JLG 67SL Service Manual

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Service & Maintenance Manual

Model

67SL

3121322

March 7, 2008

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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.

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

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 SERVICE MANUAL.

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

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3121322 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - February 6, 2007

Revised - March 7, 2007

Revised - June 7, 2007

Revised - November 19, 2007

Revised - March 7, 2008

b – JLG Lift – 3121322

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-a

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-a

SECTION 1 - SPECIFICATIONS

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

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

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

1.4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.7 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Platform Stowed/Jacks Retract Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

High Drive Speed Cutout Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maximum Drive Height/Maximum Height without Outriggers Limit Switch . . . . . . . . . . . . . 1-2

Maximum Height Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Outrigger Interlock Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.8 Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

SECTION 2 - GENERAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

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

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

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

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

2.4 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

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TABLE OF CONTENTS

2.5 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Lift Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.6 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.1 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Roll Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

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

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

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

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

3.3 Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3.4 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.5 Outrigger Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.6 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Hood Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Engine Tray Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Engine Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Gear Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Exhaust Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.7 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3.8 Ground Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3.9 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3.10 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Platform Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Extension End Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Extension Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Main Platform End Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Main Platform Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3.11 Ladder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3.12 Beacon Installation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3.13 Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Scissor Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Scissor Arms Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

SECTION 4 - HYDRAULICS

4.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Deck Extension Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Lift Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Outrigger Cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

ii – JLG Lift – 3121322

Steer Cylinder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

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

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

4.5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Valve Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Pressure Switch, Drive Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Lift/Lower Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Platform Lower Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Outrigger Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

TABLE OF CONTENTS

SECTION 5 - JLG CONTROL SYSTEM

5.1 Main Terminal Box Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Control Card Complex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

General Description of Components and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 Nivolux - Automatic Self-Leveling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

NIVOLUX Board LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Setting and Adjustment of the NIVOLUX Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 PNP5 Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.5 Trigger Control Circuit Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Relay K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Relay K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Relay K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Limit Switch & Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Height Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Tilt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Outrigger Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.7 Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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TABLE OF CONTENTS

Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.3 Applying Silicone Dielectric Compound To Amp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

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

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.4 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Limit Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-2. Engine Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-5. Torque Chart - (Nm) - (For Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

2-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

3-1. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Wheel Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Hub Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-4. Drive Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-5. Drive Motor (OMR 100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-6. Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-7. Rear Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-8. Outrigger Cylinder Removal - (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-9. Outrigger Cylinder Removal - (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-10. Hood Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-11. Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-12. Engine Tray Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-13. Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-14. Engine Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-15. Gear Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-16. Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-17. Exhaust Pipe Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-18. Air Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-19. Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-20. Hydraulic Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-21. Pressure Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-22. Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-23. Ground Control Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-24. Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-25. Platform Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-26. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-27. Platform Receptacle Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-28. Extension End Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-29. Extension Side Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-30. End Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-31. Side Rails Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

iv – JLG Lift – 3121322

3-32. Platform Removal - 1 of 2 (Front of Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-33. Platform Removal - 2 of 2 (Rear of Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-34. Ladder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-35. Beacon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-36. Scissor Arm Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-37. Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-38. Scissor Arm Removal (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-39. Scissor Arm Removal (Right Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

4-1. Lift Cylinder Valve Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2. Safety Valve and Limit Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-3. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

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

4-6. Piston Setscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-7. Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-8. Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-9. Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-10. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-11. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-12. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-13. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-14. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-15. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-16. Spacer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-17. Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-18. Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-19. Piston Setscrew Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-20. Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-21. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-22. Valve Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-23. Safety Valve and Limit Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-24. Lifting Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-25. Steering Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-26. Leveling Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-27. Extension Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-28. Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-29. Valve/Hydraulic Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-30. Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-31. Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-32. Brake Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-33. Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-34. Pressure Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-35. Main Valve Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-36. Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-37. Steer Valve Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4-38. Drive Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-39. Hand Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

4-40. Hand Pump Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-41. Lift/Lower Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-42. Platform Lower Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-43. Outrigger Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Main Terminal Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-2. Control Card Complex 2 Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-3. Nivolux Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

6-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

TABLE OF CONTENTS

. . . . . . . . . .4-23

3121322 – JLG Lift – v

TABLE OF CONTENTS

6-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-18. Electrical Schematic - Sheet 1 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-19. Electrical Schematic - Sheet 2 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6-20. Electrical Components - Sheet 3 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-21. Electrical Schematic - Sheet 4 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-22. Electrical Schematic - Sheet 5 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-23. Electrical Schematic - Sheet 6 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-24. Electrical Schematic - Sheet 7 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

6-25. Electrical Schematic - Sheet 8 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

6-26. Electrical Schematic - Sheet 9 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

6-27. Electrical Schematic - Sheet 10 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-28. Electrical Schematic - Sheet 11 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-29. Electrical Schematic - Sheet 12 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

6-30. Electrical Schematic - Sheet 13 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-31. Electrical Schematic - Sheet 14 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

6-32. Electrical Schematic - Sheet 15 of 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

6-33. Electrical Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

6-34. Electrical Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

6-35. Hydraulic Diagram - H900049 RevF - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

6-36. Hydraulic Diagram - H900049 RevF - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-37. Hydraulic Schematic - 1001091308 RevB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

vi – JLG Lift – 3121322

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

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

1-4 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5 Engine Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-6 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-7 Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-11 Mobil Hydraulic Fluid Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

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

2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

3-1 Drive Hub Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2 Drive Motor Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-3 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4 Engine Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-5 Gear Pump Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-6 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-7 Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-8 Beacon Harness MTB Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

4-1 Steering Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-2 Leveling Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-3 Extension Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

5-1 J1 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-2 J2 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-3 J3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-4 Complex 2 Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-5 NIVOLUX Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-6 PNP Circuit Board - I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-7 Connector J1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-8 Connector J2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-9 Connector CON1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-10 Trigger Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-11 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-12 Deutz Engine Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-13 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

6-1 Main Terminal Box Wiring Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

3121322 – JLG Lift – vii

TABLE OF CONTENTS

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viii – JLG Lift – 3121322

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA

Table 1-1. Operating Specifications

Description 67SL

Maximum Working Height: wit h ou tr i gg e rs de p lo yed wit h ou tr i gg e rs st o we d

Maximum Platform Height: wit h ou tr i gg e rs de p lo yed wit h ou tr i gg e rs st o we d

Tu rn in g R ad iu s: I ns i d e O ut s i de

Maximum Work Load (Capacity) Main Platform/Platform Extension

Maximum Occupants 4

Tools and Equipment Main Platform / Platform Extension

Maximum Horizontal Manual Side Force

Tilt Sensor Setting 3°

Maximum Operating Wind Speed

Gross Machine Weight (Approximate)

Drive Speed (slow)

Drive Speed (fast)

Sideslope (Machine Stowed) 5°

Gradeability (MachineStowed) 25%

Lift Speed (no load) 95 sec

Lowering Speed 60 sec

Maximum Operating Hydraulic Pressure

Power Supply Diesel Engine

Maximum Ground Bearing Pressure: Outriggers T ir e s

Maximum Tire Load

Maximum Outrigger Pad Load

Electrical System Voltage 24 V

Ground Clearance

73.2 ft (22.3 m)

56.8 ft (17.3 m)

66.7 ft (20.3 m) 50 ft (15.2 m)

3.9 ft (1.2 m)

17.1 ft (5.2 m )

1650 lbs/1100 lbs

(750 kg/500 kg)

1300 lbs/397 lbs

(430 kg/180 kg)

200 Lb force

(890N)

28 mph

(12.5 m/s)

25,133 lbs

(11,400 kg)

0.4 mph (0.6 ft/sec) (0.7 kmh)

2.2 mph (3.2 ft/sec) (3.6 kmh)

3046 psi

(210 bar)

128 psi (9 kg/cm²)

71 psi (5 kg/cm²)

9700 lbs

(4400 kg)

9458 lbs

(4290 kg)

0.9 ft

(0.27 m)

Table 1-2. Dimensional Data

Description 67SL

Machine Height (rails up)

Machine Height (rails down)

Machine Width

Machine Length

Platform Dimensions (extension retracted)

Platform Dimensions (extension extended)

Transport Dimensions (L x W x H)

1.3 CAPACITIES

Table 1-3. Capacities

Description 67SL

Fuel Tan k

Hydraulic Tank

Engine Crankcase w it h F il t er without Filter

3.8 m

(12.5 ft)

3 m

(9.9 ft)

2.4 m

(7.9 ft)

4.8 m

(15.7 ft)

4.6 x 2.4 m

(15 x 7.9 ft)

7.4 x 2.4 m

(24.3 x 7.9 f t)

4.8 x 2.4 x 3 m

(15.7 x 7.9 x 9.9 ft)

90 L

(23.8 gal)

135 L

(35.7 gal)

10.5 ltr (11 qt) 10 ltr (10.6 qt)

3121322 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.4 ENGINE

Table 1-4. Engine Specifications

Description 67SL

Ty pe

Number of Cylinders 3

Displacement

Bore 3.7 in (94 mm)

Stroke 4.4 in (112 mm)

Fuel Type Diesel

Deutz F3L 2011; or

Deutz D2011 L03i

140.4 in

Battery

Table 1-5. Engine Battery Specifications

Description 67SL

Voltage 12

Cranking Performance 100

Reser ve Capacity 880

(2.3L)

ure 1-5., Torque Chart - (Nm) - (For Metric Class Fasteners).to determine proper torque value.

1.7 LIMIT SWITCHES

Platform Stowed/Jacks Retract Limit Switch

Outriggers cannot be deployed beyond the height of 9.8 ft (3 m).

High Drive Speed Cutout Limit Switch

When the platform reaches and exceeds a height of 11.5 ft (3.5 m), the fast drive speed will be cut back to the slow drive speed. Once the platform is completely lowered, the high drive speed is possible. The High Drive Cutout LED on the platform control console will be out when the platform exceeds the limit.

Maximum Drive Height/Maximum Height without Outriggers Limit Switch

The drive function will be disabled once the platform reaches a height of 50 ft (15.2 m). The platform must be lowered below the limit to enable the drive function. The lift function is also disabled once the platform reaches a height of 50 ft (15.2 m) when the outriggers are not deployed.

1.5 TIRES

Table 1-6. Tire Specifications

Description 67SL

Size IN355/55D625

Load Range G (14 Ply Rating)

Tire Pressure (foam fill) 90 psi (6.2 bar)

Max Tire Load 9700 lbs (4400 kg)

Wheel Lug Nut Torque: Front Axle: Rear Axle:

Bolt Size M18 x 1.5

354 ft lbs (480 Nm) 354 ft lbs (480 Nm)

1.6 TORQUE REQUIREMENTS

NOTE: JLG recommends that once any locknut is removed

from the machine it is discarded and replaced with a new one. When maintenance becomes necessary or a fastener has loosened, refer to Figure 1-3., Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) to Fig-

Maximum Height Limit Switch

Once the platform has reached its maximum height of

66.6 ft (20.3 m), the lifting function will be cut off by the maximum height limit switch. This maximum height can only be achieved when the outriggers are selected and deployed. When maximum height is reached, the Lift Cutout Indicator LED on the platform control console will no longer be iluminated.

Tilt Sensor

The tilt switch cuts out lifting, driving, and steering once the platform reaches a tilt angle (slope) beyond 3° and the platform height exceeds 11.5 ft (3.5 m). At this point, the warning LED on the platform control console will be illuminate. Lowering is the only function possible.

Outrigger Interlock Sensors

Outriggers Selected - Limit switch senses ground contact for all outriggers to enable platform to be raised.

Outriggers Not Selected - Limit switch senses when all outriggers are retracted to enable platform to be raised and machine to be driven.

1-2 – JLG Lift – 3121322

SECTION 1 - SPECIFICATIONS

1. Platform Stowed/Jacks Retract Limit Switch 4. Maximum Height Limit Switch

2. High Drive Speed Cutout Limit Switch 5. Tilt Sensor

3. Maximum Drive Height/Maximum Height without Outriggers Limit Switch

Figure 1-1. Limit Switch Locations

3121322 – JLG Lift – 1-3

6. Outrigger Sensor (all 4 outriggers)

SECTION 1 - SPECIFICATIONS

1.8 PRESSURE SETTING

Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends setting the pressures with the operating temperature between 59°68°F (15°- 20°C). JLG Industries Inc. also recommends the use of a calibrated gauge. The pressures may be set with a tolerence of ± 43.5 psi (3 bar).

