JLG 80SL Service Manual

Service & Maintenance Manual

Model

80SL

3121325

March 24, 2011

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A. GENERAL

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

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

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

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

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

B. HYDRAULIC SYSTEM SAFETY

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

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

C. MAINTENANCE

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

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

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

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

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

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

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

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

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

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

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3121325 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - February 6, 2007

Revised - March 5, 2007

Revised - June 7, 2007

Revised - November 20, 2007

Revised - March 10, 2008

Revised - July 26, 2010

Revised - March 24, 2011

b – JLG Lift – 3121325

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

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

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

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

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

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

1.7 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

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

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

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

Oscillating Axle Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

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

SECTION 2 - GENERAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3121325 – JLG Lift – i

TABLE OF CONTENTS (Continued)

2.5 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.4 Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3.5 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.6 Outrigger Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.7 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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

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

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

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

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

Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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

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

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

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

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

3.8 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3.9 Ground Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3.10 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3.11 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

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

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

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

Main Platform Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Main Platform End Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Platform Extension Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Platform Extension End Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

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

3.12 Ladder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

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

3.14 Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

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

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

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

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

SECTION 4 - HYDRAULICS

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

ii – JLG Lift – 3121325

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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

4.5 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Valve Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Pressure Switch, Drive Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Drive Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Pump Engage/Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Load Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Lift/Lower Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Platform Lower Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Outrigger Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

SECTION 5 - JLG CONTROL SYSTEM

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Oscillating Axle Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

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

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

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

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

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

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

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

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

3121325 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

iv – JLG Lift – 3121325

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

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

1-3. Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-4. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

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

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

3-1. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

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

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

3-4. Torque Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

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

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

3-7. Oscillating Axle Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

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

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

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

3-11. Deutz F4L 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

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

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

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

3-15. Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-16. Variable Displacement Axial Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

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

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

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

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

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

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

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

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

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

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

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

3-28. Side Rails Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-29. End Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-30. Extension Side Rails Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-31. Extension End Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

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

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

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

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

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

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

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

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

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

4-2. Load Check Valve Romoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

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

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

4-6. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

4-9. Piston Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

. . . . . . . .4-4

3121325 – JLG Lift – v

TABLE OF CONTENTS (Continued)

4-10. Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-11. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-12. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-13. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-14. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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

4-16. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-17. Spacer Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

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

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

4-20. Piston Setscrew Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

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

4-22. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-23. Valve Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-24. Load Check Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-25. Safety Valve and Limit Switch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-26. Lifting Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-27. Steering Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-28. Outrigger Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-29. Axle Locking Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-30. Extension Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-31. Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-32. Valve/Hydraulic Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-33. Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-34. Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-35. Brake Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-36. Drive Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4-37. Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-38. Pressure Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-39. Proportional Valve Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

4-40. Pump Engage/Disengage Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-41. Hand Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-42. Hand Pump Valve Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-43. Load Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-44. Lift/Lower Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-45. Platform Lower Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-46. Outrigger Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

. . . . . . . . .6-9

vi – JLG Lift – 3121325

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6-33. Electrical Diagram - Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

6-34. Electrical Diagram - Page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

6-35. Hydraulic Components - H900067 RevE - Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

6-36. Hydraulic Components - H900067 RevD - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

6-37. Hydraulic Schematic - 1001091321 RevC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42

3121325 – JLG Lift – vii

TABLE OF CONTENTS (Continued)

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

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

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

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

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

1-7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

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

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

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

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

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

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

3-1 Torque Hub Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

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

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

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

3-5 Variable Displacement Axial Piston Pump Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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

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

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

4-1 Steer Cylinder Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-2 Outrigger Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-3 Axle Locking Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-4 Deck Extension Cylinder Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

viii – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA

Table 1-1. Operating Specifications

Parameter

Maximum Working Height:
with outriggers deployed
with outriggers stowed

Maximum Platform Height:
with outriggers deployed
with outriggers stowed

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

Wheelbase 12.8 ft (3.9 m)

Maximum Work Load (Capacity) ­Main Platform/P latform Extension

Maximum Occupants 4

Tools and Equipment

Maximum Horizontal M anual Side Force

Tilt Sensor Setting 3°

Maximum Operating Wind Speed

Gross Machine Weight (Approximate)

Drive Speed (slow)

Drive Speed (fast)

Sideslope (Machine Stowed) 5°

Gradeability (MachineStowed) 25%

Lift Speed (no load) 125 sec

Lowering Speed 80 sec

Maximum Operating Hydraulic Pressure

Power Supply Diesel Engine

Maximum Ground Bearin g Pressure:
Outriggers
Tires

Maximum Outrigger Pad Load

Maximum Tire Load Rating

Electrical System Voltage 24 V

Ground Clearance

80SL

87 ft (26.5 m)

72 ft (22 m)

80 ft (24.5 m)
65 ft (19.8 m)

14.5 ft (4.4 m)

20.3 ft (6.1 M)

1650 lbs
(750 kg)

1300 lbs
(590 kg)

200 lb force

(890 N)

28 mph

(12.5 m/s)

36,960 lbs

(16,765 kg)

0.4 mph (0.6 f t/sec)
(0.2 m/s)

1.9 mph

(0.86 m/s)

3046 psi

(210 bar)

128 psi (9 kg/cm²)

85 psi (6 kg/cm²)

17,020 lbs

(7720 kg)

14,595 lbs

(6620 kg)

10.8 in.

(27.4 cm)

Table 1-2. Dimensional Data

Parameter

Machine Height
(rails up)

Machine Height
(rails down)

Machine Width

Machine Length

Platform dimensions (extension
retracted)

Platform dimensions (extension
extended)

Transport Dimensions
(L x W x H))

1.3 CAPACITIES

Table 1-3. Capacities

Fuel Tan k

Hydraulic Tank

Engine Crankcase
with Filter
without Filter

80SL

13.9 ft

(4.24 m)

10.4 ft

(3.16 m)

8.3 ft

(2.53 m)

19 ft

(5.78 m)

8.2 x 17.8 ft

(2.5 x 5.4 m)

8.2 x 25.6 ft

(2.5 x 7.8 m)

19 x 8.3 x 10.4 ft

(5.78 x 2.5 x 3.16 m)

23.8 gal
(90 L)

68.7 gal

(260 L)

11 qt (10.5 L)

10.6 qt (10 L)

3121325 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.4 ENGINE

Table 1-4. Engine Specifications

Ty pe

Displacement 3108 cm³

Bore 94 mm

Stroke 112 mm

Powe r 42 k W

Fuel Type Diesel

Engine High Speed 2300 l/min

Engine Low Speed 850 l/min

Volt age 24 Volt

Table 1-5. Engine Battery Specifications

Voltage 12V

Amp Hour 100

Deutz F4L 2011; or

Deutz D2011 L04 i

1.7 SENSORS

Platform Stowed/Jacks Retract Limit Switch

Switch that senses when the platform is lowered to 10.5 ft
(3.2 m). Cuts out lowering function, enables drive function
when tilted, and enables outriggers retract when outrig­gers are deployed.

