tion Due 21

No Unauthorized Modificatio ns or Additions 21 21

All Relevant Safety Publ ications Incorporated 21 21

General Structural C ondition and Welds 2,4 2,4

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

Grease and Lubricate to Specifica tions 22 22

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

3120794 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownershi p 22

Footnotes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

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

4

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

Performance Codes:
1 - Check for pro per and secure installation
2 - Visual inspection for d amage, cracks, distortion or exces sive wear
3 - Check for proper adjustment
4 - Check for crack ed or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of de bris
8 - Interlocks funct ion properly
9 - Check for signs of leakage
10 - Decals inst alled and legible
11 - Check for proper fluid level
12 - Check for cha fing and proper routing
13 - Check for proper tolerances
14 - Properly lubri cated
15 - Torqued to proper spec ification
16 - No gouges, excess ive wear, or cords showing
17 - Properly inflate d and seated around rim
18 - Proper and authoriz ed components
19 - Fully charged
20 - No loose connecti ons, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Ref ill

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

2-8 – JLG Lift – 3120794

SECTION 3. TURNTABLE

3.1 TILT ALARM SWITCH

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI­MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
AND ADJUSTMENT OF SWITCH.

Manual Adjustment

1. Park the machine on a flat, level surface. Ensure
machine is level and tires are filled to rated pressure.

NOTE: Ensure switch mounting bracket is level and securely

attached.

SECTION 3 - TURNTABLE

2. Level the base of the indicator by tightening the
three flange nuts through approximately one quarter
of its spring travel. DO NOT ADJUST THE “X” NUT
DURING THE REMAINDER OF THE PROCEDURE.

3. With the electrical connections complete, using bub­ble level on top of indicator, slowly tighten or loosen
the three flange nuts until indicator is level.

4. Individually push down on one corner at a time;
there should be enough travel to cause the switch to
trip. If the switch does not trip in all three tests, the
flange nuts have been tightened too far. Loosen the
“X” nut and repeat steps (2). through (4).

Figure 3-1. Tilt Switch Adjustment

3120794 – JLG Lift – 3-1

SECTION 3 - TURNTABLE

3.2 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ

General

The throttle control system on the Deutz engine includes
the positional controller and the actuator.

Four LEDs are incorporated in the controller. They are as
follows:

• Red - failure: signals a problem with the system ­needs service or adjustment

• Green - clutch engaged; operation normal while sys­tem is powered.

• Amber - motor extend

• Amber - motor retract

The controller is designed so that when the system volt­age reaches 10.5 volts, the actuator clutch will be
released and the motor drive turned off in order to prevent
unpredictable operation from occurring.

When a failure condition occurs (i.e. position time-out) the
controller will release the clutch and turn off the actuator
motor. This will prevent unnecessary motor wear.

Table 3-1.Position Controller Truth Table

Control Wiring

Actuator Position

Black Red White Green

GND OFF X X OFF POSITION (Freewheel)

GND +12 VDC OFF OFF POSITION 1 (See Adjustments)

GND +12 VDC +12 VDC OFF POSITION 2 (Se e Adjustments)

GND +12 VDC OFF +12 VDC POSITION 3 (See Adjustments)

GND +12 VDC +12 VDC +12 VDC POS ITION 4 (See Adjustments)

1. Power the ignition switch at the ground control
panel. Set the mid rpm.

2. Supply 12 volts of power to the white wire on the
controller. Set the high engine rpm.

NOTE: Actuator rod travel must stop slightly before lever

makes contact with throttle lever stop. Failure to do
so will burn out actuator.

HIGH#2

MID #1

CW

CCW

CCW EXTEND
ACTUATOR
(HIGHER)

Figure 3-2. Addco Adjustments

Controller Status

Clutch engaged no actuator movement

Clutch engaged actuator extending

GND = POWER SUPPLY OR BATTERY GROUND
OFF = GROUND OR OPEN CIRCUIT

X = DON’T CARE
+12 VDC = +12 VOLT POWER SUPPLY OR BATTERY SYSTEM, VIA A 5 AMP FUSE
OR CIRCUIT BREAKER

TRIMMER ADJUSTMENTS

1 - POSITION 1 CW=RE TRACT
2 - POSITION 2 CW=RE TRACT
3 - POSITION 3 CW=RE TRACT
4 - POSITION 4 CW=RE TRACT

LED INDICATORS

R - RETRACT INDI CATOR (AMBER)
E - EXTEND INDICATOR (AMBER)
C - CLUTCH INDI CATOR (GREEN)
F - FAILURE INDICATOR (RED)

Procedure

NOTE: Never run fuel tank dry. Diesel engines cannot be

restarted after running out of fuel until fuel system
has been air-vented or bled of air. See Deutz Instruc­tion Manual for procedure.

3-2 – JLG Lift – 3120794

SECTION 3 - TURNTABLE

Clutch engaged actuator retracting

Controller fault - clutch disengaged and no actuator
movement

Failure Modes

Immediate Red Light

Green and either Amber light followed by a red light

or

then

Action:

1. Recycle power to determine if the problem is inter­mittent.

2. The input voltage must be greater than 10.5 Vdc.

3. Check wiring for any damage and correct.

4. Disconnect engine harness and actuator connnec­tions.

5. If problem reoccurs return unit.

Action:

1. Inspect and clean wiring connections.

2. Examine throttle linkage for any damage or bent
components and correct.

3. With linkage disconnected, check each potentiome­ter for operation.

4. Reconnect linkage and reset each potentiometer for
correct operation.

5. If failure continues to occur, replace unit.

3120794 – JLG Lift – 3-3

SECTION 3 - TURNTABLE

Figure 3-3. Swing Torque Hub Adjustment

Only green light on and no actuator movement

Action:

1. Adjust trim potentiometers.

2. If problem continues, replace unit.

3.3 SWING HUB

Adjustment Procedures

1. Ensure swing drive is located on bearing gear max
eccentric tooth (high spot).

2. With mounting free to slide, shim between pinion
and bearing gear teeth to achieve .008 - .012 back­lash.

3. Install a pry bar into hole in turntable base plate and
pry swing hub back tight against shim and bearing.

4. Torque bolts according to the torque chart in Section

1.

3.4 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for
looseness.

1. Check the frame to bearing. Attach bolts as follows:

a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the positions indicated on Figure 2-45. try and

insert the .0015" feeler gauge between the bolt
head and hardened washer at the arrow indi­cated position.

c. Assure that the .0015" feeler gauge will not pen-

etrate under the bolt head to the bolt shank.

d. Swing the turntable 90 degrees, and check

some selected bolts at the new position.

e. Continue rotating the turntable at 90 degrees

intervals until a sampling of bolts have been
checked in all quadrants.

3-4 – JLG Lift – 3120794

SECTION 3 - TURNTABLE

2. Check the turntable to bearing. Attach bolts as fol­lows:

a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the positions indicated on Figure 2-45. try and

insert the .0015" feeler gauge between the bolt
head and hardened washer at the arrow indi­cated position.

c. Lower the boom to horizontal and fully extend

the boom.

d. At the position indicated on figure 2-45. try and

insert the .0015" feeler gauge between the bolt
head and hardened washer at the arrow indi­cated position.

.0015" Feeler Gauge

c. Noise.

d. Rough rotation.

5. If bearing inspection shows no defects, reassemble
and return to service.

THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS
ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFT­ING ARE CONCENTRATED, AT THE CENTER OF ROTATION.
BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING
BEARING BOLTS IS A MUST FOR SAFE OPERATION.

TURNTABLE REF.

MEASURING

POINT

FRAME REF.

Figure 3-5. Swing Bearing Tolerance Measuring Point

SWING

BEARING

Figure 3-4. Swing Bearing Bolt Feeler Gauge Check

Wear Tolerance

1. From the underside of the machine, at rear center,
with the boom fully elevated and fully retracted, as
shown in A, Figure 3-6., Swing Bearing Tolerance
Boom Placement, using a magnetic base dial indica­tor, measure and record the distance between the
swing bearing and turntable. (See Figure 3-5., Swing
Bearing Tolerance Measuring Point.)

2. At the same point, with the boom at horizontal and
fully extended, and the tower boom fully elevated as
shown in (Figure 3-6., Swing Bearing Tolerance
Boom Placement) B, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable. (See Figure 3-5.,
Swing Bearing Tolerance Measuring Point.)

3. If a difference greater than 0.057 in. (1.40 mm) is
determined, the swing bearing should be replaced.

4. If a difference less than 0.057 in. (1.40 mm) is deter­mined, and any of the following conditions exist, the
bearing should be removed, disassembled, and
inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

Swing Bearing Replacement

1. Removal.

a. From Ground Control station, operate the boom

adequately to provide access to frame opening
or, if equipped, to rotary coupling.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING
BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD
SLING SUPPORT AND/OR BLOCKING.

b. Attach an adequate support sling to the boom

and draw all slack from sling. Prop or block the
boom if feasible.

c. From inside turntable, remove mounting hard-

ware which attach rotary coupling retaining yoke
brackets to turntable.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI­ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.

d. Tag and disconnect the hydraulic lines from the

fittings on the top of the rotary coupling. Use a
suitable container to retain any residual hydrau­lic fluid. Immediately cap lines and ports.

3120794 – JLG Lift – 3-5

SECTION 3 - TURNTABLE

Figure 3-6. Swing Bearing Tolerance Boom Placement

3-6 – JLG Lift – 3120794

SECTION 3 - TURNTABLE

e. Attach suitable overhead lifting equipment to the

base of the turntable weldment.

f. Use a suitable tool to scribe a line on the inner

race of the swing bearing and on the underside
of the turntable. This will aid in aligning the bear­ing upon installation. Remove the bolts and
washers which attach the turntable to the bear­ing inner race. Discard the bolts.

g. Use the lifting equipment to carefully lift the com-

plete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame-mounted components.

h. Carefully place the turntable on a suitably sup-

ported trestle.

i. Use a suitable tool to scribe a line on the outer

race of the swing bearing and the frame. This
line will aid in aligning the bearing upon installa­tion. Remove the bolts and washers which
attach the outer race of the bearing to the frame.
Discard the bolts. Use suitable lifting equipment
to remove the bearing from the frame, then
move the bearing to a clean, suitably supported
work area.

2. Installation.

a. Using suitable lifting equipment, carefully lower

the swing bearing into position on the frame.
Ensure the scribed line of the outer race of the
bearing aligns with the scribed line on the frame.
If a new swing bearing is used, ensure that the
filler plug fitting is at 90 degrees from the fore
and aft center line of the frame.

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING
BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS.
SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK
BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE
THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICA­TIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOM­MENDED.

b. Apply a light coating of Loctite #271 to the new

bearing bolts, and loosely install the bolts and
washers through the frame and outer race of
bearing.

