JLG 800A-AJ Service Manual

Service and Maintenance Manual

Models

800A

800AJ

P/N - 3120858

December 12, 2012

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

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

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

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

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

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

B HYDRAULIC SYSTEM SAFETY

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

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

C MAINTENANCE

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

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

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

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

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

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

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

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTED­DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3120858 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - August, 1998
Revised - September 15, 1999
Revised - August 29, 2001
Revised - January 14, 2003
Revised - October 19, 2004
Revised - July 11, 2005
Revised - June 12, 2007
Revised - May 23, 2008
Revised - December 12, 2012

A-2 – JLG Lift – 3120858

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

1.1 Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

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

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

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Load Sense Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Filter - In-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.3 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

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

1.9 Lubrication and Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

Draining Oil Build Up From The Propane Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

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

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TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

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

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

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

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

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

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

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

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

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

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

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

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

SECTION 3 - CHASSIS & TURNTABLE

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

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

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

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

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

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

3.2 Oscillating Axle Bleeding Procedure And Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

3.3 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing . . . . . . . . . . 3-3

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4 Torque Hub, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

3.5 Drive Brake - Ausco (Prior to S/N 56875) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.6 Drive Brake - Mico (S/N 56875 to 83332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.7 Drive Brake (S/N 83332 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

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

3.8 Drive Motor (Prior to S/N 83332). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Replacing the Drive Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Assembly Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Taper Roller Bearing Initial Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Testing and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.9 Drive Motor Adjustment Procedure (Prior to S/N 83332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

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TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.10 Drive Motor (S/N 83332 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.11 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

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

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3.12 Swing Hub installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3.13 Swing Hub (Prior to S/N 0300068040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

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

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

Hub Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3.14 Swing Brake - Ausco (Prior to S/N 0300068040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3.15 Swing Motor (Eaton) (Prior to S/N 0300068040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

3.16 Swing Hub (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Main Assembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Hub Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

3.17 Swing Brake (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

3.18 Swing Motor (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

3.19 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82

3.20 Tilt Alarm Switch (Prior to S/N 0300065534). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3.21 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

3.22 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . 3-90

3.23 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92

Changing from Gasoline to LP Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Changing from LP Gas to Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

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3.24 EFI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

EFI Diagnostics (Prior to S/N 0300065534) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

ECM and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

3.25 Ford LPG System (S/N 0300077500 To Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Megajector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Lockoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

Megajector Diagnostic Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

3.26 Electric Governor Installation And Adjustments - Ford LRG425 Engine

(Prior to S/N 0300065534). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-106

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

Quick-start Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

Mounting-Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

Mounting-Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Check-Out and Initial Start-Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Automatic Choke Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

3.27 Throttle Checks And Adjustments - Deutz Engine (Prior to S/N 0300065534) . . . . . . . . . . . . . . . 3-113

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

3.28 Deutz EMR 2 (S/N 85331 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116

3.29 GM Engine General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-129

Maintenance of the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129

Engine Electrical System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129

Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129

Changing The Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130

Coolant Fill Procedure - Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130

3.30 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132

Electric Lock Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132

EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132

Low Pressure Regulator (LPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133

Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133

Electronic Throttle Control (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Gasoline Multi Point Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Gasoline Pressure And Temperature Sensor Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

Fuel Injector Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

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3.31 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-136

Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136

Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137

Electronic Pressure Regulator (EPR) Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . 3-138

Temperature Manifold Absolute Pressure (TMAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

Electronic Throttle Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

MIXER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141

Coolant Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

Vapor Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

3.32 GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-143

Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143

SECTION 4 - BOOM & PLATFORM

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

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

Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Rotator and Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

4.3 Upper Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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

4.4 Upper Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.5 Upright. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6 Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Tower Out of Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7 Articulating Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

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

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

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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

4.8 Sequence For Hose Replacement In The Tower Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.9 Limit Switches Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Upper Boom Horizontal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Tower Boom Horizontal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Dual Capacity Angle Limit Switch (800A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Upper Boom Length Switch (800 A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.10 Boom Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

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4.11 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Upper Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.12 Rotator (prior to S/N 0300067538) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.13 Rotator Assembly (S/N 0300067538 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Testing the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4.14 Drive Card Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Lift, Swing, and Drive Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Flow Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

4.15 Load Sensing System machines built to s/n 0300062045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

4.16 Load Sensing System machines built s/n 62045 to 67883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

4.17 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

4.18 Upright Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Re-Synchronizing Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Calibration - Pre ADE Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Calibration - ADE Equipped Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Calibration Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Service Mode/Tower Boom Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

4.19 UMS Troubleshooting and Fault Messages - Non-ADE Machines . . . . . . . . . . . . . . . . . . . . . . . .4-65

Tower Lift Down Permanently closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Backward Stability Concern Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Forward Stability Concern Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Auto Detection Input Low Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

UMS Sensor Communications lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

UMS Sensor Not Calibrated Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

UMS Sensor Faulted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Tower Lift Down Output Short to Ground or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Tower Lift Down Output Short to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Platform Indicator Output Short to Ground or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Platform Indicator Output Short to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Ground Indicator Output Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Ground Indicator Output Short to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Turntable Sensor Not Calibrated Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Turntable Sensor Faulted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

EEPROM checksums failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

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4.20 UMS Troubleshooting and Fault Messages - ADE Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Backward Stability Concern Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Forward Stability Concern Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Auto Detection Input Low Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

UMS Sensor Communications lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Out of Usable Range Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

UMS Sensor Not Calibrated Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

UMS Sensor Faulted Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Incompatible Software Detected Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Calibration Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

SECTION 5 - HYDRAULICS

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

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

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

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

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

5.2 Valves - Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Solenoid Control Valve - Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Holding Valve Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.4 Cylinders - Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

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

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

Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.6 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

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

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.7 Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

Upper Boom Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Upper Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Upper Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Upper Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Upright Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Upright Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Tower Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Tower Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Tower Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Slave Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Slave Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5.8 Hydraulic Pump W/hayes Pump drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5.9 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29

FIRST: Set Up the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

SECOND: Adjustments Made at the Main Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5.10 Hydraulic oil change-out procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-37

5.11 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .5-38

5.12 Rexroth Variable Displacement Pump Prior to S/N 0300121643 . . . . . . . . . . . . . . . . . . . . . . . . . .5-40

5.13 Sauer Piston Pump S/N 0300121643 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

Initial start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Plug and Fitting Sizes and Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

3120858 – JLG Lift – vii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)

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

6.2 CANbus Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.3 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.4 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6.5 Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6.6 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.7 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6.8 Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.9 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

Analyzer Diagnostics Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

viii – JLG Lift – 3120858

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication and Operator Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-2. Deutz Engine Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-3. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-4. Torque Chart (SAE Fasteners - Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

1-5. Torque Chart (SAE Fasteners - Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

1-6. Torque Chart (SAE Fasteners - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

1-7. Torque Chart (SAE Fasteners - Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

1-8. Torque Chart (METRIC Fasteners - Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1-9. Torque Chart (METRIC Fasteners - Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-10. Torque Chart (METRIC Fasteners - Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

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

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

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

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

3-1. Oscillating Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Brake Valve Wiring Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-3. Torque Hub Drive (Fairfield) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-4. Drive Brake, Ausco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-5. Drive Brake - Mico (S/N 56875 to 83332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6. Drive Brake (S/N 83332 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-7. 600S Drive Motor Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-8. Flow Control Pilot Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-9. Drive Motor Adjustment (Prior to S/N 83332) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-10. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-11. Removing the Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-12. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-13. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-14. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-15. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-16. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-17. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-18. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-19. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-20. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-21. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-22. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-23. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-24. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-25. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-26. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-27. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-28. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-29. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-30. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-31. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-32. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-33. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-34. Swing Bearing Tolerance Boom Placement.(Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-35. Swing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-36. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-37. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-38. Swing Torque Hub Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3-39. Swing Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3-40. Swing Brake Assembly (Ausco) (Prior to S/N 0300068040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60

3-41. End Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61

3-42. Swing Motor (Prior to S/N 0300068040) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3-43. Swing Drive Hub (Fairfield) (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

3120858 – JLG Lift – ix

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3-44. Swing Brake (S/N 0300068040 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74

3-45. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81

3-46. Rotary Coupling Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82

3-47. Rotary Coupling Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-83

3-48. Rotary Coupling Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84

3-49. Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

3-50. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

3-51. Auxiliary Pump - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

3-52. Auxiliary Pump - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

3-53. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . .3-91

3-54. Malfunction Indicator and Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-93

3-55. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96

3-56. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

3-57. LPG System Components (S/N 0300077500 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

3-58. Addco Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-114

3-59. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117

3-60. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-118

3-61. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-119

3-62. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

3-63. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

3-64. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-122

3-65. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123

3-66. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-124

3-67. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125

3-68. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-126

3-69. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-127

3-70. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-128

3-71. Engine Oil Dip Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-129

3-72. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132

3-73. EPR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-132

3-74. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-133

3-75. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-133

3-76. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

3-77. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-134

3-78. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

3-79. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-135

3-80. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-135

3-81. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-137

3-82. EPR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

3-83. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-139

3-84. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

3-85. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-141

3-86. EPR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-143

3-87. Exhaust Venturi Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-157

3-88. Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158

4-1. Location of Components Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-3. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-4. Reassembly of Components-Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-5. Boom Power Track Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-6. Location of Components - Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-7. Location of Components - Tower Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-8. Location of Components-Articulating Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-9. Boom Valve and Limit Switches Location. (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-10. Boom Valve and Limit Switches Location. (Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-11. Boom Valve and Limit Switches Location. (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-12. Dual Capacity Switches Installation (800 Only if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

x – JLG Lift – 3120858

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-13. Transportation Switch Installation. (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-14. Tower Power Track Installation. (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-15. Tower Power Track Installation. (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-16. Location And Thickness Of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-17. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

4-18. Rotator Assembly (Prior to S/N 0300067538) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

4-19. Rotator - Exploded View (S/N 0300067538 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

4-20. Rotator- Assembly Drawing (S/N 0300067538 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

4-21. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

4-22. Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4-23. Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

4-24. Calibration Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

4-25. Load Sensing Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

4-26. Releveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

4-27. Boom Upright Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

4-28. UMS Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

4-29. UMS Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

4-30. UMS Module Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-3. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-4. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-5. Jib Lift Cylinder (800AJ Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6. Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-7. Tower Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-8. Master Cylinder - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-9. Master Cylinder - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-10. Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-11. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-12. Main Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-13. Tower Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-14. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-15. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-16. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-17. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-18. Hydro-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-19. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5-20. Installation Of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5-21. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5-22. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-23. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-24. Components Upper Boom and Tower Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-25. Load Sensing Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

5-26. Pressure Compensation Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

5-27. Main Control Valve Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-28. Main Valve Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32

5-29. Main Valve Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

5-30. Valve Component Torque - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

5-31. Valve Component Torque - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

5-32. Articulating Jib Boom Pressure adjust.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36

5-33. Variable Displacement Pump. (Rexroth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41

5-34. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

5-34. Shaft Seal and Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-35. Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-36. Plug Locations, Sizes, and Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-49

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

6-2. ADE Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

. . . . . .5-47

3120858 – JLG Lift – xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

6-3. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . .6-4

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

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

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

6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-8. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-11. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-12. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

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

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

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

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

7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

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

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

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

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

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

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

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

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

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

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

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

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

7-18. Electrical Components Installation (Prior to S/N 0300065534) - Sheet 1 of 2 . . . . . . . . . . . . . . . .7-10

7-19. Electrical Components Installation (Prior to S/N 0300065534) - Sheet 2 of 2 . . . . . . . . . . . . . . . .7-11

7-20. Electrical Components Installation (S/N 0300065534 to S/N 0300064007) - Sheet 1 of 2 . . . . . . 7-12

7-21. Electrical Components Installation (S/N 0300065534 to S/N 0300064007) - Sheet 2 of 2 . . . . . . 7-13

7-22. Electrical Components Installation w/ADE (S/N 0300064007 to 0300069000) - Sheet 1 of 2 . . . . 7-14

7-23. Electrical Components Installation w/ADE (S/N 0300064007 to 0300069000) - Sheet 2 of 2 . . . . 7-15

7-24. Electrical Components Installation w/ADE (S/N 0300069000 to Present) - Sheet 1 of 2. . . . . . . .7-16

7-25. Electrical Components Installation w/ADE (S/N 0300069000 to Present) - Sheet 2 of 2. . . . . . . .7-17

7-26. Electrical Schematic - Deutz Engine (Prior to S/N 0300065634) - Sheet 1 of 2. . . . . . . . . . . . . . .7-18

7-27. Electrical Schematic - Deutz Engine (Prior to S/N 0300065634) - Sheet 2 of 2 . . . . . . . . . . . . . . .7-19

7-28. Electrical Schematic - Ford Engine (Prior to S/N 0300048538) - Sheet 1 of 4. . . . . . . . . . . . . . . . 7-20

7-29. Electrical Schematic - Ford Engine (Prior to S/N 0300048538) - Sheet 2 of 4. . . . . . . . . . . . . . . . 7-21

7-30. Electrical Schematic - Ford Engine (Prior to S/N 0300048538) - Sheet 3 of 4. . . . . . . . . . . . . . . . 7-22

7-31. Electrical Schematic - Ford Engine (Prior to S/N 0300048538) - Sheet 4 of 4. . . . . . . . . . . . . . . . 7-23

7-32. Electrical Schematic - Ford EFI Engine (S/N 0300048538 to S/N 0300065634) - Sheet 1 of 2. . .7-24
7-33. Electrical Schematic - Ford EFI Engine (S/N 0300048538 to S/N 0300065634) - Sheet 2 of 2. . .7-25

7-34. Electrical Schematic Isuzu Engine (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

7-35. Electrical Schematic Isuzu Engine (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

7-36. Electrical Schematic - UL - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7-37. Electrical Schematic - UL - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-38. Electrical Schematic ADE W/External Tilt - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-39. Electrical Schematic ADE W/External Tilt - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7-40. Electrical Schematic ADE W/External Tilt - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7-41. Electrical Schematic ADE W/External Tilt - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