High Drive Speed Cutout Limit Switch

When the platform reaches and exceeds a height of 12.1 ft
(3.7 m), the fast drive speed will be cut back to the slow
drive speed. Once the platform is completely lowered the
high drive speed is possible. The warning LED will be out
when this limit is exceeded.

Maximum Drive Height/Maximum Height without Outriggers Limit Switch

The drive function will be disabled once the platform
reaches a height of 65 ft (19.8 m). The platform must be
lowered below the limit to enable the drive function. The
lift function is also disabled once the platform reaches a
height of 65 ft (19.8 m) when the outriggers are not
deployed.

Amp 880

1.5 TIRES

Table 1-6. Tire Specifications

Size

Pressure 101.5 psi (7.0 bar)

Wheel Lug Nut Torque:
F ro n t A x l e:
R ea r Ax l e :

Bolt Size M18 x 1.5

315/80R 22.5

Foam Filled

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

1.6 TORQUE REQUIREMENTS

NOTE: JLG recommends that once any locknut is removed

from the machine it is discarded and replaced with a
new one. When maintenance becomes necessary or
a fastener has loosened, refer to Figure 1-3., Torque
Chart (SAE Fasteners - Sheet 1 of 3) to Figure 1-8.,
Torque Chart (METRIC Fasteners - Sheet 3 of 3) to
determine proper torque value.

Maximum Height Limit Switch

Once the platform has reached it's maximum height of 80
ft (24.5 m), the lifting function will be cut off by the maxi­mum height limit switch. When maximum height is
reached, the Lift Cutout Indicator LED on the platform
control console will no longer be illuminated.

Tilt Sensor

The tilt switch cuts out lifting, driving, and steering once
the platform reaches a tilt angle (slope) beyond 3° and the
platform height exceeds 12.1 ft (3.7 m). At this point, the
warning LED on the platform control console will illumi­nate and lowering is the only function possible.

Outrigger Sensors

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

Oscillating Axle Limit Switch

When the platform is raised above 12.8 ft (3.9 m) and the
axle inclination is >1°, the drive function is cutout by a
limit switch. When the platform is below 12.8 ft, the inclina­tion of the axle is ignored and driving is possible.

1-2 – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

123

456

7

1. Platform Stowed/Jacks Retract Limit Switch 5. Tilt Sensor

2. High Drive Speed Cutout Limit Switch 6. Outrigger Sensor (all 4 outriggers)

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

4. Maximum Height Limit Switch

Figure 1-1. Limit Switch Locations

7. Oscillating Axle Limit Switches (rear axle)

3121325 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

1.8 PRESSURE SETTING

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

Table 1-7. Pressure Settings

Main Pressure Relief ±43.5 psi (3 bar)

Pump Charge Pressure ±43.5 psi (3 bar)

3046 psi

(210 bar)

203 psi

(14 bar)

1.9 MAJOR COMPONENT WEIGHTS

Table 1-8. Major Component Weights

Component 80SL

Platform Assembly (including extension)

Platform Extension

Chassis

Arm Assembly

Lift Cylinder

2414 lbs

(1095 kg)

1058 lbs
(480 kg)

12,787 lbs

(5800 kg)

15,653 lbs

(7100 kg)

1821 lbs
(826 kg)

1.11 LUBRICATION

Hydraulic Oil

Table 1-10. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0° to +23°F

(-18° to -5°C)

0° to +210°F

(-18° to +100°C)

+50° to +210°F

(+10° to +100°C)

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

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

152.

When temperatures remain below 20°F (-7°C), JLG
Industries recommends the use of Mobil DTE13M.

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.

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

1.10 CRITICAL STABILITY WEIGHTS

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

Table 1-9. Critical Stability Weights

Component 80SL

Wheel and Tire Assembly (each)

Wheel/Tire and Drive Assembly (each)

Batteries - Standard (each)

573 lbs

(260 kg)

675 lbs

(306 kg)

54.2 lbs

(24.6 kg)

ISO Viscosity Grade

Specific Gravity

Pour Poin t, Ma x

Flash Point, Min.

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

Table 1-11. Mobil Hydraulic Oil Specs

Description Mobil 424

10W-30 #32 46

29.0 0.877 0.922

-46°C

(-43°F)

228°C

(442°F)

55 cSt

9.3 cSt
152

Mobil DTE

13M

-40°C

(-40°F)

166°C

(330°F)

Viscosity

33 cSt

6.5 cSt
140

Mobil EAL 46

(Envirosyn H 46 )

-39°C

(-38.2°F)

310°C

(590°F)

47 cSt

9 cSt

176

1-4 – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

Figure 1-2. Engine Operating Temperature Specifications

3121325 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

1.12 TORQUE CHARTS

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

1-6 – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 3))

3121325 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

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

1-8 – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

3121325 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 2 of 3))

1-10 – JLG Lift – 3121325

SECTION 1 - SPECIFICATIONS

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

3121325 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

NOTES:

1-12 – JLG Lift – 3121325

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

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

3121325 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Typ e Frequency

Pre-Start

Inspection

Pre-Delivery

Inspection

Frequent

Inspection

Annual Machine

Inspection

Preventative
Maintenance

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

In service for 3 months or 150 hours, which-

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

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

Owner, Dealer, or User

Owner, Dealer, or User

Owner, Dealer, or User

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

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

Service

Qualification

Qualified JLG

Mechanic

Qualified JLG

Mechanic

Factory-Certified

Service Technician

(recommended)

Qualified JLG

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Components Removal and Installation

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

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

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

2-2 – JLG Lift – 3121325

SECTION 2 - GENERAL

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

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

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

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

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

Gaskets

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

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.)

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.

3121325 – JLG Lift – 2-3

SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

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

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

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

Changing Hydraulic Oil

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

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

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

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

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

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

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

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

NOTE: Start-up of hydraulic system with oil temperatures

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

Lubrication Specifications

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

Table 2-2. Lubrication Specifications

KEY SPECIFICATIONS

Multipurpose Grease having a minimum dripping point

MPG

EPGL

EO

HO

of 350°F (177°C). Excellent water resistance and

adhesive qualities, and being of extreme pressure

type. (Timken OK 40 pounds minimum.)