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH­MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL
SHOULD BE CHECKED PRIOR TO USE.

c. Refer to the Torque Sequence diagram as

shown in Figure 3-7., Swing Bearing Torque

Sequence. Spray a light coat of Safety Solvent
13 on the new bearing bolts. Then apply a light
coating of Loctite #271 to the new bearing bolts,
and install the bolts and washers through the
frame and outer race of the bearing. Tighten the
bolts to an initial torque of 240 FT. LBS. (326
Nm) w/Loctite.

d. Remove the lifting equipment from the bearing.

e. Using suitable lifting equipment, carefully posi-

tion the turntable assembly above the machine
frame.

f. Carefully lower the turntable onto the swing

bearing, ensuring that the scribed line of the
inner race of the bearing aligns with scribed line
on the turntable. If a new swing bearing is used,
ensure that the filler plug fitting is at 90 degrees
from the fore and aft center line of the turntable.

g. Spray a light coat of Safety Solvent 13 on the

new bearing bolts. Then apply a light coating of
Loctite #271 to the new bearing bolts, and
install the bolts and washers through the turnta­ble and inner race of the bearing.

h. Following the Torque Sequence diagram shown

in Figure 3-7., Swing Bearing Torque Sequence,
tighten the bolts to a torque of 240 ft. lbs. (326
Nm) w/Loctite.

i. Remove the lifting equipment.

j. Install the rotary coupling retaining yoke brack-

ets, apply a light coating of Loctite #242 to the
attaching bolts and secure the yoke to the turn­table with the mounting hardware.

k. Connect the hydraulic lines to the rotary cou-

pling as tagged prior to removal.

l. At ground control station, use boom lift control

to lower boom to stowed position.

m. Using all applicable safety precautions, activate

the hydraulic system and check the swing sys­tem for proper and safe operation.

Swing Bearing Torque Values.

1. Outer Race - 240 ft. lbs. (326 Nm) w/Loctite, 220 ft.
lbs. (298 Nm) dry.

2. Inner Race - 240 ft. lbs. (326 Nm) w/Loctite, 220 ft.
lbs. (298 Nm) dry.

3. See Swing Bearing Torquing Sequence.

CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR
MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERA­TION, AND EVERY 600 HOURS THEREAFTER.

3120794 – JLG Lift – 3-7

SECTION 3 - TURNTABLE

3.5 SWING BRAKE - MICO

Disassembly

1. With shaft protrusion downward, remove end cover
(13) by removing capscrews (12).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
2000 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP­SCREWS AND LOCKWASHERS.

2. Remove case seal (11) from housing (7) then
remove bleeder screw (14) from end cover (52).

3. Remove piston (22) from end cover (13).

4. Remove o-ring (17), back-up ring (16), o-ring (19)
and back-up ring (18) from piston (22).

5. Remove separators (10) from housing (52).

6. Remove stack assembly, consisting of discs (21),
return plate (8) and friction discs (20) from housing
(52).

9. Remove shaft by pressing or using a soft mallet on
male end of shaft (51).

10. Remove retaining ring (54) bearing (2) from shaft
(51).

11. Press rotary seal (1) from housing (51).

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur­faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Press new rotary seal (1) into housing (52). Note the
direction of seal.

7. Remove dowel pins (15), springs (5 & 6) from hous­ing (52).

8. Remove retaining ring (3) from housing (52).

2. Install new bearing (2) on shaft (51).

3. Install shaft assembly and retaining ring (3) into
housing (52).

Figure 3-7. Swing Bearing Torque Sequence

3-8 – JLG Lift – 3120794

SECTION 3 - TURNTABLE

Figure 3-8. Swing Brake Assembly (Mico)

3120794 – JLG Lift – 3-9

SECTION 3 - TURNTABLE

4. Install dowel pins (15), spring retainer (55), and
springs (5 & 6) into housing (52).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.

5. Position new large diameter return plate (8) in hous­ing with tabs guided by dowel pins (15) until disc
rests on springs (5 & 6).

NOTE: Discs (21 & 8) and friction discs (20) should remain

dry during installation. Oil will contaminate disc sur­faces.

6. Place new disc (20) on shaft (51) until it contacts
return plate (8).

7. Add additional discs (21) as required to complete
assembly.

8. Insert separators (10) in holes of return plate (8).

9. Install new o-ring (17), new back-up ring (16), new o­ring (19) and new back-up ring (18) on piston (22).
Insert piston (22) into end cover (13), being careful
not to shear o-rings or back-up rings.

10. Install new case seal (11) in housing (52), then
install bleeder screw (14) in end cover.

11. Position end cover (13) on housing (52), aligning
dowel pins (15) with holes in end cover.

12. Insert capscrews (12) and tighten evenly to draw
end cover (13) to housing (52). Torque capscrews to
55 ft. lbs. (75 Nm).

3-10 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 PLATFORM

Platform Sections Replacement

The platform is made up of five sections: floor, right side,
left side, back (console box mounting.) and gate. The sec­tions are secured with huck magna grip fastener and col­lars. Replace damaged platform sections as follows:

1. Support the huck collar with a sledge hammer or
other suitable support.

2. Using a hammer and chisel, remove the collar from
the fastener as shown in the diagram below.

Figure 4-1. Platform Section Replacement

4.2 BOOM ROPE TORQUING PROCEDURES

Torque Procedures

1. Position boom in fully down and fully retracted posi­tion.

Figure 4-2. Dimensions of Boom Sections

2. Clamp both threaded ends of wire rope to prevent
rotation.

NOTE: Do not clamp on threads.

3. When installing new section of platform replace
huck fasteners with 1/4 x 20 NC x 2 1/4" grade 5
bolts, flatwashers and locknuts.

4. When installing a new gate to platform, replace riv­ets with 1/4 x 20 NC x 2 “grade 5 bolts, flatwashers
and locknuts.

Figure 4-3. Clamping Wire Ropes

3. Install adjusting nuts (or remove nylon collar lock­nuts if re-adjusting) to both retract and extend wire
ropes.

4. Torque retract adjusting nuts (platform end) to 15 ft.
lbs. (20 Nm) alternating between the two wire ropes
and keeping approximately the same amount of
thread beyond the adjusting nut.

NOTE: Do not allow wire rope to rotate. This may damage

the wire rope.

3120794 – JLG Lift – 4-1

SECTION 4 - BOOM & PLATFORM

5. Repeat the torque procedure in step #4 to the
extend wire ropes (turntable end).

6. Extend the boom 2 - 3 feet using the telescope func­tion. Repeat step #4.

7. Retract the boom 1 - 2 feet using the telescope func­tion. Do not bottom out telescope cylinder. Repeat
step #5.

8. Extend the boom approximately 2 - 3 feet again and
check torque on the retract wire ropes.

9. Retract the boom without bottoming out telescope
cylinder and check torque on the extend wire ropes.

NOTE: Step #8 and #9 may need to be repeated to equalize

the torque on all 4 wire ropes.

10. After all wire ropes have been properly torqued,
install nylon collar locknuts. Remove all clamping
devices and install all covers and guards. Check the
boom for proper function.

4.3 WEAR PADS

Main Boom

1. Shim up wear pads to within 1/32 inch (.79 mm) tol­erance between wear pad and adjacent surface.

2. Replace wear pads when worn within 1/16 inch (1.59
mm) and 1/8 inch (3.18 mm) - B, C, D of threaded
insert. See Location and Thickness Of Wear Pads.

3. Adjusting wear pads, removing or adding shims,
bolt length must also be changed.

a. When adding shims, longer bolts must be used

to ensure proper thread engagement in insert.

b. When shims are removed, shorter bolts must be

used so bolt does not protrude from insert and
come into contact with boom surface.

Figure 4-4. Location and Thickness of Wear Pads

4-2 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

4.4 WIRE ROPE

NOTE: The pictures in this paragraph are just samples to

show the replacement criteria of the rope.

Inspection

1. Inspect ropes for broken wires, particularly valley
wire breaks and breaks at end terminations.

Flexing a wire rope can often expose broken wires

hidden in valleys between strands.

2. Inspect ropes for corrosion.

3. Inspect ropes for kinks or abuse.

Three Month Inspection

1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays,
abuse, or any signs of abnormalities.

2. Check rope tension by deflecting the ropes by
hand...properly tensioned ropes should have little or
no movement.

Five Year Inspection

1. Mandatory wire rope and sheave replacement.

Additional inspection required if:

a. Machine is exposed to hostile environment or

conditions.

b. Erratic boom operation or unusual noise exists.

c. Machine is idle for an extended period.

d. Boom is overloaded or sustained a shock load.

e. Boom exposed to electrical arc...wires may be

fused internally.

Replacement Criteria

A kink is caused by pulling down a loop

in a slack line during improper handling,

installation, or operation.

4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)

5. Inspect sheaves for condition of flanges. (See
Dimension Of Sheaves for proper dimension.)

6. Inspect sheaves with a groove wearout gauge for
excessive wear.

Observe the groove so that it may be clearly seen

whether the contour of the gauge matches the

contour of the bottom of the groove.

7. Ropes passing inspection should be lubricated with
wire rope lubricant before reassembly.

1. Sheaves and wire rope must be replaced as sets.

2. Rusted or corroded wire ropes.

3. Kinked, “bird caged”, or crushed ropes.

4. Ropes at end of adjustment range.

5. Sheaves failing wearout gage inspection.

6. Ropes with 6 total broken wires in one rope lay, 3 in
one strand in one rope lay, 1 valley break, or 1 break
at any end termination.

4.5 BOOM MAINTENANCE

Removal

1. Remove the platform/support as follows:

a. Disconnect electrical cable from control con-

sole.

b. Remove the eight (8) bolts securing the platform

to the platform support, then remove the plat­form.

c. Using an overhead crane or suitable lifting

device, strap support the platform support.

d. Remove the six (6) bolts and locknuts securing

the support to the rotator.

3120794 – JLG Lift – 4-3

SECTION 4 - BOOM & PLATFORM

Figure 4-5. Location of Components - Platform Support

Figure 4-6. Location of Components - Rotator and

Leveling Cylinder

e. Using a suitable brass drift and hammer, remove

the rotator shaft, then remove the support from
the rotator.

2. Remove the rotator and slave level cylinder from the
fly boom as follows:

a. Tag and disconnect hydraulic lines to rotator.

Use suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.

b. Remove hardware from pin #1. Using a suitable

brass drift and hammer remove pin #1 from the
fly boom.

c. Supporting the rotator, remove the hardware

from pin #2. Using a suitable brass drift and
hammer, remove pin #2 from the fly boom and
remove the rotator.

d. Telescope the fly section out approximately 20

inches (50.8 cm) to gain access to the slave lev­eling cylinder.

e. Supporting the slave, cylinder remove the hard-

ware from pin #3. Using a suitable brass drift
and hammer remove pin #3 from the fly boom.

f. Tag and disconnect hydraulic lines to the slave

leveling cylinder. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic
lines and ports. Remove the slave cylinder.

3. Remove the powertrack from the boom as follows:

a. Disconnect wiring harness from ground control

box.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI­ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.

b. Tag and disconnect hydraulic lines from boom

to control valve. Use a suitable container to
retain any residual hydraulic fluid. Cap hydraulic
lines and ports.

c. Disconnect the dual capacity indicator limit

switch from side of boom section.

d. Remove hydraulic lines and electrical cables

from powertrack.

e. Using a suitable lifting equipment, adequately

support powertrack weight along entire length.

f. Remove bolts #1 securing the push tube on the

fly boom section.

g. Remove bolts #2 securing the push tube on the

mid boom section.

h. With powertrack support and using all applica-

ble safety precautions, remove bolts #3 and #4
securing rail to the base boom section. Remove
powertrack from boom section.

Figure 4-7. Location of Components - Boom Powertrack

4-4 – JLG Lift – 3120794

4. Remove boom assembly from machine as follows:

a. Using suitable lifting equipment, adequately

support boom assembly weight along entire
length.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI­ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.

b. Tag and disconnect hydraulic lines from tele-

scope cylinder. Use a suitable container to retain
any residual hydraulic fluid. Cap hydraulic lines
and ports.