7-42. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34

7-43. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35

7-44. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36

xii – JLG Lift – 3120858

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-45. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-46. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-47. Electrical Schematic w/Internal Tilt - Deutz S/N 65634 to 85331, Cat & Ford

Prior to S/N 99884 - Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-48. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 1 of 6 . . . . . . . . .7-40

7-49. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 2 of 6 . . . . . . . . .7-41

7-50. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 3 of 6 . . . . . . . . .7-42

7-51. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 4 of 6 . . . . . . . . .7-43

7-52. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 5 of 6 . . . . . . . . .7-44

7-53. Electrical Schematic w/Internal Tilt - Deutz & GM S/N 85331 to 99884 - Sheet 6 of 6 . . . . . . . . .7-45

7-54. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 1 of 6 . . . . . . . . . .7-46

7-55. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 2 of 6 . . . . . . . . . .7-47

7-56. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 3 of 6 . . . . . . . . . .7-48

7-57. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 4 of 6 . . . . . . . . . .7-49

7-58. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 5 of 6 . . . . . . . . . .7-50

7-59. Electrical Schematic - Caterpillar, Deutz, & GM S/N 99884 to Present - Sheet 6 of 6 . . . . . . . . . .7-51

7-60. Hydraulic Schematic 2 Wheel Drive - Prior to S/N 83332. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52

7-61. Hydraulic Schematic 4 Wheel Drive - Prior to S/N 83332 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . .7-54

7-62. Hydraulic Schematic 4 Wheel Drive - Prior to S/N 83332 (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . .7-55

7-63. Hydraulic Schematic - Prior to S/N 83332 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56

7-64. Hydraulic Schematic - Prior to S/N 83332 (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57

7-65. Hydraulic Schematic - S/N 83332 to Present (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

7-66. Hydraulic Schematic - S/N 83332 to Present (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

7-67. Hydraulic Schematic - S/N 83332 to Present (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

7-68. Hydraulic Schematic - S/N 83332 to Present (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-69. Hydraulic Schematic - S/N 83332 to Present (Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

7-70. Hydraulic Schematic - S/N 83332 to Present (Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

3120858 – JLG Lift – xiii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-3 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 Deutz F4M2011F Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-5 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-6 Caterpillar 3044C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-7 Isuzu 4JB1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-8 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-9 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-10 Drive System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-11 Swing System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-12 Hydraulic Drive Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-13 Variable Displacement Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-14 Hydraulic Load Sense Pump Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-15 Auxiliary Power Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-16 Hydraulic FIlter Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-17 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-18 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-19 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-20 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-21 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-22 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-23 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-24 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-25 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-26 Cylinder Specifications - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-27 Cylinder Specifications - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-28 Major Component Weights - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-29 Major Component Weights - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-30 Critical Stability Weights - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-31 Critical Stability Weights - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-32 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

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

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

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

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

3-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-3 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-4 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-5 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-6 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-7 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-8 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-9 Coupling Port Information Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

3-10 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94

3-11 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-113

3-12 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144

3-13 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-147

3-14 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-155

4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-2 Ramp Current Setting Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

4-3 Ramp time Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

5-1 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

5-3 Symbols Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-4 Gauge and Port Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

5-5 Excessive Noise and/ or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43

xiv – JLG Lift – 3120858

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

5-6 Actuator Response Is Sluggish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44

5-7 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-8 Low Pump Output Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45

5-9 Pressure or Flow Instability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5-10 System Pressure Not Reaching Pressure Compensator Setting . . . . . . . . . . . . . . . . . . . . . . . . . .5-46

5-11 High Inlet Vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-46

6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . . 6-18

6-3 Machine Configuration Programming Information Software Version P5.3 to P6.1 . . . . . . . . . . . .6-22

6-4 Machine Configuration Programming Information Software Version P6.1 to Present. . . . . . . . . .6-27

6-5 Machine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

6-6 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

6-7 Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931. . . . . . . . . . . .6-42

6-8 Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066931 to Present . . . . . . . . . 6-46

6-9 Analyzer Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56

6-10 ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64

6-11 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67

3120858 – JLG Lift – xv

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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xvi – JLG Lift – 3120858

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS Capacities

SECTION 1 - SPECIFICATIONS

Table 1-1. Operating Specifications

Travel Speed
2 WD
4 WD

Gradeability
2 WD
4 WD

Tur ning Radius (Outs ide)
2 WS
4 WS

Tur ning Radius (Ins ide)
2 WS
4 WS

Overall Width 8 ft.-0 in. (2.44 m)

Machine Height Stowed 9 ft. 9.5 in.(2.98 m)

Machine Length (Stowed)
800A
800AJ

Wheel base 10 ft.- 0 in. (3.05 m)

Boom Elevation - 800A
A bo v e Gr a de
B el o w Gr a de

Boom Elevation - 800AJ
A bo v e Gr a de
B el o w Gr a de

Max. Ground Bearing Pressure

Max. Tire Load 17,755 lbs. (8060 kg)

Drive Speed (2WD)
F or w a rd
R ev e rs e

Drive Speed (4WD)
F or w a rd
R ev e rs e

Machine Weight approximately
IN 385/65D 19.5 Pneumatic
15 X 19.5 Pneumatic
IN 445/55D 19.5
18 X 19.5 Pneumatic Tires
IN 385/65D 19.5
15 X 19.5 Foam Filled Tires
IN 445/55D 19.5
18 X 19.5 Foam Filled Tires

3.0 MPH (4.83 Km/hr.)

3.0 MPH (4.83 Km/hr.)

30%
45%

22 ft.- 6 in. (6.86 m)
14 ft.- 6 in. (4.42 m)

12 ft.- 0 in. (3.66 m)
11 ft.- 0 in. (2.13 m)

36 ft.-9 in. (11.25 m)
36 ft.-6 in. (11.13 m)

+80 ft.-3 in. (24.46 m)

-15 ft.-7 in. (4. 75 m)

+80 ft.-3 in. (24.46 m)

-13 ft.- 1 in. (3.99 m)

84 psi. (5.9 kg/cm2)

42 - 48 Seconds for 200 Ft
42 - 48 Seconds for 200 Ft

42 - 48 Seconds for 200 Ft
42 - 48 Seconds for 200 Ft

34,200 lbs.(15,520 kg)

34,200 lbs.(15,520 kg)
34,270 lbs. (15,550 kg)
34,270 lbs. (15,550 kg)
33,100 lbs. (15,020 kg)
33,100 lbs. (15,020 kg)
33,550 lbs. (15,220 kg)
33,550 lbs. (15,220 kg)

Table 1-2. Capacities

Fuel Tank Approx. 40 gallons (151.4 liters)

Hydraulic Tank Approx. 40 gallons (151.4 liters)

Hydraulic System (Including Tank) 77 Gal. (291.4 L)

Drive Hub* (Prior to S/N 83332) 17 ounces (0.5 L)

Drive Hub* (S/N 83332 to Present) 44 ounces (1.3 L)

Drive Brake (S/N 8332 to Present) 2.7 ounces (80 ml)

Engine Oil Capacity
F or d
D eu t z
C o ol i ng S ys t e m
C r an k ca s e
To t al C ap a c it y
C at e r pi l la r
I su z u
G M

NOTE: Torque hubs should be one half full of lubricant.

4.5 Quarts (4.25 L) w/Filter

5 Quarts (4.5 L)

11 Quarts (10.5 L) w/Filter

16 Quar ts (15 L)

10.6 quarts (10 L)

8.5 Quar ts (8.0 L)

4.5 Quarts (4.25 L) w/Filter

1.2 COMPONENT DATA

Engine Data

Table 1-3. Ford LRG-425 Specifications

Type Water-cooled

Fuel Gasoline

Oil Capacity 4.5 Quar ts (4.25 L) w/Filter

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 95 Amp, Belt Drive

Fuel Co nsumption
L ow R P M
H ig h R PM

Battery 1000 Cold Cranking Amps, 210

minute reser ve Capacity, 12 VDC

Horsepower 74 @ 3000 RPM, full load

Cooling System 16 Quarts (15.14 L)

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

3.45 GPH (13.06 lph)

4.60 GPH (17.41 lph)

3120858 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Table 1-4. Deutz F4M2011F Specifications

Type Liquid Cooled (Oil)

Fuel Diesel

Oil Capacity
C oo l i ng S ys t em
Crankcase
Total Capacity

11 Quar ts (10.5 L) w/Filter

5 Quarts (4.5 L)

16 Quarts (15 L)

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 55 Amp, belt drive

Fuel Consumption
L ow R P M
H ig h R PM

1.90 GPH (7.19 lph)

2.50 GPH (9.46 lph)

Battery 1000 Cold Cranking Amps, 210

minutes Reserve Capacity, 12 VDC

Horsepower 65 @ 2800 RPM, full load

Table 1-5. Deutz D2011L04 Specifications

Type Liquid Cooled (Oil)

Fuel Diesel

Oil Capacity
C oo l i ng S ys t em
Crankcase
Total Capacity

11 Quar ts (10.5 L) w/Filter

5 Quarts (4.5 L)

16 Quarts (15 L)

Idle RPM 1000

Low RPM 1800

High RPM 2600

Alternator 55 Amp, belt drive

Fuel Consumption
L ow R P M
H ig h R PM

1.90 GPH (7.19 lph)

2.50 GPH (9.46 lph)

Battery 1000 Cold Cranking Amps, 210

minutes Reserve Capacity, 12 VDC

Horsepower 64 @ 2600 RPM, full load

Table 1-6. Caterpillar 3044C

Ty pe Fou r St ro k e C ycl e

Cylinders 4 in-line

Bore 3.70 inch (94 mm)

Stroke 4.72 inch (120 mm)

Aspiration turbocharged

Compression ratio 19:1

Displacement

203 in

3

(3.33 L)

Firing Order 1-3-4-2

Rotation (viewed from flywheel) Counterclockwise

Oil Capacity (w/filter) 10.6 quarts (10 L)

Cooling System (Engine Only) 5.8 quar ts (5.5 L)

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 60 Amp, belt drive

Table 1-7. Isuzu 4JB1

Type Water-cooled

Oil Capacity (w/filter) 8.5 Quarts (8.0 L)

Cooling System (Engine Only) 5.8 quar ts (5.5 L)

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 55 Amp, belt drive

Battery 1000 Cold Cranking Amps, 210

minutes Reserve Capacity, 12 VDC

Horsepower 66 @ 2800 RPM, full load

Table 1-8. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4

BHP
G as o l in e
L P

83 hp @ 3000 rpm
75 hp @ 3000 rpm

Bore 4.0 in. (101.6 mm)

Stroke 3.6 in. (91.44 mm)

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

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

Minimum Oil Pressure
a t i d l e
H ot

6 psi (0.4 Bar) @ 1000 rpm

18 psi (1.2 Bar) @ 2000 rpm

Compression Ratio 9.2:1

Firing Order 1-3-4-2

Max. RPM 2800

1-2 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

Table 1-12. Hydraulic Drive Pump Specifications

Pump Output 35.5 GPM (134 lpm) @ 2800 RPM

Pump Displacement

2.8 cu. in. (46 cm

3

)

Charge Pump Displacement

0.85 cu. in. (14 cm

3

)

Charge Pump Output 9.5 GPM (37 ipm) @ 2800 RPM

Charge Pump Pressure 400 PSI. (27.5 Bar)@ 2800 RPM

Clockwise Rotation

Tires

Table 1-9. Tire Specifications

Size Type

IN 385/65D 19.5 pneumatic 16 H 95PSI

IN 445/55D 19.5 pneumatic 16 H 85 PSI (6.0

15 X 19.5 pneumatic 16 H 95PSI

18 X 19.5 pneumatic 16 H 85 PSI (6.0

IN 385/65D 19.5 foam-filled 16 H N/A

IN 445/55D 19.5 foam-filled 16 H N/A

15 X 19.5 foam-filled 16 H N/A

18 X 19.5 foam-filled 16 H N/A

Ply

Rating

Load

Range

Pressure

(6.5 Bar)

Bar)

(6.5 Bar)

Bar)

Drive System

Table 1-10. Drive System Specifications

Drive Motor Displacement
2 W D

4 WD

Drive Hub Ratio.
2 W D
4 W D

Drive Brake Automatic spring applied, hydrauli-

2.74 cu. in. max. 1.425 cu. in. min.

( 4 6 cm

2.74 cu. in. max. 1.000 cu. in. min.

( 4 6 cm

cally released disc brakes.

3

max. 23.4 cm

3

max. 16.4 cm

86.7:1

59.3:1

min.)

min.)

Hydraulic Drive Pump

Variable Displacement Pump

Table 1-13. Variable Displacement Pump Specifications

Type Variable, swashplate design

Nominal Pressure 3600 psi (248 bar)

Peak Pressure 4600 psi (317 bar)

Pump Circuit Open

Displacement Vgmax

Pressure and Flow Control DFR1

Rotation Clockwise

NBR seals Nitrile rubber to DIN ISO 1629

3

3

Shaft SAE 1.00 in. (2.54 cm) splined

Hydraulic Load Sense Pump

Table 1-14. Hydraulic Load Sense Pump Specifications

Pump Displacement

Pump Output 15.5 GPM (59 lpm) @ 1800 RPM

Stand By Pressure 400 PSI.(27.5 Bar) @ 1800 RPM

High Pressure Relief High Pressure Relief - 2700 PSI.(186

Rotation Clockwise

2.1cu. in. (34.4 cm

2.75 in

3

(45 cm3)

3

) Max.

Bar)

Swing System

Table 1-11. Swing System Specifications

Swing Motor Displacement

Swing Brake Automatic spring applied hydraulically

Swing Hub Ratio 50:1

3120858 – JLG Lift – 1-3

4.9 cu. in. (80 cm

released disc brak es

Auxiliary Power Pump

3

)

Table 1-15. Auxiliary Power Pump Specifications

Pump Output 2.1 GPM (9.5 lpm) @ 1400 PSI. (69

BAR)

Pump Displacement

Valving Non-Adj. Unloader Preset to 230 psi

A d ju s ta b le R el i ef S e t a t 18 0 0 p s i .