Extreme Pressure Gear Lube (oil) meeting API service

c la ss if i ca ti on GL- 5 or MI L-S p ec MI L-L- 21 0 5.

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

2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L­2104C.

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

Mobil 424.

2-4 – JLG Lift – 3121325

SECTION 2 - GENERAL

1. Arm Pins

2. Outrigger Cylinders

3. Engine Compartment

4. Tie Rod End

5. Spindles

6. Oscillating Axle

7. Lift Cylinder

8. Fuel Tank (Opposite Side)

9. Deck/Arm Pivot Pin

10. Upper Slide Pads

11. Lower Slide Pads

Figure 2-1. Lubrication Diagram

2.4 OPERATOR MAINTENANCE

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

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

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

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

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

3121325 – JLG Lift – 2-5

SECTION 2 - GENERAL

NOTE: The following numbers correspond with those in

Figure 2-1., Lubrication Diagram.

1. Arm Pins

• Lube Points - 41 Grease Fittings

• Capacity - As Required

3. Engine Compartment

a. Engine Oil Check/Fill

•Lube - MPG

• Interval - As Required

2. Outrigger Cylinders

• Lube Points - 4 Grease Fittings

• Lube Points - Fill Cap & Dip Stick

• Capacity - See Engine Manual

• Lube - EO SAE 20W20

• Interval - Every 3 months or 150 hours of operation

• Oil Drain Plug (1)

• Capacity - As Required

•Lube - MPG

• Interval - As Required

2-6 – JLG Lift – 3121325

SECTION 2 - GENERAL

b. Oil Filter

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

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

d. Air Filter

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

• Interval - Every 6 months or 300 hours of operation

c. Fuel Filter

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

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

e. Hydraulic Oil Check/Fill

• Lube Points - Fill Cap & Site Gauge

• Capacity - 68.7 gal (260 L)

•Lube - HO

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

3121325 – JLG Lift – 2-7

SECTION 2 - GENERAL

4. Tie Rod Ends

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

5. Spindles

6. Oscillating Axle

• Lube Points - 3 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

7. Lift Cylinder

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

2-8 – JLG Lift – 3121325

SECTION 2 - GENERAL

8. Fuel Tank (Opposite Engine Compartment)

• Capacity - 23.8 gal (90 L)

• Lube - Diesel Fuel

• Interval - Check fuel periodically during each shift

9. Deck/Arm Pivot Pin

10. Upper Slide Pads

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

11. Lower Slide Pads

• Lube Points - 2 Grease Fittings

• Capacity - As Required

•Lube - MPG

• Interval - As Required

3121325 – JLG Lift – 2-9

SECTION 2 - GENERAL

2.5 CYLINDER DRIFT TEST

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

Platform Drift

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

perature.

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

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

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

4. Wait 15 minutes.

5. Measure distance of mark from head.

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

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

greater than 3mm, check holding valve (refer to Fig­ure 4-44., Lift/Lower Valve Block). If still greater than
3mm, replace cylinder seals (refer to Section 4.4,
Cylinder Repair).

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

Forms are supplied with each new machine and are also
available from JLG Customer Service. Forms must be
completed and returned to JLG Industries.

NOTE: This machine requires periodic safety and mainte-

nance inspections by a JLG Dealer. A decal located
on the frame affords a place to record (stamp)
inspection dates. Notify dealer if inspection is over­due.

The inspection and maintenance code numbers are as fol­lows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

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

5. Check for leakage.

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

7. Check for proper operation and freedom of move­ment.

8. Check for excessive wear or damage.

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

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

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

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

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

12. Check for proper lubrication.

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

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

15. Check for proper inflation

2-10 – JLG Lift – 3121325

SECTION 2 - GENERAL

Table 2-3. Preventive Maintenance and Safety Inspection

AREA INTERVAL

Daily Weekly

PL AT F OR M

1. Controller 1,11

2. Switches 1,11

3. Placards and Decals 1,2

4. Control Tags 1,2

5. Hoses and Cables 4,8

6. Wear Pads 8,12

7. Handrails and Chains 1,4

CH A SS I S

1. Battery 3 5

2. Hydraulic Pump 1 5

3. Valves 1 5

4. Hydraulic Filter ANNUAL

5. Hydraulic Hoses and Tubing 1 5

6. Hydraulic Oil Tank 5 3,4

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

9. Limit Switch 1,7

10. Tilt Alarm Switch 1,7

11. Placards and Decals 1,2

12. Wheel and Tire Assemblies 1 8,9

13. Drive Motors 1,5,6

14. Drive Brakes 1,6 8

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

16. Steer Cylinder 1 5,6,13 4

17. Steer Components 1 4,6 8

18. Wheel Bearings 812

19. Scissor Arms 1,4

20. Safety Props 1,4

21. Sliding Wear Pads 8,12

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

23. Switches, Ground Control 1,11

24. Control Tags 1,2

25. Frame - including doubler plate,
gu s se t s, a nd s ur r ou n di n g a r ea

1, 4

100 Hours

(3 Months)

200 Hours

(6 Months)

400 Hours

(1 year)

3121325 – JLG Lift – 2-11

SECTION 2 - GENERAL

NOTES:

2-12 – JLG Lift – 3121325

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS

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

Leveling Jacks

The machine is equipped with auto leveling jacks. The
automatic self leveling system is controlled by 4 double
acting cylinders mounted at each corner of the machine
chassis. These cylinders incorporate pilot operated hold­ing valves on the piston side. The cracking pressure of
these valves is 15 psi (1 bar) for the rear and116 psi ( 8
bar) for the front.

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

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

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

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

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

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

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

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

ing System for detailed information regarding the
automatic leveling system.

3.2 WHEEL ASSEMBLY

Drive System

Wheel drive is achieved by orbital type (100cc/rev)
hydraulic motors driving a wheel type gearbox (29.8:1
reduction) through a spring-applied brake. The brake is
released by actuating a 3-way solenoid valve. This valve
provides hydraulic power from the pump directly to the
brakes. The brake resets by deactivating the valve and
restricting flow to the tank through an orifice to smooth out
hard stops.

Drive is controlled by 2 proportional solenoid valve sec­tions within the main control valve. Flow to the drive
motors passes through a 4-section solenoid drive valve
manifold 2 for differential lock and 2 for fast drive.