SECTION 4 - BOOM & PLATFORM

c. Remove hardware securing the lift cylinder rod

end to the base boom section.

d. Using a suitable brass drift and hammer, remove

the lift cylinder pin from the base boom.

e. Remove hardware securing the master cylinder

rod end to the base boom section.

f. Using a suitable brass drift and hammer, remove

the master cylinder pin from the base boom.

g. Remove hardware securing the pushbar to the

turntable upright.

WHEN REMOVING PIN FROM PUSHBAR. CARE MUST BE TAKEN
NOT TO DROP THE PUSHBAR ONTO THE WIRE ROPE ADJUST­MENT THREADS. FAILURE TO DO SO WILL RESULT IN DAMAG­ING THREADS.

h. Using a suitable brass drift and hammer, remove

the push bar pin from the turntable upright.

i. Remove hardware securing the boom pivot pin

to the turntable upright.

j. Using a suitable brass drift and hammer, remove

the pivot pin from the turntable upright.

k. Using all applicable safety precautions, carefully

lift boom assembly clear of turntable and lower
to ground or suitably supported work surface.

4. Remove hardware securing the wire rope adjust­ment block to aft end of the base boom section and
remove the block.

5. Remove hardware securing the telescope cylinder
to aft end of the mid boom section.

WHEN REMOVING THE TELESCOPE CYLINDER FROM THE
BOOM, IT MAY BE NECESSARY AT SOME POINT IN ORDER TO
CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM. CARE MUST
BE TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM.
DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE
IMPACT WITH THESE ASSEMBLIES.

6. Remove bolts securing wire rope attach bar to top of
fly boom section.

7. Pull the telescope cylinder and wire ropes partially
from aft end of the base boom section; secure the
cylinder with a suitable sling and lifting device at
approximately the center of gravity.

Disassembly of Boom Sections

1. Remove hardware securing the push bar to aft end
of the telescope cylinder, then remove pin from cyl­inder.

2. Remove hardware securing the cover plate on the
bottom front of the base boom section.

NOTE: Do not allow wire rope to rotate. This may damage

the wire rope.

3. Clamp both threaded ends of wire rope to prevent
rotation. Note: Do not clamp on threads. Remove
jam nuts and nuts which secure the wire rope
adjustments to the bottom front of the base boom
section.

3120794 – JLG Lift – 4-5

SECTION 4 - BOOM & PLATFORM

Figure 4-8. Boom Assembly Cutaway - S Models - Sheet 1 of 3

4-6 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Figure 4-9. Boom Assembly Cutaway - S Models - Sheet 2 of 3

3120794 – JLG Lift – 4-7

SECTION 4 - BOOM & PLATFORM

Figure 4-10. Boom Assembly Cutaway - S Models - Sheet 3 of 3

8. Carefully remove the telescope cylinder and sheave
assembly. Place telescope cylinder on a suitable
trestle.

a. Remove hardware from the wear pads; remove

wear pads from cylinder.

b. Remove hardware from the wire rope guard;

remove guard from cylinder.

c. Remove hardware from the sheave pin; remove

pin and sheave from cylinder.

Figure 4-11. Disassembly of Sheave Assembly

4-8 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

9. Remove hardware which secures the wear pads to
the front of base boom section; remove wear pads
from the top, sides and bottom of the base boom
section.

10. Using an overhead crane or suitable lifting device,
remove mid and fly boom sections from base sec­tion. Note: When removing mid and fly boom sec­tions from base boom section, retract wire rope
must be dragged along with boom sections.

11. Remove hardware which secures the wear pads to
the aft end of mid boom section; remove the wear
pads from the top, sides and bottom of the mid
boom section.

12. Remove hardware which secures the sheave guards
and sheave assemblies to mid boom section,
remove sheave assemblies from mid boom section.

13. Remove hardware which secures the wear pads to
the front of mid boom section; remove wear pads
from the top, sides and bottom of the mid boom sec­tion.

14. Using an overhead crane or suitable lifting device,
remove fly boom section from mid section. Note:
When removing fly boom section from mid boom
section, retract wire rope must be dragged along
with fly boom section.

16. When removing wire rope from fly boom section,
push the cable into fly boom. Route wire rope back
through holes in the side of the fly boom section.

15. Remove hardware which secures the wear pads to
the aft end of fly boom section; remove wear pads
from the top, sides and bottom of the fly boom sec­tion.

Figure 4-12. Disassembly Wire Rope Routing Proce-

Inspection

NOTE: When inspecting pins and bearings Ref. to Pins and

Composite Bearing Repair Guidelines in Section 2.

1. Inspect all sheaves (extend and retract wire ropes
and telescope cylinder) for excessive groove wear,
burrs or other damage. Replace sheaves as neces­sary.

3120794 – JLG Lift – 4-9

SECTION 4 - BOOM & PLATFORM

Figure 4-13. Dimension of Sheaves When New

NOTE: To check the size, contour and amount of wear, a

groove gauge is used. Replace the sheave if worn as
shown in the following drawing.

10. Inspect extend and retract wire rope attach point
components for cracks, stretching, distortion, or
other damage. Replace components as necessary.

11. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.

12. Inspect structural units of boom assembly for bend­ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.

Assembly

NOTE: When installing fly section wear pads, install same

number and thickness of shims as were removed
during disassembly.

1. Measure inside dimensions of the base and mid
sections to determine the number of shims required
for proper lift.

2. Measure inside dimensions of the mid section to
determine the number of shims required for proper
lift.

3. Install side, top and bottom wear pads to the aft end
of fly section; shim evenly to the measurements of
the inside of mid section.

2. Inspect extend and retract wire rope sheave bear­ings for wear, scoring, or other damage, and for
ovality.

3. Inspect extend wire rope and retract wire rope
sheave pins for scoring, tapering and ovality.
Replace pins as necessary.

4. Inspect telescope cylinder sheave pin for scoring,
tapering and ovality. Replace pins as necessary.

5. Inspect boom pivot pin for wear, scoring, tapering
and ovality, or other damage. Replace pins as nec­essary.

6. Inspect telescope cylinder attach point for scoring,
tapering and ovality. Replace pins as necessary.

7. Inspect upper lift cylinder attach pin for wear, scor­ing, tapering and ovality, or other damage. Ensure
pin surfaces are protected prior to installation.
Replace pins as necessary.

8. Inspect inner diameter of boom pivot bushing for
scoring, distortion, wear, or other damage. Replace
bearing as necessary.

9. Inspect all wear pads for excessive wear or other
damage. Replace pads when worn to within 1/8 inch
(3.2 mm) of threaded insert.

4-10 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

4. Install retract wire ropes into aft end of fly section,
route wire ropes thru holes in side of fly boom sec­tion and pull into slot.

8. Install wear pads into the forward position of the mid
boom section. Shim boom, if necessary, for a total of
2/10 inch (0.20 m) clearance.

9. Properly position the retraction wire rope sheaves
assemblies at the aft end of the mid boom section;
ensure all sheave-to-mounting block attachment
holes align. Install the sheave pins and secure them
with mounting hardware. Position retract wire ropes
onto the sheaves.

10. Install sheave guards to aft end of mid boom section
and secure with mounting hardware.

11. Slide mid boom section into the base boom section.
Allow the retraction wire ropes to trail between the
bottom surfaces of boom sections. Shim boom, if
necessary, for a total of 1/16 inch (0.062) clearance.

12. Install wear pads into the forward position of the
base boom section. Shim boom, if necessary, for a
total of 2/10 inch (0.20) clearance.

13. Install sheave block to bottom of base boom section
and adjust block so that retract wire ropes do not
come into contact with boom surfaces.

14. Install wire rope threaded ends thru attachment
holes in the bottom of base boom section. Loosely
install nuts and jam nuts onto the threaded ends of
wire ropes.

Figure 4-14. Routing Installation of Retract Wire Ropes

5. Install side, top and bottom wear pads to the aft end
of mid section; shim evenly to the measurements of
the inside of mid section.

WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE
BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARED OF
CHAINS, TOOLS, AND OTHER OBSTRUCTIONS.

6. Shim the insides of the boom sections for a total of
1/16 inch (0.062) clearance (if the action is centered,
there will be 1/32 clearance on each side).

7. Slide fly boom section into the mid boom section.
Shim boom, if necessary, for a total of 1/16 inch
(0.062) clearance.

15. Align the telescope cylinder barrel-to-sheave attach­ment point. Install extend sheave pin through the
telescope cylinder barrel and sheave assembly;
secure pin with mounting hardware.

16. Route extend wire ropes around extend sheave and
secure wire ropes to the telescope cylinder.

17. Install extend wire rope mounting blocks to threaded
ends of wire ropes. Loosely install nuts and jam nuts
onto the threaded ends of wire ropes.

NOTE: When installing wire ropes, care must be taken not to

twist or cross the wire ropes.

3120794 – JLG Lift – 4-11

SECTION 4 - BOOM & PLATFORM

18. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.

WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLIN­DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYL­INDER SLOWLY INTO POSITION. DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM­BLIES.

19. Align the cylinder with the slots at aft end of mid
boom section, then secure cylinder with mounting
hardware.

20. Align holes in aft end of the fly boom section with
holes in wire rope mounting block, then secure with
mounting hardware.

21. Align holes in aft end of the mid boom section with
holes in wire rope mounting block, then secure with
mounting hardware.

NOTE: Boom wire ropes must be torqued after installation of

the boom assembly.

b. Install powertrack to rail with mounting hard-

ware.

c. Attach push tube bracket to the side of the mid

boom section with mounting hardware.

NOTE: Do not over tighten attach bolt on push tube bracket.

It should pivot freely.

d. Install slide block and wear pads to the power-

track rail with mounting hardware.

e. Install powertrack to push tube with mounting

hardware.

f. Carefully feed the hoses and electrical cables

through the aft end of the powertrack rail, power­track and push tube.

g. Ensure all hoses and cables are properly routed

through the powertrack rail, powertrack and
push tube. Tighten or install all clamping or
securing apparatus to the hoses or cables, as
necessary.

h. Install powertrack cover and push tube rods with

mounting hardware.

22. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure
with mounting hardware.

23. Install the hydraulic lines and electrical cables, and
the harnessing powertrack components as follows:

a. Align holes in powertrack rail with attachment

holes in side of the base boom section. Secure
the rail with mounting hardware.

Figure 4-15. Reassembly of Components - Boom

Powertrack Assembly

4-12 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Figure 4-16. Boom Powertrack Installation

3120794 – JLG Lift – 4-13

SECTION 4 - BOOM & PLATFORM

Installation

1. Using a suitable lifting device, position boom
assembly on turntable so that the pivot holes in both
boom and turntable are aligned.

2. Install boom pivot pin, ensuring that location of hole
in pin is aligned with attach point on turntable.

3. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.

4. Align push bar pivot hole with pivot holes in turnta­ble. Install push bar pivot pin, ensuring that location
of hole in pin is aligned with attach point on turnta­ble.

5. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.

6. Connect all wiring to the ground control box.

7. Connect all hydraulic lines running along side of
boom assembly.

8. Using all applicable safety precautions, operate lift­ing device in order to position boom lift cylinder so
that holes in the cylinder rod end and boom struc­ture are aligned. Insert the lift cylinder pin, ensuring
that location of hole in pin is aligned with attach
point on boom.

9. Align holes in boom structure with hole in master
cylinder. Insert the master cylinder pin, ensuring that
location of hole in pin is aligned with attach point on
boom.