Table 1-7. Pressure Setting

Main Relief Steer Relief Pressure Switch

3046 psi

(210 bar)

2538 psi

(175 bar)

2683 psi

(185 bar)

1.9 MAJOR COMPONENT WEIGHTS

Table 1-8. Major Component Weights

Description Weight

Platform Assembly (including extension)

Platform Extension

Chassis

Arm Assembly

1962 lbs (890 kg)

860 lbs

(390 kg)

8377 lbs

(3800 kg)

11,243 lbs

(5100 kg)

1.11 LUBRICATION

Hydraulic Oil

Table 1-10. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0° to +23° F

(-18° to -5° C)

0° to +210° F

(-18° to +100° C)

+50° to +210° F

(+10° to +100° 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.

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.

When temperatures remain below 20°F (-7°C), JLG Industries recommends the use of Mobil DTE 13M.

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

Lift Cylinder

1.10 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-9. Critical Stability Weights

Description Weight

Engine 478 lbs (217 kg)

Wheel and Tire Assembly (each) 441 lbs (200 kg)

Wheel/Tire and Drive Assembly (each) 542 lbs (246 kg)

Batteries - Standard (each) 54 lbs (24.6 kg)

992 lbs

(450 kg)

Table 1-11. Mobil Hydraulic Fluid Specs

Description Mobil 424 Mobil DTE 13M

ISO Viscosity Grade

Specific Gravity

Pour Poin t, Max

Flash Point, Min.

at 40° C (104°F) at 100°C (212°F) Viscosity Index

10W-30 #32

29.0 0.877

-43°F (-46°C) -40°F (-40°C)

442°F (228°C) 330°F (166°C)

Viscosity

55 cSt

9.3 cSt 152

33 cSt

6.5 cSt 140

1-4 – JLG Lift – 3121322

SECTION 1 - SPECIFICATIONS

4150548

NO OPERATION ABOVE THIS AMBIENT TEMPERATURE

ENGINE SPECIFICATIONS

ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY

ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

NO OPERATION BELOW THIS AMBIENT TEMPERATURE

180°F (82°C) (HYD. OIL TANK TEMP.

AMBIENT AIR TEMPERATURE

SUMMER GRADE FUEL

SAE OW-30

SAE OW-40

WINTER GRADE FUEL

WINTER GRADE FUEL WITH KEROSENE ADDED

EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180°F (82°C) OR ABOVE

IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE)

AMBIENT AIR TEMPERATURE

120°F (49°C)

110°F (43°C)

100°F (38°C)

90°F (32°C)

80°F (27°C)

70°F (21°C)

60°F (16°C)

SAE 5W-30

SAE 5W-40

SAE 10W-40

SAE 10W-30

SAE 15W-40

SAE 20W-50

50°F (10°C)

40°F (4°C)

30°F (-1°C)

20°F (-7°C)

10°F (-12°C)

0°F (-18°C)

-10°F (-23°C)

-20°F (-29°C)

-30°F (-34°C)

-40°F (-40°C)

120°F (49°C)

110°F (43°C)

100°F (38°C)

90°F (32°C)

80°F (27°C)

70°F (21°C)

60°F (16°C)

50°F (10°C)

40°F (4°C)

30°F (-1°C)

20°F (-7°C)

10°F (-12°C)

0°F (-18°C)

-10°F (-23°C)

-20°F (-29°C)

-30°F (-34°C)

-40°F (-40°C)

NO OPERATION ABOVE THIS

MOBIL DTE 13

AMBIENT TEMPERATURE

MOBIL 424 10W-30

EXXON UNIVIS HVI 26

NO OPERATION BELOW THIS AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE

PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100°F (38°C) OR ABOVE

HYDRAULIC SPECIFICATIONS

Figure 1-2. Engine Operating Temperature Specifications

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL

°F °C

+32 0

+23 -5

+14 -10

+5 -15

-4 -20

-13 -25

AMBIENT TEMPERATURE

-22 -30

0 10 20 30 40 50 60

% OF ADDED KEROSENE

SUMMER - GRADE FUEL

WINTER - GRAD FUEL

3121322 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

UNBRAKO 1960 SERIES

LOAD

CLAMP

271

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

263

DRY OR

LOCTITE

& SOCKET HEAD CAP SCREWS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

TORQUE

LOAD

CLAMP

271

242 OR

LOCTITE

262

LOCTITE

LUB

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

GRADE 2 NUTS

SAE GRADE 5 BOLTS &

DRY OR

CLAMP

STRESS

TENSILE

BOLT

THDS.

LOCTITE

LOAD

AREA

DIA.

PER

SIZE

263

INCH

0.00604 380 8 6 — — 540 12 9 — — — — —

IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB

0.1120

48 0.00661 420 9 7 — — 600 13 10 — — — — —632

0.00909 580 16 12 — — 820 23 17 — — — — —

0.1380

40 0.01015 610 18 13 — — 920 25 19 — — — — —832

0.01400 900 30 22 — — 1260 41 31 — — — — —

0.1640

36 0.01474 940 31 23 — — 1320 43 32 — — — — —1024

0.01750 1120 43 32 — — 1580 60 45 — — — — —

0.1900

0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28

0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50

0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77

0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120

0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170

0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231

0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400

0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645

0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950

0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365

0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925

1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550

12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070

1.3750

1-3/8

12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685

1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345

1.5000

1-1/2

12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600

Note: These torque values do not apply to cadmium plated fasteners.

0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168

IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB

0.3125

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

0.8750

1.0000

1.1250

12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520

1-1/8

1.2500

1-1/4

0.2500

24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30

24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55

20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82

20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127

18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182

18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242

5/8

3/4

32 0.02000 1285 49 36 — — 1800 68 51 — — — — —

28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178

1/4

5/16

3/8

7/16

1/2

9/16

16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440

7/8

14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700

12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000

Figure 1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)

1-6 – JLG Lift – 3121322

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

SECTION 1 - SPECIFICATIONS

UNBRAKO 1960 SERIES

LOAD

CLAMP

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

DRY OR

LOCTITE

& SOCKET HEAD CAP SCREWS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

TORQUE

LOAD

CLAMP

242 OR

LOCTITE

262

LOCTITE

LUB

GRADE 2 NUTS

SAE GRADE 5 BOLTS &

DRY OR

LOCTITE

271

263

271

263

LOAD

CLAMP

TENSILE

BOLT

THDS.

STRESS

AREA

DIA.

PER

SIZE

INCH

IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m

0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —

0.1120

48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —632

0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —

0.1380

40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —832

0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —

0.1640

36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —1024

0.01750 1120 5 3.6 — — 1580 7 5 — — — — —

0.1900

0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19

32 0.02000 1285 6 4 — — 1800 8 6 — — — — —

0.2500

28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20

1/4

IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m

0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38

0.3125

5/16

0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68

0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163

0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230

0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313

0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542

0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874

0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288

0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851

0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610

1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457

1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

0.8750

1.0000

1.1250

1.2500

1.3750

1.5000

24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41

24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75

20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111

20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172

18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247

18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328

16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597

14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949

12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356

12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1-1/8

1-1/4

12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807

12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640

1-3/8

12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

1-1/2

Note: These torque values do not apply to cadmium plated fasteners.

Figure 1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners)

3121322 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS &

CLASS 8 METRIC NUTS

TORQUE

LUB

LOCTITE

262

LOCTITE

242 OR

271

CLAMP

SIZE PITCH

TENSILE STRESS

AREA

CLAMP

LOAD

DRY OR

LOCTITE

263

sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m

3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1

3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3

4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8

5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7

6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17

7 1 28.9 12.6 18 13 16 19 18 25 19 20 28

81.2536.615.92519232822.837272940

101.558.025.25038455536.172545879

12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139

14 2 115 50.0 140 105 126 154 71.6 200 150 160 220

16 2 157 68.3 219 164 197 241 97.8 313 235 250 344

18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473

20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671

22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915

24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170

27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690

30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310

33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860

36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020

42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS

LOAD

DRY OR LOCTITE

263

LUB

TORQUE

LOCTITE

262

LOCTITE

242 OR

271

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8METRIC CLASS 10.

Figure 1-5. Torque Chart - (Nm) - (For Metric Class Fasteners).

1-8 – JLG Lift – 3121322

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

JLG recommends that the Annual Machine Inspection 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.

3121322 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Typ e Frequency

Pre-Start

Inspection

Pre-Delivery

Inspection

Frequent

Inspection

Annual Machine

Inspection

Preventative Maintenance

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

In service for 3 months or 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 specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

Cleanliness

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

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User

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

Qualified JLG

Mechanic

Qualified JLG

Mechanic

Factory-Certified

Service Technician

(recommended)

Qualified JLG

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Components Removal and Installation

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

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

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 – 3121322

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

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.

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

Bolt Usage and Torque Application

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

3121322 – 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 quantity of oil in supply tube.

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.

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 annually unless operating in extreme conditions. 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 replace the filter and clean magnet 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.

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

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

machines due to the wear-in of meshing components.

Hydraulic Oil

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

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

NOTE: Start-up of hydraulic system with oil temperatures

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

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.

Table 2-2. Lubrication Specifications

KEY SPECIFICATIONS

Multipurpose Grease having a minimum dripping

MPG

EPGL

point of 350°F (177°C). Excellent water resistance and adhesive qualities, and being of extreme pres-

sure type. (Timken OK 40 pounds minimum.)

Extreme Pressure Gear Lube (oil) meeting API ser-

vice classification GL-5 or MIL-Spec MIL-L-2105.

Engine (crankcase) Oil. Gas - API SF/SG class, MIL-

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

MIL- L-2 10 4C .

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

Mobil 424.

2-4 – JLG Lift – 3121322

SECTION 2 - GENERAL

2.4 OPERATOR MAINTENANCE

TO AVOID PERSONAL INJURY, USE SAFETY PROPS FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.

NOTE: Be sure to lubricate like items on each side.

NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in

multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank. Oil should be visible in ADD sight window on hydraulic tank. If oil is not visible, add oil until oil is visible in both ADD and FULL sight windows on tank. Do not overfill tank.

1. Arm Pins

2. Outrigger Cylinders

3. Tie Rod Ends

4. Spindles

5. Lift Cylinder

6. Upper Slide Pads

Figure 2-1. Lubrication Diagram

7. Lower Slide Pads

8. Engine Compartment (opposite side not shown)

9. Fuel Tank (opposite side not shown)

3121322 – JLG Lift – 2-5

SECTION 2 - GENERAL

NOTE: The following numbers correspond with those in Fig-

ure 2-1., Lubrication Diagram.

1. Arm Pins

• Lube Points - 39 Grease Fittings

• Capacity - As Required

3. Tie Rod Ends

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube -MPG

• Interval - As Required

•Lube - MPG

• Interval - As Required

2. Outrigger Cylinders

• Lube Points - 4 Grease Fittings

• Capacity - As Required

4. Spindles

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

•Lube - MPG

• Interval - As Required

2-6 – JLG Lift – 3121322

SECTION 2 - GENERAL

5. Lift Cylinder

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

7. Lower Slide Pads

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

6. Upper Slide Pads

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

8. Engine Compartment

a. Engine Oil Check/Fill

• Lube Points - Fill Cap & Dip Stick

• Capacity - See Engine Manual

• Lube - EO SAE 20W20

• Interval - Every 3 months or 150 hours of operation

3121322 – JLG Lift – 2-7

SECTION 2 - GENERAL

b. Oil Filter

• Maintenance - Replaceable Element (JLG P/N 7016331)

• Interval - Change every 500 hours or 6 months, whichever comes first. Change filter every time engine oil is changed.

c. Hydraulic Oil Check/Fill

d. Hydraulic Oil Filter

• Maintenance - Replaceable Element (JLG P/N 70000899)

• Interval - 250 hours

• Comments - Change after first 50 hours, then every 250 hours of operation thereafter

• Lube Points - Fill Cap & Site Gauge

• Capacity - 35.7 gal (135 L)

•Lube - HO

• Interval - Check oil daily, change every 1200 hours of operation

e. Air Filter

• Lube Points - Replaceable Element (JLG P/N H005232 & 70000054)

• Interval - Every 6 months or 300 hours of operation

2-8 – JLG Lift – 3121322

SECTION 2 - GENERAL

f. Fuel Filter

• Maintenance - Replaceable Element (JLG P/N 7020023)

• Interval - Change every year or 600 hours of operation, whichever comes first.

2.5 CYLINDER DRIFT TEST

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

Lift Cylinder Drift

NOTE: Test cylinder drift with machine oil at ambient tem-

perature.