There are three modes for drive selected by the drive
speed select switch on the platform control console:

1. Normal Drive - 4 wheel drive

2. Differential Lock - 4 wheel drive with flow dividers

3. Fast Drive - 2 wheel drive

Normal Drive:

Flow passes from section 9 to the front drive section of the
drive valve (ports A1 & B1) and from section 2 to the rear
section of the drive valve ports (A2 & B2).

All 4 solenoids on the drive valve are in the passive (non­energized) mode. Flow from A/B1 passes directly to the
front drive motor ports (C/D1 & C/D2) and from A/B2 to
the rear drive motors (C/D3 & C/D4).

Differential Lock:

As in normal drive, flow passes from section 9 to the front
drive section of the drive valve (ports A1 & B1) and from
section 2 to the rear section of the drive valve ports (A2 &
B2).

The 2 differential lock solenoids are energized which
directs the flow through 2 flow dividers in the drive valve.
These split the flow to the left and right front motors (1 &

2) and to the rear motors (3 & 4).

Fast Drive:

Valve section 2 is not used in fast drive. Flow from section
9 passes to the front section of the drive valve. The 2 fast
drive solenoids are energized which connect the ports of
the rear drive motors (C3 to D3) and (C4 to D4). This
allows the rear drive motors to free wheel.

3121325 – JLG Lift – 3-1

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

123

4

Figure 3-1. Torque Hub

1. Drive Hub

2. Screw

3. Circlip

4. Pin

Drive Hub

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

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

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

Roll Test

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

Leak Test

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

Hub Disengaging and Oil Checking Procedure:

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

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

3. Remove the Pin (4).

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

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

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

facing the inside of the hub.

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

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

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

Lubricant

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

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

3-2 – JLG Lift – 3121325

Table 3-1. Torque Hub Technical Specifications

1

2

3

4

5

6

Max Torque 5.5 kNm

Max Input Speed 4000 rpm

Weight

Brake

Static Torque

Releasing Pressure

Max Pressure

Max Input Torque

101.4 lbs
(46 kg)

147.5 lb ft
(200 Nm)

174-217.5 psi

(12-15 bar)

1450.3 psi
(100 bar)

147.5 lb ft
(200 Nm)

Tire Replacement

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

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

• Tire tread contact width equal or greater than original

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

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

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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:

NOTE: Tires are foam filled to 108.8 psi (7.5 bar).

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.

3121325 – JLG Lift – 3-3

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

nuts per wheel torque chart.

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

150-190 lb ft

(210 - 270 Nm)

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

230 - 270 lb ft

(320-380 Nm)

305 - 343 lb ft

( 440 - 480 Nm)

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

8

9

5

6

7

10

Figure 3-2. Wheel Assembly Removal

1. Wheel Nut (6 per tire)

2. Drive Hub

3. Bolt, M16 x 55mm (6 per wheel)

4. Flatwasher, M16 (6 per wheel)

5. Capscrew, M16 x 35mm
(2 per wheel)

6. Double Shock Valve (Rear Wheels)

Travel Brake Valve (Front Wheels)
(Not Shown)

7. Capscrew, M10 x 45mm (Rear)
(4 per valve)

Capscrew, M10 x 55mm (Front)
(Not Shown) (4 per valve)

8Drive Motor

9 Bolt, M12 x 35mm (2 per motor)

10 Lockwasher, M12 (2 per motor)

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

NOTE: Follow these steps when servicing/replacing the

Removal

1. Elevate machine with jacks or other suitable device

1. Remove 6 Wheelnuts (1).

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

wheel/tire assembly.

and secure.

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

4. Unscrew Capsrews (7) on Valve (6) and carefully

5. Remove two Bolts (6) and Lockwashers (7) attach-

6. Remove the eight Bolts (3) and Flatwashers (4)

Installation

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

remove valve.

ing the Drive Motor to the Drive Hub. Carefully
remove the Drive Motor.

attaching the Drive Hub to the Spindle (8). Carefully
remove the Drive Hub.

3-4 – JLG Lift – 3121325

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Drive Motor Side

1

2

3

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

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

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

Figure 3-3. Hub Torque Values

3121325 – JLG Lift – 3-5

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

11

24

1

12

1023132312

27

22

25

6

7

17

183938

36

37

15

16

48 2 35

21

46

31

40

45

28

42 32

47 41

49

34

20

230

20

19

14

52

3

44

43

294

9

11

26

Figure 3-4. Torque Hub Assembly

1. Spindle

2. Hub

3. Gear Ring

4. Cover

5. Flange

6. Coupling

7. Thrust Washer

8. Thrust Washer

9. Circlip

10. Planetary Gear

11. Pin

12. Thrust Washer

13. Spacer

14. Sun Pinion

15. Piston

16. Spring

17. Disc

18. Disc

19. Lock Nut

20. Bearing

21. Bearing

22. Bearing

23. Bearing

24. Circlip

25. Circlip

26. Disc

27. Circlip

28. Plug

29. O-Ring

30. O-Ring

31. O-Ring

32. O-Ring

33. O-Ring

34. Oil Seal

35. Gasket

36. O-Ring

37. Blocking Ring

38. O-Ring

39. Blocking Ring

40. Screw

41. Screw

42. Screw

43. Plug

44. Washer

45. Plug

46. Disc

47. Threaded Stud

48. O-Ring

49. Reduction Gear Kit

3-6 – JLG Lift – 3121325

3.3 DRIVE MOTOR

1

2

3

4

5

6

7

8

88

9

10

11

12

13

Figure 3-5. Drive Motor (OMR 100)

1. Dust Seal

2. Motor Housing

3. Shaft Seal

4. Bearing Race

5. Axel Needle Bearing

6. Output Shaft

7. Cardan Shaft

8. O-Ring

9. Distributor Plate

10. Gear Wheel Set

11. End Cover

12. Washer

13. Screw

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3121325 – JLG Lift – 3-7

Displacement 99.8 cm³

Max Speed 600 rpm

Max Torque

Max Power 13 kw

Max Oil Flow

Table 3-2. Drive Motor Specs

177 lb ft

(240 Nm)

15.9 gal/min
(60 L/min)

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Motor Disassembly

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

(OMR 100).

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

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

3. Remove the End Cover (11) sideways.

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

5. Remove the Cardan Shaft (7).

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

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

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

9. Remove the Axel Needle Bearing (5).

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

commutation slot leading up to the front annular
channel.

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

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

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

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

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

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

NOTE: When cleaning parts, clean parts carefully with low

aromatic kerosine.

Check all parts carefully and replace if necessary.