10. Adjust retract and extend cables to the proper
torque. Refer to paragraph 2-6, boom cable torque
procedures.

11. Using all applicable safety precautions, operate
machine systems and raise and extend boom fully,
noting the performance of the extension cycle.

12. Retract and lower boom, noting the performance of
the retraction cycle.

4.6 ARTICULATING JIB BOOM

Removal

1. For platform/support removal see platform/support
removal diagram. See Section 4.5, Boom Mainte­nance.

2. Position the articulating jib boom level with ground.

3. Remove mounting hardware from slave leveling cyl­inder pin #1. Using a suitable brass drift and ham­mer, remove the cylinder pin from articulating jib
boom.

Figure 4-17. Location of Components - Articulating

Jib Boom

4. Remove mounting hardware from articulating jib
boom pivot pin #2. Using a suitable brass drift and
hammer, remove the pivot pin from boom assembly.

Disassembly

1. Remove mounting hardware from articulating jib
boom pivot pins #3 and #4. Using a suitable brass
drift and hammer, remove the pins from articulating
jib boom pivot weldment.

2. Remove mounting hardware from rotator support
pins #5 and #6. Using a suitable brass drift and
hammer, remove the pins from rotator support.

3. Remove mounting hardware from lift cylinder pin
#7. Using a suitable brass drift and hammer, remove
the cylinder pin from articulating jib boom.

4-14 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Inspection

NOTE: When inspecting pins and bearings refer to Pins and

Composite Bearing Repair Guidelines in Section 2.

1. Inspect articulating fly boom pivot pin for wear, scor­ing, tapering and ovality, or other damage. Replace
pins as necessary.

2. Inspect articulating fly boom pivot attach points for
scoring, tapering and ovality, or other damage.
Replace pins as necessary.

3. Inspect inner diameter of articulating fly boom pivot
bearings for scoring, distortion, wear, or other dam­age. Replace bearings as necessary.

4. Inspect lift cylinder attach pin for wear, scoring,
tapering and ovality, or other damage. Ensure pin
surfaces are protected prior to installation. Replace
pins as necessary.

5. Inspect inner diameter of rotator attach point bear­ings for scoring, distortion, wear, or other damage.
Replace bearing as necessary.

6. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.

7. Inspect structural units of articulating jib boom
assembly for bending, cracking, separation of
welds, or other damage. Replace boom sections as
necessary.

3. Align bottom tubes with attach holes in rotator sup­port. Using a soft head mallet, install rotator support
pin #5 into articulating jib boom and secure with
mounting hardware.

4. Align articulating jib boom with attach hole in articu­lating jib boom pivot weldment. Using a soft head
mallet, install rotator support pin #4 into articulating
jib boom and secure with mounting hardware.

5. Align bottom tubes with attach holes in articulating
jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #3 into articulating jib
boom pivot weldment and secure with mounting
hardware.

6. Align articulating jib boom pivot weldment with
attach holes in fly boom assembly. Using a soft head
mallet, install pivot pin #2 into fly boom assembly
and secure with mounting hardware.

7. Align the slave leveling cylinder with attach holes in
articulating jib boom pivot weldment. Using a soft
head mallet, install slave leveling cylinder pin #1
into articulating jib boom pivot weldment and secure
with mounting hardware.

4.7 LIMIT SWITCH ADJUSTMENT

Adjust switches and cam valve as shown in Limit Switches
Adjustment.

Assembly

NOTE: For location of components See Section 4-17., Loca-

tion of Components - Articulating Jib Boom.

1. Align lift cylinder with attach holes in articulating jib
boom. Using a soft head mallet, install cylinder pin
#7 into articulating jib boom and secure with mount­ing hardware.

2. Align rotator support with attach hole in articulating
jib boom. Using a soft head mallet, install rotator
support pin #6 into articulating jib boom and secure
with mounting hardware.

3120794 – JLG Lift – 4-15

SECTION 4 - BOOM & PLATFORM

Figure 4-18. Limit Switches Adjustments

4-16 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

4.8 ROTATOR - HELAC

Disassembly

1. Place actuator on a clean workbench.

2. Remove all hydraulic fittings.

3. Using a suitable hammer and chisel remove the por­tion of end cap securing setscrew.

Figure 4-20. Removing Portion of End Cap

5. Remove the two (2) setscrew (4) from bottom of
actuator (1). Discard setscrew.

Figure 4-22. Removing Setscrew

6. Place two (2) 3/8"x16NC bolts in threaded holes in
bottom of the actuator. Using a suitable bar, unscrew
the end cap (5). Remove the end cap from actuator
(1).

4. Using a torch, apply heat to the setscrews on the
bottom of actuator.

Figure 4-21. Heating Setscrew

Figure 4-23. Removing End Cap

3120794 – JLG Lift – 4-17

SECTION 4 - BOOM & PLATFORM

Figure 4-19. Rotator Assembly (Helac)

4-18 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

7. Remove the shaft (2) from piston sleeve (3) and the
actuator housing (1).

Figure 4-24. Removing Shaft from Housing

8. Remove piston sleeve (3) from housing (1).

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.

NOTE: A small amount of wear in the spline teeth will have

little effect on the actuator strength. New spline sets
are manufactured with a backlash of about 0.005 in.
per mating set. After long service, a backlash of
about 0.015 per set may still be acceptable in most
cases, depending on the required accuracy of the
application.

3. Check the ring gear for wear and weld damage to
the pins.

4. Inspect the cylinder bore for wear and scratches.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Install new seal (7) and bearing (6) on the piston
sleeve (3).

Figure 4-25. Removing Sleeve from Housing

9. Remove all seals and bearings from grooves. Dis­card seals.

NOTE: Apply a coat of grease to the thrust ring before slid-

ing onto the shaft.

2. Install new seal (8), thrust ring (10) and bearing (9)
on shaft (2).

NOTE: Apply a coat of grease to the thrust ring before slid-

ing onto the end cap.

3. Install new seals (11), back-up ring (12), cap bearing
(13), bearing packing (14) and thrust ring (10) on
end cap (5).

4. Place the actuator in the vertical position, install the
piston sleeve (3) in timed relation to the housing (1).

DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS IT
WILL MARK THE CYLINDER BORE.

3120794 – JLG Lift – 4-19

SECTION 4 - BOOM & PLATFORM

Figure 4-26. Actuator Timing

NOTE: The timing marks (the small punch marks on the

face of each gear), must be aligned for proper shaft
orientation. (See Actuator Timing.)

5. Install the shaft (2) into housing (1) by aligning the
proper punched timing marks. (See Actuator Tim­ing.)

6. Temporarily tape the threaded portion of the shaft
will help installation past the shaft seals (masking
tape).

7. The end cap (5) is torqued to 40 - 50 ft. lbs. (54 - 68
Nm), such that the actuator begins rotation at
approximately 100 psi (6.895 Bar) pressure.

8. The end cap must be secured against the shaft by
installing axial set screws (4).

4.10 SUPERFLEX CONTROLLER

System Overview

The SUPERFLEX Controller is a stand alone control sys­tem that electrically drives the machine’s electrohydraulic
valves.

It receives input
"DIGISENSOR", as well as pressure, temperature, flow,
angle, length, load cell, and strain gauge transducers. The
input signals can "condition" the DC outputs, via software,
if desired. It provides four (4) Pulse Width Modulated
(PWM) DC outputs, as well as a 5th channel for use as a
discrete (on/off) signal. Dual coil, single coil, and flow con­trol type valves can be controlled in a bidirectional or uni­directional mode of operation.

The SUPERFLEX has been designed with the following
user benefits in mind:

a. Easy to use

b. Easy to adjust

c. Fast set-up

d. Self diagnostics

, electrical signals, from OEM's proprietary

System Elements

The SUPERFLEX System is composed of several compo­nents:

4.9 FOOT SWITCH ADJUSTMENT

Adjust so that functions will operate when pedal is at cen­ter of travel. If switch operates within last 1/4 in. (6.35 mm)
of travel, top or bottom, it should be adjusted.

1. SUPERFLEX Controller

2. DIGISENSOR and Joysticks

3. OPTIMIZER

SUPERFLEX CONTROLLER

The SUPERFLEX Controller is a microprocessor-based
electronic device, which converts the changing input val­ues from the Joystick/DIGISENSORs, analog sensors,
tachometers, and on/off contact closures into digital sig­nals which are used by the computer in the SUPERFLEX
controller. The controller will then provide [PWM] outputs
to electrohydraulic valves and coils. The desired output
(PWM) signals are fine tuned independently in each direc­tion. The OEM "OPTIMIZER" is used to perform this tuning.

DIGISENSOR AND JOYSTICKS

Joysticks actuate special sensors (DIGISENSORs) which
transmit joystick position information to the SUPERFLEX
Controller via two wires. The proper polarity must be used
as indicated on the wiring diagrams. The uniqueness of
this sensor allows it to be remote, up to 500 feet, from the
SUPERFLEX Controller. It can operate in hostile EMI/RFI
environments.

4-20 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

OPTIMIZER

The hand-held programmer provides a simple means of
optimizing the contra of the equipment. The sixteen (16)
function, membrane keypad, in conjunction with a two (2)
line liquid crystal display (LCD) of sixteen characters each,
connects to the SUPERFLEX Controller via a pluggable
terminal strip. The OPTIMIZER performs the following
functions:

1. Optimizes - Changes/modifies the operating param­eters for each joystick handle direction.

2. Te s ts - Checks the SUPERFLEX Controller’s opera­tions from end-to-end (self-test). Inputs, outputs and
internal functions are tested to verify proper operat­don.

3. Displays - All operational settings, conditions and
test results.

4. Collects - Information for later evaluation.

5. Downloads - Allows the Superflex Controller to be
programmed.

6. Interfaces - Facilitates the communications path
between the SUPERFLEX and a personal computer.

General Description

Inputs are under software control. Their functions can
change depending on what software is employed. In a
typical application, the DIGISENSOR operated by a joy­stick connected to Input (terminals 1 and 2), produces a
proportional PWM output on (terminals 13 and 14). The
DIGISENSOR connected to Input (terminals 3 and 4), pro­duces a proportional PWM output on (terminals 15 and

16). Inputs #3 and 4 can be used to further condition out­puts depending on the software programmed into the
SUPERFLEX.

The SUPERFLEX controller has an eighteen (18) point ter­minal strip. Terminals 1 through 12 are for "inputs and
power" and terminals 13 through 17 are used for outputs.
In a typical application, a DIGISENSOR operated by a joy­stick, is connected to terminals 1 and 2 (Input Signal #1).
Another DIGISENSOR is corrected to terminals 3 and 4
input Signal #2). The Input Signal #1 produces a propor­tional PWM output on terminals 13 or 14, and Input Signal
#2 produces a proportional PWM output on terminals 15
or 16.

Additional inputs can be connected to allow for "applica­tion specific functions". A "toggle switch", when wired to
terminals 7 and 10, can produce a Hi/Low Range "PWM
Output" at terminals 13 or 14. Also, an additional toggle
switch wired to terminals 9 and 10 can similarly produce a
Hi/Low Range at terminals 15 or 16. Terminal 17 produces
a +12VDC output whenever an input is turned on. Termi­nal 17 can be used to advance a throttle or dump valve.

3120794 – JLG Lift – 4-21

SECTION 4 - BOOM & PLATFORM

Figure 4-27. SUPERFLEX Terminal Identification

SUPERFLEX Terminal Identification

Refer to Figure 4-27., SUPERFLEX Terminal Identification.