1. Place maximum work load onto platform (Refer to Table 1-1, Operating Specifications).

2. Extend lift cylinder to achieve a platform height 3 to 5 meters from fully stowed.

3. Wipe cylinder rod clean and place a mark on the rod 50mm from the cylinder head.

4. Wait 15 minutes.

5. Measure distance of mark from head.

6. Difference (cylinder drift) must not exceed 3mm.

NOTE: If cylinder drift exceeds 3mm, repeat test. If still

greater than 3mm, check holding valve (refer to Figure 4-41., Lift/Lower Valve Block). If still greater than 3mm, replace cylinder seals (refer to Section 4.4, Cylinder Repair).

9. Fuel Tank

• Capacity - 23.8 gal (90 L)

• Lube - Diesel Fuel

• Interval - Check fuel periodically during each use

3121322 – JLG Lift – 2-9

SECTION 2 - GENERAL

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed. The “INTERVAL” portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

NOTICE

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION REPORT" FORM.

6. Check for presence of excessive dirt or foreign material.

7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while pump/motor is running.

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and for straightness of rod.

14. Check for condition of element; replace as necessary.

15. Check for proper inflation.

NOTE: This machine requires periodic safety and mainte-

nance inspections by a JLG Dealer. Notify dealer if inspection is overdue.

The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.

5. Check for leakage.

2-10 – JLG Lift – 3121322

SECTION 2 - GENERAL

Table 2-3. Preventive Maintenance and Safety Inspection

AREA INTERVAL

Daily Weekly

PL AT F OR M

1. Controller 1,11

2. Switches 1,11

3. Placards and Decals 1,2

4. Control Tags 1,2

5. Hoses and Cables 4,8

6. Wear Pads 8,12

7. Handrails and Chains 1,4

CH A SS I S

1. Battery 3 5

2. Hydraulic Pump 1 5

3. Valves 1 5

4. Hydraulic Filter ANNUAL

5. Hydraulic Hoses and Tubing 1 5

6. Hydraulic Oil Tank 5 3,4

8. Lift Cylinder 1,12 5,6,13 4

9. Limit Switch 1,7

10. Tilt Alarm Switch 1,7

11. Placards and Decals 1,2

12. Wheel and Tire Assemblies 1 8,9

13. Drive Motors 1,5,6

14. Drive Brakes 1,6 8

15. Drive Torque Hubs 1,3,5,6

16. Steer Cylinder 1 5,6,13 4

17. Steer Components 1 4,6 8

18. Wheel Bearings 812

19. Scissor Arms 1,4

20. Safety Props 1,4

21. Sliding Wear Pads 8,12

22. Pivot Pins/Bolts 1,4 7,8

23. Switches, Ground Control 1,11

24. Control Tags 1,2

100 Hours (3 Months)

200 Hours

(6 Months)

400 Hours

(1 year)

3121322 – JLG Lift – 2-11

SECTION 2 - GENERAL

NOTES:

2-12 – JLG Lift – 3121322

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS

NOTICE

ANYTIME SERVICING OF ELECTRICAL OR HYDRAULIC COMPONENTS IS REQUIRED, DISCONNECT BATTERY VIA THE DISCONNECT SWITCH ON THE GROUND CONTROL PANEL AND SHUT VALVE LEVERS AT THE BASE OF THE HYDRAULIC TANK TO STOP FLOW OF HYDRAULIC FLUID.

Leveling Jacks

The machine is equipped with auto leveling jacks. The automatic self leveling system is controlled by 4 double acting cylinders mounted at each corner of the machine chassis. These cylinders incorporate pilot operated holding valves on the piston side. The cracking pressure of these valves is 15 psi (1 bar) for the rear and 116 psi (8 bar) for the front.

1. Activate the leveling jack switch located on the ground control console.

2. Extend the jacks by moving the joystick on the platform control box forward.

NOTE: The jacks deploy at idle engine speed. Once all four

jacks make contact with the ground the system will go from set mode into level mode. Once level, engine rpm’s will increase and lift is allowed.

3.2 WHEEL ASSEMBLY

Drive System

Wheel drive is achieved by orbital type (100cc/rev) hydraulic motors driving a wheel type gearbox (29.8:1 reduction) through a spring-applied brake.

The brake is released by actuating a 3 way solenoid valve. This valve provides hydraulic power from the pump directly to the brakes. The brake can be reset by deactivating the valve and restricting flow to the tank through an orifice to smooth out hard stops. Drive is controlled by a proportional solenoid valve section within the main control valve (see Figure 4-33.).

Flow to the drive motors passes through a series /parallel solenoid. When all 3 solenoids are in the passive (nonenergised) mode, flow is split by 3 flow dividers:

•Front/Rear

• Rear - Left/Right

• Front - Left/Right

When the solenoids are activated, all ports on the rear hydraulic motors are connnected so that they free the wheel. The front motors are connected in series (output of one motor to the input of the other) to enable fast drive low torque mode.

3. The tilt indicator LED’s on the Main Terminal Box will go out once the machine is level.

NOTE: There are limit switches mounted at each jack cyli-

inder. These sense when the jack makes ground contract and enable the lift function. All four switches must have contact (lift indicator LED on the platform will light) to enable lift. When elevated, if a contact signal is lost (jack loses ground contact, wire cut, etc.), the lift function is stopped and only lowering is permitted. The jacks are operational (extend or retract) if the machine is in the stowed position. The minimum height limit switch must sense the machine is stowed. A failure of the limit switch will prevent the jacks from being activated.

NOTE: Refer to Section 5.3, Nivolux - Automatic Self-Level-

ing System for detailed information regarding the automatic leveling system.

3121322 – JLG Lift – 3-1

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Drive Hub

NOTICE

DRIVE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE WORKING PROPERLY.

The following information briefly outlines what to look for when performing these tests.

IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH.

Roll Test

The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You should be able to rotate the wheel or hub of the gearbox by hand. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency.

1. Drive Hub

2. Screw

3. Circlip

4. Pin

Figure 3-1. Drive Hub

Hub Disengaging and Oil Checking Procedure:

Leak Test

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

NOTE: Due to the small air volume inside this Torque-Hub, it

will pressurize to 10 psi very quickly. If the pressure becomes excessive in the unit the seals will be destroyed.

Lubricant

The torque hub unit is shipped with 90W gear oil. It is designed to utilize the same oil throughout its service life. However, should it need to be serviced the oil will need to be drained and replaced.

In the event of servicing, fill the unit with Arco H.D. 120# Drum or Exxon GX 80W-90.

1. Loosen the two Screws (2) securing the Circlip (3).

2. Slide the Circlip (3) in the direction of the arrow.

3. Remove the Pin (4).

4. The proper gear oil level should be to the base of the opening. Add gear oil if needed.

5. Turn the Pin (4) around and place back onto Hub (1).

NOTE: Side of Pin that was facing outside should now be

facing the inside of the hub.

6. Slide Circlip (3) in opposite direction of arrow to secure the Pin. Tighten Screws (2) to secure the Circlip in place.

3-2 – JLG Lift – 3121322

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-1. Drive Hub Technical Specifications

Max Torque 5,5 kNm

Max Input Speed 4000 rpm

Weight

Brake

Static Torque

Releas ing Pressur e

Max Pressure

Max Input Torque

101.4 lbs (46 kg)

147.5 lb ft (200 Nm)

174-217.5 psi

(12-15 bar)

1450.3 psi (100 bar)

147.5 lb ft (200 Nm)

Tire Replacement

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

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

• Tire tread contact width equal or greater than original.

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

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

Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows:

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

2. Tighten nuts in the following sequence:

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

NOTE: Tires are foam filled to 90 psi (6.2 bar).

3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten the

nuts per wheel torque chart.

Wheelnut Tightening Pattern

Wheel Replacement

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

NOTICE

IT IS EXTREMELY IMPORTANT TO APPLY AND MAINTAIN PROPER WHEEL MOUNTING TORQUE.

1st Stage 2nd Stage 3rd Stage

150-190 ft lbs

(210 - 270 Nm)

4. Wheel nuts should be torqued after the first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.

3121322 – JLG Lift – 3-3

TORQUE SEQUENCE

230 - 270 ft lbs (320-380 Nm)

305 - 343 ft lbs

( 440 - 480 Nm)

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Wheelnut (6 per wheel)

2. Drive Hub

3. Bolt, M16 x 55mm (8 per wheel)

4. Hardened Washer (8 per wheel)

5. Drive Motor

Figure 3-2. Wheel Assembly Removal

SECURE MACHINE WITH JACKS AND CHALK BLOCKS WHEN REMOVING AND/OR INSTALLING WHEELS.

NOTE: Follow the below steps when servicing/replacing the

wheel/tire assembly.

Removal:

1. Elevate machine with jacks or other suitable device and secure.

2. Remove 6 Wheelnuts (1).

6. Bolt, M12 x 35mm (2 per wheel)

7. Lockwasher, M12 (2 per wheel)

8. Spindle

3. Carefully remove tire from Drive Hub (2).

4. Disconnect all hoses/wires from Drive Motor (5).

5. Remove two Bolts (6) and Lockwashers (7) attaching the Drive Motor to the Drive Hub. Carefully remove the Drive Motor.

6. Remove the eight Bolts (3) and Hardened Washers (4) attaching the Drive Hub to the Spindle (8). Carefully remove the Drive Hub.

Installation:

• Follow the removal steps in reverse order when installing the wheel assembly.

3-4 – JLG Lift – 3121322

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Drive Motor Side

1. Torque to 354 lb ft Dry (480 Nm)

2. Torque to 230.9 lb ft Dry (313 Nm)

Figure 3-3. Hub Torque Values

3121322 – JLG Lift – 3-5

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

132312

48 2

183938

47 41

1. Spindle

2. Hub

3. Gear Ring

4. Cover

5. Flange

6. Coupling

7. Thrust Washer

8. Thrust Washer

9. Circlip

10. Planetary Gear

11. Pin

12. Thrust Washer

13. Spacer

14. Sun Pinion

15. Piston

16. Spring

17. Disc

18. Disc

19. Lock Nut

20. Bearing

21. Bearing

22. Bearing

23. Bearing

24. Circlip

25. Circlip

26. Disc

27. Circlip

28. Plug

29. O-Ring

30. O-Ring

31. O-Ring

32. O-Ring

33. O-Ring

34. Oil Seal

35. Gasket

36. O-Ring

37. Blocking Ring

38. O-Ring

39. Blocking Ring

Figure 3-4. Drive Hub Assembly

40. Screw

41. Screw

42. Screw

43. Plug

44. Washer

45. Plug

46. Disc

47. Threaded Stud

48. O-Ring

49. Reduction Gear Kit

3-6 – JLG Lift – 3121322

Drive Motor

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Dust Seal

2. Motor Housing

3. Shaft Seal

4. Bearing Race

5. Axel Needle Bearing

Displacement

Max Speed 600 rpm

Max Torque

Max Power 13 kw

Max Oil Flow

98 10 8 1112

6. Output Shaft

7. Cardan Shaft

8. O-Ring

9. Distributor Plate

10. Gear Wheel Set

Figure 3-5. Drive Motor (OMR 100)

Table 3-2. Drive Motor Specs

99.8 cm

177 lb ft

(240 Nm)

15.9 gal/min (60 L/min)

11. End Cover

12. Washer

13. Screw

3121322 – JLG Lift – 3-7

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Motor Disassembly

NOTE: For numbers in ( ), refer to Figure 3-5., Drive Motor

(OMR 100).

1. Place the Motor Housing (2) in a holding tool with the flange upwards.

2. Use a 13mm spanner socket to remove the screws (13) and washers (12).

3. Remove the End Cover (11) sideways.

4. When removing the Gear Wheel Set (10) and two ORings (8), keep fingers under the the gear wheel set to prevent the parts from falling out.

5. Remove the Cardan Shaft (7).

6. Remove the Distributor Plate (9) and O-Ring (8).

7. To remove the Output Shaft (6), place the motor housing (2) on a work bench and press the shaft out of the motor housing.

8. Remove the Bearing Race (4) from the motor housing (2).

9. Remove the Axel Needle Bearing (5).

10. With a mandrel and plastic hammer, carefully knock out the Shaft Seal (3) and Dust Seal Ring (1).

NOTE: When cleaning parts, clean parts carefully with low

aromatic kerosine.