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

Motor Assembly

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

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

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

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

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

6. Output Shaft (6): Grease the journals with hydraulic
oil. The rear shaft end must be marked before fitted.
The mark must be positioned vertically above a

Table 3-3. Tightening Torques

Item To rqu e

Screws (item 13 in Figure 3-5.)

Plug (if applicable) (not shown)

270 - 315 lbf in

(3.0 - 3.5 daNm)

445 - 620 lbf in

(5 -7 daNm)

3-8 – JLG Lift – 3121325

3.4 STEERING ASSEMBLY

1

2

3

4
5

6
7

8
9

10

11

12

13
14

15
16

17

18

19

20

21

22

23

25

24

26

27

28

29

30

32

31

33

1. Right Spindle

2. Left Spindle

3. Cap

4. Grease Fitting Cap

5. Grease Fitting

6. Bolt, M12 x 30mm

7. Lockwasher, M12

8. O-Ring

9. Ring

10. Bushing*

11. Ring

12. Pin

13. Grease Fitting Cap

14. Grease Fitting

15. Bolt, M12 x 20mm

16. Lockwasher, M12

17. Bushing

18. Tie Bar

19. Steer Cylinder

20. Bolt, M12 x 150mm

21. Flatwasher, M12

22. Washer

23. Washer

24. Flatwasher, M12

25. Nut, M12

26. Pin

27. Grease Fitting Cap

28. Grease Fitting

29. Grease Fitting Cap

30. Grease Fitting

31. Bolt, M12 x 20mm

32. Lockwasher, M12

33. Pin

Figure 3-6. Steering Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: * = not used on later machines.

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

Removal

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

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

3121325 – JLG Lift – 3-9

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

3. Spindles can now be removed from the chassis.

Installation

1. Follow the Removal Steps in reverse order when

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

assembling the steering system.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2

3

4

5

6

7

8

9

10

11

12

13

1

14, 15, 16

Figure 3-7. Oscillating Axle Limit Switches

1. Rear Axle

2. Limit Switch Cover

3. Bolt, M12 x 70mm

4. Flatwasher, M12

5. Lockwasher, M12

6. Bushing

7. Limit Switch

8. Capscrews, M5 x 50mm

9. Plate

10. Bolt, M12 x 80mm

11. Lockwasher, M12

12. Bushing

13. Bushing

14. Capscrew, M20 x 80mm

15. Hardened Washer, 20mm

16. Nut, M20

3.5 REAR AXLE

Limit Switches

NOTE: Limit switches are located on the front side of the

rear axle.

Follow the below procedures when removing and/or
replacing limit switches.

Removal:

1. Disconnect battery by turning the handle on the
ground control panel.

2. Remove the Limit Switch Cover (2) and Bushings (6)
by unscrewing and removing the two Bolts (3), Flat­washers (4), and Lockwashers (5).

3. The Limit Switches (7) can now be removed.
Unscrew the four Capscrews (8) at each corner of
the limit switch. Disconnect any electrical wires.
Remove limit switch from Plate (9).

4. The Plate can be removed from the Axle (1) by
unscrewing and removing the two Bolts (10), Lock­washers (11), and Bushings (12 and 13).

3-10 – JLG Lift – 3121325

Installation:

1. Follow the removal steps in reverse order when
installing the limit switches and/or any of the compo­nents.

2. Limit Switch Adjustment:

Axle Removal:

1. Secure the machine and the axle.

2. Remove the eight Capscrews (14), Hardened Wash­ers (15), and Nuts (16). Carefully remove the axle
from the chassis.

3. When installing the axle, torque the Capscrews (14)
to 450 lb ft (610 Nm) dry.

a. Adjust limit switches to trip when axle is oscil-

lated 1°.

3.6 OUTRIGGER CYLINDER REMOVAL

1

2

3

4

5
6

7

8

9

A

B

1. Cover

2. Bolt, M8 x 160mm

3. Lockwasher, M8

4. Outrigger Cylinder

5. Bolt, M8 x 50mm

6. Lockwasher, M8

7. Valve Assembly

8. Limit Switch Bracket

9. Limit Switch

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

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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

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

Removal:

A )

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

B )

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

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

NOTE: Support cylinder rod to prevent rod extension and

consequential oil spillage.

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

C )

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

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

D )

6. Carefully lower the Cylinder out of the frame.

3121325 – JLG Lift – 3-11

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

C

D

10

11

12

13

14

15

16

16

10. Bolt, M6 x 16mm

11. Lockwasher, M6

12. Plate

13. Gasket

14. Bolt, M12 x 70mm

15. Lockwasher, M12

16. Outrigger Cylinder

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

Installation:

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

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

NOTE: At this point the frame may be lowered.

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

4. Reconnect all hydraulic lines and electrical wires.

3-12 – JLG Lift – 3121325

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

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

3.7 ENGINE COMPARTMENT

ENGINE SIDE

VALVE SIDE

1

2

2

2

3

4

131415

8

7

15

5

10

11
12

9

15

15

16

13

14

7

8

13

14

6

16

1. Hood

2. Gas Spring

3. Bolt, M8 x 30mm

4. Nut, M8

5. Cabinet Top Panel (Left)

6. Cabinet Panel (Right)

7. Special Bolt

8. Flatwasher, M12

9. Air Intake Pipe

10. Bolt, M8 x 25mm

11. Flatwasher, M8

12. Locknut, M8

13. Bolt, M10 x 30mm

14. Nut, M10

15. Flatwasher, M10

16. Nut, M10

Figure 3-10. Hood Assembly

Hood Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: Removing the hoods will allow for easier access to

the components inside the engine compartment and
valve compartment.

1. Open and secure Hood (1).

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

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

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

ment.

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

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

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

hood and top panel.