SUPERFLEX Terminal Assignments

1. DIGiSENSOR Input #1 - BLACK

2. DIGISENSOR Power Source - RED

3. DIGISENSOR Input #2 - BLACK

4. DIGISENSOR Power Source - RED

5. Special Input #3

6. Special input #4 - Power source

7. Hi-Range for Input #1 at Terminal 1

8. Specified Output

9. Hi-Range for Input #2 at Terminal 3

10. Specified Output

11. +12VDC Power Supply

12. Power Supply Return (Ground)

13. Output A}

14. Output B} Output # 1

15. Output A}

16. Output B} output # 2

17. Output - Switched

18. Not Used

xxxx - Factory Use

A,B,C,D - OPTIMIZER - Connections

Figure 4-28. Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis

4-22 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Setup and Tuning

The operating parameters of the system: Threshold, Max
Out, Low Range, Ramp up, Ramp Down are preadjusted
at the factory with preset values, called default settings.
For optimum machine performance, these settings may
require fine-tuning. This section describes the procedures
for charging the settings of each of the five (5) functions
for each direction of handle movement.

These setting adjustments can be made in two (2) ways:
Normal-Active or Bench-Static. In the Normal-Active
mode, the adjustments will be made with the equipment
and joystick operational. In the Bench-Static
stick/DIGISENSORs may or may not be wired to the
SUPERFLEX Controller. For best results, it is recom­mended that all adjustments be made in the Normal­Active mode.

mode, Joy-

In the Normal-Active
ments are active
accordingly, if hydraulic and electrical power are applied
to the electrohydraulic valves. The operator is cautioned
to be in an area clear of obstructions and to be cautious
during the set-up procedure, as changes in the data can
cause sudden motion of the equipment.

To m ak e No rm a l- A ct iv e adjustments, move the joystick
handle in a direction. Controller #1 or #2 and Direction A
or B will be shown on the OPTIMIZER LCD display. For
best results, operate and make adjustments for all func­tions in both directions of handle travel.

mode, set-up and tuning of all adjust-

(live) and the equipment will respond

Figure 4-29. Controller Pattern

3120794 – JLG Lift – 4-23

SECTION 4 - BOOM & PLATFORM

How to Perform the Normal-Active Tuning Process

Attach the "OPTIMIZER" programmer with the 4 wire cord
& connector to the SUPERFLEX controller terminals A, B,
C, D). Refer to Figure 4-34., OPTIMIZER Keypad and Fig­ure 4-33., Typical SUPERFLEX System Wiring Diagram.

ADJUST THRESHOLD

Threshold is the initial current flow to a valve when the joy­stick handle is moved approximately 4 degrees from its
neutral position. The Threshold point is normally adjusted
such that the control function does not move at 4 degrees,
but further increase in joystick position causes movement
to begin. To adjust Threshold:

Table 4-1. Adjusting Threshold

Perform the following: Action and display:

Connect 12 VDC power to the
(+)and (-) term inals of the
SUPERFLEX Controller

Operate a joystick in any direc­tion & maintain it in an operated
position, at threshold point of 4°
handle movement

Operate a joystick in the oppo­site direction and maintain it in an
operated position (Note that the
display changes.)

Press THRESHOLD] To begin
tuning (Joystick must be oper­ated)

Press [+] Display shows the increase in

Press [-] Disp lay shows the decrease in

I f T h re s ho l d s e tt i ng s ar e OK f or b ot h di r ec t io n s o f ha n d le mo v e­ment, proceed to save new data and run the equipment.

Press [ENTER] This will save new values in the

Press[RUN] This places SUPERFLEX in

The center LED located at the

SUPERFLEX Contro ller will

blink. The OPTlMIZ ER display

will read:

RUN MODE, NORMAL

CONTROLLERS OFF

Display reads:

RUN: CONTROL 1 (or 2)

XX %, DIR A (or B.)

Display reads:

RUN: CONTROL 1 (or 2)

XX%, DIR B (or A)

Display reads:

THRESHOLD 1 (or 2)

XX %, DIR A (or B.)

%.

%.

SUPERFLEX.

operation.

ADJUST MAX OUT

Max Out determines the maximum current flow to the
valve when the joystick handle is at its fullest deflection
Max Out should be adjusted so that the function runs at
fun speed with the joystick handle fully deflected, but
starts to slow down as soon as the handle is moved away
from fun deflection. To change the Max Out setting in both
directions, perform the same procedure as that for
Threshold, just substitute the Max Out for Threshold.

ADJUST LOW RANGE

Low Range determines the maximum amount of current to
be supplied to a valve with the joystick at full deflection,
and the High/Low Range Switch in the low position. The
adjustment is identical to that of Threshold and Max Out. If
the Low Range function is not used, be sure that the Low
Range setting is set for 100%. The Low Range current will
be equal to the "Thresholds current plus a percentage (0
to 100%) of the difference between Max Out and Thresh­old.

In the event of a loss of voltage at the Low Range input,
the SUPERFlEX will automatically revert to the Low Range
setting.

The Low Range Adjustment is indicated in the same units
as Max Out and Threshold. Its range of adjustment
extends from the threshold setting to the maximum output
setting. By design, this setting is dependent on the thresh­old and maxout settings. It may require readjusting.

ADJUST RAMP UP

Ramp up determines the time it will take to accelerate
from Threshold to Max Out when the joystick handle is
moved abruptly. This function prevents sudden, jerky
movements of the machinery. The adjustment is identical
to that for Threshold. The ramp time is adjustable in 0.1
second steps. The time adjustment range is application
dependent.

ADJUST RAMP DOWN

Ramp Down specifies the amount of time it will take to
decelerate from Max Out to Threshold when a joystick
handle is returned to neutral. The adjustment of the Ramp
Down function is done in 0.1 second steps in the same
manner as that for Ramp up. (Press RUN button on OPTI­MIZER to return to normal operation and store the new
setting).

4-24 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

RECORD THE VALUES SELECTED

When all adjustments are finalized for desired machine
performance, the values of each setting, in both directions
of joystick handle travel, should be recorded for future
use.

Ta b l e 4 - 2 . Ad j u st me nt Va l u e s

THRESHOLD

MAX OUT

LOW RANGE

RAMP UP

RAMP DOWN

.

Joystick 1

Handle Direction

A B A

_____ _____ _____ _____

_____ _____ _____ _____

_____ _____ _____ _____

_____SEC _____SEC _____SEC _____SEC

_____SEC _____SEC _____SEC _____SEC

Joystick 2

Handle Direction

B

Table 4-3. Factory Defaults

THRESHOLD

MAX OUT (HIGH)

LOW RANGE

RAMP UP

RAMP DOWN

Default
Setting

15% 15%

85% 50%

50% 67%

00

00

Assembly

Setting

Press [SEL ECT] Display reads:

CONTROLLER 1 (or 2)

USE +/- TO CHANGE

Press [+] or [-] Display reads:

CONTROLLER 2 (or 1)

Press [DIRECTION A/B]
DIR
A/B

Display will not change until a

function is selected, i.e., "Thresh-

old" display will read:
THRESHOLD 1 (or 2)

XX%, DIR A (or B)

Additional pressing + or - will

change readout accordingly

QUICK SUMMARY OF ADJUSTMENTS (NORMAL­ACTIVE SET UP)

’’OPTIMIZER" Keypad Adjustment Procedure. Refer to Fig­ure 4-30., Calibration Flow Diagram.

To make precise adjustments, the following steps are
required:

1. Operate a Joystick.

2. Press the desired function [Threshold, Max Out, Low
Range, Ramp up, Ramp Down].

3. Press the [+] key to increase the function.

4. Press the [-] key to decrease the function.

5. When all adjustments are made in both directions
(A/B), press the "ENTER" key and the "RUN" key to
save the new settings.

ENSURE THE MAXIMUM OUTPUT IS ADJUSTED TO 50% PRIOR
TO OPERATING THE DRIVE FUNCTION.

NOTE: When joystick is actuated the OPTIMIZER displays

direction.

How to make Bench-Static Adjustments

It is not necessary to operate any joysticks. First apply
12VDC power to the SUPERFLEX Controller. Then, con­nect an OPTIMiZER to the SUPERFLEX using terminal
strip A.B.C.D. Adjustments can now be made.

MAKING ADJUSTMENTS

1. Joystick/DIGISENSOR #1 [called Controller #1] is
input terminals (1) and (2).

2. Joystick/DIGISENSOR #2 [called Controller #2] is
input terminals (3) and (4).

3120794 – JLG Lift – 4-25

SECTION 4 - BOOM & PLATFORM

4-26 – JLG Lift – 3120794

Figure 4-30. Calibration Flow Diagram

SECTION 4 - BOOM & PLATFORM

Troubleshooting

TOOLS REQUIRED (INSTALL/REPLACE)

Screwdriver (Flat blade), Voltmeter, Wire Stripper, OEM
OPTIMIZER, and cable - 4 conductor

GENERAL DESCRIPTION

The SUPERFLEX Control System has been designed to
perform in the harsh environments that are present in the
mobile equipment industry. Experience shows that the
most common problems encountered are external to the
system. Broken wires, loose connections, defective con­nections, wiring errors, wiring shorts, and the improper
supply voltage are the major source of field problems.

Three (3) diagnostic LED’s are provided on the SUPER-
FLEX Controller. To help isolate an internal or external
problem, use Figure 4-31., Testing the SUPERFLEX to
determine the fault condition.

How To Troubleshoot the SUPERFLEX Controller

Refer to Figure 4-31., Testing the SUPERFLEX, and follow
the "TO TEST" instructions. These are located on the gold
cover of the SUPERFLEX.

How to Troubleshoot the Digisensor

To check for proper DIGISENSOR operation, the following
simple test with a 9 VDC battery or 12 VDC power source
will work:

1. Connect +9V(or 12VDC) to the red wire and the
negative terminal to the black wire.

2. Observe the LEDs located in opposite corners. A
correctly functioning DIGISENSOR, when properly
applied, will always have one or both LEDs turned
on. If in the following tests, both LEDs turn off while
power is present, the DIGISENSOR must be
replaced.

NOTE: If no LED activity is observed, check the battery

voltage to assure the battery is O.K.

3. DIGISENSOR test steps while powered, refer to the
drawing above.

a. Warn the shaft fully clockwise (C.W.). LED #1

must be turned on and LED #2 must be turned
off.

b. Turn the shaft fully counter-clockwise (C.C.W.).

LED #1 Must be turned off and LED #2 must be
turned on.

c. To find the center of shaft rotation, turn the shaft

slowly to find a point at which both LED #1 and
LED #2 turn on simultaneously. This position
occurs in a narrow transition location between
steps A and B.

Figure 4-31. Testing the SUPERFLEX

3120794 – JLG Lift – 4-27

SECTION 4 - BOOM & PLATFORM

Figure 4-32. Digisensor Troubleshooting

4-28 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Figure 4-33. Typical SUPERFLEX System Wiring Diagram

3120794 – JLG Lift – 4-29

SECTION 4 - BOOM & PLATFORM

Figure 4-34. OPTIMIZER Keypad

4-30 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Important Reminders

OPTIMIZER:

• The Optimizer only has (3) usable keys during the
scrolling and data entering steps these keys are; (+) (-)
(ENTER). (RUN) does not work with the Crawler
Series, also the other keys are covered with a white
decal.