Check all parts carefully and replace if necessary.

Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline.

Motor Assembly

1. Place the Motor Housing (2) in a holding tool with the flange upwards.

2. Lubricate the Shaft Seal (3) on the outside with hydraulic oil. Fit the shaft seal correctly onto the mandrel and carefully press the shaft seal into position into the motor housing.

3. Place the Dust Seal Ring (1) in the spigot flange and knock it into position with a plastic hammer and appropriate mandrel.

4. Fit the Bearing Race (4) onto the shaft and mount together with the shaft.

5. Place the Axel Needle Bearing (5) back onto shaft.

6. Output Shaft (6): Grease the journals with hydraulic oil. The rear shaft end must be marked before fitted. The mark must be positioned vertically above a commutation slot leading up to the front annular channel.

7. Grease the O-Ring (8) and put it in the O-ring groove of the housing.

8. Turn the Distributor Plate (9) so that the holes line up.

9. Guide the Cardan Shaft (7) down into the motor housing. In case of different splines lengths turn the cardan shaft to ensure the long splines end is fitted in the output shaft. Transfer marking from output shaft to cardan shaft.

10. Place the two O-Rings (8) (greased) in the O-ring grooves of the Gearwheel. In gearwheels with non through splines place the gearwheel with the recess in the spline hole facing down towards the housing. Place the Gear Wheel Set (10) on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the mark on the cardan shaft. Turn the gearwheel set counterclockwise until the cardan shaft and the gearwheel start to mesh (15°). Turn the gearwheel rim so that the holes made for the screws line up.

11. Turn the End Cover (11) so that the holes line up.

12. Place the Washers (12) onto the Screws (13). Use a 13mm spanner socket to tighten the screws..

Table 3-3. Tightening Torques

Item Tor que

Screws (item 13 in Figure 3-5.)

270 - 315 lbf in

(3.0 - 3.5 daNm)

3-8 – JLG Lift – 3121322

3.3 STEERING ASSEMBLY

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

31 32

1. Right Spindle

2. Left Spindle

3. Cap

4. Grease Fitting Cap

10. Bushing*

11. Ring

12. Pin

13. Grease Fitting Cap

15 16

19. Steer Cylinder

20. Bolt, M12 x 150mm

21. Flatwasher, M12

22. Washer

6 7

3 8 9

4 5

28. Grease Fitting

29. Grease Fitting Cap

30. Grease Fitting

31. Bolt, M12 x 20mm

5. Grease Fitting

6. Bolt, M12 x 30mm

7. Lockwasher, M12

8. O-Ring

9. Ring

NOTE: * = not used on all machines.

Remove wheel and tire assemblies before attempting to service the steering assembly. Disconnect electrical supply and any wires and/or hoses. Secure machine with proper stabilizing devices.

Removal:

1. Remove Steer Cylinder (19) by removing Bolts (20,

31), Washers (21, 22, 23, 32), Nuts (25) and Pins (26, 33).

14. Grease Fitting

15. Bolt, M12 x 20mm

16. Lockwasher, M12

17. Bushing

18. Tie Bar

Figure 3-6. Steering Assembly

23. Washer

24. Flatwasher, M12

25. Nut, M12

26. Pin

27. Grease Fitting Cap

2. Disconnect Tie Bar (18) from both Spindles (1, 2) by removing Bolts (15), Lockwashers (16), Pins (12), and Bushings (17). Remove Tie Bar.

3. Spindles can now be removed from the chassis. Secure Spindle. Remove Grease Cap (4) and Fitting (5). Remove Bolts (6), Lockwashers (7), Cap (3), ORing (8), Ring (9), and Bushings* (10). The Spindle can now be removed for repair/replacement.

Installation:

1. Follow the Removal Steps in reverse order when assembling the steering system.

32. Lockwasher, M12

33. Pin

3121322 – JLG Lift – 3-9

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.4 REAR AXLE ASSEMBLY

1. Rear Axle Weldment

2. Bolt, M20 x 65mm

3. Nut, M20

4. Hardened Washer

Figure 3-7. Rear Axle Removal

NOTICE

SECURE THE MACHINE AND AXLE WELDMENT WHEN SERVICING/REMOVING. THE AXLE WEIGHS APPROXIMATELY 325 LBS (147.5 KG).

NOTE: Remove the tire and wheel assemblies before

removing the axle. (Refer to Figure 3-2., Wheel Assembly Removal).

Removal:

1. Remove the eight Bolts (2), Nuts (3), and sixteen Hardened Washers (4) attaching the Rear Axle Weldment (1) to the frame.

2. Carefully remove the Rear Axle.

Installation:

1. Raise Axle to the frame.

2. Secure the axle to the frame using the eight Bolts (2), Nuts (3), and sixteen Hardened Washers (4).

3. Torque Bolts to 450 lb ft (610 Nm) dry.

3-10 – JLG Lift – 3121322

3.5 OUTRIGGER CYLINDER REMOVAL

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

5 6

1. Cover

2. Bolt, M8 x 160mm

3. Lockwasher, M8

4. Outrigger Cylinder

5. Bolt, M8 x 50mm

6. Lockwasher, M8

7. Valve Assembly

8. Limit Switch Bracket

Figure 3-8. Outrigger Cylinder Removal - (Sheet 1 of 2)

NOTE: Refer to Figure 3-8., Outrigger Cylinder Removal -

(Sheet 1 of 2) and Figure 3-9., Outrigger Cylinder Removal - (Sheet 2 of 2).

Shut off flow of hydraulic oil before attempting to remove any outrigger cylinder.

Removal:

A )

1. Remove the Cover (1) by removing the four Bolts (2) and Lockwashers (3).

B )

2. Disconnect all hydraulic hoses and wires attached to the Valve Assembly (7) and Limit Switch (9).

3. Remove the Valve Assembly, Limit Switch Bracket (8) and Limit Switch from the top of Outrigger Cylinder (4) by removing the four Bolts (5) and Lockwashers (6)

9. Limit Switch

NOTE: Support cylinder rod to prevent rod extension and

consequential oil spillage.

After "Removal Step #3," the frame must be elevated greater than the length of the stowed outrigger cylinder to remove the cylinder.

C )

4. Remove the Plate (12) and Gasket (13) by removing the four Bolts (10) and Lockwashers (11).

5. Secure the Outrigger Cylinder (16). Remove the four Bolts (14) and Lockwashers (15) attaching the cylinder to the frame.

D )

6. Carefully lower the Cylinder out of the frame.

3121322 – JLG Lift – 3-11

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

10. Bolt, M6 x 16mm

11. Lockwasher, M6

12. Plate

13. Gasket

Figure 3-9. Outrigger Cylinder Removal - (Sheet 2 of 2)

Installation:

1. Carefully insert Outrigger Cylinder (16) back into the frame and secure with the four Bolts (14) and Lockwashers (15).

2. Replace Gasket (13) and Plate (12). Secure with four Bolts (10) and Lockwashers (11).

NOTE: At this point the frame may be lowered.

3. Place Valve Assembly (7), Limit Switch Bracket (8), and Limit Switch (9) back onto the top of the cylinder and secure with the four Bolts (5) and Lockwashers (6).

4. Reconnect all hydraulic lines and electrical wires.

14. Bolt, M12 x 70mm

15. Lockwasher, M12

16. Outrigger Cylinder

5. Return flow of hydraulic oil and ensure there is no leakage. Operate cylinder to ensure it works properly.

6. Replace Cover (1) and secure with four Bolts (2) and Lockwashers (3).

3-12 – JLG Lift – 3121322

3.6 ENGINE COMPARTMENT

Hood Assembly

11 12

ENGINE SIDE

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

VALVE SIDE

1. Hood

2. Gas Spring

3. Bolt M8 x 30mm

4. Nut M8

5. Cabinet Top Panel (Left)

6. Cabinet Panel (Right)

7. Special Bolt

8. Flatwasher M12

9. Air Intake Pipe

10. Bolt M8 x 25mm

11. Flatwasher M8

12. Locknut M8

13. Bolt M10 x 25mm

14. Nut M10

15. Flatwasher M10

Figure 3-10. Hood Assembly

NOTE: Removing the hoods will allow for easier access to

the components inside the engine compartment and valve compartment.

1. Open and secure Hood (1).

2. Remove Bolt (3) and Nut (4) on both Gas Springs (2). Return Hood to closed position.

3. Remove both Bolts (7) and Flatwashers (8) connecting hoods to the Cabinet Top Panel (5 & 6).

16. Nut M10

NOTE: Step 4 applies only to the Engine Side Compart-

ment.

4. Remove the Air Intake Pipe (9) by removing the four Bolts (10), Flatwashers (11), and Locknuts (12).

5. Remove the Cabinet Top Panel (5 & 6) by removing the 4 Bolts (13), eight Flatwashers (14), and four Nuts (16).

NOTE: Follow the steps in reverse order to re-attach the

hood and top panel.

3121322 – JLG Lift – 3-13

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Deutz Engine

1. Deutz F3L2011

2. Hydraulic Tank

3. Air Filter

4. Hydraulic Pump

Figure 3-11. Deutz Engine

Table 3-4. Engine Technical Data

Description F3L 2011F D2011 L03 i

Fuel Diesel

Number of Cylinders 3

Cylinder Arrangement Vertical In Line

Bore 3.7 in (94 mm)

Stroke 4.4 in (112 mm)

To ta l D i sp l ac e me nt

Engine Speed: H ig h L ow

Swept Volume 2331 cm³

Vol tag e 24 Volt s

140.4 in

2300l/min

850 l/min

( 2. 3 L)

3-14 – JLG Lift – 3121322

Engine Tray Slide

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1, 2

1. Bolt, M16 x 30mm

2. Lockwasher, M16

3. Bolt, M16 x 60mm

Figure 3-12. Engine Tray Slide

The engine tray can be slide outward approximately 5.9 in. (15 cm) when servicing components inside the engine compartment.

1. Remove the two Bolts (1) and Lockwashers (2) on the front of the engine tray.

2. Loosen the two top Bolts (3) at both ends of the engine compartment. Slide engine tray outward.

3. Be sure to return engine tray to stowed position when finished servicing. Secure engine tray with the two front Bolts (1) and Lockwashers (2) and two top Bolts (3).

1, 2

3121322 – JLG Lift – 3-15

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Glow Plugs

1. 30 amp Fuses

2. Timer Relay N6

3. Relay K3

Engine Solenoid

Figure 3-13. Glow Plugs

1. Solenoid

2. 30 amp Fuse

Figure 3-14. Engine Solenoid

3-16 – JLG Lift – 3121322

Gear Pump Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Hydraulic Pump

2. Bolt (M8 x 25mm) and Lockwasher (M8)

3. Pump Mounting Flange

4. Capscrew (M8 x 25mm) and Lockwasher (M10)

5. Coupling

Figure 3-15. Gear Pump Assembly

Removal:

1. Shut off flow of hydraulic fluid to the Pump (1).

2. Disconnect any hoses and/or wires attached to the pump.

3. Remove the 4 Bolts and Lockwashers (2) connecting the pump to the Pump Mountng Flange (3). Carefully remove the pump.

4. To remove the pump mounting flange, unscrew the 12 Capscrews and Lockwashers (4).

5. The Coupling (5) can be removed by unscrewing the 6 Screws and Lockwashers (6).

Installation:

1. Follow the Removal steps in reverse order, installaing components as opposed to removing them.

3121322 – JLG Lift – 3-17

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-16. Gear Pump

Table 3-5. Gear Pump Specs.

FIRST STAGE

Displacement 22,8 cc/rev

Rated Pressure 2611 psi (180 bar)

Peak Pressure 2901 ps i (200 bar)

Maximum Speed 3000 rpm

Minimum Speed at Rated Pressure 1000 rpm

SECOND STAGE

Displacement 8,4 cc/rev

Rated Pressure 3626 ps i (250 bar)

Peak Pressure 4061 ps i (280 bar)

Maximum Speed 4000 rpm

Minimum Speed at Rated Pressure 1000 rpm

THIRD STAGE

Displacement 2 ,09 cc/rev

Rated Pressure 3626 ps i (250 bar)

Peak Pressure 3916 ps i (270 bar)

Maximum Speed 4000 rpm

Minimum Speed at Rated Pressure 1000 rpm

Operation

3 Sections to the pump:

• Section 1 (22.5cc/rev - 51 L/m) Main flow to control valve

• Section 2 (8cc/rev - 18 L/m) Secondary flow to control valve

• Section 3 (2cc/rev - 4.5 L/m) Flow to steering valve

Pump Flow

• Flow from the first 2 pump sections to the control valve is protected by dump valves which normally open to tank ports. To generate hydraulic power to the control valve, the dump valves need to be activated. Section 1 valve for main flow and section 2 valve to enable high drive speed.