3121325 – JLG Lift – 3-13

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

34

1. Diesel Engine

2. Air Filter

3. Air Intake

4. Hydraulic Oil Tank

Figure 3-11. Deutz F4L 2011

Deutz Engine

Table 3-4. Engine Technical Data

Description Deutz F4L 2011 Deutz D2011 L04 i

# of cylinders 4

Cylinder Arrangement Vertical In Line

Bore 94 mm

Stroke 112 mm

Total Displacement 3108 cm³

Working Cycle 4 Stroke Diesel Engine

Specific Fuel Consumption 214 g/kWh

Engine Speed:
H ig h
L ow

Vol tag e 24 V

Starter Batter y (qty 2) 12 V, 88 Ah

Alternator 14 V, 60 Ah

Weight 256 kg

3-14 – JLG Lift – 3121325

2300 l/min

850 l/min

Engine Tray Slide

3

1, 2

1, 2

3

1. Capscrew, M16 x 30mm

2. Lockwasher, M16

3. Capscrew, M16 x 60mm

Figure 3-12. Engine Tray Slide

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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

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

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

3121325 – JLG Lift – 3-15

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. 30 amp Fuses

2. Timer Relay N6

3. Relay K3

Figure 3-13. Glow Plugs

1. Solenoid

2. 30 amp Fuse

Figure 3-14. Engine Solenoid

Glow Plugs

Engine Solenoid Fuse

3-16 – JLG Lift – 3121325

Hydraulic Pump Assembly

1

2

3

4

5

6

7

8

9

1. Hydraulic Pump

2. Bolt, M12 x 30mm

3. Lockwasher, M12

4. Flange

5. Capscrew, M10 x 25mm

6. Lockwasher, M10

7. Coupling

8. Hex Head Screw, M8 x
25mm - see installation

note below

9. Lockwasher, M10

Figure 3-15. Hydraulic Pump Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

REMOVAL:

1. Disconnect any hoses and/or wires on the Hydraulic
Pump (1).

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

3. To remove the Flange, unscrew and remove the
twelve Capscrews (5) and Lockwashers (6).

4. Remove the Coupling (7) by unscrewing and remov­ing the six bolts (8) and Lockwashers (9).

INSTALLATION:

1. Follow the Removal Procedures in reverse order
when installing the hydraulic pump assembly.

Torque item (5) Capscrews and lockwasher to 50Nm
(37 lb-ft) DRY.

NOTE: Do not reuse the lockwashers item (10) when reas-

sembling item (8), Hexhead Screws. Apply Loctite
#242 to the treads of item (8), Coupling Plate ­Screws - M8 x 25mm upon reassembly and torque to
25Nm (18.5 lb-ft).

3121325 – JLG Lift – 3-17

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

Figure 3-16. Variable Displacement Axial Piston Pump

1. Drain Port

• tighten to 177 lb ft (240 Nm)

2. Pressure Port

• tighten to 30 lb ft (40 Nm)

3. Inlet Port

• tighten to 66 lb ft (90 Nm)

Hydraulic Pump

Pump Flow

• Flow from the pump to the control valve is protected by
a full flow and a load sensing dump valve, both nor­mally-open to tank ports. To generate hydraulic power
to the control valve, both dump valves need to be acti­vated.

Table 3-5. Variable Displacement Axial Piston Pump Specs

Displacement 45 cc/rev

Max Speed 2300 rpm

Power 40 Kw

Delta "P" 203 psi at 3046 psi (14 bar at 210 bar)

Max Torque 146 lb ft (200 Nm)

Torque 53 lb ft (72 Nm)

Filling Volume 0.26 gal (1.0 L)

Nominal Pressure 4000 psi (280 bar)

Max Pressure 5100 psi (350 bar)

Weight (dry) 46.3 lbs (21 kg)

THIS PUMP IS FACTORY SET FOR FLOW, PRESSURE, AND
HORSEPOWER CONTROL AND SHOULD NOT BE ADJUSTED.
CONTACT THE JLG SERVICE DEPARTMENT FOR INFORMATION.

3-18 – JLG Lift – 3121325

Exhaust Pipe Assembly

1

2

3

4

5

6

7

8

9

1. Muffler

2. Exhaust Clamp

3. Exhaust Elbow

4. Exhaust Clamp

5. Exhaust Flex Pipe

6. Exhaust Clamp

7. Tailpipe

8. Bolt, M10 x 20mm

9. Lockwasher, M10

Figure 3-17. Exhaust Pipe Assembly

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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

17., Exhaust Pipe Assembly.

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

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

3. Loosen the Exhaust Clamp (4).

4. The exhaust elbow can now be removed.

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

6. The tail pipe can be removed by unscrewing and
removing the two Bolts (8) and Lockwashers (9)
connecting the pipe to the engine tray.

NOTE: Follow the previous steps in reverse order to install

the exhaust system. Be sure to securely tighten the
exhaust clamps.

3121325 – JLG Lift – 3-19

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

5

6

7

8

9

10

11

12

13

Figure 3-18. Air Filter Assembly

1. Air Filter

2. Bolt, M8 x 45mm

3. Flatwasher, M8

4. Locknut, M8

5. Hose Clamp Clip

6. Air Intake Hose

7. Hose Clamp Clip

8. Reducing Sleeve

9. Clamp

10. Air Intake Elbow

11. Clamp

12. Air Intake Hose

13. Clamp

Air Filter Assembly

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

for service and/or replacements. Follow the steps
below when removing/installing any components.

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

2. To remove the Air Filter (1), unscrew and remove the
2 Bolts (2), four Flatwashers (4), and two Locknuts
(3). Remove the air cleaner from the bracket.

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

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

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

3-20 – JLG Lift – 3121325

Engine Removal

1
2

2

3

231

2

2
3

2

1

4

1. Bolt, M12 x 110mm

2. Flatwasher, M12

3. Locknut, M12

4. Oil Drain Port

Figure 3-19. Engine Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

engine compartment.

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

1. Disconnect electrical supply.

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

3. Secure engine with appropriate lifting device. (Refer

attached to the engine assembly.

to Deutz Operation Manual included with the
machine)

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

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

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

NOTE: When installing the engine, follow the steps in

reverse order.

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

3121325 – JLG Lift – 3-21

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2, 3, 4

2, 3, 4

1

6

1. Hydraulic Tank

2. Capscrew, M10 x 25mm

3. Flatwasher, M10 (2 per capscrew)

4. Nut, M10

5. Shutoff Valve Lever

6. Filler

Figure 3-20. Hydraulic Tank Removal

Hydraulic Tank

Removal:

1. Close shutoff valve lever (5) to turn off flow of
hydraulic fluld. Drain hydraulic fluid by opening the
drain port on the underside of the Hydraulic Tank
(1). Store fluid in appropriate receptacle. Disconnect
all hoses.

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

3. Carefully remove the tank from the engine compart­ment.

4. If required, remove and replace Filter (see Figure 3-

21.).

NOTE: Close hydraulic shutoff valve lever when servicing

the hydraulic system and components. Make certain
to open lever when finished to return flow of hydrau­lic fluid.

Installation:

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

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

3. Replace all hydraulic hoses.

4. Ensure the drain port is closed.

5. If required, replace Filter.

6. Remove Filler cap (6) fill tank with hydraulic fluid to
its designated capacity, 68.7 gal (260 L).

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

3-22 – JLG Lift – 3121325

Pressure Filter

1

2, 3

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

Figure 3-21. Pressure Filter Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Removal:

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

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

3. Remove the Pressure Filter.

NOTE: Replace filter every 250 hours of operation.