Motor 12 V.D.C. 2T Extended EMC Prot ected

Rotation Counterclockwise

0.305 cu. in. (5 cm

Intermittent Duty

3

)

SECTION 1 - SPECIFICATIONS

Table 1-16. Hydraulic FIlter Specifications

Return Filter 10 Microns Absolute

Charge Filter 10 Microns Absolute

Hydraulic Strainers (In Tank) 30 Microns

Table 1-17. Function Speeds

Function Speed (In Seconds)

Main Lift Up 45 - 50

Main Lift Down 45 - 50

Swing Right & Left 79 - 101

NOTE: No more than 10% difference between swing left

and swing right.

Main Telescope In
800A
800AJ

30-40
24-34

Main Telescope Out
800A
800AJ

35-45
30-40

Platform Rotate Right & Left 19 - 30

NOTE: No more that 15% difference between rotator left

and rotator right.

Jib Up & Down 16-22

Tower Lif t Up 57 - 70

Tower Lif t Down 44 - 53

To we r Te l es co p e O ut 2 4 - 32

To we r Tel es c op e In 1 5- 25

Drive (2WD) Forward & Reverse 33-45

Drive (4WD) Forward & Reverse 33-45

Drive Above Elevation
2WD Forward & Reverse Min 61

Drive Above Elevation
4WD Forward & Reverse Min 122

4150241-D

Hydraulic Filter - In-line

1.3 FUNCTION SPEEDS

Machine Orientation When Doing Speed Tests

To w e r L i f t : Upper Boom Horizontal, Telescoped In. Tower
Lift Up, Record Time. Tower Lift Down, Record Time.

To w e r Te l e s c o p e : Tower Lift Fully Elevated, Upper Boom
Horizont a l , Te l e s c o ped In. Tow e r Te l e O u t, Record T i m e .
Tower Tele In, Record Time.

Lift: Tower Lift Fully Elevated, Tower Telescope Fully
Extended, Main Telescope Fully Retracted.

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

Test No tes

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

2. Drive test results reflect 15x19.5 or 18x19.5 tires,
pneumatic or foam filled.

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

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

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

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

Te l es c o pe : Boom at Full Elevation; Telescope Retracted;
Telescope Out, Record Time. Telescope In, Record Time.

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

Drive (Above Horizontal): Test should be done on a
smooth, level surface. Drive Select Switch should be set to
Low Engine, Low Drive. The Platform Speed Knob control
should be positioned to Creep Speed. This simulates
machine speed when the boom is above horizontal.
Results should be recorded for a 50 ft. (15.2 m) course.
Drive Forward, Record Time. Drive Reverse, Record Time.

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

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

1-4 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

1.4 TORQUE REQUIREMENTS

Wheel Bolts 300 ft. lbs.

Support to Rotator Bolts 50 ft. lbs.

Rotator Center Bolt 480 ft.lbs.

Swing Bearing Bolts 190 ft. lbs.

Star ter or Aux Pump
Solenoid
C on t a ct s
C oi l

Oxygen Sensor (Ford
Engine)

Megajector Mounting
Bolts (Ford Engine)

Lockoff Solenoid (Ford
Engine)

*Check swing bearing bolts for security after first 50 hours

of operation and every 600 hours thereafter. (See Swing

NOTE: When maintenance becomes necessary or a fas-

Table 1-18. Torque Requirements

Description

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

Torque Va l u e

(Dry)

(407 Nm)

(68 Nm)

(651 Nm)

(260 Nm)

95 in. lbs. (10.5 Nm)

40 in. lbs. (4.5 Nm)

29.5-40 ft. lbs.
(40-54 Nm)

60 in. lbs.

(7 Nm)

8-12 ft.lbs.

(11-16 Nm)

Bearing in Section 3.)

Interval Hours

150

150

150

50/600*

As required

At Installation

As required

At Installation

1.5 LUBRICATION

Hydraulic Oil

Table 1-19. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

+0° to + 180° F (-18° to +83° C) 10W

+0° to + 210° F (-18° to +99° C) 10W-20, 10W30

+50° to + 210° F (+10° to +99° C 20W-20

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

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

152.

NOTE: When temperatures remain consistently below 20

degrees F. (-7 degrees C.), JLG Industries recom­mends the use of Mobil DTE13.

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

Table 1-20. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

S.A.E. Viscosity

Grade

3120858 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Table 1-24. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be

checked on a yearly basis for viscosity.

Table 1-21. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

Table 1-22. Mobil EAL 224H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max -25°F (-32°C)

Flash Point, Min. 428°F (220°C)

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

Weight

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

NOTE: Must be stored above 32°F (14°C)

7.64 lb. per gal.

(0.9 kg per liter)

1.6 PRESSURE SETTINGS

Table 1-25. Pressure Settings

Upper boom Lift Dow n Relief 1400 PSI. (97 Bar)

Swing Relief 1400 PSI. (97 Bar)

Platform Level Relief:
U p
D ow n

Steer Relief
2 WS
4 WS

To we r B o om Tel e sc op e 2 20 0 P S I. (1 5 1. 7 B a r)

Articulating Jib Boom
U p
D ow n

2800 PSI. (193 Bar)
1800 PSI. (124 Bar)

1800 PSI. (124.11Bar)

2500 PSI. (172 Bar)

2500 PSI. (172 Bar)

1200 PSI. (83 Bar)

Table 1-23. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Viscosity

at 0° C (32° F) 340 cSt (1600SUS)

at 40° C (104° F) 46 cSt (215SUS)

at 65° C (150° F) 22 cSt (106SUS)

1-6 – JLG Lift – 3120858

Viscosity Index 170

1.7 CYLINDER SPECIFICATIONS

Table 1-26. Cylinder Specifications - 800A

DESCRIPTION BORE STROKE ROD DIA.

Lower Left

To we r Tele s cope

Upright Level

Upper Lift

Upper Telescope

Steer

Lockout

Master

Slave

8.00

(203.2)

4.00

(101.6)

8.00

(203.6)

8.00

(203.2

3.50

(88.9)

3.00

(76.2)

4.00

(101.6)

2.50

(63.5)

3.50

(88.9)

49.38

(1254.1)

79.50

(2019.3)

42.00

(1066.8)

28.75

(730.3)

244.0

(6197.6)

10.75

(273.1)

3.88

(98.4)

18.50

(469.9)

8.94

(227.1)

SECTION 1 - SPECIFICATIONS

3.00

(76.2)

2.50

(63.5)

3.50

(88.9)

3.50

(88.9)

2.75

(69.9)

1.50

(38.1)

1.50

(38.1)

1.25

(31.8)

1.75

(44.5)

Table 1-27. Cylinder Specifications - 800AJ

DESCRIPTION BORE STROKE ROD DIA.

Lower Left

To we r Tele s cope

Upright Level

Upper Lift

Upper Telescope

Steer

Lockout

Master

Slave

Lift (Jib)

8.00

(203.2)

4.00

(101.6)

8.00

(203.6)

8.00

(203.2)

3.50

(88.9)

3.00

(76.2)

4.00

(101.6)

3.50

(88.9)

3.50

(88.9)

3.00

(76.2)

49.38

(1254.1)

79.50

(2019.3)

42.00

(1066.8)

28.75

(730.3)

206.5

(5245.1)

10.75

(273.1)

3.88

(98.4)

18.50

(469.9)

17.50

(444,5)

25.50

(647.7)

3.00

(76.2)

2.50

(63.5)

3.50

(88.9)

3.50

(88.9)

2.75

(69.9)

1.50

(38.1)

1.50

(38.1)

1.50

(38.1)

1.50

(38.1)

1.50

(38.1)

3120858 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

1.8 MAJOR COMPONENT WEIGHTS

Table 1-28. Major Component Weights - 800A

MAJOR COMPONENTS LBS. KG.

Platform & Control Console 250 113

Upper Boom (Inc. Slave Cylinder Rotator, Support) 3135 1445

Upper Lift Cylinder 500 230

Main Telescope Cylinder 540 245

Upright 1175 535

Upright Level Cylinder 585 265

Tower Boom Complete 3450 1565

Tower Lift Cylinder 625 285

Tower Telescope Cylinder 250 115

Tur ntable Counterweight 4805 2180

Tur ntable Complete (Including Engine) 11025 5001

Chassis Complete (Pneumatic Tires) 13750 6237

Chassis Complete (Foam Filled Tires) 12620 5724

Machine Complete (GVW) w/ Pneumatic Tires 34200 15520

Machine Complete (GVW) w/ Foam Filled Tires 33100 15020

NOTE: The above components are separate assemblies.
example: "TURNTABLE COMPLETE" does not include
booms, upright, lift cylinders or platform. The weights of
these components must be added for the total weight.

Table 1-29. Major Component Weights - 800AJ

MAJOR COMPONENTS LBS. KG.

Platform & Control Console 250 113

Upper Boom (Inc. Slave Cylinder Rotator, And
Support)

Upper Lift Cylinder 500 230

Main Telescope Cylinder 480 220

Upright 1175 535

Upright Level Cylinder 585 265

Tower Boom Complete 3450 1565

To we r L i ft C yl in d er 62 5 28 5

To we r Te l es co p e C yl i nd er 2 50 1 15

Tur ntable Counterweight 4805 2180

Tur ntable Complete (Including Engine) 11025 5001

Chassis Complete (Including Pneumatic Tires) 13750 6237

Chassis Complete (Including Foam Filled Tires) 12620 5724

Machine Complete (GVW) w/ Pneumatic Tires 34200 15520

Machine Complete (GVW) w/ Foam Filled Tires 33100 15020

NOTE: The above components are separate assemblies.
example: "TURNTABLE COMPLETE" does not include
booms, upright, lift cylinders or platform. The weights of
these components must be added for the total weight.

3185 1445

1-8 – JLG Lift – 3120858

Critical Stability Weights

Table 1-31. Critical Stability Weights - 800AJ

COMPONENTS LBS. KG.

Tire & Wheel Size
(Foam Filled Only)

365/65D19.5

565 255

445/55D19.5

675 305

15 X 19.5 565 255

18 X 19.5 675 305

Engine Ford 600 209

Deutz 534 242

Isuzu 463 210

GM w/pumps 1030 468

Counterweight Turntable 4805 2180

Wheel Hubs Rear 218 99

Front 2WD 110 99

Front 4WD 218 99

Platform Size 6 FT. (1.83 M) 205 93

8 FT. (2.44 M) 230 105

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

Table 1-30. Critical Stability Weights - 800A

COMPONENTS LBS. KG.

SECTION 1 - SPECIFICATIONS

Tire & Wheel Size
(Foam Filled Only)

Engine Ford

Counterweight Turntable

Wheel Hubs Rear

Platform 6 FT. (1.83 M)

365/65D19.5

445/55D19.5

15 X 19.5

18 X 19.5

Deutz

Isuzu

GM w/pumps

Front 2 WD

Front 4 WD

8 FT. (2.44 M)

565 255

675 305

565 255

675 305

600 209

534 242

463 210

1030 468

4805 2180

218 99

210 99

218 99

205 93

230 105

3120858 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

Figure 1-1. Lubrication and Operator Maintenance Diagram

1.9 LUBRICATION AND OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Fig-

ure 1-1., Lubrication and Operator Maintenance
Diagram.

Table 1-32. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350°

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

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

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

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

424.

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

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

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

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

filters at the same time.

1. Swing Bearing - Internal Ball Bearing

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

1-10 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

2. Wheel Bearings

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

3. Wheel Drive Hub

4. Hydraulic Return Filter

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

5. Hydraulic Charge Filter

Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation
Comments - Place Fill port at 12 o’clock position
and Check port at 3 o’clock position. Pour lubri­cant into fill port until it just starts to flow out of
check port.

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

6. Hydraulic Tank

Lube Point(s) - Fill Cap
Capacity - 40 gallons (151 L) Tank; 77 gallons
(291.4 L) System
Lube - HO
Interval - Check Level daily; Change every 2 years
or 1200 hours of operation.

3120858 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

MINIMUM LEVEL,
OIL HOT

MINIMUM OIL
LEVEL

MINIMUM LEVEL,
OIL COLD

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

MAXIMUM LEVEL,
OIL HOT

MAXIMUM LEVEL,
OIL COLD

MAXIMUM OIL
LEVEL

Figure 1-2. Deutz Engine Dipstick

7. Suction Strainers

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

9. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts(10.5 L) Crankcase
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual. Refer to Figure 1-2.,
Deutz Engine Dipstick.

8. Oil Change w/Filter - Ford

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 4.5 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

1-12 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

10. Oil Change w/Filter - Isuzu

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 8.5 qt. (8.0L) engine; 5.3 qt. (5.L) cooler
Lube - EO
Interval - Change oil after first 50 and every 200
hrs. there after. Change oil filter after 50hrs. and
every 400 hrs. there after.
Comments - Check level daily/Change in accor­dance with engine manual.

11. Oil Change w/Filter - Caterpillar

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 10.6 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

12. Oil Change w/Filter - GM

14. Fuel Filter - Deutz

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

15. Fuel Filter - Isuzu

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

16. Fuel Filter - Caterpillar

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

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

13. Fuel Filter - Ford

17. Fuel Filter (Gasoline) - GM

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

18. Air Filter

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

Lube Point(s) - Replaceable Element
Interval - Every Year or 1200 hours of operation

3120858 – JLG Lift – 1-13

SECTION 1 - SPECIFICATIONS

19. Electronic Pressure Regulator (LP only)

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

20. Fuel Filter (Propane) - GM Engine

2. Start the engine and bring to operating temperature.

3. With the engine running, close the manual tank
valve and run the engine out of fuel.

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

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

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

Draining Oil Build Up From The Propane Regulator

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

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

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

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

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

drain freely from the regulator at this point.