• Always keep your foot on the footswitch to read the
Optimizer display while checking from the platform or
MTB; failure to do so will clear the screen display.

• Static checks on the unit using the Optimizer can be
accomplished in the platform, it’s tricky to run the
engine and change the settings from the platform.
Once the drive/steer joystick is brought back to the
neutral position, you only have seconds to adjust your
settings, if you cannot accomplish this, what ends up
happening the timer times out and now you will have to
remove your foot from the foot switch to reset, causing
your optimizer to clear and return to it’s original start­up default setting.

• If possible two people can adjust the machine settings
easily and quickly, plugging the optimizer at the MTB,
this way the optimizer will never clear it’s display as
long as the operator in the platform has his foot on the
footswitch while the engine is running, all adjustments
can be made from the technician at the MTB, while the
operator in the platform can test the new settings to the
controls.

• During the scanning of the menus on the Optimizer,
there is no way to back up to a certain setting if you
mistakenly passed it up, you must scroll through the
(+) key to get where you want.

DIGISENSOR:

• When you lift the lid on the control panel there will be
two digisensors with two red LED’s on each one, they
are positioned one vertically and one horizontally, the
one vertical is (DRIVE) (DS2), the one horizontally is
STEER (DS1).

• When you activate STEER the way the LED’s are posi-
tioned you would think the left LED on the horizontal
digisensor would light? It doesn’t the right one does,
the digisensor moves CCW when using left and CW
using right, the same applies for DRIVE. To check to
see if a digisensor is any good, try a resistance check.
Remove the plug from the micro switch follow the red
wires from digisensors on the drive/steer controller,
also remove the main plug which holds the ground
wires (black from the digisensor), next set your voltme­ter to ohm’s install your positive lead into the plug
where you will see two red wires loaded into the same
connector install the lead here, next take your ground
and install it into two individually separate ground pins
in the other plug following the black wires coming out
of the digisensors, the first pin at the top of the plug
should read approximately 8.5 ohms the second pin
should read approximately 8.8 ohms, remember this is
without any movement of the joystick.

• The field has two types of digisensors installed on our
Crawlers, early version is a gray plastic appearance
with two led’s, and current production which is a gold
colored metal version with two red led’s, neither one is
waterproof.

• Always remember to keep the Superflex powered up
when storing data using the ENTER key, failure to do
so will lose all changed data back to original default
settings.

• For any reason the Optimizer shows an INTIALIZING
SYSTEM displayed, check the power connections
between the Optimizer and the Superflex, a poor com­munication link maybe the problem, check for proper
wiring hook ups at both Optimizer connections, drive/
steer joystick and drive pump EDC connections

.

3120794 – JLG Lift – 4-31

SECTION 4 - BOOM & PLATFORM

Crawler Tracking Adjustments

NOTE: Before making any tracking adjustments, make sure

the tracks are free of debris and adjusted per Ser­vice Manual.

To properly adjust the tracks on the Crawler, you will need
a stopwatch, pencil & paper and two fixed landscape
objects to use as a guide for centering the tracks. The
guide tube mounted on the top front of the base boom is
used as a cross hair for centering the machine between
the two fixed landscape objects. To achieve proper adjust­ment of the tracks we must first set the tracks to drive in a
straight line in FWD & REV. in both speeds low and high.
Use the following default settings as a starting point, once
everything is entered in the Optimizer, mark off a 50 ft.
(low) and a 200 ft. (high) start to finish point to use as a
measurement.

ADJUSTMENT EXAMPLE:
Position your machine inline with the two fixed landscape
objects, using the guide tube as your crosshair, now
squeeze the trigger on your joystick and operate the
machine in a straight line through the 50 ft. start to finish
line, checking the position of the machine and the amount
of seconds it took to drive 50 ft. Now record the low range
settings, take time to think things out, for example if your
machine is positioned too far to the left and timed out too
slow in low drive in the direction you were testing, you will
want to increase the settings on your low range adjust­ment up and decrease the settings on your right track.
Remember the direction you moved, this will determine
which setting to change on the Optimizer, you will be able
to judge which track is moving faster when your testing
your machine, focus your attention to the links on the
tracks. Write the information down, so you won’t forget!

THRESHOLD:
Always keep in mind when adjusting Threshold, both
tracks have to operate simultaneously!

Controller Adju stment Optimizer

Default Setting

Threshold 15% 15%

Max Out (High) 85 % 50%

Low Range 50% 70%

Ramp Up 0% 0.5%

Ramp Down 0% 0.5%

Optimizer

Manufacturing Setting

(STEER) (FWD) TRACK CHARACTERISTICS:

COUNTER STEERING:One track moves in the reverse
direction, the other the forward direction

GRADUAL STEER:One track comes to a stop, the oppo­site track moves forward

(STEER) (REV) Is just the opposite of FWD.

Drive & Steer Function Check

BEFORE PLUGGING IN OPTIMIZER MAKE SURE THE WIRES ARE
INSTALLED CORRECTLY, ALSO KEYSWITCH IN PLATFORM POSI­TION ONLY!!!!

Optimizer Plug: Red (1) Black (2) White (3) Green (4)

JLG Harness At Platform Control Box Optimizer Con­nection:

49-3 (3) Wht/Red 57-1 (4)

The Superflex Controller is a rugged, microprocessor-con­trolled device that can directly operate four bi-directional
electric over hydraulic valves. The Superflex receives
inputs from Digisensors mounted on the dual axis control­ler (Drive/Steer) and converts these signals into propor­tional PWM outputs to the EDC drive pumps A & B. Each
output signal can be independently fine-tuned and cali­brated using the hand held Optimizer.

• THE FOLLOWING STEPS ARE VIEWING THE PER-

• THE FOLLOWING DEFAULT SETTING NUMBERS ARE

• DRIVE AND STEER FUNCTIONS WILL REQUIRE ONE

Wht/Blk 58-1 (1) Orn/Red 49-2 (2) Orn/Red

CENTAGE OF INPUT, TRAVELING INTO THE SUPER­FLEX. THE FOLLOWING CAN BE DONE WITH OR
WITHOUT THE ENGINE RUNNING.

APPROXIMATE VALUES; THE SETTINGS YOU WILL
SEE ON YOUR UNIT MAY NOT BE IDENTICAL, THIS
IS DUE TO FRICTION, PART TOLERANCES AND
HOURS OF OPERATION.

TRACK TO MOVE SLOWER AND THE OPPOSITE
DIRECTION TO ACHIEVE PROPER TRACKING.

Drive Speed Feet Seconds

High 200 ft. 85-90

Low 50 ft. 80-85

Maximum drive speed: 1.6 MPH

4-32 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

1. When the optimizer is first plugged in, the following
will be displayed.

3. Next move the joystick into the forward or reverse
position (DRIVE) (DS1), this will tell you the percent­age of input traveling into the Superflex, the range of
travel is 17% at Threshold to 38% Max Out.

Ex: Max Out

2. Next, move the joystick into the left or right positions
(STEER) (DS2), this will tell you the percentage of
input traveling into the Superflex, the range of travel
is 15% at Threshold to 23% Max Ou

t.

Ex: Threshold R= Rear F= Forward

3120794 – JLG Lift – 4-33

SECTION 4 - BOOM & PLATFORM

NOTE: The following steps are adjusting parameters.

THRESHOLD/ MAX OUT/ RAMP UP/ RAMP DOWN/
LOW RANGE / TACHOMETER

1. With the machine EMS up, foot switch pressed on,
you will now see the following display;

2. Next push the (+) key. This should bring you to
THRESHOLD, now push the ENTER key you should
now see on the display BOTH THRESHOLD F and
the default settings blinking.

3. Next push the ENTER key, this will now show the
individual THRESHOLD settings.

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SECTION 4 - BOOM & PLATFORM

4. Next push the ENTER key, this will now show the
RIGHT FWD THRESHOLD setting in the display, the
default setting will blink now letting you know you
can adjust.

6. Next push the ENTER key, this will show the LEFT
REV THRESHOLD setting on the display, the default
setting will blink now letting you know you can
adjust.

5. Next push the ENTER key, this will now show BOTH
of the REV THRESHOLD settings on the display, the
default setting will blink now letting you know you
can adjust.

7. Next push the ENTER key this will show RIGHT REV
THRESHOLD setting on the display, the default set­ting will blink now letting you know you can adjust.

3120794 – JLG Lift – 4-35

SECTION 4 - BOOM & PLATFORM

8. Next push the ENTER key, this will now show the
newly adjusted settings if you chose to change
them.

10. Next push the ENTER key, this will now show you
the BOTH MAX OUT FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

9. Now push the (+) key, this should show you the
MAX OUT adjustment mode.

11. Next push the ENTER key, this will now show you
the LEFT MAX OUT FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

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SECTION 4 - BOOM & PLATFORM

12. Next push the ENTER key, this will now show you
the RIGHT MAX OUT FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

14. Next push the ENTER key, this will now show you
the LEFT MAX OUT REV settings on the display, the
default settings will now blink letting you know you
can adjust.

13. Next push the ENTER key, this will now show you
the BOTH MAX OUT REV settings in the display, the
default settings will now blink letting you know you
can adjust.

15. Next push the ENTER key, this will show you the
RIGHT MAX OUT REV settings on the display, the
default settings will now blink letting you know you
can adjust.

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SECTION 4 - BOOM & PLATFORM

16. Next push the ENTER key, this will now show the
newly adjusted settings if you chose to change
them.

18. Next push the ENTER key this will now show you the
RAMP UP FWD settings on the display, the default
settings will blink now letting you know you can
adjust.

17. Now push the (+) key this should put you in the
RAMP UP mode.

19. Next push the ENTER key, this will now show you
the RAMP UP REV settings on the display, the
default settings will now blink letting you know you
can adjust.

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SECTION 4 - BOOM & PLATFORM

20. Next push the ENTER key, this will now show the
newly adjusted settings if you chose to change
them.

22. Now push the ENTER key, this will now show the
RAMP DOWN FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

21. Now push the (+) key this should put you in the
RAMP DOWN mode.

23. Next push the ENTER key, this will show the RAMP
DOWN REVERSE setting on the display, the default
setting will blink now letting you know you can
adjust.

3120794 – JLG Lift – 4-39

SECTION 4 - BOOM & PLATFORM

24. Next push the ENTER key, this will now show the
newly adjusted settings if you chose to change
them.

26. Next push the ENTER key, this will now show the
LEFT LOW RANGE FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

25. Next push the (+) key, this should put you in the
LOW RANGE mode.

27. Next push the ENTER key this will now show the
RIGHT LOW RANGE FWD setting on the display, the
default setting will blink now letting you know you
can adjust.

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SECTION 4 - BOOM & PLATFORM

28. Next push the ENTER key, this will now show the
LEFT LOW RANGE REV settings on the display, the
default setting will blink now letting you know you
can adjust.

30. Next push the ENTER key, this will now show the
newly adjusted settings if you chose to change,
remember to push the RUN key before shutdown of
the Superflex

29. Next push the ENTER key, this will show the RIGHT
LOW RANGE REV settings on the display, the
default setting will blink now letting you know you
can adjust.

31. Next push the (+) key this should put you in the
SYSTEM VOLTAGE mode this is a read only mode.

3120794 – JLG Lift – 4-41

SECTION 4 - BOOM & PLATFORM

32. Next push the (+) key this will now show you the
OEM PART NUMBER of the Superflex.

34. Now push the (+) key, this will now show you the
DUAL ACTIVATED LEFT & RIGHT mode.

33. Next push the (+) key this will now show the SERIAL
NUMBER of the Superflex.

Currently this mode does not apply to the Crawler.