Installation:

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

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

hydraulic tank.

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

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

3121325 – JLG Lift – 3-23

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

5

6

7

8

9

10

9
10

4

1. Fuel Tank

2. Fuel Line Hose, 5.5 mm

3. Clamp

4. Hose Fitting

5. Fuel Line Hose, 7.5mm

6. Clamp

7. Hose Fitting

8. Fuel Tank Strap

9. Nut, M8

10. Lockwasher, M8

Figure 3-22. Fuel Tank Removal

3.8 FUEL TANK

Removal:

NOTE: Drain Fuel Tank (1) before removing. Store diesel

fuel in approved receptacle.

1. Disconnect the Fuel Line Hoses (2, 5) from the fuel
tank by loosening the Clamps (3, 6). Pull hose from
Hose Fittings (4, 7).

2. Remove the Fuel Tank (1) by removing the four Nuts
(9) and Lockwashers (10) on the two fuel Tank
Straps (8).

Installation:

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

2. Secure Hose Fittings to Hoses with Clamps.

3. Refuel Tank with diesel fuel.

NOTE: Empty fuel tank weighs approximately 36.6 lbs

(16.6 kg).

3-24 – JLG Lift – 3121325

3.9 GROUND CONTROL PANEL

1

2

3

4

5

1. Ground Control Panel

2. Electrical Compartment

3. Bolt, M6 x 20mm

4. Nut, M6

5. Flatwashers, M6

Figure 3-23. Ground Control Panel Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Removal:

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

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

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

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

damage any plug receptacles and switches.

3121325 – JLG Lift – 3-25

Installation:

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

2. Carefully attach all wires and reconnect to battery.

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

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

5

6

7

ENGINE

STARTER

BATTERIES

BATTERY
DISCONNECTOR

ENGINE
CHECK BOX

Battery
Schematic

1. Batteries

2. Battery Cable (Battery - to Battery +)

3. Battery Cable (Battery + to Battery
Disconnector)

4. Battery Cable (Battery - to Engine)

5. Bolts, M8 x 35mm

6. Lockwashers, M8

7. Battery Hold Clamp

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

the back side of the battery (not
shown)

Figure 3-24. Battery Removal

3.10 BATTERY REMOVAL

Removal:

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

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

3. Remove the Battery Hold Clamp.

Installation:

1. Place Batteries into electrical compartment.

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

3. Secure Clamps with Bolts and Lockwashers.

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

4. Remove Batteries(1).

3-26 – JLG Lift – 3121325

3.11 PLATFORM

1

2

3

1. Control Box Lid

2. Control Box

3. Screw, M4 x 30

Figure 3-25. Platform Control Box

Platform Control Box

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

1. Disconnect platform control box connector from the
machine.

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

3. Carefully lift the lid from the box.

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

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

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

3121325 – JLG Lift – 3-27

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-26. Joystick

Joystick Controller

Table 3-6. Joystick Specifications

Input Voltage 24V (±0.05V)

Centered Output Voltage 12V (±0.25V)

Reverse Voltage 5.5 - 6.5V

Forward Voltage 17.5 - 18.5V

Terminal Color Function

Table 3-7. Plug Loading Chart

1 Green Steer Left

2 Yellow Steer Right

3Brown Pot Out

4N/C

5N/C

6N/C

7Blue 24V In

8 Red Enable / 24V Out

9White / Black Ground

3-28 – JLG Lift – 3121325

Receptacles

2, 3, 4

1

5

6

7, 8, 9

1. Receptacle Box

2. Bolt, M6 x 20mm

3. Flatwasher, M6 (qty 2)

4. Nut, M6

5. 110V Receptacle

6. Platform Control Box Outlet

7. Bolt, M5 x 16

8. Flatwasher, M5 (qty 2)

9. Nut, M5

Figure 3-27. Platform Receptacle Box Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

3121325 – JLG Lift – 3-29

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

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

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

4. Lift box from platform.

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

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

Installation:

1. Follow Removal steps in reverse order.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

14

15

16

1. Side Rail

2. Cotter Pin

3. Pin

4. Bar

5. Pin

6. Bolt, M12 x 40mm

7. Locknut, M12

8. Pin

9. Cotter Pin

10. Pin

11. Hinge Bracket

12. Bolt, M10 x 120mm

13. Chain Assembly Mounting Plate

14. Flatwasher, M10

15. Locknut, M10

16. Tube

Figure 3-28. Side Rails Removal

Main Platform Side Rails

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

SIDE RAILS WEIGH APPROXIMATELY 72.3 LBS (32.8 KG) EACH.
USE CAUTION WHEN REMOVING ANY PLATFORM RAIL.

NOTE: All procedures apply to the opposite side.

NOTE: The below procedures apply to both right and left

3-30 – JLG Lift – 3121325

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

Removal:

side rails.

1. Disconnect side rail (1) from the end rail by pulling
the Cotter Pin (2) from the Pin (3). Remove the Pin
from the Bar (4) and Pin (5) located on the end rail.

2. Remove the Cotter Pins (9) from the Pins (10) on all
three Hinge Brackets (11). Pull the Pin out of the
side rail. Carefully fold rail down to the stowed posi­tion.

3. Side rail can now be removed from the platform by
removing the Bolts (12), Chain Assembly Mounting
Plates (13), Flatwashers (14) and Locknuts (15) on
all three rail legs.

4. Remove the Tubes (16) once the rail is removed.

Installation:

NOTE: The below procedures apply to both the right and left

side rails.

1. Follow the removal procedures in reverse order
when installing the side rails.

Main Platform End Rails

1

2

3

5

6

7

8

9

10

8

11

4

1. End Rail (right side)

2. End Rail (left side)

3. Gate

4. Platform

5. Cotter Pin

6. Pin

7. Bolt, M10 x 120mm

8. Flatwasher, M10

9. Chain Assembly Mounting Plate

10. Locknut, M10

11. Hinge

Figure 3-29. End Rail Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Removal:

1. If applicable, disconnect end rails (1,2,3) from side
rails. (see removal instructions for side rails on pre­vious page).

2. Remove Cotter Pins (5) from Pins (6) on rail legs.

3. Fold rails down to the stowed position.

4. Remove Bolts (7), Flatwashers (8), Locknuts (10),
and Chain Assembly Mounting Plates (9).

5. Carefully remove the rail.

6. The Gate (3) can be detached from the right side
End Rail (1) by removing the screws on the two
Hinges (11).

3121325 – JLG Lift – 3-31

Installation:

NOTE: Place the rail(s) on the platform in their stowed posi-

tion when installing.