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

8. Open the fuel tank manual valve.

9. Start the engine and verify all connections are
secure.

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

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

1-14 – JLG Lift – 3120858

Propane Fuel Filter Replacement

11

2

13

33

44

55

6

77

88

99

OR

10 10

11

11

12

1. Electric Lock Off Solenoid

2. Mounting Plate

3. Housing Seal

4. Filter Magnet

5. Filter Housing

6. Seal

7. Electrical Connector

8. Fuel Outlet

9. O-ring

10. Filter

11. Fuel Inlet

12. Retaining Bolt

Figure 1-3. Filter Lock Assembly

SECTION 1 - SPECIFICATIONS

REMOVAL

INSTALLATION

1. Relieve the propane fuel system pressure. Refer to
Propane Fuel System Pressure Relief.

2. Disconnect the negative battery cable.

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

3. Slowly loosen the Filter housing retaining bolt and
remove it.

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

5. Locate Filter magnet and remove it.

6. Remove the filter from the housing.

7. Remove and discard the housing seal.

8. Remove and discard the retaining bolt seal.

9. Remove and discard mounting plate to lock off O­ring seal.

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

2. Install the retaining bolt seal.

3. Install the housing seal.

4. Drop the magnet into the bottom of the filter hous­ing.

5. Install the filter into the housing.

6. Install the retaining bolt into the filter housing.

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

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

3120858 – JLG Lift – 1-15

9. Open manual shut-off valve. Start the vehicle and
leak check the propane fuel system at each serviced
fitting. Refer to Propane Fuel System Leak Test.

SECTION 1 - SPECIFICATIONS

Propane Fuel System Pressure Relief

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

To relieve propane fuel system pressure:

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

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

3. Turn the ignition switch OFF.

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

1-16 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

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

Description

0100011

242

TM

Vibra-TITE

TM

121

Medium Strength (Blue)

0100019

271

TM

Vibra-TITE

TM

140

High Strength (Red)

0100071

262

TM

Vibra-TITE

TM

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

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

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

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

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 3/8 6 1.3750 1.1550 64100 1460 1 979 1100 1491 1525 2074 1322 1792

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

1 1/2 6 1.5000 1.4050 78000 1940 2 630 1460 1979 2025 2754 1755 2379

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

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

Torque

Lubricated

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TIT E

TM

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

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

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

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

3120858 – JLG Lift – 1-17

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

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

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

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

1320 43 5

1580 60 7

1800 68 8
2860 143 16 129 15
3280 164 19 148 17

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

4720 25 35 20 25 20 25
5220 25 35 25 35 20 25
7000456040 553550
7900 50 70 45 60 35 50

9550 70 95 65 90 50 70
10700 80 110 70 95 60 80
12750 105 145 95 130 80 110
14400 120 165 110 150 90 120
16400 155 210 140 190 115 155
18250 170 230 155 210 130 175
20350 210 285 190 260 160 220
23000 240 325 215 290 180 245
30100 375 510 340 460 280 380
33600 420 570 380 515 315 430
41600 605 825 545 740 455 620
45800 670 910 600 815 500 680
51500 860 1170 770 1045 645 875
59700 995 1355 895 1215 745 1015
68700 1290 1755 1160 1580 965 1310
77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855
96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760
126500 3165 4305 2845 3870 2370 3225
142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140) K=.18

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

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

Torque

(Dry or Loctite® 263)

K= 0.20

1-18 – JLG Lift – 3120858

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

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

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

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

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

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

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

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

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

SECTION 1 - SPECIFICATIONS

3120858 – JLG Lift – 1-19

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 4

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

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

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

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

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

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

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

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

1-20 – JLG Lift – 3120858

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

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

Torque

(Lub)

Torque

(Loctite® 262

TM

OR Vibra-

TITE

TM

131)

Torque

(Loctite®

242

TM

or 271

TM

OR Vibra-

TITE

TM

111 or

140)

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

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

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

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

16 2 157 68.3

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

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

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

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

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

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

NO. 5000059 REV. J

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

3120858 – JLG Lift – 1-21

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

K = 0.20

Torque

(Lub OR Loctite®

242

TM

or 271TM OR

Vibra-TITE

TM

111 or

140)

K= 0.18

Torque

(Loctite® 262

TM

OR

Vibra-TITE

TM

131)

K=0.15

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

3 0.5 5.03 3.13

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

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

16 2 157 97.8

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

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

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

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

ADDITIONAL TESTING IS REQUIRED.

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

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

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

NO. 5000059 REV. J

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 2 of 3)

1-22 – JLG Lift – 3120858

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

TM

)

K = .17

Torque

(Lub OR Loctite®

242

TM

or 271

TM

OR Vibra-TITE

TM

111 or 140)

K = .16

Torque

(Loctite® 262

TM

OR Vibra-TITE

TM

131)

K = .15

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

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

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

16 2 157

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

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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

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

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HAR DEN ED WASHER OR FASTENER IS PLAC ED AGAINST PLATED
STEEL OR RAW ALUMINUM

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

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

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

3120858 – JLG Lift – 1-23

Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 1 - SPECIFICATIONS

NOTES:

1-24 – JLG Lift – 3120858

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

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

3120858 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspection Prior to use each day; or

At each Operator change.

Pre-Delivery

Inspection

Frequent Inspection In service for 3 months or 150 hours, which-

Annual Machine

Inspection

Preventative
Maintenance

Prior to each sale, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

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

Cleanliness

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

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qu alified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Fact ory-Certified

Owner, Dealer, or User Qualified JLG

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

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

Service

Qualification

Mechanic

Mechanic

Service Technician

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Components Removal and Installation

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

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

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

2-2 – JLG Lift – 3120858

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.

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.

Gaskets

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

Bolt Usage and Torque Application

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

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

2.3 LUBRICATION AND INFORMATION

Hydraulic System

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

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

3120858 – JLG Lift – 2-3

SECTION 2 - GENERAL

Section 1. Always examine filters for evidence of
metal particles.

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

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

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

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

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

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

NOTE: Start-up of hydraulic system with oil temperatures

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

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

Changing Hydraulic Oil

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

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

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

Lubrication Specifications

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

2.4 CYLINDER DRIFT TEST

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

Platform Drift

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

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

8 203.2 0.0038 0.10

9 228.6 0.0030 0.08

Max. Acceptable Drift

in 10 Minutes

Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temper-

2-4 – JLG Lift – 3120858

SECTION 2 - GENERAL

ature and temperature stabilized.

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

If the cylinder passes this test, it is acceptable.

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

inder leakage.

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

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

ing.

d. Debris embedded in liner surface.

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

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to

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

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG Equipment

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

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

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

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

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

a. Detectable wear in the bearing area.

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

surface.

c. Rusting of the pin in the bearing area.

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

a. Housing should be blown out to remove all dirt

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

b. Bearing / pins should be cleaned with a solvent

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

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

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

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

3120858 – JLG Lift – 2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Boom Assembly

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

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

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

Extend/Retract Chain or Cable Systems 1,3,5,22

UMS System Functional Check 1,2,3

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5 15

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

Turntable Assembly

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

Oil Coupling 9

Swing Drive System 11 11

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

Hood, Hood Props, Hood Latches 51,2,5

Chassis Assembly

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

Wheel Nuts/Bolts 115 1515

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

Drive Hubs 11 11

Functions/Controls

Pre-Start

Inspection

9

9

9

9

9

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

Annual

(Yearly)

Inspection

4

Every 2

Years

2-6 – JLG Lift – 3120858

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

Platform Controls 55 66

Ground Controls 55 66

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

Footswitch 1,5 5 5

Emergency Stop Switches (Ground & Platform) 555

Function Limit or Cutout Switch Systems 555

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/Sequencing Systems 5

Manual Descent or Auxiliary Power 55

Power System

9

Engine Idle, Throttle, and RPM 33

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

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

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

Hydraulic/Electric System

9

Hydraulic Pumps 1,9 1,2,9

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

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

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

Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

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

Holding Valve Checks 1,5,9,22

General

Operation and Safety Manuals in Storage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21

Annual

(Yearly)

Inspection

4

Every 2

Years

3120858 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

Capacity Decals Installed, Secure, Legible 21 21 21

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

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

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

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

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

4

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

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

Annual

(Yearly)

Inspection

4

Every 2

Years

2-8 – JLG Lift – 3120858

-40° F(-40° C)

-30° F(-34° C)

-20°F(- 29°C)

-10

°

F(- 23°C)

0

°

F(- 18°C)

10

°

F(- 12°C)

20

°

F(- 7°C)

30

°

F(- 1°C)

40

°

F(4°C)

50

°

F(10°C)

60

°

F(16°C)

70

°

F(2 1°C)

80

°

F(2 7°C)

90

°

F(3 2°C)

100

°

F(3 8°C)

110

°

F(4 3°C)

120°

F(4 9°C)

ENGINE

SPECIFICATIONS

ENGINE WILL START AND OPERATE AT TH I

S TEMPERATURE

WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIF

IED COLD WEATHER

PACKAGE (IE. ENGINE BLOCK HEATER, ET

HER INJECTION OR

GLOW PLUGS, BATTERY WARMER AND HYDRA

ULIC OIL TANK HEATER)

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

SUMMER

GRADE

FUEL

WINTER

GRADE

FUEL

WINTER

GRADE

FUEL
WITH

KEROSENE

ADDED

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS

THE ADDITION OF A HYDRAULIC

OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

PROLONGED OPERATION IN

AMBIENT AIR TEMPERATURES

OF 100°F(38°C) OR ABOVE.

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

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

M

O

B

I

L

4

2

4

1

0

W

-

3

0

HYDRAULIC

SPECIFICATIONS

NO OPERATION ABOVE 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

E

X

X

O

N

U

N

I

V

I

S

H

V

I

2

6

M

O

B

I

L

D

T

E

1

3

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 102030405060

% OF ADDED KEROSENE

A

M

B

I

E

N

T

T

E

M

P

E

R

A

T

U

R

E

SUMMER-GRADE

FUEL

WINTER-GRADE

FUEL

Figure 2-1. Engine Operating Temperature Specifications - Deutz

4150548 E

SECTION 2 - GENERAL

3120858 – JLG Lift – 2-9

SECTION 2 - GENERAL

Figure 2-2. Engine Operating Temperature Specifications - Ford

4150548 E

2-10 – JLG Lift – 3120858

-40 F(-40 C)

-30 F(-34 C)

-20 F(-29 C)

-10 F(-23 C)

0F(-18C)

10 F(-12 C)

20 F(-7 C)

30 F(-1 C)

40 F(4 C)

50 F(10 C)

60 F(16 C)

70 F(21 C)

80 F(27 C)

90 F(32 C)

100 F(38 C)

110 F(43 C)

120 F(49 C)

ENGINE
SPECIFICATIONS

ENGINE WILL START AND OPERATE AT THI

S TEMPERATURE

WITH THE RECOMMENDED FLUIDS, A FULLY

CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIF

IED COLD WEATHER

PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND

HYDRAULIC OIL TANK HEATER)

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A
FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS

EXIST JLG HIGHLY RECOMMENDS
THE ADDITION OF A HYDRAULIC

OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

PROLONGED OPERATION IN
AMBIENT AIR TEMPERATURES

OF 100° F (38°C) OR ABOVE.

EXTENDED DRIVING WITH
HYDRAULIC OIL TANK
TEMPERATURES OF 180° F

(82°C) OR ABOVE.

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

M

O

B

I

L

4

2

4

1

0

W

-

3

0

HYDRAULIC
SPECIFICATIONS

NO OPERATION ABOVE 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 WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE

E

X

X

O

N

U

N

I

V

I

S

H

V

I

2

6

M

O

B

I

L

D

T

E

1

3

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES

CONSISTENTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

Figure 2-3. Engine Operating Temperature Specifications - Caterpillar

4150548 E

SECTION 2 - GENERAL

3120858 – JLG Lift – 2-11

SECTION 2 - GENERAL

Figure 2-4. Engine Operating Temperature Specifications - GM

4150548 E

2-12 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

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

Tire Damage

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

For polyurethane foam filled tires, JLG Industries, Inc. rec­ommends that when any of the following are discovered,
measures must be taken to remove the JLG product from
service immediately and arrangements must be made for
replacement of the tire or tire assembly.

• a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies
which exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria,
the tire must be inspected on a daily basis to insure the
damage has not propagated beyond the allowable crite­ria.

Tire Replacement

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

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

Wheel Replacement

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

Wheel Installation

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

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

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

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

2. Tighten nuts in the following sequence:

• 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

Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a
pneumatic tire. When selecting and installing a replace-

3120858 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-1. Oscillating Valve Adjustment.

Figure 3-2. Brake Valve Wiring Connection.

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

Following the recommended sequence, tighten nuts
per wheel torque chart.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

70 ft. lbs.

(95 Nm)

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

170 ft. lbs.

(225 Nm)

300 ft. lbs.

(405 Nm)

3.2 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST

Lockout Cylinder Bleeding

To start the test, the axle must be fully oscillated in one
direction. Start with oscillating the axle so that the left lock­out cyl. is fully retracted (left front tire up), and the right
lock-out cyl. Is fully extended (right front tire down).

ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN­TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PRO­CEDURE. MAKING SURE MACHINE IS ON A LEVEL SURFACE AND
REAR WHEELS ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.

1. Making sure machine is on a level surface and rear
wheels are blocked, brake wire is disconnected.

2. Center boom over rear axle making sure that cam
valve is depressed.

3. Using a Phillips screwdriver, remove screw from
connection on the brake valve and remove connec­tor as shown.

4. Use suitable container to retain any residual hydrau­lic fluid, place container under the lockout cylinder.

5. With the left lock-out cyl. retracted, open the bleeder
on top of the cylinder, then have an operator from
the platform (on high engine) feather drive. Activate
drive just enough so the engine is under load but
not enough to stall the engine.