3-18 – JLG Lift – 3121322

Exhaust Pipe Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Muffler

2. Exhaust Clamp

3. Exhaust Elbow

NOTE: In the event any or all exhaust piping needs repaired

or replaced follow the below steps. Refer to Figure 3-

17., Exhaust Pipe Assembly.

1. Loosen the Exhaust Clamp (2) located on the muffler (2).

2. Slide the Exhaust Elbow (3) out of the muffler.

3. Loosen the Exhaust Clamp (4).

4. The exhaust elbow can now be removed.

5. Remove the Exhaust Flex Pipe (5) by loosening the Exhaust Clamp (6). Slide the pipe out of the Tailpipe (7).

6. The tail pipe can be removed by unscrewing the Bolt (8) connecting it to the engine tray.

4. Exhaust Clamp

5. Exhaust Flex Pipe

6. Exhaust Clamp

Figure 3-17. Exhaust Pipe Assembly

7. Tailpipe

8. Bolt (M10 x 20mm) and Lockwasher (M10)

Installation:

1. Follow the steps in reverse order to assemble the exhaust system. Take care to securely tighten the exhaust clamps.

3121322 – JLG Lift – 3-19

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Air Filter Assembly

1. Air Filter

2. Bolt, Nut, Flatwasher

3. Intake Hose

4. Hose Clamp

5. Hose Clamp

6. Hose Clamp

7. Reducing Sleeve

8. Hose Clamp

9. Air Intake Elbow

10. Hose Clamp

11. Air Intake Tube

12. Hose Clamp

13. Air Intake Elbow

14. Air Intake Tube

15. Hose Clamp

16. Intake Pipe

17. Hose Clamp

18. Rubber Intake Tube

19. Hose Clamp

Figure 3-18. Air Filter Assembly

NOTE: Refer to Figure 3-18. when dismantling the Air Filter

for service and/or replacements.

1. Removing the pipes and tubes requires loosening the hose clamps. Once the hose clamps are loosened, the tubes and pipes can be removed for maintenance or replacement.

2. To remove the Air Filter (1), unscrew the 2 Bolts (2). Remove the air cleaner from the bracket.

3. Lift the latches on the end of the Air Filter to access the safety element (not shown).

NOTE: When assembling the air filter system, take care to

securely fit all tubing and piping together and to securely tighten all hose clamps.

3-20 – JLG Lift – 3121322

Engine Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Bolt, M12 x 110 mm

2. Flatwasher, M12

3. Nut, M12

4. Oil Drain Port

Figure 3-19. Engine Removal

NOTE: Refer to Figure 3-19. when removing engine from

engine compartment.

ENGINE REMOVAL REQUIRES HEAVY LIFTING DEVICES. USE EXTREME CAUTION WHEN REMOVING THE ENGINE.

1. Disconnect all electrical wires, hoses, pipes, etc.

2. Secure engine with appropriate lifting device. (Refer to Deutz Operation Manual included with the machine)

3. Remove 4 Nuts (3) and Flatwashers (2) from the underside of the engine tray.

4. Remove all 4 Bolts (1) and second set of Flatwashers.

5. Carefully lift engine from engine compartment with appropriate lifting device.

NOTE: When installing the engine, follow the steps in

reverse order.

The machine comes with an engine oil drain hose (located in the plastic bag in the valve compartment) to use when draining the oil from the engine. Remove the cover on the Oil Drain Port (4). Attach the drain hose to the Port. The valve on the hose releases the valve on the Port to drain the oil. Run the hose through the opening on the bottom of the engine tray.

3121322 – JLG Lift – 3-21

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Hydraulic Tank

2, 3, 4

1. Hydraulic Tank

2. Capscrew, M10 x 25mm

3. Flatwasher, M10 (2 per capscrew)

4. Nut, M10

5. Filler

6. Shutoff Valve Levers

Removal:

1. Shut the two valve levers (6) at the base of the tank to turn off flow of hydraulic fluld. Drain hydraulic fluid by opening the drain port on underside of the Hydraulic Tank (1). Store fluid in appropriate receptacle. Disconnect all hoses.

2. Remove hydraulic tank by removing the four Capscrews (2), Nuts (4) and eight Flatwashers (3).

3. Carefully remove the tank from the engine compartment.

2, 3, 4

Figure 3-20. Hydraulic Tank Removal

Installation:

1. Place tank into engine compartment lining up the bolt holes.

2. Replace Capscrews, Flatwashers and Nuts into their respectable holes. Tighten.

3. Replace all hydraulic hoses.

4. Ensure the drain port is closed.

5. If required, replace Filter.

6. Remove Filler cap (5) and fill tank with hydraulic fluid to its designated capacity, 37 gal (135 L).

7. Open valve lever to turn on flow of hydraulic fluid.

3-22 – JLG Lift – 3121322

Pressure Filter

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2, 3

1. Pressure Filter 2. Capscrew, M10 x 20mm 3. Lockwasher, M10

Figure 3-21. Pressure Filter Removal

Removal:

1. Disconnect hose(s) from the Pressure Filter (1).

2. Loosen and remove the four Capscrews (2) and Lockwashers (3).

3. Remove the Pressure Filter.

Installation:

1. Align the pressure filter so that the screw holes match up with the screw holes on the holding bracket.

NOTE: Be sure arrow on top of filter points towards the

hydraulic tank.

2. Insert the four Lockwashers and Capscrews into the holes and tighten.

3. Reconnect any hose(s) disconnected during removal.

3121322 – JLG Lift – 3-23

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.7 FUEL TANK

1. Fuel Tank Shield

2. Bolt, M10 x 12mm

7, 8

6 10 11

3. Lockwasher, M10

4. Fuel Tank

5. Fuel Line Hose, 5.5mm

6. Fuel Line Hose, 7.5mm

7. Strain Relief Connector

8. Strain Relief Nut

9. Hose Fitting

10. Hose Fitting

11. Clamp

12. Fuel Tank Strap

13. Nut, M8

14 13

Figure 3-22. Fuel Tank Removal

Removal:

NOTE: Drain Fuel Tank (4) before removing. Store diesel

fuel in approved receptacle.

1. Remove Fuel Tank Shield (1) by removing the four Bolts (2) and Lockwashers (3).

2. Disconnect the Fuel Line Hoses (5, 6) from the engine compartment by unscrewing and removing the Strain Relief Nut (8) from the inside of the compartment.

3. The fuel line hoses can be removed from the fuel tank by removing the Hose Fittings (9, 10). The hoses can be removed from the Hose Fittings by removing the Clamps (11).

4. Remove the Fuel Tank (4) by removing the four Nuts (13) and Lockwashers (14) on the two fuel Tank Straps (12).

14. Lockwasher, M8

Installation:

1. Place Fuel Tank onto the chassis. Secure tank with Fuel Tank Strap. Fasten with Bolts and Lockwashers.

2. If applicable, secure Hose Fittings to Hoses with Clamps. Connect Fuel Line Hoses to Tank.

3. Reconnect the Fuel Line Hoses to the engine compartment by screwing the Strain Relief Nut on the inside of the compartment.

4. Install the Fuel Tank Shield by replacing the four Bolts and Lockwashers.

5. Refuel Tank with diesel fuel.

NOTE: Empty fuel tank weighs approximately

36.6 lbs (16.6 kg).

3-24 – JLG Lift – 3121322

3.8 GROUND CONTROL PANEL

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Ground Control Panel

2. Electrical Compartment

Figure 3-23. Ground Control Panel Removal

Removal:

3. Bolt, M6 x 20mm

4. Nut, M6

NOTICE

DISCONNECT GROUND CONTROL PANEL (1) FROM BATTERY BEFORE REMOVING AND/OR SERVICING.

1. Disconnect all plugs and wires from the back of the control panel.

2. Remove the panel from the the Electrical Compartment (2) by removing the six Bolts (3), Nuts (4), and twelve Flatwashers (5).

NOTE: When removing the control panel, take care not to

damage any plug receptacles and switches.

5. Flatwashers, M6

Installation:

1. Attach the Ground Control Panel to the Electrical Compartment with the Bolts, Flatwashers, and Nuts.

2. Carefully attach all wires and reconnect to battery.

3. Make certain all LED’s and switches work properly.

3121322 – JLG Lift – 3-25

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.9 BATTERY REMOVAL

1. Batteries

2. Battery Cable (Battery - to Battery +)

3. Battery Cable (Battery + to Battery Disconnector)

4. Battery Cable (Battery - to Engine)

5. Bolts, M8 x 35mm

6. Lockwashers, M8

7. Battery Hold Clamp

NOTE: Items 5, 6, and 7 are also located on the

back side of the battery (not shown)

STARTER

ENGINE

Battery Schematic

Figure 3-24. Battery Removal

Removal:

1. Disconnect and remove the Battery Cables (2, 3, 4) from the battery terminals. Loosen the bolt on the terminal clamps to remove the cables.

2. Remove the Bolts (5), Flatwashers (6) securing both the front (shown) and rear (not shown) Battery Hold Clamp (7) to the electrical compartment.

ENGINE CHECK BO

BATTERY DISCONNECTOR

BATTERIE

Installation:

1. Place Batteries into electrical compartment.

2. Align Battery Hold Clamps with bolt holes on floor.

3. Secure Clamps with Bolts and Lockwashers.

4. Reconnect Battery Cables to the battery terminals. Tighten bolt on the terminal clamps.

3. Remove the Battery Hold Clamp.

4. Remove Batteries(1).

3-26 – JLG Lift – 3121322

3.10 PLATFORM

Platform Control Box

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Control Box Lid

2. Control Box

3. Screw, M4 x 30

Figure 3-25. Platform Control Box

For access to the inside of the platform control box, follow these steps:

1. Disconnect platform control box connector from the machine.

2. Remove the six Screws (3) securing the Control Box Lid (1) to the Control Box (2).

3. Carefully lift the lid from the box.

4. At this point, wires, plugs, and other parts may be disconnected for repair/replacement.

NOTE: When assembling the platform control box, be care-

ful not to pinch wires when replacing the lid back onto the box.

3121322 – JLG Lift – 3-27

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Joystick Controller

Figure 3-26. Joystick

Table 3-6. Joystick Specifications

Input Voltage 24V (±0.05V)

Centered Output Voltage 12V (±0.25V)

Reverse Voltage 5.5 - 6.5V

Forward Voltage 17.5 - 18.5V

Table 3-7. Plug Loading Chart

Te rm in al Color Function

1 Green Steer Left

2 Yellow Steer Right

3Brown Pot Out

4N/C

5N/C

6N/C

7Blue 24V In

8RedEnable / 24V Out

9 White / Black Ground

3-28 – JLG Lift – 3121322

Receptacles

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2, 3, 4

7, 8, 9

1. Receptacle Box

2. Bolt, M6 x 20mm

3. Flatwasher, M6 (qty 2)

Figure 3-27. Platform Receptacle Box Removal

Removal:

DISCONNECT BATTERY SUPPLY ON GROUND CONTROL PANEL BEFORE REMOVING RECEPTACLE BOX.

1. Remove front platform floor panel to expose the bolts connecting the Receptacle Box (1) to the platform.

2. Disconnect all wires connected to the 110V Receptacle (5) and Platform Control Box Outlet (6).

4. Nut, M6

5. 110V Receptacle

6. Platform Control Box Outlet

7. Bolt, M5 x 16

8. Flatwasher, M5 (qty 2)

9. Nut, M5

5. The 110V Receptacle (5) can be removed from the box by removing the four screws on the backside.

6. The Platform Control Box Outlet (6) can be removed by removing the four Bolts (7), eight Flatwashers (8), and four Nuts (9).

Installation:

1. Follow Removal steps in reverse order.

3. Remove the four Bolts (2), eight Flatwashers (3), and four Nuts (4).

4. Lift box from platform.

3121322 – JLG Lift – 3-29

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Extension End Rails

Figure 3-28. Extension End Rail Removal

NOTE: Before rails can be lowered, loosen the bolt on the

plastic rail-guide rollers and lower the roller so that it is not hindering the lowering of the rails.