35. Next push the (+) key, this will put you in the
TACHOMETER mode.

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SECTION 4 - BOOM & PLATFORM

36. Next push the ENTER key, this will now show you
the SET POINT ADJUSTMENT setting on the dis­play, the default setting will blink now letting you
know you can adjust.

38. Next push the ENTER key, this will now show you
the LOAD RESUME RAMP settings on the display,
the default display will blink letting you know you
can adjust.

37. Next push the ENTER key, this will now show you
the LOAD SHED RAMP setting on the display, the
default setting will blink letting you know you can
adjust.

39. Next push the ENTER key, this will show the SHED
HYSTERESIS setting on the display, the default set­ting will blink letting you know you can adjust.

3120794 – JLG Lift – 4-43

SECTION 4 - BOOM & PLATFORM

40. Next push the ENTER key, this will show you the
RESUME HYSTERESIS setting on the display, the
default setting will blink letting you know that you
can adjust.

42. Next push the ENTER key this will bring you back to
the TACHOMETER mode with the new settings if
you chose to change them.

43. Next push the (+) key this will now show you the
DS1 and DS2 settings, these are digisensor inputs
that can be tested with or without the engine run­ning.

41. Next push the ENTER key, this will show the SENSI­TIVITY settings on the display, the default settings
will blink letting you know you can adjust.

DEFAULT SETTINGS TACHOMETER

Threshold 15% Set Point Adj . 2553 (RP M)

Max Out 48% Load Shed 3.0 seconds

Ramp Up 0.5 seconds Load Resume Ramp 5.0 seconds

Ramp Down 0.5 seconds Shed Hysteresis 25 53 (RPM)

Low Range 70% Resume Hysteresis 25 53 (RPM)

DS1 & DS2 128% Sensiti vity 2553 (RPM)

4-44 – JLG Lift – 3120794

SECTION 4 - BOOM & PLATFORM

Superflex Inputs And Outputs

18 Pin Connector (Green)

Inputs

#1 (Red Wire) Digisensor (Steer)

#2 (Not Used)

#3 (Red Wire) Digisensor (Drive)

#4 (Not Used)

#5 (Red) Tach Input-Speed

#6 (Not Used)

#7 (Yel/Red) Horsepower Input

#8 (Not Used)

#9 (Red) Hi- Speed Input for Drive

Digisensor

#10 Specified Output

12 Volt Power

#11 (Yel/Red) Positive

#12 (Black) Negative

Outputs

#13 (Red) Left Track Fwd

#14 (Red) Left Track Rev.

#15 (Red) Right Track Fwd.

#16 (Red) Right Track Rev.

#17 (Red) Auxiliary (Dump Valve)

Optimizer Plug

A (Wht/Blk) 58-2

B (Org/Red) 49-21

C (Org/Red) 49-22

D (Wht/Red) 57-2

Superflex LED’s

• The Superflex has 3 LED’s the top is input, the center is
power, and the bottom is out put.

• Footpedal pressed and joystick trigger engaged, you
will light up the center LED on the Superflex, also their
will be 12 volts at #11 & #12 on the 18 pin plug, once
you release the pedal the 12VDC will disappear.

• Once the joystick is moved in any position, the 3 LED’s
will chase each other letting you know the Superflex
has received the input and that it is sending it out to the
drive pumps EDC.

Amperage & Ohm Values (Approximate Values)

(Engine Bell Housing) EDC:

Resistance: 16. 0 ohms

Steer: (Left) Wire Org. 7/3 60 – 63 ma

Steer: (Right) Wire Org. 8/3 60 – 63 ma

Drive: (Fwd) Wire Org. 7/3 100 – 103 ma

Drive: (Rev) Wire Org. 8/3 100 – 103 ma

(Pump Side) EDC:

Resistance: 16. 0 ohms

Steer: (Left) Wire Org. 7/4 60 – 63 ma

Steer: (Right) Wire Org. 8/4 60 – 63 ma

Drive: (Fwd) Wire Org. 8/4 100 - 103 ma

Drive: (Rev) Wire Org. 7/4 100 – 103 ma

3120794 – JLG Lift – 4-45

SECTION 4 - BOOM & PLATFORM

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4-46 – JLG Lift – 3120794

SECTION 5. HYDRAULICS

SECTION 5 - HYDRAULICS

5.1 CYLINDERS - THEORY OF OPERATION

Systems Incorporating Double Acting Cylinders

Cylinders are of the double acting type. Systems incorpo­rating double acting cylinders are as follows: Slave Level,
Master Level, Lift, Telescope, Articulating Jib Boom Lift. A
double acting cylinder is one that requires oil flow to oper­ate the cylinder rod in both directions. Directing oil (by
actuating the corresponding control valve to the piston
side of the cylinder) forces the piston to travel toward the
rod end of the barrel, extending the cylinder rod (piston
attached to rod). When the oil flow is stopped, movement
of rod will stop. By directing oil to the rod side of the cylin­der, the piston will be forced in the opposite direction and
the cylinder rod will retract.

Systems Incorporating Holding Valves

Holding valves are used in the - Lift, Telescope, Lockout,
Slave Level and Articulating Jib Boom Lift circuits to pre­vent retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and its
related control valve.

5.2 VALVES - THEORY OF OPERATION

Solenoid Control Valve - Rexroth

Control valves used are four-way three-position solenoid
valves of the sliding spool design. When a circuit is acti­vated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to per­mit oil flow to the component in the selected circuit with
the opposite work port opening to reservoir. Once the cir­cuit is deactivated (control returned to neutral) the valve
spool returns to neutral (center) and oil flow is then
directed through the valve body and returns to reservoir. A
typical control valve consist of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring loaded
to center position, therefore when the control is released,
the spool automatically returns to neutral, prohibiting any
flow through the circuit.

Relief Valves

Relief valves are installed at various points within the
hydraulic system to protect associated systems and com­ponents against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of
travel and the flow of pressurized fluid continues from the
system control. The relief valve provides an alternate path
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir­cuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pres­sure of the component is reached.

5.3 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system

component is replaced or when improper system
operation is suspected.

Cylinders Without Counterbalance Valves ­Master Cylinder and Steer Cylinder

1. Using all applicable safety precautions, activate
engine and fully extend cylinder to be checked. Shut
down engine.

2. Carefully disconnect hydraulic hoses from retract
port of cylinder. There will be some initial weeping of
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be
no further drainage from the retract port.

3. Activate engine and extend cylinder.

4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repair must be
made.

5. With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.

6. Activate engine and retract cylinder. Check extend
port for leakage.

7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
than activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate of

3120794 – JLG Lift – 5-1

SECTION 5 - HYDRAULICS

6-8 drops per minute or more, cylinder repairs must
be made.

Cylinders With Single Counterbalance Valve

Upper Lift Cylinder.

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

1. Using all applicable safety precautions, activate
hydraulic system.

WHEN WORKING ON THE MAIN LIFT CYLINDER, RAISE THE
BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXI­MATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. DO NOT
WORK ON THE CYLINDER WITHOUT A SUITABLE PROP IN
PLACE.

2. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn IGNI­TION SWITCH to ON, move control switch or lever
for applicable cylinder in each direction, then turn
IGNITION SWITCH to OFF. If machine is equipped
with hydraulic control valves, move control lever for
applicable cylinder in each direction. This is done to
relieve pressure in the hydraulic lines. Carefully
remove hydraulic hoses from appropriate cylinder
port block.

3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should be no further leakage from
the ports. If leakage continues at a rate of 6-8 drops
per minute or more, the counterbalance valve is
defective and must be replaced.

4. To check piston seals, carefully remove the counter­balance valve from the retract port. After initial dis­charge, there should be no further leakage from the
ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.

5. If no repairs are necessary or when repairs have
been made, replace counterbalance valve and care­fully connect hydraulic hoses to cylinder port block.

6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic sys­tem and run cylinder through one complete cycle to
check for leaks.

Cylinders With Dual Counterbalance Valves

(Articulating Jib Boom Lift, and Slave), Slave Level, Lower
Lift, Upright level, Main Telescope and Tower Telescope.

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

1. Using all applicable safety precautions, activate
hydraulic system.

IF WORKING ON THE TOWER BOOM LIFT CYLINDER, RAISE
TOWER BOOM HALFWAY, FULLY ELEVATE MAIN BOOM WITH
TELESCOPE CYLINDER FULLY RETRACTED AND ATTACH AN
OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING
APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR
SLING FOR TEST PURPOSES. IF WORKING ON THE UPRIGHT
LEVEL, RAISE THE TOWER BOOM HALFWAY, THEN RAISE MAIN
BOOM TO HORIZONTAL AND POSITION A SUITABLE BOOM
PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW MAIN BOOM. IF
WORKING ON THE PLATFORM LEVEL CYLINDER, STROKE PLAT­FORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS AT A
45 DEGREES ANGLE.

2. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn IGNI­TION SWITCH to ON, move control switch or lever
for applicable cylinder in each direction, then turn
IGNITION SWITCH to OFF. If machine is equipped
with hydraulic control valves, move control lever for
applicable cylinder in each direction. This is done to
relieve pressure in the hydraulic lines. Carefully
remove hydraulic hoses from appropriate cylinder
port block.

3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should be no further leakage from
the ports. If leakage continues at a rate of 6-8 drops
per minute or more, the counterbalance valve is
defective and must be replaced.

4. To check piston seals, carefully remove the counter­balance valve from the retract port. After initial dis­charge, there should be no further leakage from the
ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.

5. If no repairs are necessary or when repairs have
been made, replace counterbalance valve and care­fully connect hydraulic hoses to cylinder port block.

6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic sys­tem and run cylinder through one complete cycle to
check for leaks.

5-2 – JLG Lift – 3120794

SECTION 5 - HYDRAULICS

5.4 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES­SURE.

2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli­cable.

3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis­card o-rings.

4. Place the cylinder barrel into a suitable holding fix­ture.

the eight (8) cylinder head retainer cap screws, and
remove cap screws from cylinder barrel.

Figure 5-2. Cap Screw Removal

6. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL­INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF­CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.

7. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.

Figure 5-1. Cylinder Barrel Support

5. Mark cylinder head and barrel with a center punch
for easy realignment. Using an allen wrench, loosen

8. Using suitable protection, clamp the cylinder rod in

Figure 5-3. Cylinder Rod Support

a vise or similar holding fixture as close to the piston
as possible.

3120794 – JLG Lift – 5-3

SECTION 5 - HYDRAULICS

Figure 5-4. Tapered Bushing Removal

9. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.

10. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.

11. Remove the bushing from the piston.

12. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.

13. Remove and discard the piston o-rings, seal rings,
and backup rings.

14. Remove piston spacer, if applicable, from the rod.

15. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applica­ble. Discard the o-rings, back-up rings, rod seals,
and wiper seals.

7. Inspect threaded portion of piston for damage.
Dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.

10. Inspect threaded portion of head for damage. Dress
threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.

13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs,

dirt etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other damage.

If steel bushing is worn or damaged, rod/barrel
must be replaced.

c. Lubricate inside of steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

NOTE: Install pin into the Gar-Max bearing dry. Lubrication

is not required with nickel plated pins and bearings.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive dam­age. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scor­ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.

6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.