6. Close the bleeder when there is a steady stream of
oil and not air.

7. With the axle in the same position, go to the right
lock-out cyl. and open the bleeder at the rod end.
Activate drive in the same manner and close when
all air has been purged.

8. Close the bleeder when there is a steady stream of
oil and not air.

9. Oscillate the axle the other direction, left lock-out cyl.
extended (tire down), right lock-out cyl. retracted
(tire up). Use the same procedure for the bleeder in
the rod end of the left lock-out cyl., Then the piston
end of the right lock-out cyl. then close.

10. Repeat this process one more time to ensure that all
air has been purged from the system.

11. Perform oscillating axle lockout test.

12. If necessary, repeat steps 1 thru 9.

13. Reinstall the brake wires. See Figure 3-2.

NOTE: Bleeding of the oscillating axles is an infrequent

operation performed after hydraulic line failure and or
lock-out cylinder repair.

NOTE: To oscillate the axle, the lock-out valve plunger must

be depressed.

3-2 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

Oscillating Axle Lockout Test

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lock­out cylinder test.

1. Place a 6 inch (15.2 cm) high block with ascension
ramp in front of left front wheel.

2. From platform control station, activate machine
hydraulic system.

3. Place FUNCTION SPEED CONTROL and DRIVE
SPEED/TORQUE SELECT control switches to their
respective LOW positions.

4. Place DRIVE control lever to FORWARD position
and carefully drive machine up ascension ramp until
left front wheel is on top of block.

5. Carefully activate SWING control lever and position
boom over right side of machine.

6. With boom over right side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.

7. Have an assistant check to see that left front wheel
remains locked in position off of ground.

8. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). When boom reaches center, stowed posi­tion, lockout cylinders should release and allow
wheel to rest on ground, it may be necessary acti­vate DRIVE to release cylinders.

9. Place the 6 inch (15.2 cm) high block with ascension
ramp in front of right front wheel.

10. Place DRIVE control lever to FORWARD and care­fully drive machine up ascension ramp until right
front wheel is on top of block.

11. Carefully activate SWING control lever and position
boom over left side of machine.

12. With boom over left side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.

13. Have an assistant check to see that right front wheel
remains locked in position off of ground.

14. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). When boom reaches center, stowed posi­tion, lockout cylinders should release and allow
wheel to rest on ground, it may be necessary acti­vate DRIVE to release cylinders.

15. If lockout cylinders do not function properly, have
qualified personnel correct the malfunction prior to
any further operation.

3.3 FREE WHEELING OPTION

To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing

1. Chock wheels securely if not on flat level surface.

2. Disconnect both drive hubs by reversing the discon-

nect caps in the center of the hubs.

To Engage Drive Motors and Brakes (Normal Operation)

1. If equipped, move steer/tow valve to steer position
by pushing valve knob in.

2. Connect both drive hubs by inverting disconnect
cap in center of hub.

3. Remove chocks from wheels as required.

3120858 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

3.4 TORQUE HUB, DRIVE

Disassembly

1. Position hub over suitable container and remove
drain plugs (10) from unit. Allow oil to completely
drain, then replace drain plugs.

2. Remove eight bolts (41) and four shoulder bolts (42)
securing cover assembly to hub (7). Remove cover
assembly (23) and discard o-ring seal (22).

3. Lift carrier assembly and top thrust washer and
thrust bearing(39, 40) from hub. Thrust washer may
stick inside cover.

4. Pry ring gear (21) loose from hub and remove it.
Remove o-ring seal (22) from hub counter bore and
discard it.

5. Remove input gear (37) and thrust spacer (36) from
input shaft assembly and remove input shaft assem­bly from hub.

6. Lift internal gear (12) and thrust washer and thrust
bearing (39, 40) from hub. Thrust washer may stick
to bottom of carrier.

7. Remove retaining ring (9) from spindle (1) and dis­card; lift hub from spindle.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL.

8. Remove inside bearing cone (6) and bearing shim
(8).

9. If necessary, pry seal (2) out of hub using screw­driver or pry bar. With seal removed, outside bearing
cone (4) can be removed.

10. If necessary, remove inner and outer bearing cones
(3, 5) using a suitable slide hammer puller.

WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL
O-RINGS AND RETAINING RINGS.

Cleaning and Inspection

1. Thoroughly clean all parts in an approved cleaning
solvent.

4. Inspect all geared components for chipped or bro­ken teeth and for excessive or uneven wear pat­terns.

5. Inspect carrier for damage, especially in anti-roll pin
and planet shaft hole areas.

6. Inspect all planet shafts for scoring or other dam­age.

7. Inspect all threaded components for damage includ­ing stretching, thread deformation, or twisting.

8. Inspect seal mounting area in hub for burrs or sharp
edges. Dress applicable surfaces or replace compo­nents as necessary.

9. Inspect cover for cracks or other damage, and o­ring sealing area for burrs or sharp edges. Dress
applicable surfaces or replace cover as necessary.

Repair

1. Cover Assembly.

a. Remove two bolts (25) securing disconnect cap

(26) to cover (23) and remove cap.

b. Remove two bolts (25) securing cover cap (24)

to cover and remove cap.

c. Remove disconnect rod (27) from cap and

remove o-rings (28, 29) from cover cap. Discard
o-rings.

d. If necessary, remove pipe plug (30) from cover.

e. Clean and inspect parts in accordance with

Cleaning and Inspection procedures. Replace
parts as necessary.

f. If removed, screw pipe plug into cover.

g. Slip o-ring (29) over cover cap and against face.

h. Place o-ring (28) into cover cap internal groove.

Disconnect rod may be used to push o-ring into
groove.

i. Place cover cap into cover with large hole

located over pipe plug. Secure cover cap to
cover with two bolts. Torque bolts to 70-80 in.
lbs. (7.9-9.0 Nm).

j. Place disconnect cap over cover cap with nipple

facing out and secure with two bolts. Torque
bolts to 70-80 in. lbs. (7.9-9.0 Nm).

k. Turn cover over and push disconnect rod into

cover cap. Rod will be held in place by friction
from o-ring.

2. Inspect bearing cups and cones for damage, pitting,
corrosion, or excessive wear. If necessary, replace
bearings as a complete set ensuring that they
remain covered until use.

3. Inspect bearing mounting surfaces on spindle, hub,
input shaft and carrier. Replace components as nec­essary.

3-4 – JLG Lift – 3120858

2. Carrier Assembly.

a. Drive anti-roll pin (19) into planet shaft (17) using

a suitable punch.

b. Using a suitable press, press planet shaft from

carrier (13). After planet shaft is removed, drive
anti-roll pin from shaft.

c. Remove cluster gear (18) and thrust washers

(14) from carriers.

d. Remove sixteen needle rollers (15) from cluster

gear bore.

e. Remove spacer (16) from cluster gear bore and

remove second set of sixteen needle rollers (15).

f. Repeat steps (a) through (e) for remaining two

cluster gears.

g. Clean and inspect all parts in accordance with

Cleaning and Inspection procedures. Replace
parts as necessary.

h. Apply a coat of grease or petroleum jelly to clus-

ter gear bore.

SECTION 3 - CHASSIS & TURNTABLE

k. Place second set of sixteen needle rollers into

cluster gear.

l. Apply grease or petroleum jelly to tang side of

two thrust washers. Place thrust washers against
bosses in carrier with washer tang fitting into slot
in carrier outside diameter.

i. Place sixteen needle rollers into cluster gear

bore.

j. Place spacer into opposite side of cluster gear

and against needle rollers.

m. While keeping thrust washers in place, slide

cluster gear into carrier with larger gear on side
with small pin hole.

n. Line up cluster gear and thrust washers with

hole in carrier and slide planet shaft through.
Ensure chamfered side of hole in planet shaft is
lined up with pin hole in carrier.

3120858 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

o. Drive anti-roll pin flush into carrier hole, locking

planet shaft into place.

p. repeat steps (h) through (o) for remaining two

cluster gears.

3. Input Shaft Assembly.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL AND INSTALLATION

a. Carefully remove retaining ring (33) from counter-

bore in the spindle (1) and discard retaining ring.

b. Remove two spacers (31) and spring (32) from

input shaft.

c. Clean and inspect all parts in accordance with

Cleaning and Inspection procedures. Replace
parts as necessary.

d. Place washer (31), spring (32), and washer (31), in

that order, onto input shaft.

Install retaining ring into input shaft groove to secure spac­ers and spring to shaft.

Assembly

1. Using a suitable press, press new bearing cups (3, 5),
with large inside diameters facing out, into hub (7)
counter bores.

2. Place bearing cone (4) into bearing cup (3) in small
end of hub.

3-6 – JLG Lift – 3120858

3. Press new seal (2) into hub counter bore with flat
metal side facing in. Use a flat object to ensure that
seal is pressed evenly and is flush with hub face.

SECTION 3 - CHASSIS & TURNTABLE

6. Place bearing shim (8) over end of spindle and
against bearing cone.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
INSTALLATION.

7. Install new retaining ring (9) completely into spindle
groove and against bearing shim. Ensure retaining
ring is entirely in groove.

4. Lower hub onto spindle (1) with large open end up.

5. Place bearing cone (6) over end of spindle and into

bearing cup.

3120858 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

8. Place internal gear (12) onto end of spindle.

9. Install thrust washers and thrust bearing (39, 40) on

the portion of the spindle which extends into the
internal gear.

10. Install retaining ring (34) into input shaft retaining
ring groove.

12. Place thrust spacer (36) over input shaft (35) with
counter bore side facing spindle.

13. Locate the four counter reamed holes in the face of
the hub, mark them for later identification.

14. Place o-ring (22) into hub counter bore. Use petro-

11. Place input shaft assembly (35) into spindle bore

with unsplined end facing out.

leum or grease to hold o-ring in place. Slight stretch­ing of o-ring may be necessary to insure proper
seating.

3-8 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

15. Place carrier assembly on a flat surface with large
gears up and positioned as shown. Find punch
marked tooth on each large gear and locate at 12
o’clock (straight up) from each planet pin. Marked
tooth will be located just under carrier on upper two
gears

16. With shoulder side of ring gear (21) facing down,
place ring gear over (into mesh with) large gears.
Ensure punch marks remain in correct location dur­ing ring gear installation.

18. Install input gear (37) into carrier, meshing with large
diameter cluster gears (18). Counter bore in bore of
input gear must be to outside of carrier assembly.

19. After inserting at least one shoulder bolt in the
proper location, rotate the carrier. Check freedom of
rotation and timing.

17. While holding ring gear, input gear, and cluster
gears in mesh, place small side of cluster gears into
mesh with internal gear. On ring gear, locate hole
marked ‘X’ over one of counter bored holes in hub.

NOTE: If gears do not mesh easily or carrier assembly does

not rotate freely, then remove carrier and ring gear
and check cluster gear timing.

20. Install thrust washers and thrust bearing (39, 40) into
carrier counter bore.

3120858 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

21. Place o-ring (22) into cover assembly counter bore.
Use petroleum jelly or grease to hold o-ring in place.

22. Place cover assembly over ring gear with oil level
check plug in cover located approximately 90
degrees from oil fill plug in hub.

23. Locate four shoulder bolts (42), 90 degrees apart
into counter bored holes in hub marked in step (13).
Torque shoulder bolts to 47 ft. lbs. (64 Nm).

24. Install bolts (41) in remaining holes. Torque bolts to
47 ft. lbs. (64 Nm).

25. Place coupling (1) into spindle and onto input shaft.

26. Fill hub one-half full of EPGL 90 lubricant before

operation.

3-10 – JLG Lift – 3120858

Figure 3-3. Torque Hub Drive (Fairfield)

1. Spindle

2. Seal

3. Bearing Cup

4. Bearing Cone

5. Bearing Cup

6. Bearing Cone

7. Hub

8. Spacer

9. Retaining Ring

10. Plug

11. Wheel Bolt

12. Internal Gear

13. Carrier

14. Thrust Washer

15. Needle Roller

16. Spacer

17. Piston Shaft

18. Cluster Gear

19. Roll Pin

20. Not Used

21. Cluster Gear

22. O-ring

23. Cover

24. Cover Cap

25. Bolt

26. Disconnect Cap

27. Disconnect Rod

28. O-ring

29. O-ring

30. Pipe Plug

31. Washer

32. Spring

33. Retaining Ring

34. Retaining Ring

35. Input Shaft

36. Thrust Spacer

37. Input Gear

38. Not Used

39. Thrust Washer

40. Thrust Bearing

41. Bolt

42. Shoulder Bolt

43. Coupling

SECTION 3 - CHASSIS & TURNTABLE

3120858 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

3.5 DRIVE BRAKE - AUSCO (PRIOR TO S/N

56875)

Disassembly

1. With shaft protrusion downward, disassemble the
parts in the following order; bolts (24 alternately,
washers (23), power plate (21), and gasket.

2. Remove the following parts; stationary discs (14),
rotating discs (12), primary disc (11), torque pins (3),
springs (8&9), and the spring retainer (7).

NOTE: If the bearing and seal are removed for any reason,

both must be replaced.

3. Further disassembly is not recommended and
should not be attempted unless necessary to
replace the bearing (4), the seal (6), or the shaft (10).
If further dissembly is needed, proceed as follows;

a. The shaft (10) may be removed by pressing on

the end of the shaft with a shop press.

b. Using an appropriate tool, pry the seal (6) out

from the inside of the brake. Take care not to
damage the bore. Remove the retaining ring (5).
Tap the bearing (4) out with a plastic mallet.

4. Remove the piston (15) from the power plate (21) by
introducing low pressure air into the hydraulic inlet
and make sure the piston is directed away from the
operator. Remove the o-rings (17&19) and backup
rings (16&18) from the piston O.D. and I.D. grooves.
Do not remove backup rings (16 & 18) unless
replacement is necessary because they will be dam­aged. With shaft protrusion downward, remove the
end cover (13) by removing capscrews (12).