Removal:

1. Disconnect End Rail (1) from Side Rail (2) by removing the two Spring Cotters (3).

2. The Chain Assembly can be removed from the End Rail by removing the Bolts (4), Nuts (5), and Flatwashers (6).

3. Remove the Spring Cotter (7) on each leg of the End Rail. Carefully fold the end rail inward to its stowed position.

4. The End Rail can be removed by removing the Capscrews (8), Locknuts (9), and Washers (10) on each leg of the End Rail.

Installation:

1. Extension End Rail

2. Extension Side Rail

1. Lay end rail on the platform deck in the rails stowed position, lining up the bolt holes with the appropriate connection points on the platform.

2. Follow the removal instructions in reverse order.

3. Spring Cotter

4. Bolt, M8 x 20mm

5. Nut, M8

6. Flatwasher, M8

7. Spring Cotter

8. Capscrew, M10 x 80mm

9. Locknut, M10

10. Washer, 10mm

3-30 – JLG Lift – 3121322

Extension Side Rails

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Extension Side Rail

2. Spring Cotter

3. Capscrew, M10 x 80mm

4. Locknut, M10

5. Washer, 10mm

Figure 3-29. Extension Side Rail Removal

NOTE: Stow or remove the Extension End Rail before

removing the Extension Side Rails. (See the procedures on the previous page).

Removal:

NOTE: Procedures apply to both left and right sides.

1. Remove the Spring Cotters (2) on each leg of the Side Rail (1).

2. Carefully fold the rails inward to the stowed position.

3. Remove the rail by removing the Capscrews (3), Locknuts (4), and Washers (5) from each leg of the rail.

NOTE: Extension side rails weigh approximately 43 lbs

(19.5 kg) each.

Installation:

NOTE: Procedures apply to both left and right sides.

1. Carefully place extension side rails on the platform in their stowed position, lining up the bolt holes on the rail legs with the appropriate connecting points on the platform.

2. Follow the removal procedures in reverse order.

3121322 – JLG Lift – 3-31

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Main Platform End Rails

14,15,16

Figure 3-30. End Rail Removal

1. End Rails (Right, Left, and Gate)

2. Hairpin Spring, M3

3. Pin

4. Hairpin Spring, M3

5. Pin

6. Hairpin Spring, M4

7. Bolt, M8 x 20mm

8. Nut, M8

9. Flatwasher, M8

10. Link

11. Bolt, M10 x 40mm

12. Nut, M10

13. Flatwasher, M10

14. Bolt, M10 x 80mm

15. Nut, M10

16. Flatwasher, M10

Removal:

1. Disconnect End Rails (1) from side rails by removing the Hairpin Springs (2). Remove the Pins (3).

2. Remove second set of Hairpin Springs (4) and Pins (5).

3. Rotate Link (10) to opposite side.

4. Remove Hairpin Springs (6) on the legs of the end rails.

5. Carefully fold end rails inward so they are in the stowed position.

6. Remove the end rails from the platform by removing the four Bolts (14), Nuts (15), and Flatwashers (16).

NOTE: The gate can be detached from the left end rail by

removing the screws on each of the hinges.

Installation:

1. Lay end rails on the platform deck in the rails stowed position, lining up the bolt holes with the appropriate connection points on the platform.

2. Follow the removal instructions in reverse order.

NOTE: The gate can be attached to the left end rail by

replacing the screws on each of the hinges.

3-32 – JLG Lift – 3121322

Main Platform Side Rails

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

6, 7, 8

Figure 3-31. Side Rails Removal

NOTE: Stow or remove Main Platform End Rails and Plat-

form Extension Side Rails before removing the Main Platform side rails. (See instructions on previous pages).

All removal procedures apply to both left and right sides.

Removal:

1. Remove the two Hairpin Springs (2) on each leg of the rail.

2. The Chain Assemblies can be removed from the platform by removing the Bolts (3), Nuts (4), and Flatwashers (5).

3. Carefully fold the rails inward to the stowed position.

1. Side Rail

2. Hairpin Spring, M4

3. Bolt, M8 x 20mm

4. Nut, M8

5. Flatwasher, M8

6. Capscrew, M10 x 80mm

7. Locknut, M10

8. Washer, 10mm

NOTE: Procedures below apply to both left and right sides.

Installation:

1. Carefully place side rails on the platform in their stowed position, lining up the bolt holes on the rail legs with the appropriate connecting points on the platform.

2. Follow the removal procedures in reverse order.

4. Remove rails from the platform by removing the Capsrews (6), Locknuts (7), and Washers (8) from the legs on each rail.

NOTE: Each side rail weighs approximately 43 lbs (19.7 kg).

3121322 – JLG Lift – 3-33

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Platform Removal

2, 3

1. Platform Pivot Pin

2. Bolt, M20 x 35mm

3. Lockwasher, M20

NOTE: Illustration shows scissor arm assembly connection point

to underside of platform at the front of the platform.

Figure 3-32. Platform Removal - 1 of 2 (Front of Platform)

Machine Stabilization:

The arm stack can be supported by using an overhead crane, Figure 4-28. If an overhead crane is not available the stack may also be lifted by using a forktruck using the following instructions:

1. With the forks on the forktruck slid close together, enter from the front of the machine and place the forks on the cross tube of the second arm weldment below the platform.

2. Slowly lift the arm stack with the forktruck while the manual descent valve is being engaged (this allows the oil to drain back into the tank).

3. Place machine on safety prop and leave the forktruck in place.

If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and platform removal.

NOTE: Procedures apply to both left and right sides.

Removal:

1. Disconnect all wiring and hydraulic lines attached to the platform or platform components. Cap hydraulic lines to prevent leakage.

2. Support the platform along the sides with the forktruck forks or use suitable straps or chains at the four corners of the platform.

3. Remove the two Bolts (2) and Lockwashers (3) attaching the two Platform Pivot Pins (1) to the Platform.

4. Continue on to the rear of the machine. (See next page)

3-34 – JLG Lift – 3121322

2, 3

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2, 3

NOTE: Illustration shows scissor arm assembly connection point to underside of

platform at the rear of the platform.

Figure 3-33. Platform Removal - 2 of 2 (Rear of Platform)

Platform Removal:

NOTE: Procedures apply to both left and right sides.

1. Support the platform along the sides with the forktruck forks or use suitable straps or chains at the four corners of the platform.

2. Remove the fourteen Capscrews (2) and Flatwashers (3) attaching both Platform Retaining Brackets (1) to the Platform.

3. Lift the platform from the armstack.

1. Platform Retaining Bracket

2. Capscrew, M10 x 20mm

3. Flatwasher, M10

3121322 – JLG Lift – 3-35

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.11 LADDER INSTALLATION

1. Ladder

2. Bolt, M10 x 20mm

3. Spring Lockwasher, M10

Figure 3-34. Ladder Installation

Removal:

1. The Ladder (1) can easily be removed by removing the four Bolts (2) and Spring Lockwashers (3).

USE CAUTION WHEN REMOVING THE LADDER. THE LADDER WEIGHS APPROXIMATELY 85.6 LBS (38.9 KG)

Installation:

1. Lift ladder so that the four mounting brackets align with the bolt holes on the chassis.

2. Secure ladder to the chassis with the four Bolts (2) and Spring Lockwashers (3).

3-36 – JLG Lift – 3121322

3.12 BEACON INSTALLATION (OPTION)

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Front Beacon

5, 7

Front and Rear

1. Beacon & Protective Cage

2. Mounting Bracket

3. Screw, 6mm x 16mm

4. Washer, 6mm

Rear Beacon

Harness

Position W11

MTB Underside

5. Bolt, M4 x 25mm

6. Nut, M4

7. Washer

8. Guiding Rods

Figure 3-35. Beacon Installation

Removal:

NOTE: Procedures apply to both the Front and Rear Bea-

cons.

1. Disconnect electrical supply.

2. Disconnect beacon harness from beacon and MTB, if needed.

3. Remove Bolts (5), Nuts (6), and Washers (7) to remove the Beacon and Protective Cage (1).

4. The Mounting Bracket (2) can be removed from the chassis by removing the two Screws (3) and Washers (4).

5. Repair/Replace if necessary.

Installation:

1. Follow Removal Procedures in reverse order.

3121322 – JLG Lift – 3-37

2. Route Front Beacon Cable behind the Guiding Rods (8) to avoid contact with the tie bar. Follow route of the signal cable for Outrigger 1. Fix with tie straps.

3. Route Rear Beacon Cable together with signal cable for Outrigger 3. Fix with tie straps.

4. Route Harness through Position W11 on the underside of the Main Terminal Box (MTB).

Table 3-8. Beacon Harness MTB Connections

Side Wire Color Signal Termiinal Position

Front

Rear

Brown + X1/34B-1

Blue GND X1/1-3

Brown + X1/34B-2

Blue GND X1/1-4

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.13 SCISSOR ARMS

Limit Switches

1. Cam 1

2. Cam 2

3. Cam 3

4. Cam 4

Figure 3-36. Scissor Arm Limit Switch Adjustment

Cam Adjustment:

1. Adjust Cam 1 (1) to activate Platform Stowed/Jacks Retract Limit Switch (5) when platform is completely stowed.

2. Adjust Cam 2 (2) to activate High Drive Speed Cutout Limit Switch (6) when platform is at a height of

11.5 ft (3.5 m).

5. Platform Stowed/Jacks Retract Limit Switch

6. High Drive Speed Cutout Limit Switch

7. Max Drive Height/Max Height without Outriggers Limit Switch

8. Max Height Limit Switch

3. Adjust Cam 3 (3) to activate Max Drive Height/Max Height without Outriggers Limit Switch (7) when platform is at a height of 50 ft (15.3 m).

4. Adjust Cam 4 (4) to activate Max Height Limit Switch (8) when platform is at a height of 66.6 ft (20.3 m).

NOTE: The limit switch plate can be removed by removing

the bolts, washers and nuts at each end of the mounting plate.

3-38 – JLG Lift – 3121322

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Scissor Arm Assembly Removal

EXTREME CAUTION MUST BE USED WHILE REMOVING ANY LARGE COMPONENTS. THESE COMPONENTS ARE EXTREMELY HEAVY AND CAN CAUSE SERIOUS INJURY OR DEATH IF NOT REMOVED CAUTIOUSLY.

NOTE: It is recommended to remove the scissor arm

assembly as a whole unit.

1. Disconnect all hoses and wires connecting the scissor assembly to the chassis and platform.

2. Remove platform from the scissor arm stack. (see Figure 3-32. and Figure 3-33.)

3. Secure scissor arm assembly with two lifting straps attached to an overhead lifting device.

NOTE: Scissor arm assembly weighs approximately 11,243

lbs (5100 kg). Straps and lifting device must be capable of lifting the scissor assembly.

STRAP STRAP

3121322 – JLG Lift – 3-39

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Remove one pin from the steering linkage to gain access to the scissor arms pin behind the wheel. (see Section 3.3, Steering Assembly).

5. Remove the cable from the ground control socket in the valve compartment. Remove the hydraulic hoses for the platform extension. (refer to Figure 4-33., Main Valve Block). Cap the fittings and secure the cable and hoses to the arm stack with tape. As soon as possible, brace the lift cylinder so that when it is disconnected from the arm stack it will be secured and will not fall.

6. Remove the Bolts (1), Flatwashers (2), and Locknnuts (4) on the bottom arm pin at the rear of the machine.

8. Remove the Coverplates (3) from both sides of the machine by removing the two Bolts (1) and Lockwashers (2). Once the coverplates are removed the Pin (4) can be pushed out.

1. Bolt, M6 x 10mm

2. Lockwasher, M6

9. Remove the plate with the limit switches attached. (refer to Figure 3-36., Scissor Arm Limit Switch Adjustment)

3. Coverplate

4. Pin

1. Bolt, M16 x 140mm

2. Flatwasher, M16

3. Spacer

4. Locknut, M16 (not shown)

7. Slightly lift the scissor stack up with the overhead crane so that the rear sliding blocks in the chassis are free.

10. Remove the bottom arm Pin (3) at the front of the machine by removing the Bolt (1) and Lockwasher (2). Pull the Pin out and secure the pin to the chassis.

1. Bolt, M20 x 35mm

2. Lockwasher, M20

3. Pin

3-40 – JLG Lift – 3121322

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

11. Lift the arm stack up and to the front. The lift cylinder (1) is still attached to the chassis and the arm stack will pivot about the Pin (2). When sufficient clearance is achieved between the lift cylinder and frame, secure the cylinder.