5-4 – JLG Lift – 3120794

Figure 5-5. Gar-Max Bearing Installation

14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

SECTION 5 - HYDRAULICS

17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used. See your JLG Parts Manual.

Apply a light film of hydraulic oil to all components prior to
assembly.

1. A special tool is used to install a new rod seal into
the applicable cylinder head gland groove.

2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland
groove.

Figure 5-7. Poly-Pak Piston Seal Installation

Figure 5-6. Rod Seal Installation

WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA­TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

WHEN INSTALLING THE WIPER SEAL ON THE LOWER (TOWER)
LIFT CYLINDER, APPLY LOCTITE #609 ON THE WIPER SEAL IN
THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE
SEAL.

Figure 5-8. Wiper Seal Installation

3120794 – JLG Lift – 5-5

SECTION 5 - HYDRAULICS

Figure 5-9. Installation of Head Seal Kit

3. Place a new “o”ring and back-up seal in the applica-
ble outside diameter groove of the cylinder head.

4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod.

NOTE: Upper telescope cylinder piston has an o-ring

installed inside the spacer.

7. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D.of the pis­ton is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on

one side. This side faces the solid seal.(See magni­fied insert in Figure 5-10.)The split of seals and
backup rings are to be positioned so as not to be in
alignment with each other.

6. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side fac­ing the O-ring is grooved.)

Figure 5-10. Piston Seal Kit Installation

8. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as
possible.

9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.

10. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.

5-6 – JLG Lift – 3120794

SECTION 5 - HYDRAULICS

NOTE: When installing the tapered bushing, piston and mat-

ing end of rod must be free of oil.

WHEN REBUILDING THE MASTER, SLAVE, LOWER LIFT, UPPER
LIFT, ARTICULATING FLY BOOM LIFT, UPRIGHT LEVEL, TOWER
TELESCOPE, OR UPPER TELESCOPE CYLINDERS, TIGHTEN
SECURELY. (SEE TABLE 2-1 AND 2-3. TORQUE SPECIFICA­TIONS).

11. Assemble the tapered bushing loosely into the pis­ton and insert JLG capscrews (not vendor cap­screws) through the drilled holes in the bushing and
into the tapped holes in the piston.

b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces
between the capscrews.

Figure 5-12. Seating the Tapered Bearing

14. Retorque the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifi­cations.)

15. Remove the cylinder rod from the holding fixture.

Figure 5-11. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifi­cations..

13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;

a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between
the capscrews.

16. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 5-10.)

17. Position the cylinder barrel in a suitable holding fix­ture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.

18. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.

19. Continue pushing the rod into the barrel until the cyl­inder head gland can be inserted into the barrel cyl­inder.

3120794 – JLG Lift – 5-7

SECTION 5 - HYDRAULICS

Figure 5-13. Rod Assembly Installation

20. Secure the cylinder head gland using the washer
ring and socket head bolts. (See Table 5-1 .)

21. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.

22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 5-2, Holding Valve Torque
Specifications).

Ta b l e 5 - 1 . Cylinder Head and Tapered Bushing Torque

Specifications.

Description

Head Torque

Value (Wet)

Ta p er e d B us h i n g

To r qu e Val ue

(Wet)

Ta b l e 5 - 2 . Holding Valve Torque Specifications

Description To r qu e Va lu e

SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

(41-48 Nm)

SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

(61-68 Nm)

SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

(204-217 Nm)

RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

(68-75 Nm)

RACINE - 1 3/8 HEX 1 3/16 - 12 THDS. 75-80 ft. lbs.

(102-109 Nm)

RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs.

(136-149 Nm)

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON
THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE
EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD.

Lift Cylinder 275 ft. lbs.

(373 Nm)

Articulating Lift
Cylinder

Slave Cylinder 30 ft. lbs.

Master Cylinder 30 ft. lbs.

Te le sc o pe
Cylinder

Lockout Cylinder 80 ft. lbs.

Articulating Slave
Cylinder

Articulating
Master Cylinder

30 ft. lbs.

(41 Nm)

(41 Nm)

(41 Nm)

50 ft. lbs.

(68 Nm)

(109 Nm)

50 ft. lbs.

(68 Nm)

50 ft. lbs.

(68 Nm)

30 ft. lbs.

(41 Nm)

5 ft. lbs.

(9 Nm)

5 ft. lbs.

(9 Nm)

5 ft. lbs.

(9 Nm)

9 ft. lbs.

(12 Nm)

N/A

9 ft. lbs.

(12 Nm)

9 ft. lbs.

(12 Nm)

5-8 – JLG Lift – 3120794

SECTION 5 - HYDRAULICS

5.5 CYLINDER REMOVAL AND INSTALLATION

Main Boom Telescope Cylinder Removal

1. Place machine on a flat and level surface, with main
boom in the horizontal position.

2. Shut down engine. Support main boom basket end
with a prop. (See Figure 5-14., Boom Positioning
and Support, Cylinder Repair).

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI­ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.

3. Tag and disconnect hydraulic lines to telescope cyl­inder. Use a suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.

4. Remove the hardware securing cover plate on bot­tom of the base boom section and remove cover.

NOTE: Do not allow cable to rotate. This may damage the

cable.

5. Clamp both threaded ends of cable to prevent rota­tion. Note: Do not clamp on threads. Remove jam
nuts and loosen adjustment nuts so there is slack in
the cables. Remove the hardware securing push bar
to turntable and telescope cylinder.

6. Using a suitable brass drift, carefully drive the push
bar pins from the telescope cylinder rod and turnta­ble.

8. Remove hardware securing telescope cylinder to aft
end of the mid boom section.

WHEN REMOVING THE TELESCOPE CYLINDER FROM THE
BOOM, IT MAY BE NECESSARY AT SOME POINT TO TURN THE
CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES
MOUNTED WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE
THE CYLINDER SLOWLY INTO POSITION: DAMAGE TO COMPO­NENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE
ASSEMBLIES.

9. Remove bolts securing cable attach bar to top of fly
boom section.

10. Pull the telescope cylinder and cables partially from
aft end of the base boom section; secure the cylin­der with a suitable sling and lifting device at approxi­mately the center of gravity.

11. Carefully remove the telescope cylinder and sheave
assembly. Place telescope cylinder on a suitable
trestle.

Main Boom Telescope Cylinder Installation

1. Route extend cables around extend sheave and
secure cables to the telescope cylinder.

2. Install extend cables mounting blocks to threaded
ends of cables. Loosely install nuts and jam nuts
onto the threaded end of cables.

NOTE: When installing cables care must be taken not to

twist or cross the cables.

7. Remove hardware securing cable adjustment block
to aft end of the base boom section and remove
block.

Figure 5-14. Boom Positioning and Support, Cylinder Repair

3. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.

3120794 – JLG Lift – 5-9

SECTION 5 - HYDRAULICS

4. Install extend cable mounting blocks to threaded
ends of cables. Loosely install nuts and jam nuts
onto the threaded ends of cables.

NOTE: When installing cables, care must be taken not to

twist or cross the cables.

5. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.

WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLIN­DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYL­INDER SLOWLY INTO POSITION: DAMAGE TO COMPONENTS
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM­BLIES.

6. Carefully install the telescope cylinder barrel end
support into slots in mid boom and secure with
blocks and bolts. Use Loctite #242 on bolts.

7. Align holes in aft end of the fly boom section with
holes in cable mounting block, then secure with
mounting hardware.

8. Align holes in aft end of the base boom section with
holes in cable mounting block, then secure with
mounting hardware.

9. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.

10. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure
with mounting hardware.

11. Align holes in push bar with holes in turntable. Install
push bar pin and secure with mounting hardware.

NOTE: Boom cables must be torqued after installation of the

telescope cylinder. (See Section 4 - Boom & Plat­form)

Main Boom Lift Cylinder Removal

1. Place the machine on a flat and level surface. Start
the engine and place the main boom in the horizon­tal position. Shut down engine and prop the boom.
(See Figure 2-31. Boom Positioning and Support,
Cylinder Repair. (S Models)

2. Remove the hardware retaining the cylinder rod
attach pin to the boom. Using a suitable brass drift,
drive out the cylinder rod attach pin.

3. Using auxiliary power, retract the lift cylinder rod
completely.

4. Disconnect, cap and tag the main boom lift cylinder
hydraulic lines and ports.

5. Remove barrel end attach pin retaining hardware.
Using a suitable brass drift drive out the barrel end
attach pin from the turntable.

6. Remove the cylinder from the turntable and place in
a suitable work area.

Main Boom Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings or
supports, aligning attach pin mounting holes on the
turntable.

2. Using a suitable drift, drive the barrel end attach pin
through the mounting holes in the lift cylinder and
the turntable. Secure in place with the pin retaining
hardware.

3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.

4. Using auxiliary power, extend the cylinder rod until
the attach pin hole aligns with those in the boom.
Using a suitable soft mallet, drive the cylinder rod
attach pin through the boom and lift cylinder. Secure
the pin in place with attaching hardware.

5. Remove boom prop and overhead crane. Activate
hydraulic system.

6. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.

7. Check fluid level of hydraulic tank and adjust as nec­essary.

5-10 – JLG Lift – 3120794

SECTION 5 - HYDRAULICS

5.6 PRESSURE SETTING PROCEDURES

Main Relief, Steer, Swing and Lift Down

1. Install pressure gauge at quick disconnect on port
MP on main valve.

2. With the aid of an assistant, activate telescope in.

3. While monitoring pressure gauge, adjust main relief
to 3000 PSI (206.85 Bar).

4. With the aid of an assistant, activate steer left.

5. While monitoring pressure gauge, adjust steer left
relief to 1800 PSI (124.1 Bar).

6. With the aid of an assistant, activate steer right.

7. While monitoring pressure gauge, adjust steer right
relief to 1800 PSI (124.1 Bar).

8. With the aid of an assistant, activate swing left or
right.

9. While monitoring pressure gauge, adjust swing relief
to 1700 PSI (117.2 Bar).

10. With the aid of an assistant, activate lift down.

11. While monitoring pressure gauge, adjust lift down
relief to 1500 PSI (103.4 Bar).

Platform Level

Articulating Jib Boom (If Equipped)

1. Install pressure gauge at quick disconnect on articu­lating valve.

2. With the aid of an assistant, activate articulating jib
up.

3. While monitoring pressure gauge, adjust articulating
jib up relief to 2500 PSI (172.4 Bar).

4. With the aid of an assistant, activate articulating jib
down.

5. While monitoring pressure gauge, adjust activate
articulating jib down relief to 1200 PSI (82.7 Bar).

Figure 5-15. Articulating Jib Boom Pressure

Adjustments

1. Install pressure gauge at quick disconnect on port
M3 on main valve.

2. With the aid of an assistant, activate platform level
forward.

3. While monitoring pressure gauge, adjust platform
level relief to 2800 PSI (193.06 Bar).

4. Install pressure gauge at quick disconnect on port
M4 on main valve.

5. With the aid of an assistant, activate platform level
backward.

6. While monitoring pressure gauge, adjust platform
level relief to 1800 PSI (124.11 Bar).

3120794 – JLG Lift – 5-11

SECTION 5 - HYDRAULICS

Figure 5-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2

5-12 – JLG Lift – 3120794

SECTION 5 - HYDRAULICS

Figure 5-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2

3120794 – JLG Lift – 5-13

SECTION 5 - HYDRAULICS

Figure 5-18. Location of Components - Main Control Valve (Sheet 1)

5-14 – JLG Lift – 3120794