Inspection

5. Clean all parts thoroughly.

6. Closely inspect all parts for excessive wear, cracks

and chips. Replace parts as necessary.

7. Discard seals and o-rings.

8. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

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

they are inspection, they are found to be in good
condition.

Assembly

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

oil prior to assembly.

THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR
BRAKE REQUIRES. CHECK THE PARTS LIST CAREFULLY FOR THE
EXACT QUANTITY. IN THE CASE OF SPRINGS, SPACE THE
SPRINGS AS SHOWN IN FIGURE 3-4.

1. Worn o-rings and damaged or worn Teflon backup
rings must be replaced prior to assembly.

2. The cylinder of the power plate, piston, and o-rings
must be clean prior to assembly and pre-lubed with
the system hydraulic fluid.

THE DEPTH THE PISTON IS INSTALLED INTO THE POWER PLATE
IS CRITICAL. THE SURFACE OF THE PISTON AT THE CUTOUTS
MUST BE FLUSH TO 0.120 IN.(3.0 MM) BELOW THE SURFACE OF
THE POWER PLATE. DO NOT EXCEED THE 0.120"(3.0 MM) DEPTH
OR THE PISTON WILL COCK RESULTING IN COMPLETE LOSS OF
BRAKING.

3. Assemble the piston (15) into the power plate (21)
using a shop press, being careful not to damage the
o-rings or Teflon back-up rings. Visually align the
center of the cutouts in the piston with the torque pin
(3) holes in the power plate (21).

4. For replacement of the seal;

a. Use a shop press to install the bearing (4) into

the housing. Press the outer surface of the bear­ing only. Install the retaining ring (5) into the
groove.

b. Press the seal (6) into the housing (1) until it is

flush with the face of the housing. The lip of the
seal must face towards the bearing.

5. Press the shaft into the housing until it stops on the
bearing. Support the inner race of the bearing dur­ing the press operation.

6. Rotating discs must be clean and dry. The lining
material and mating surfaces of the stationary discs
must be thoroughly clean and free of debris. Worn
or scored rotating discs must be replaced.

7. Install bolts (24) with washers (23) in the power plate
(21. Tighten sequentially, one turn at a time, until the
power plate is properly seated. Torque 105-115 Ft.
Lbs.(142.4-155.9 Nm)

3-12 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-4. Drive Brake, Ausco

1. Housing

2. Gasket

3. Torque Pin

4. Ball Bearing

5. Retaining Ring

6. Seal

7. Spring Retainer

8. Small Compression Ring

9. Large Compression Ring

10. Shaft

11. Primary D isc

12. Rotating Disc

13. Not Used

14. Stationary Disc

15. Piston

16. Backup Ring

17. O-ring

18. Backup Ring

19. O-ring

20. Bleeder Screw

21. Power Plate

22. Protective Plug

23. Washer

24. Bolt

25. Gasket

3120858 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

3.6 DRIVE BRAKE - MICO (S/N 56875 TO

83332)

Disassembly

1. Remove pressure plate (3) from cover plate (16) by
removing cap screws (1) and washers (2).

PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI­MATELY 907 KGF (2000 IBS). THE TWO CAP SCREWS MUST BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE, 1361 KGF (3000 IBS) MINIMUM, THE
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING
THE CAP SCREWS. COVER PLATE (16) MUST BE SUPPORTED AS
SHOWN IN FIGURE 3-5.

2. Remove case seal (4) from cover plate (16).

3. Remove piston (7) from pressure plate (3).

4. Remove a-ring (5), back-up ring (6), a-ring (8) and

back-up ring (9) from piston (7).

5. Remove stator disc (11), rotor disc (12) and return
plate (13) from cover (16).

NOTE: Not all models use the same number of springs or

spring pattern.

3. Press bearing (18) into position until it bottoms out
on borestep.

NOTE: Cover plate (16) must be supported as indicated in

Figure 1.

4. Install retaining ring (20) in cover plate (16).

5. Press shaft (10) into bearing (18) until it bottoms on

shoulder.

NOTE: Bearing (18) inner race and cover plate (16) must be

supported as indicated in Figure 1 during this opera­tion.

6. Install retaining ring (19) on shaft (10).

7. Insert dowel pins (15) and springs (14) in cover plate

(16).

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

spring pattern as recorded during disassembly.

8. Position return plate (13) on springs (14).

NOTE: Discs (11 & 12) and return plate (13) must remain

dry during installation. No oil residue must be
allowed to contaminate disc surfaces.

6. Remove dowel pins (15) and springs (14) from cover
plate (16). Record this information for assembly pur­poses.

7. Remove retaining ring (19) from cover plate (16).

8. Remove shaft (10) by pressing or using a soft mallet

on male end of shaft (10).

NOTE: Cover plate (16) must be supported as shown in FIG-

URE 3-5.

9. Remove retaining ring (20) from cover plate (16) and
press out oil seal (17) and bearing (18) if required.

NOTE: Cover plate (16) must be sup¦ported as indicated in

Figure 3-5.

Assembly

LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH
CLEAN TYPE FLUID USED IN THE SYSTEM.

1. Use an alkaline wash to clean parts before assem­bly.

2. Press oil seal (17) into cover plate (16) until it is flush
with bearing shoulder. Note direction of seal.

9. Install rotor disc (12) and stator disc (13).

10. Install o-ring (5), back-up ring (6), a-ring (8) and

back-up ring (9) on piston (7). Note order of a-rings
and back-up rings. Insert piston (7) into pressure
plate (3).

NOTE: Be careful not to shear o-rings or back-up rings. Be

careful not to scratch or mar piston.

11. Install new case seal (4) in cover plate (16).

12. Position pressure plate (3) on cover plate (16) align-

ing dowel pins (15) with holes in pressure plate.

13. Install cap screws (1) and washers (2) and tighten
evenly to draw pressure plate (3) to cover plate (16).
Torque cap screws 65.1-67.8 N-m (48-50 Ib-ft).

NOTE: A hydraulic press will simplify installation of pressure

plate on cover. Clamp pressure plate in position
while tighten¦ing the cap screws. Cover plate (16)
must be supported as indicated in Figure 3-5.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED

134.5 BAR (500 PSI).

3-14 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

1. Capscrew

2. Washer

3. Pressure Plate

4. Case Seal

5. O-ring

6. Backup Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Stator Disc

12. Rotor Disc

13. Return Plate

14. Springs

15. Dowel Pin

16. Cover Plate

17. Oil Seal

18. Bearing

19. Retaining Ring

20. Retaining Ring

Figure 3-5. Drive Brake - Mico (S/N 56875 TO 83332)

3120858 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

Bleeding

1. Install brake in system and connect pressure lines.

2. Bleed pressure release section of brake by pressur-

izing side inlet port and allowing air to escape from

Table 3-2. Troubleshooting

PROBLEM CAUSE EXPLANATION ACTION

Brake slips Excessive pressure in hydraulic system If there is back pressure in the actuation

line of the brake, holding torque will be
reduced.

Oil in brake if designed for dry use Wet linings generate 67% of the dry

torque rating. If the brake has oil in it,
check the type of oil hydraulic or gearbox.

1. Gearbox oil

2. Hydraulic oil

Disc plates worn The thickness of the disc stack sets the

torque level. A thin stack reduces torque.

Springs broken or have taken a perma­nent set

Brake drags or runs hot Low actuation pr essure The brake should be pressurized to mini-

Bearing failure If the bearing should fail, a large amount of

Brake will not release Stuck or clogged valve Brakes are designed to come on when

Bad o-rings If release piston will not hold pressure,

Discs frozen These brakes are designed for only lim-

Broken or set springs can cause reduced
torque - a rare occurrence.

mum of 1.38 bar (20 psi) over the full
release pressure under normal operating
conditions. Lower pressures will cause
the brake to drag thus generating heat.

drag can be generated.

system pressure drops below stated
release pressure. If pressure cannot get to
brake, the brake will not release.

brake will not release.

ited dynamic braking. A severe emer­gency stop or prolonged red uced release
pressure operation may result in th is type
of damage.

top port. Pressure should not exceed 6.9 bar (100
psi) during bleeding.

3. Apply sufficient pressure to release brake and check
for proper operation in system.

Check filters, hose size, restrictions in
other hydraulic components.

Replace oil seal in brake.
Check motor seal
Check piston seals

NOTE: Internal components will

Check disc thickness.

Check release pressure. (See spring
replacement).

Place pressure gauge in bleed port &
check pressure with system on.

Replace bearing.

Place pressure gauge in bleed port ­check for adequate pressure. Replace
inoperative line or component.

Replace o-rings.

Replace disc stack.

need to be inspected,
cleaned and replaced as
required.

3-16 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

3.7 DRIVE BRAKE (S/N 83332 TO PRESENT)

Disassembly

1. Supporting brake on face A:, remove the six socket
head capscrews and washers [Items 13 & 14) In
equal increments to ensure the spring pressure
within the brake is reduced gradually and evenly.

If a press is available, the cylinder housing (8) can
be restrained on face B while removing the six cap­screws and washers (13 & 14).

The brake assembly can now be fully dismantled
and the parts examined.

2. Remove cylinder housing (8) and piston (9) subas­sembly and dismantle if required, removing O-ring
seals (15 & 17) and backing rings (16 & 18) as nec­essary.

3. Remove gasket (7) from housing (2).

4. Remove friction plates (3 & 6) and pressure plate

(4).

5. Remove 2 dowel pins (19).

6. Remove springs (22 & 23).

7. Should it be necessary to replace ball bearing (10)

or shaft seal (12), reverse remainder of brake subas­sembly, supporting on face C of housing (2).

8. Remove internal retaining ring (11).

9. Using arbor press or similar to break Loctite seal,

remove brake shaft (1) from housing (2) and lay
aside.

10. Reverse housing (2) and press out ball bearing (10).
Shaft seal (12) can also be removed if necessary.

Assembly

1. Lightly lubricate rotary shaft seal (12) and assemble
to housing (2) taking care not to damage seal lip.

2. Apply ring of Loctite 641 or equivalent adhesive to
full circumference of housing (2) bearing recess
adjacent to shoulder.

Apply complete coverage of Loctite 641 to outside
diameter of bearing (10) and assemble fully In hous­ing (2), retaining with internal retaining ring (11).
Remove excess adhesive with a clean cloth.

Press shaft (1) through bearing (10), ensuring bear­ing inner ring Is adequately supported.

3. Assemble correct quantity of springs (22 & 23) in ori­entation required.

4. Lubricate O-ring seals (15 & 17) with Molykote 55M
(or equivalent) silicon grease and assemble together
with backing rings (16 & 18) to piston (9). To ensure
correct brake operation. It is important that the back­ing rings are assembled opposite to the pressurized
side of piston.

5. Correctly orientate piston (9) aligning spaces with
the two dowel pin holes and, assemble into cylinder
housing (8) taking care not to damage seals and
carefully lay aside.

6. Locate 2-off pins (19) in housing (2) followed by
pressure plate (4) and friction plates i.e. an inner (3)
followed by an outer (6) in correct sequence.

7. Position gasket (7) in correct orientation.

8. Align two holes in cylinder with dowel pins (19) and

assemble piston & cylinder sub-assembly to remain­der of brake securing with 6 capscrews and washers
(13 & 14). Torque to 55 ft.Ibs. (75 Nm).

NOTE: The use of a suitable press (hydraulic or arbor)

pressing down on cylinder end face B will ease
assembly of the capscrews (13).

Inspection

1. Inspect friction plates (3 & 6) and friction surface on
pressure plate (4) for wear or damage.

2. Examine friction plates (3) and brake shaft (1) for
wear or damage to the splines.

3. Examine input and output splines of brake shaft (1)
for wear or damage.

4. Examine compression springs (22 & 23) for damage
or fatigue.

5. Check ball bearing (10) for axial float or wear.

6. Examine O-ring seals (15 & 17) and backing rings

(16 & 18) for damage.

3120858 – JLG Lift – 3-17

SECTION 3 - CHASSIS & TURNTABLE

5

11

10

12

21219

22

23

4

3

3

1

9

7

8

14

131615

181720

6

6

1. Shaft

2. Housing

3. Friction Plate

4. Pressure Plate

5. Gasket

6. Outer Plate

7. Gasket

8. Cylinder

9. Piston

10. Ball Bearing

11. Retaining Ring

12. Shaft Seal

13. Capscrew

14. Lockwasher

15. O-ring

16. Backup Ring

17. O-ring

18. Backup Ring

19. Dowel Pin

20. Plug

21. Plug

22. Spring (Natural)

23. Spring (Blue)

Figure 3-6. Drive Brake (S/N 83332 to Present)

3-18 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

3.8 DRIVE MOTOR (PRIOR TO S/N 83332)

Spare Parts Kits

Sealing kit, existing spare parts: shaft sealing ring, 6 differ­ent O-rings and a circlip (sealing mat.: perbunan)

Same sealing kit like shown above only seal material
changed to Viton

Rotary group complete 9 pistons, cylinder sub-assembly,
valve plate (cw or ccw corresponding to the order) retain­ing plate and retaining ball.

Swash Plate

Drive shaft

Bearing set/miscellaneous parts

Parts of the control device: control piston, piston rod,

plug, spring stopper max

Spare parts kit DFR pilot valve

flow, hex. nut, and hex. head nut

3120858 – JLG Lift – 3-19

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-7. 600S Drive Motor Cutaway

Replacing the Drive Shaft Seal

1. Remove the snap ring

2. Change the shaft seal and check its sliding surface

(drive shaft) and housing, grease the sealing ring.

3-20 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

3. Be careful while you seal the drive shaft, use an
adhesive tape to protect the splines.

4. Assemble the sealing ring. The fitting tool will hold
the sealing ring in the correct position in the pump
housing.

Disassembly and Assembly

1. Disassemble the pilot valve.

2. Mark the position of the port plate and remove the

socket screw from the port plate.