NOTICE

NEVER EXTEND THE LIFT CYLINDER WHEN THERE IS NO LOAD ON THE CYLINDER. THE CYLINDER IS SINGLE ACTING AND WILL HAVE NO MEANS OF RETRACTING.

STRAP

12. Disconnect the Lift Cylinder from the arm stack by removing the Bolt (3) and Lockwasher (4). Pull out the Pin (2).

1. Lift Cylinder

2. Pin

13. The arm stack can now be moved away from the machine. Place the arm stack in a holding device or on secure blocks.

3. Bolt, M12 x 35mm

4. Lockwasher, M12

NOTE: Follow the removal steps in reverse order when

installing the arm assembly.

3121322 – JLG Lift – 3-41

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Lift Cylinder Removal

USE CAUTION WHEN REMOVING AND MOVING THE LIFT CYLINDER. THE LIFT CYLINDER ASSEMBLY WEIGHS APPROXIMATELY 992 LBS (450 KG). USE APPROPRIATE LIFTING DEVICES.

1. Follow the procedures on the previous pages to remove the platform and scissor arm assemblies.

2. Shutoff flow of hydraulic fluid by closing the shutoff levers on the hydraulic tank (see Figure 3-20.). Remove all hoses and/or wires from the Lift Cylinder (1).

NOTICE

MAKE SURE THE FITTING ON THE LEAK OIL LINE IS CLOSED TO PREVENT EXTENSION OF THE CYLINDER WHILE LIFTING FROM THE MACHINE.

3. Place a strap, attached to an overhead lifting device, through the top portion of the lift cylinder to secure the cylinder.

4. Put the cylinder into a vertical position with the overhead lifting device.

5. Remove the Bolt (2) and Lockwasher (3). Pull the Pin (4) out of the machine.

6. Carefully raise the Lift Cylinder (1) from the chassis using an overhead crane or other suitable lifting device.

STRAP

1. Lift Cylinder

2. Bolt, M20 x 35mm

Figure 3-37. Lift Cylinder Removal

NOTE: Follow the removal procedures in reverse order

when installing the lift cylinder.

3-42 – JLG Lift – 3121322

3. Lockwasher, M20

4. Pin

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Scissor Arms Disassembly

INDIVIDUAL SCISSOR ARMS ARE HEAVY. USE CAUTION WHEN REMOVING. USE APPROPRIATE LIFTING DEVICES.

1. Disconnect battery and shutoff flow of hydraulic fluid by closing the shutoff levers on the hydraulic tank (see Figure 3-20.).

2. Remove Platform [see Figure 3-32., Platform Removal - 1 of 2 (Front of Platform) and Figure 3-33., Platform Removal - 2 of 2 (Rear of Platform)].

3. Hydraulic lines and electrical lines run through the insides of the scissor arms. These hoses and wires must be removed before removing the arm components.

4. Brace the Scissor Arm Assembly as well as the individual Scissor Arm(s) being removed.

NOTE: The below steps apply to each scissor arm pin.

5. On the left side of the machine, remove the Nut (2) with a spanner wrench. Next, remove the Retaining Washer (3) and Washer and Pin (4).

6. Move to the right side of the machine. The Arm Pin (1) can now be pulled out of the scissor arm stack. Remove the four Bushings (2), two Ball Thrust Bearings (3), and two Bushings (4).

1. Arm Pin (75mm, 90mm, 100mm, or 120mm)

2. Bushing (75 x 60mm, 90 x 60mm, 100 x 60mm, or 120 x 60mm)

3. Ball Thrust Bearing

4. Bushing (75 x 60mm, 75 x 80mm, 100 x 80mm, 90 x 90mm, or 120 x 100mm)

Figure 3-39. Scissor Arm Removal (Right Side)

7. Repeat steps 4 and 5 at each Arm Pin in order to remove the individual scissor arm.

8. Carefully lift the arm from the assembly.

NOTE: Follow the removal steps in reverse order when

installing the scissor arms.

Tighten the Lock Nuts until there is zero clearance

1. Arm Pin (75mm, 90mm, 100mm, or 120mm)

2. Nut (M60, M80, M90, or 100mm)

3. Retaining Washer (MB18, MB20, 60mm, or 80mm)

4. Washer & Pin

Figure 3-38. Scissor Arm Removal (Left Side)

between the arms and the bearings. Back off one quarter of a revolution. Bend the lip on the corresponding Retaining Washer into the notch on the lock nuts.

3121322 – JLG Lift – 3-43

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTES:

3-44 – JLG Lift – 3121322

SECTION 4. HYDRAULICS

SECTION 4 - HYDRAULICS

4.1 CYLINDERS - THEORY OF OPERATION

Deck Extension Cylinder:

The deck is extended and retracted by means of a double acting cylinder controlled by the first section in the main control valve (see Figure 4-33., Main Valve Block). The service line relief valve in the control valve is set at 1160 psi (80 bar) for extend and 3046 psi (210 bar) for retract.

Lift Cylinder:

The lift cylinder is a single acting cylinder incorporating dual solenoid holding valves and a pilot operated check valve for emergency lowering. The lifting function is con-

trolled by the 3 Figure 4-33.). Lift speed is limited by flow from section 1 in the pump.

Lowering is operated by energising the two solenoid holding valves together with the 3rd section of the main control valve (see Figure 4-33.). Descent speed is controlled by an adjustable line mounted flow control valve.

To enable lowering at full speed when the engine is stopped (i.e. there is no hydraulic power available to act as a pilot supply for the electrical actuator), a pilot line can be connected to the auxiliary port "M" on the control valve via a check valve. This provides the hydraulic power necessary to shift the lower valve section.

section of the main control valve (see

Outrigger Cylinders:

The automatic self leveling system is controlled by 4 double acting cylinders mounted at each corner of the machine chassis. These cylinders incorporate pilot operated holding valves on the piston side. The cracking pressure for these valves is 15 psi (1 bar) for the rear and 116 psi (8 bar) for the front.

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 consists 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 springloaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Relief Valves

Main 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.

Steer Cylinder:

Steering has a dedicated solenoid valve mounted in the valve compartment. This valve receives hydraulic power from the 3rd pump section and is protected by an inline filter. The steering valve incorporates a full flow pressure relief valve which is set at 2538 psi (175 bar).

4.2 VALVES - THEORY OF OPERATION

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral relief’s are provided for each side of the circuit.

Solenoid Control Valves (Bang-Bang)

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

3121322 – JLG Lift – 4-1

Proportional Valve

Flow is proportional to the amount of voltage supplied to the valve coil. Voltage is gained by the machine controller and determined by the position of the joystick.

SECTION 4 - HYDRAULICS

4.3 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system

component is replaced or when improper system operation is suspected.

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, then activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made.

4.4 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. Refer to Figure 4-24. thru Figure 4-27. for specific cylinder assembly breakdowns and for specific parts references. Refer to JLG Parts Manual 3121323 for seal kits and part numbers.

Disassembly

BEFORE REMOVING CYLINDERS FROM THE MACHINE BE SURE TO SUPPORT THE MACHINE AND SCISSOR ARMS/PLATFORM WITH SAFETY PROPS, FORKLIFTS, OR OVERHEAD CRANE TO PREVENT RELEVANT COMPONENTS FROM COLLAPSING AND CAUSING SERIOUS INJURY OR DEATH. (SEE FIGURE 4-28.)

1. Remove cylinder(s) from the machine by first disconnecting all hoses and/or wires and any valves. Next, unscrew bolts connecting cylinder(s) to the machine. If applicable, remove any pins connecting the cylinders to the machine.

NOTE: Step 2 applies only to the Lift Cylinder.

2. To prevent damage, remove the hydraulic block, load retaining valve block, and check valve block from the lift cylinder barrel by unscrewing the 8 set screws.

Cylinder Barrel

Valve Blocks

Setscrews

Figure 4-1. Lift Cylinder Valve Block Removal

4-2 – JLG Lift – 3121322

SECTION 4 - HYDRAULICS

NOTE: Step 3 applies only to the Outrigger Cylinders.

3. To prevent damage, remove the safety valve and limit switch from the top of the outrigger cylinders.

Limit Switch

Safety Valve

Outrigger Cylinder

Figure 4-2. Safety Valve and Limit Switch Removal

7. Place the cylinder barrel into a suitable holding fixture.

Figure 4-3. Cylinder Barrel Support

8. Using a spanner wrench, loosen and remove the cylinder head from the barrel.

Cylinder Rod

NOTICE

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

4. 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.

5. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source.

6. Adequately support the cylinder rod, if applicable.

Cylinder Head

Barrel

Figure 4-4. Cylinder Head Removal

NOTICE

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.

3121322 – JLG Lift – 4-3

SECTION 4 - HYDRAULICS

9. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

Figure 4-5. Cylinder Rod Support

10. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

11. Loosen and remove the setscrew which attaches the piston to the rod, and remove the piston.

12. Unscrew the piston counter-clock-wise, by hand, and remove the piston from the cylinder rod.

Piston

Cylinder Rod

Figure 4-7. Piston Removal

13. Remove and discard the piston o-rings, seal rings, and, if applicable, the snap ring.

Snap Ring (Outrigger Cylinder Only)

O-Ring

Pistons

Setscrews

Figure 4-6. Piston Setscrew Removal

Piston

Piston Seal

Figure 4-8. Piston Seals

4-4 – JLG Lift – 3121322

SECTION 4 - HYDRAULICS

14. If applicable, remove the spacer from the rod.

Spacer

Cylinder Rod

Figure 4-9. Spacer Removal

15. Remove the rod from the holding fixture.

16. Remove the cylinder head from the cylinder rod.

Cylinder Head

17. If applicable, remove and discard the cylinder head seal, rod seal, wiper, o-ring(s), back-up ring, and snap ring.

Snap Ring (Outrigger Cylinder Only)

Backup Ring (Outrigger Cylinder Only)

Wiper

Head Seal

O-Ring

Rod Seal

Cylinder Head

O-Ring

Figure 4-11. Cylinder Head Seals

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.

Cylinder Rod

Figure 4-10. Cylinder Head Removal

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.

7. If applicable, 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.

3121322 – JLG Lift – 4-5

SECTION 4 - HYDRAULICS

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 bushings for signs of excessive wear or damage. Replace as necessary.

a. Thoroughly clean bushing housing of burrs, dirt,

etc. to facilitate bearing installation.

b. Inspect bushing housing for wear or other dam-

age. If the bushing housing is worn or damaged, rod/barrel must be replaced.

c. Lubricate inside of bushing housing with WD40

prior to bushing installation.

d. Using an arbor of the correct size, carefully

press the bushing(s) into bushing housing on the cylinder rod and cylinder barrel, if applicable.

Bushing Housing

Bushing

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used. See your JLG Parts Manual

3121323. Always replace seals when servicing cylinders.

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.

ROD SEAL

Figure 4-13. Rod Seal Installation

Arbor To ol

Figure 4-12. Bushing Installation

NOTE: Step 14 applies only to the Lift Cylinder.

14. Inspect the hydraulic block, load retaining valve block, and check valve block for any damage. Replace as necessary.

15. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

NOTICE

WHEN INSTALLING PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

WHEN INSTALLING THE WIPER SEAL, APPLY LOCTITE #609 ON THE WIPER SEAL IN THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE SEAL.

2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new rod seal into the applicable cylinder head glandgroove.

16. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

4-6 – JLG Lift – 3121322

SECTION 4 - HYDRAULICS

3. Install a new head seal, new o-rings, and, if applicable, a new backup ring, in the appropriate outside diameter groove of the cylinder head.

Snap Ring (Outrigger Cylinder Only)

Backup Ring (Outrigger Cylinder Only)

Wiper

Head Seal

O-Ring

Rod Seal

Cylinder Head

O-Ring

Figure 4-14. Cylinder Head Seal Installation

4. Carefully install the cylinder head on the rod, ensuring that the wiper, o-ring, 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 onto the cylinderrod.

Spacer

Cylinder Rod

Figure 4-16. Spacer Installation

6. If applicable, correctly install new o-ring and snap ring in the inner piston diameter groove.

Cylinder Head

Cylinder Rod

Figure 4-15. Cylinder Head Installation

7. If applicable, correctly place new seals in the outer piston diameter groove(s). (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal.)