5. Assemble the snap ring.

6. Assemble the snap ring in the correct position.

3. Remove the port plate together with the valve plate

(hold the valve plate so that the plate can’t fall
down).

3120858 – JLG Lift – 3-21

SECTION 3 - CHASSIS & TURNTABLE

4. Remove the O-ring.

5. Disassemble the taper roller bearing.

8. Loosen the retaining nut of the stopper max flow and

remove it.

9. Turn in the stopper max flow to get swivel angle
zero.

6. Remove the adjustment shim.

7. Unscrew the cap nut and remove it.

10. Disassemble the rotary group in horizontal position.

11. Disassemble the stopper - max. flow.

3-22 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

12. Remove the threaded pin (stopper - max.flow)

13. Disassemble the plug.

14. Disassemble the control piston while moving the

swash plate.

16. Disassembly of the swash plate.

17. Remove the spring.

18. Remove both bearing shells.

19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disas-

semble the piston rod.

3120858 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

20. Remove the snap ring.

21. Disassemble the sealing ring.

23. Remove the O-ring. Lifting of the valve plate isn’t

shown.

24. A usual commercial bearing puller is used to disas­semble the external bearing ring of the taper roller
bearing inside the port plate. Take care not to dam­age the surface of the port plate.

22. The external front bearing ring is pulled out of the
pump housing.

25. The spring has additional pretension while you dis­assemble the three pressure pins inside the cylinder.

3-24 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

Assembly Notes

1. Measurement of the taper roller bearing pretension.

2. Note that there is a correct connection of the piston

rod and the swash plate.

4. Pumps counterclockwise driven must have a posi­tion of the valve plate 4 degrees de-centered in ccw
position.

5. Assembly of the port plate and the pump housing:
Note the correct position of the drilling that connects
high pressure to the control valve. Check control
valve drill position at the pump housing and fit
together.

3. Pumps clockwise driven must have a position to the
valve plate 4 degrees out of center in the same
direction de-centered like drive direction. (Note
spare parts exist as cw and ccw valve plates.)

Taper Roller Bearing Initial Tension

Cast iron pump housing must have initial tension of the

bearings: 0........0,05 mm, grind Pos. 12 if necessary.

3120858 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Differential volume if you are rotating the threaded pin -

each rotation is appr. 3,1 cm3.

Figure 3-8. Flow Control Pilot Valves

3-26 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

mm

4-WD

11 0.433

1.000

inches

cu. in . /r e v

Figure 3-9. Drive Motor Adjustment (Prior to S/N 83332)

Testin g and Setup

DR: When pressure line is closed adjust the pressure of
the controller (if it’s DFR design then open the adjustable
orifice and increase force of the spring - FR -).

FR: If swivel angle is in the mid position adjust differential
pressure 14 bar adjustable orifice is partly closed).

Mechanical flow limiter: While screwing in the threaded
pin you will be able to reduce the flow from Vg max to 50%
of Vg max.

3.9 DRIVE MOTOR ADJUSTMENT PROCEDURE (PRIOR TO S/N 83332)

1. Remove the cap nut from adjustment screw.

2. Loosen jam nut on the adjustment screw and make

adjustment.

3. Measure from top of jam nut to the end of adjust­ment screw. Refer to Figure 3-9., Drive Motor Adjust­ment (Prior to S/N 83332).

4. Tighten jam nut, install cap nut.

NOTE: The “o” ring must be seated in groove in cap nut.

3120858 – JLG Lift – 3-27

SECTION 3 - CHASSIS & TURNTABLE

Bias spring

Servo piston

Swashplate

Output

Shaft

Piston

Slipper

Cylinder
Block

Endcap

Shaft
Seal

Bearing

Minimum
Angle
Stop

Valv

e plate

Figure 3-10. Drive Motor Cross Section

1

2

3

1. Snap Ring

2. Support Washer

3. Shaft Seal

Figure 3-11. Removing the Shaft Seal

3.10 DRIVE MOTOR (S/N 83332 TO PRESENT)

Description

The drive motors are low to medium power, two-position
axial piston motors incorporating an integral servo piston.
They are designed for operation in both open and closed
circuit applications. The standard control is a direct acting
single line hydraulic control. The integral servo piston con­trols motor displacement.

The motors are spring biased to maximum displacement
and hydraulically shifted to minimum displacement. Mini­mum and maximum displacement can be set with fixed
internal stops. The large diameter servo piston allows
smooth acceleration and deceleration with relatively large
circuit orificing.

Shaft Seal Replacement

REMOVAL

1. Remove the snap ring (1) retaining the shaft seal

and support washer.

2. Remove the support washer (2).

3. Carefully pry out the shaft seal (3).

To avoid damaging the shaft during removal, install
a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and
use the slide hammer to pull the seal.

4. Discard the seal.

INSPECT THE COMPONENTS

Inspect the new seal, the motor housing seal bore, and
the sealing area on the shaft for rust, wear, and contami­nation. Polish the shaft and clean the housing if neces­sary.

INSTALLATION

1. Cover the shaft splines with an installation sleeve to

3-28 – JLG Lift – 3120858

protect the shaft seal during installation.

2. Install a new shaft seal with the cupped side facing
the motor. Press seal into housing until it bottoms
out. Press evenly to avoid binding and damaging
the seal.

3. Install seal support washer.

4. Install snap ring.

5. Remove the installation sleeve.

SECTION 3 - CHASSIS & TURNTABLE

2

6

9

11

1

4

8

10

12

5

3

7

13

(37 Nm)

27 ft.lbs.

11/16 in

(37 Nm)

27 ft.lbs.

11/16 in

(27 Nm)

20 ft.lbs.

5/8 in

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shift Spool

13. Orifice Poppet

Figure 3-12. Loop Flushing Spool

Loop Flushing Valve

REMOVAL

1. Using a 11/16 in internal hex wrench remove plug

(1) and (2).

INSPECT THE COMPONENTS

Inspect new O-rings and the sealing area for rust, wear, or
contamination. Also check springs and poppet for wear.

INSTALLATION

1. Install orifice poppet (13).

2. Install shift spool (12).

3. Install spring retaining washers onto springs (10 and

11).

4. Carefully install centering springs (7, 8, and 9).

5. Install new O-rings (6, 4, and 5).

6. Using a 1/4 in hex wrench torque plug (3) to 20 ft.

lbs. (27 Nm).

7. Using a 11/16 in internal hex, torque plugs (2 and 1)
to 27 ft.lbs. (37 Nm).

2. Using a 1/4 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3120858 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

Table 3-3. Excessive Noise and/or Vibration

Item Description Action

Check oil level in reservoir
and oil supply to the motor.

Insufficient hydraulic fluid could lead to cavitation tha t would
cause system noise.

Fill the reservoir to the proper level and ensure that oil supply to
the motor is adequate and the lines are unobstructed.

Check for air in the system. Air trapped within the system lines, or the motor itself, could

result in cavitation that would cause system noise.

Inspect the output shaft cou­plings.

Inspect the output shaft
alignment.

Hydraulic oil viscosity above
limits.

Item Description Action

Check oil level in reservoir
and oil supply to the pump.

Inspect the heat exchanger,
(if so equipped).

Check the system relief
valves.

A loose or incorrect shaft coupling will produce vib rations that
could result in system noise.

Misaligned shafts create excessive frictional vibra tion that
could result in system noise.

Viscosity above acceptable limits will result in cavitation that
would lead to system noise.

Table 3-4. System Operating Hot

Insufficient amount of hydraulic fluid will not meet the cooling
demands of the system.

If the heat exchanger fails, or becomes obstructed, it may not
meet the cooling demands of the system.

If a system relief valve becomes unseated for an extended
period of time or fails for any other reason, the system could
become overheated.

Ensure that all of the system lines and components are purged
of air.

Ensure that the correct coupling is used and that it fits properly
onto the shaft.

Ensure that the shafts are prop erly aligned.

Replace hydraulic oil with app ropriate fluid for operating condi­tions.

Fill the reservoir to the proper level.

Ensure that heat exchanger is receiving adequate ai r flow and
that the heat exchanger is in good operating con dition. Repair
or replace as necessary.

Repair or replace any malfunc tioning relief valves as applica­ble and verify that the loads on the machine are not excessive.

Table 3-5. Won’t Shift or Slow to Start

Item Description Action

Check the signal line to the
servo control port.

Check that the correct supply
and drain orifices are prop­erly installed, and are not
obstructed.

Obstructed or restricted flow through the servo control sign al
lines could result in slow shift or no shift conditions within the
motor.

Supply and drain orifices determine the shift rate of the motor.
The smaller the orifice, the longer the time it takes to shift the
motor. Obstruction will also increase shift times.

Ensure that the signal lines are not obstru cted or restricted and
that signal pressure is adequate to shift the motor.

Ensure that the proper control ori fices are installed in the motor
and verify that they are not obstructed. Clean or rep lace as
necessary.

3-30 – JLG Lift – 3120858

Disassembly

5

3

7

13

2

6

9

11

1

4

8

10

12

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shift Spool

13. Orifice Poppet

Figure 3-13. Loop Flushing Spool

15

20161619171821

14

14. Lock Nut

15. O-ring Plug

16. Control Line Plug

17. Control Line Plug

18. Cavity Plug

19. Drain Plug

20. Drain Plug

21. Work Port Plug

Figure 3-14. Plugs, Fittings, and Speed Sensor

NOTE: Removal of the endcap voids warranty.

During assembly, coat all moving parts with a film of
clean hydraulic oil. This assures that these parts will
be lubricated during start-up.

Replace all O-Rings and gaskets.

It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.

SECTION 3 - CHASSIS & TURNTABLE

1. Using a 11/16 in wrench remove plug (1) and (2).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

2. Using a 5/8 in hex wrench remove plug (3).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3120858 – JLG Lift – 3-31

8. Remove all fittings from the unit. Discard any O-rings
on the fittings.

9. Using an 11/16 inch hex wrench, loosen the speed
sensor lock nut (14) if equipped. Then remove the
speed sensor using a Vi inch hex wrench. Units with­out speed sensor have an O-ring plug (15) installed
in that location; remove it with a Va inch internal hex
wrench.

10. Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm
hex wrench, remove cavity plug (18, if equipped with
two-line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard
O-rings.

SECTION 3 - CHASSIS & TURNTABLE

24

22

23

22. Screw

23. End Cap

24. O-ring

Figure 3-15. End Cap

26

28

29

30

292725

25. Valve Plate

26. End Cap

27. O-ring

28. O-ring

29. Angle Stop

30. Servo Spring

Figure 3-16. Valve Plate & Rear Shaft Bearing

13. Using an 8 mm internal hex wrench, remove the

endcap screws (22).

14. Remove the endcap (23). Remove O-ring (24) from
the housing or endcap.

When the endcap screws are removed, pressure
from the servo spring will cause the endcap to bind
on the shaft. Press down on the portion of the end-

TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE
PLATE.

cap covering the servo piston and hold the endcap
level while removing.

15. Remove the valve plate (25) and timing pin (26) from
the endcap.

Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate
part number are stamped on its surface.

16. Remove and discard the O-rings (27, 28).

17. Remove the rear shaft bearing (29) from the endcap

with a bearing puller.

The bearing may be difficult to remove with a puller.
Try this as an alternative: Pack the bearing cavity
with heavy grease. After the shaft is removed, insert
it into the bearing cavity and tap lightly with a soft
mallet on the splined end. The grease will force the
bearing out. Use caution not to drive the bearing
past the rear shaft journal as the bearing may
become trapped on the shaft and damaged.

3-32 – JLG Lift – 3120858

18. Remove minimum angle stop (29) and servo spring

31

31. Cylinder Kit Assembly

Figure 3-17. Cylinder Kit

32

33

34

32. Snap Ring

33. Suppor t Washer

34. Shaft Seal

Figure 3-18. Shaft Seal

38

37

36

35

35. Inner Snap Ring

36. Snap Ring

37. Bearing

38. Shaft

Figure 3-19. Shaft & Front Bearing

(30) from the housing.

19. Turn the housing on its side and remove the cylinder
kit assembly (31). Set the assembly aside, being
careful not to scratch the running surface.

NOTE: Grooves on the surface of the cylinder kit identify its

displacement:

SECTION 3 - CHASSIS & TURNTABLE

To avoid damaging the shaft during seal removal.
Install a large sheet metal screw into the chuck of a
slide hammer. Drive the screw into the seal surface
and use the slide hammer to pull the seal.

Table 3-6. Displacement Identifiers

# of Grooves Frame L Frame K

1 25 38

2 30 45

3 35 - -

21. Remove the inner snap ring (35) and the shaft /
bearing assembly.

22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).

20. Turn the housing over and remove the snap ring (32)
retaining the shaft seal and support washer. Remove
the support washer (33) and carefully pry out the
shaft seal (34). Discard the seal.

3120858 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

41

42

40

Lift here

39

43

39. Swashplate

40. Servo Piston

41. Piston Seal

42. O-ring

43. Journal Bearings

Figure 3-20. Swash Plate & Servo Piston

51505253464948

474544

44. Piston

45. Slipper Retainer

46. Cylinder Block

47. Ball Guide

48. Holddown Pins

49. Retaining Ring

50. Block Spring Washer

51. Spiral Retaining Ring

52. Block Spring

53. Inner Block Spring Washer

Figure 3-21. Cylinder Kit Disassembly

3-34 – JLG Lift – 3120858

23. Turn housing over and remove the swashplate (39)
by lifting on the end opposite the servo lever.

24. Remove the servo piston (40). Remove the piston
seal (41) and O-ring (42) from the servo piston. Dis­card the seal and O-ring.

25. Remove the journal bearings (43) from the housing.
If the bearings are to be reused, note the location
and orientation of each bearing for reassembly.