Snap Ring (Outrigger Cylinder

O-Ring

Only)

Piston

Piston Seal

Figure 4-17. Piston Seal Installation

8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.

3121322 – JLG Lift – 4-7

SECTION 4 - HYDRAULICS

9. Carefully thread the piston clock-wise on the cylinder rod hand tight until it abuts the spacer, ensuring that the o-ring, snap ring, and piston seals are not damaged or dislodged.

Piston

Spacer

Cylinder Rod

Figure 4-18. Piston Installation

NOTICE

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.

13. 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.

Cylinder Head

Cylinder Rod

10. Insert the setscrews on the piston and tighten to lock piston in place on cylinder rod.

Pistons

Setscrews

Figure 4-19. Piston Setscrew Installation

11. Remove the cylinder rod from the holding fixture.

12. Position the cylinder barrel in a suitable holding fixture.

Piston

Cylinder Barrel

Figure 4-20. Rod Installation

14. Continue pushing the rod into the barrel until the cylinder head can be inserted into the barrel cylinder.

4-8 – JLG Lift – 3121322

Cylinder Rod

SECTION 4 - HYDRAULICS

Limit Switch

Safety Valve

Cylinder Head

Barrel

Figure 4-21. Rod Assembly Installation

15. Use a spanner wrench to tighten the cylinder head on the barrel.

16. If applicable, after the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any valve block or load check valve.

Cylinder Barrel

Valve Blocks

Outrigger Cylinder

NOTE: Outrigger Cylinders only.

Figure 4-23. Safety Valve and Limit Switch Installation

NOTE: Refer to Figure 1-3., Torque Chart - (In/Lb - Ft/Lb).

(For ASTM Fasteners) to Figure 1-5., Torque Chart (Nm) - (For Metric Class Fasteners). for setscrew torques.

Setscrews

NOTE: Lift Cylinder only.

Figure 4-22. Valve Block Installation

3121322 – JLG Lift – 4-9

SECTION 4 - HYDRAULICS

1. Barrel Weldment

2. Rod Weldment

3. Piston

4. Cylinder Head

5. Wear Ring

6. Piston Seal

7. O-Ring

8. Cylinder Head

9. Wiper Ring

10. Rod Seal

11. O-Ring

12. Valve Cartridge

Figure 4-24. Lifting Cylinder Assembly

13. Test Fitting

14. Holding Valve Assembly

15. Capscrew, M6 x 50mm

16. Capscrew, M8 x 45mm

17. Check Valve Assembly

18. Valve Cartridge

19. O-Ring

20. O-Ring

21. Bushing

22. Bushing

4-10 – JLG Lift – 3121322

SECTION 4 - HYDRAULICS

1. Barrel Weldment

2. Piston

3. Setscrew

4. Piston Seal

5. Spacer

6. Cylinder Head

7. Wiper

8. Rod Seal

9. O-Ring

10. Head Seal

11. Rod

12. Bushing

Figure 4-25. Steering Cylinder Assembly

Table 4-1. Steering Cylinder Specs

Maximum Working Pressure

Piston Head Torque (apply Loctite 242 prior to tightening)

Max Speed

Max Operating Temperature

3046 psi

(210 bar)

191.8 lb ft (260Nm)

1.6 ft/sec

(0.5 m/sec)

- 4° F to 1 7 6° F

(-20°C to 80°C)

3121322 – JLG Lift – 4-11

SECTION 4 - HYDRAULICS

1. Barrel

2. Mounting Flange

3. O-Ring

4. Piston

5. Setscrew

6. Piston Seal

7. Spacer

8. O-Ring

9. Cylinder Head

10. O-Ring

11. Backup Ring

12. Head Seal

13. Rod Seal

14. Wiper

15. Snap Ring

16. O-Ring

17. Rod

Figure 4-26. Leveling Cylinder Assembly

Table 4-2. Leveling Cylinder Specs

Max Working Pressure

Piston Head Torque (Apply Loctite 243 prior to tightening)(torque with Rod End)

Setscrew Torque (Apply Loctite 222 prior to tightening)

Max Speed

Max Operating Temperature

2683.1 psi (185 bar)

442.5 lb ft (600 Nm)

14.8 lb ft (20 Nm)

1.6 ft/sec

(0.5 m/sec)

-22°F to 212°F

(-30°C to 100°C)

4-12 – JLG Lift – 3121322

SECTION 4 - HYDRAULICS

1. Barrel

2. Piston

3. Setscrew

4. Piston Seal

5. Spacer

6. Cylinder Head

7. O-Ring

8. Head Seal

9. Wiper

10. Rod Seal

11. O-Ring

12. Rod

Figure 4-27. Extension Cylinder Assembly

Table 4-3. Extension Cylinder Specs

Max Working Pressure

Bore Relief Pressure

Piston Torque (Apply Loctite 242 prior to tightening)

Set screw Torque (Apply Loctite 222 prior to tightening)

Max Speed

Max Operating Temperature

3121322 – JLG Lift – 4-13

3046 psi

(210 bar)

1160 psi

(80 bar)

147.5 lb ft (200 Nm)

14.8 lb ft (20 Nm)

1.6 ft/sec

(0.5 m/sec)

-22°F to 176°F

(-30°C to 80°C)

SECTION 4 - HYDRAULICS

REMOVE ANY LOAD FROM PLATFORM. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING.

STRAP

ARM SAFET PROP

Figure 4-28. Arms and Platform Positioning and Support

4-14 – JLG Lift – 3121322

4.5 VALVES

Valve Compartment

SECTION 4 - HYDRAULICS

1. Pressure Switch, Drive Enable & Brake Valve

2. Main Valve Block

Pressure Switch, Drive Enable

3. Steering Valve

4. Drive Valve

Figure 4-29. Valve/Hydraulic Compartment

• Operate the lower function to retract the jacks and adjust the switch (screw on the top of the switch) to trip at 2683 psi (185 bar)

5. Hand Pump

6. Pressure Manifold

Figure 4-30. Pressure Switch Adjustment

3121322 – JLG Lift – 4-15

SECTION 4 - HYDRAULICS

Brake Valve

Brake Valve Adjustment:

1. Torque to 5 ft lbs (6.8 Nm)

VALVE SCHEMATIC

Figure 4-31. Brake Valve

2. Torque to 20 ft lbs (27.1 Nm)

• Operating Pressure: 3000 psi (207 bar)

• Voltage: 24VDC

Figure 4-32. Brake Valve Adjustment

• To achieve smooth deceleration when the joystick is returned quickly from the max forward or backward position to the neutral position, completely close the valve knob (shown to the left) then open the knob 1/2 of a revolution.

4-16 – JLG Lift – 3121322

Main Valve Block

SECTION 4 - HYDRAULICS

1. Main Pressure Block

2. Platform

3. Drive 1

4. Lifting

5. Leveling Rear Left

6. Leveling Rear Right

7. Leveling Front Left

8. Leveling Front Right

VALVE SCHEMATI

185

210

PLATFORM

BAB

210

DRIVE 1

Figure 4-33. Main Valve Block

LIFTING

210

LEVELING

210

REAR LEFT

210

LEVELING

REAR RIGHT

210

LEVELING

FRONT LEFT

210

LEVELING

FRONT RIGHT

3121322 – JLG Lift – 4-17

SECTION 4 - HYDRAULICS

Adjust main pressure on top of the Main Pressure Block

• remove the cap and attach a pressure gauge to pressure test port (see Figure 4-35.)

• remove rubber plug from adjustment port

• adjust to 3045.8 psi (210 bar)(see Figure 4-35.)

Figure 4-34. Pressure Test Port

Steering Valve

Figure 4-35. Main Valve Pressure Adjustment

ALVE SCHEMATIC

Figure 4-36. Steering Valve

Pressure Adjustment:

• remove the cap and attach a pressure gauge to pressure test port (see Figure 4-34.)

• operate the Steer Cylinder to end of stroke

• pressure can be set/adjusted by adjusting the screw in the port

• set pressure to 2538 psi (175 bar)

4-18 – JLG Lift – 3121322

Steer Valve Pressure Adjustment:

SECTION 4 - HYDRAULICS

Figure 4-37. Steer Valve Pressure Adjustment

• remove the cap and attach a pressure gauge to pressure test port (see Figure 4-34.)

• remove the black cover (shown in top picture) to gain access to the adjustment screw (shown in bottom picture)

• operate the Steer Cylinder to end of stroke

• pressure can be set/adjusted by adjusting the screw in the port

• set pressure to 2538 psi (175 bar)

3121322 – JLG Lift – 4-19

SECTION 4 - HYDRAULICS

Drive Valve

A1 B1

VALVE SCHEMATIC

Figure 4-38. Drive Valve

4-20 – JLG Lift – 3121322

Hand Pump

SECTION 4 - HYDRAULICS

Pump Assembly

Valve Assembly

Pump Assembly

1. Valve, Suction

2. Plug

3. Plug

4. Body

5. Rod, connecting

6. Lever

7. Piston

8. Seal

9. Seal

10. Pin

11. Ring, Retaining

12. Ball

13. Ring

14. Washer

15. RIng, Internal Retaining

16. Seal

17. Spring

Valve Assembly

18. Body

19. Ball

20. Ring

21. Bolt, M8 x 8mm

22. Spinner (Not Shown)

23. Spring

24. Plug

25. Screw

26. Fitting, Straight

28. Spring

29. Nut, M10

30. Seal

31. Setscrew

32. Relief, Valve

33. Pin, Ball Driving

34. Plate, Seal

35. Valve Body

36. Knob Assembly

37. Valve Body

27. Seal

Figure 4-39. Hand Pump Assembly

3121322 – JLG Lift – 4-21

SECTION 4 - HYDRAULICS

VALVE SCHEMATIC

Figure 4-40. Hand Pump Schematic

Lift/Lower Valve Block

Diagnostic Te s t Por t

Lift Cylinder

Solenoid

Valves

Figure 4-41. Lift/Lower Valve Block

Solenoid Valves (Qty. 2)

1. Torque to 5 ft lbs (6.8 Nm)

2. Torque to 20 ft lbs (27.1 Nm)

• Operating Pressure: 5000 psi (345 bar)

Diagnostic Test Port

• Pressure Rating: 9137 psi (630 bar)

4-22 – JLG Lift – 3121322

Platform Lower Flow Valve

SECTION 4 - HYDRAULICS

• with the rated load on the platform (see Table 1-1), adjust the knob shown to the left to obtain the lowering speed as specified in (Table 1-1)

Figure 4-42. Platform Lower Flow Valve

Outrigger Safety Valves

Outrigger Cylinder

Safety Valve

Front Outriggers:

• Operating Pressure: 116 psi (8 bar)

Rear Outriggers:

• Operating Pressure: 14.5 psi (1 bar)

Figure 4-43. Outrigger Valves

3121322 – JLG Lift – 4-23

SECTION 4 - HYDRAULICS

NOTES:

4-24 – JLG Lift – 3121322

JLG 67SL Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

A. GENERAL

B. HYDRAULIC SYSTEM SAFETY

C. MAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA

1.3 CAPACITIES

1.4 ENGINE

Battery

1.7 LIMIT SWITCHES

Platform Stowed/Jacks Retract Limit Switch

High Drive Speed Cutout Limit Switch

Maximum Drive Height/Maximum Height without Outriggers Limit Switch

1.5 TIRES

1.6 TORQUE REQUIREMENTS

Maximum Height Limit Switch

Tilt Sensor

Outrigger Interlock Sensors

1.8 PRESSURE SETTING

1.9 MAJOR COMPONENT WEIGHTS

1.11 LUBRICATION

1.10 CRITICAL STABILITY WEIGHTS

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Changing Hydraulic Oil

Hydraulic Oil

Lubrication Specifications

2.4 OPERATOR MAINTENANCE

2.5 CYLINDER DRIFT TEST

Lift Cylinder Drift

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS

Leveling Jacks

3.2 WHEEL ASSEMBLY

Drive System

Drive Hub

Roll Test

Leak Test

Lubricant

Tire Replacement

Wheel Replacement

Drive Motor

Motor Disassembly

Motor Assembly

3.3 STEERING ASSEMBLY

3.4 REAR AXLE ASSEMBLY

3.5 OUTRIGGER CYLINDER REMOVAL

3.6 ENGINE COMPARTMENT

Hood Assembly

Deutz Engine

Engine Tray Slide

Glow Plugs

Engine Solenoid