26. Remove pistons (44) and slipper retainer (45) from
the cylinder block (46).

The pistons are not selectively fitted, however units
with high hourly usage may develop wear patterns.
Number the pistons and bores for reassembly if they
are to be reused.

27. Remove the ball guide (47), hold-down pins (48),
and retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems
with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING
REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE
A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON­ABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE
ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING
IS REMOVED.

SECTION 3 - CHASSIS & TURNTABLE

Slipper

Maximum end play

M inimum
slipper fo ot
thick ness

A

Table 3-8. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness 0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

28. Turn the block over. Using a press, apply pressure
on the block spring washer (50) to compress the
block spring. Compress the spring enough to safely
remove the spiral retaining ring (51). While maintain­ing pressure, unwind the spiral retaining ring (51).
Carefully release the pressure and remove the outer
block spring washer (50), block spring (52), and
inner block spring washer (53) from the cylinder
block.

Inspection

After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow to
air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area
and keep all parts free from contamination. Clean and dry
parts again after any rework or resurfacing.

PISTON

Inspect the pistons for damage and discoloration. Discol­ored pistons may indicate excessive heat; do not reuse.

SLIPPERS

Inspect the running surface of the slippers. Replace any
piston assemblies with scored or excessively rounded
slipper edges. Measure the slipper foot thickness.
Replace any piston assemblies with excessively worn slip­pers. Check the slipper axial end-play. Replace any piston
assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end­play are given in the table below.

Table 3-7. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness mm

(in.)

Piston/Slipper End Play 0.15

2.71

(0.11)

4.07

(0.16)

(0.006)

CYLINDER BLOCK

Measure the cylinder block height. Replace blocks worn
beyond the minimum height specification. Inspect the run­ning surface of the cylinder block. Replace or resurface
worn or scratched blocks. Blocks may be resurfaced to
the specifications shown in the drawing, provided resur­facing will not reduce the block height below the minimum
specification. Table 3-8, Cylinder Block Measurements.

3120858 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

Slipper retainer

Ball guide

3.83 mm [0.151 in] min.

0.025 mm
[0.001 in]

0.0076 mm
[0.00030 in]

convex max

LV

25.8 mm
[1.015 in]

24.6 mm
[0.969 in]

KV

Thickness equality
side to side:

0.05 mm [0.002 in]

0.0025 mm
[0.0001 in]

BALL GUIDE AND SLIPPER RETAINER

Inspect the ball guide and slipper retainer for damage,
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not reuse.

VALVE PLA TE

The condition of the valve plate is critical to the efficiency
of the motor. Inspect the valve plate surfaces carefully for
excessive wear, grooves, or scratches. Replace or resur­face grooved or scratched valve plates. Measure the valve
plate thickness and replace if worn beyond the minimum
specification. Valve plates may be resurfaced to the speci­fications shown in the drawing, provided resurfacing will
not reduce the thickness below the minimum specifica­tion.

Replace swashplate if the difference in thickness from one
side to the other exceeds specification.

Inspect the journal bearings for damage or excessive
wear. Replace journal bearings if scratched, warped, or
excessively worn. The polymer wear layer must be
smooth and intact.

SHAFT BEARINGS

Inspect bearings for excessive wear or contamination.
Rotate the bearings while feeling for uneven movement.
Bearings should spin smoothly and freely. Replace bear­ings that appear worn or do not rotate smoothly.

3-36 – JLG Lift – 3120858

SWASHPLATE AND JOURNAL BEARINGS

Inspect the running face, servo ball-joint, and swashplate
journal surfaces for damage or excessive wear. Some
material transfer may appear on these surfaces and is
acceptable providing the surface condition meets specifi­cations shown. Measure the swashplate thickness from
the journals to the running face. Replace swashplate if
damaged or worn beyond minimum specification.

SHAFT

Inspect the motor shaft. Look for damage or excessive
wear on the output and block splines. Inspect the bearing
surfaces and sealing surface. Replace shafts with dam­aged or excessively worn splines, bearing surfaces, or
sealing surfaces.

SECTION 3 - CHASSIS & TURNTABLE

3

2

1

3

1. O-ring

2. Piston Seal

3. Servo Piston

Figure 3-22. Servo Piston

SERVO PISTON AND MINIMUM ANGLE STOP

Inspect the minimum angle stop, servo piston head, and
servo piston ball-socket for damage or excessive wear.
Replace if necessary.

LOOP FLUSHING SPOOL

Inspect the loop flushing spool. Check for cracks or dam­age. Replace if necessary.

Assembly

1. Install new O-ring (1) and piston seal (2) to the servo
piston (3). Install the piston seal over the O-ring.

Installing the piston seal stretches it, making it diffi­cult to install the servo piston in its bore. Allow 30
minutes for the seal to relax after installation. To
speed up seal relaxation, compress the seal by
installing the piston head into the servo cavity in the
end-cap and let it stand for at least five minutes.

2. After piston seal has relaxed, lubricate and install
servo piston into the housing bore. Align the piston
with the ball socket facing the inside of the housing.

3120858 – JLG Lift – 3-37

SECTION 3 - CHASSIS & TURNTABLE

7

6

5

4

8

9

10

12

11

4. Block Spring Washer

5. Block Spring

6. Outer Washer

7. Spiral Retaining Ring

8. Retaining Ring

9. Holddown Pins

10. Ball Guide

11. Piston

12. Slipper Retainer

Figure 3-23. Cylinder Kit Assembly

14

13

13

13. Journal Bearings

14. Swash Plate

Figure 3-24. Swash Plate and Journal Bearing

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING
REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE
A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON­ABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE
ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING
IS INSTALLED.

3. Install the inner block spring washer (4), block
spring (5), and outer washer (6) into the cylinder
block. Using a press, compress the block spring
enough to expose the retaining ring groove. Wind
the spiral retaining ring (7) into the groove in the cyl­inder block.

5. Install the pistons (11) to the slipper retainer (12).
Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer
seats on the ball guide. If you're reusing the pistons,
install them to the original block bores. Lubricate the
pistons, slippers, retainer, and ball guide before
assembly. Set the cylinder kit aside on a clean sur­face until needed.

6. Install the journal bearings (13) into the housing
seats. Use assembly grease to keep the bearings
seated during assembly. Ensure the locating nubs
drop into the cavities in the seats. If you're reusing
the bearings, install them in the original location and
orientation. Lubricate the journal bearings.

7. Install the swashplate (14) into the housing. Tilt the
swashplate and guide the servo lever ball into its
socket in the servo piston rod. Ensure the swash­plate seats into the journal bearings and moves
freely. Lubricate the running surface of the swash­plate.

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylin­der block.

3-38 – JLG Lift – 3120858

SECTION 3 - CHASSIS & TURNTABLE

16

15

17

18

15. Front Shaft Bearing

16. Shaft

17. Snap Ring

18. Snap Ring

Figure 3-25. Shaft and Front Bearing

19

19. Cylinder Kit

Figure 3-26. Cylinder Kit Installation

20

21

20. Servo Spring

21. Minimum Angle Stop

Figure 3-27. Servo Spring and Minimum

Angle Stop

8. Press front shaft bearing (15) onto shaft (16). Press

bearing onto shaft with lettering facing out. Lubricate
bearing rollers. Install snap-ring (17) onto shaft.

10. Verify swashplate and bearings are properly seated.
Install the cylinder kit (19) onto the shaft. Install with
the slippers facing the swashplate. Rock the shaft to
align the block splines and slide the cylinder kit into
place. Orient the motor with the shaft pointing down­ward and verify the cylinder kit, swashplate, journal
bearings, and servo piston are all secure and prop­erly installed.

11. Lubricate and install the servo spring (20), and mini­mum angle stop (21) into the housing bore.

9. While holding the swashplate in place, turn the
housing on its side. Install the install shaft/bearing
assembly into housing from the flange end. Install
the snap-ring (18).

3120858 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

23

23

22

24

3 mm

[0.12 in]

2 mm

[0.08 in]

23

22

22. Rear Shaft Bearing

23. Timing Pin

24. Valve Plate

Figure 3-28. Valve Plate and Rear Bearing

26

25

8 mm

(47-61 Nm)

35-45 ft.lbs.

25. End Cap

26. Screw

Figure 3-29. End Cap

12. Press the rear shaft bearing (22) into the endcap.

Install the bearing with letters facing out. Press until
bearing surface is 0.08 ±0.01 in (2 ±0.25 mm)
above endcap surface.

15. Install the endcap (25) onto the housing with the
endcap screws (26). Check to ensure the endcap
will properly seat onto the housing without interfer­ence. Improper assembly of the internal compo­nents may prevent the endcap from seating
properly. Ensure the O-rings seat properly when
installing the endcap.

16. Using an 8 mm internal hex wrench, tighten the end-

13. Install timing pin (23) into its bore in the endcap.

Install the pin with its groove facing toward or away
from the shaft. Press the pin until the end protrudes

0.12 ±0.01 in (3 ±0.25 mm) above endcap surface.

14. Install the valve plate (24) onto the endcap. Install
the valve plate with the yellow surface toward the
cylinder block. Align the slot in the valve plate with
the timing pin. Apply a liberal coat of assembly
grease to the endcap side of the valve plate to keep
it in place during installation.

3-40 – JLG Lift – 3120858

cap screws. Tighten the screws in opposite corners
slowly and evenly to compress the servo spring and
properly seat the endcap. Torque endcap screws
35-45 ft.lbs. (47-61 Nm).

17. Before installing the shaft seal, ensure the shaft
turns smoothly with less than 120 in.lbs. (13.5 Nm)
of force. If the shaft does not turn smoothly within
the specified maximum force, disassemble and
check the unit.

SECTION 3 - CHASSIS & TURNTABLE

29

28

27

27. Shaft Seal

28. Seal Suppor t Washer

29. Snap Ring

Figure 3-30. Shaft Seal

1/4 in

(45 Nm)

33 ft.lbs.

5/16 in
(85 Nm)

63 ft.lbs.

5/16in
(85 Nm)

63 ft.lbs.

1/4 in
(45 Nm)

33 ft.lbs.

9/16 in

(170 Nm)

125 ft.lbs.

3 mm

(2.03 to 3.39 Nm)

1.5 to 2.5 ft.lbs.

Figure 3-31. Plugs and Fittings Installation

18. Cover shaft splines with an installation sleeve. Install

a new shaft seal (27) with the cup side facing the
motor. Press seal into housing until it bottoms out.
Press evenly to avoid binding and damaging the
seal. Install seal support washer (28) and snap ring
(29).

19. Install remaining plugs and fittings to the housing.
Refer to the drawing below for wrench sizes and
installation torques.

3120858 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

39

40

34

30

41

37

36

33

42

38

35

32

31

(27 Nm)

20 ft.lbs.

5/8 in

(37 Nm)

(37 Nm)

27 ft.lbs.

27 ft.lbs.

11/16 in

11/16 in

30. Orifice Poppet

31. Shift Spool

32. Spring

33. Spring

34. Spring

35. Spring

36. Spring

37. O-ring

38. O-ring

39. O-ring

40. Plug

41. Plug

42. Plug

Figure 3-32. Loop Flushing Spool

20. Install orifice poppet (30).

21. Install shift spool (31).

22. Install spring retaining washers onto springs (32 and

33).

23. Carefully install centering springs (34, 35, and 36).

24. Install new O-rings (37, 38, and 39).

25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs.

(27 Nm).

26. Using a 11/16 in wrench, torque plugs (41 and 42) to
27 ft.lbs. (37 Nm).

Initial Start-up Procedures

Follow this procedure when starting-up a new motor or
when installing a motor that has been removed.

Prior to installing the motor, inspect for damage incurred
during shipping. Make certain all system components
(reservoir, hoses, valves, fittings, heat exchanger, etc.) are
clean prior to filling with fluid.

1. Fill the reservoir with recommended hydraulic fluid.
Always filter fluid through a 10 micron filter when
pouring into the reservoir. Never reuse hydraulic
fluid.

2. Fill the inlet line leading from the pump to the reser­voir. Check the inlet line for properly tightened fit­tings and be certain it is free of restrictions and air
leaks.

3. Fill the pump and motor housing with clean hydrau­lic fluid. Pour filtered oil directly into the upper most
case drain port.

4. To ensure the pump and motor stay filled with oil,
install case drain lines into the upper most case
drain ports.

5. Install a 0 to 500 psi (0 to 35 bar) gauge in the
charge pressure gauge port of the pump to monitor
system pressure during start up.

6. While watching the pressure gauge, run the engine
at the lowest possible speed until system pressure
builds to normal levels (minimum 160 psi [11 bar]).
Once system pressure is established, increase to full
operating speed. If system pressure is not main­tained, shut down the prime mover, determine
cause, and take corrective action.

7. Operate the hydraulic system for at least fifteen min­utes under light load conditions.

8. Check and adjust control settings as necessary after
installation.

3-42 – JLG Lift – 3120858

9. Shut down the prime mover and remove the pres­sure gauge. Replace plug at the charge pressure
gauge port.

10. Check the fluid level in the reservoir; add clean fil­tered fluid if necessary. The motor is now ready for
operation.

SECTION 3 - CHASSIS & TURNTABLE

3.11 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

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

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

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

a. Elevate the fully extended upper boom to hori-

zontal. (See Figure 3-34.)

b. At the positions indicated on Figure 3-35. try to

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

c. Ensure that the 0.0015” feeler gauge will not

penetrate under the bolt head to the bolt shank.

d. Swing the turntable 90 degrees, and check

some selected bolts at the new position.

e. Continue rotating the turntable at 90 degrees

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

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

a. Elevate the fully retracted upper boom to full ele-

vation.

b. At the position indicated on Figure 3-33. try to

insert the 0.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi­cated position.

c. Lower the boom to horizontal and fully extend

the boom.

d. At the position indicated on Figure 3-35., try and

insert the 0.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi­cated position.

3120858 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-33. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2)

3-44 – JLG Lift – 3120858