1. Follow the removal instructions in reverse order.

2. Attach End Rails to Side Rails via the pins in Figure
3-28.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1234567

8

9

10

11

12

13

14

15

16

1. Extension Side Rail

2. Cotter Pin

3. Pin

4. Bolt, M6 x 16mm

5. Lockwasher, M6

6. Flatwasher, M6

7. Chain Assembly Mounting Plate

8. Cotter Pin

9. Pin

10. Extension Rail Bracket

11. Bolt, M12 x 100mm

12. Flatwasher, M12

13. Locknut, M12

14. Chain Assembly Mounting Plate

15. Bolt, M10 x 25mm

16. Lockwasher, M10

Figure 3-30. Extension Side Rails Removal

Platform Extension Side Rails

THE EXTENSION SIDE RAILS WEIGH APPROXIMATELY 58 LBS
(26.2 KG) EACH. USE CAUTION WHEN REMOVING ANY PLAT­FORM RAIL.

NOTE: All procedures apply to the opposite side.

Removal:

1. Disconnect Side Rails (1) from end rail by removing

NOTE: The Chain Assembly/Pin/Cotter Pin can be removed

3-32 – JLG Lift – 3121325

Cotter Pin (2) from Pin (3).

by removing the Bolt (4), Lockwasher (5), and Flat­washer (6).

2. Remove the Cotter Pins (8) from the Pins (9) on
each Bracket (10). Pull the pin out of the bracket.

3. Carefully fold rails inward to the stowed position.

4. Remove the Bolts (11), Locknuts (13), Flatwashers
(12), and Chain Assembly Mounting Plates (14).
The rail can now be removed.

Installation:

NOTE: Place the rail(s) on the platform in their stowed posi-

tion when installing.

1. Follow the removal instructions in reverse order.

Platform Extension End Rail

1

2

3

4

5

6

7

7

8

9

1. Extension End Rail

2. Cotter Pin

3. Pin

4. Hinge Bracket

5. Bolt, M10 x 120mm

6. Locknut, M10

7. Flatwasher, M10

8. Chain Assembly Mounting Plate

9. Tube

Figure 3-31. Extension End Rail Removal

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Removal

1. If applicable, detach the end rail (1) from the side
rails (see removal instructions for side rails on previ­ous page).

2. Remove Cotter Pins (2) from Pins (3).

3. Pull Pins out of Hinge Brackets (4).

4. Carefully lower rail to its stowed position.

5. Secure rail.

6. Remove the Bolts (5), Locknuts (6), Flatwashers (7),
and Chain Assembly Mounting Plate (8).

7. Carefully remove the rail.

8. Remove the Tube (9) from the rail.

Installation

1. Follow the Removal instructions in reverse order
when installing the platform extension end rail.

3121325 – JLG Lift – 3-33

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2, 3

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

1. Platform Pivot Pin

2. Bolt, M12 x 25mm

3. Lockwasher, M12

NOTE: Illustration shows scissor arm assembly connection point to

underside of platform at the front of the platform.

Platform Removal

Machine Stabilization:

The arm stack can be supported by using an overhead
crane, Figure 4-31. If an overhead crane is not available
the stack may also be lifted by using a forktruck using the
following instructions:

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

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

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

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

3-34 – JLG Lift – 3121325

NOTE: Procedures apply to both left and right sides.

Removal:

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

2. Support the platform along the sides with the fork-

3. Remove the two Bolts (2) and Lockwashers (3)

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

truck forks or use suitable straps or chains at the
four corners of the platform.

attaching the two Platform Pivot Pins (1) to the Plat­form.

page)

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2, 3

2, 3

2, 3

2, 3

2, 3

2, 3

1

1. Platform Retaining Bracket

2. Bolt, M10 x 16mm

3. Lockwasher, M10

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

NOTE: Illustration shows scissor arm assembly connection point to

underside of platform at the rear of the platform.

Platform Removal:

NOTE: Procedures apply to both left and right sides.

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

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

3. Lift the platform from the armstack.

3121325 – JLG Lift – 3-35

Installation:

1. The removal steps should be followed in reverse
order when installing the platform.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

1. Ladder

2. Bolt, M10 x 25mm

3. Spring Lockwasher, M10

4. Flatwasher, M10 (if applicable)

Figure 3-34. Ladder Installation

3.12 LADDER INSTALLATION

Removal:

1. The ladder can easily be removed from the chassis
by removing the four Bolts (2), Spring Lockwashers
(3), and Flatwashers (4).

USE CAUTION WHEN REMOVING THE LADDER. THE LADDER
WEIGHS APPROXIMATELY 104 LBS (47.2 KG).

Installation:

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

2. Secure ladder to the chassis with the four Bolts (2),
Spring Lockwashers (3), and Flatwashers (4).

3-36 – JLG Lift – 3121325

3.13 BEACON INSTALLATION (OPTION)

1

2

3

4

6

7

Position W11

MTB Underside

Front and Rear

Front Beacon

Rear Beacon

Harness

8

5, 7

1. Beacon & Protective Cage

2. Mounting Bracket

3. Screw, 6mm x 16mm

4. Washer, 6mm

5. Bolt, M4 x 25mm

6. Nut, M4

7. Washer

8. Guiding Rods

Figure 3-35. Beacon Installation

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Removal:

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

Installation:

3121325 – JLG Lift – 3-37

cons.

1. Disconnect electrical supply.

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

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

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

5. Repair/Replace if necessary.

1. Follow Removal Procedures in reverse order.

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

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

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

Table 3-8. Beacon Harness MTB Connections

Side Wire Color Signal Termiinal Position

Front

Rear

Brown + X1/34B-1

Blue GND X1/1-3

Brown + X1/34B-2

Blue GND X1/1-4

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

5

6

7

8

1. Platform Stowed/Jacks Retract Limit Switch

2. High Drive Speed Cutout Limit Switch

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

4. Max Height Limit Switch

5. Cam 1

6. Cam 2

7. Cam 3

8. Cam 4

Figure 3-36. Limit Switch Adjustment

3.14 SCISSOR ARMS

Limit Switches

Cam Adjustment:

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

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

12.1 ft (3.7 m).

3-38 – JLG Lift – 3121325

3. Adjust Cam 3 (7) to activate Max Drive Height/Max
Height without Outriggers Limit Switch (3) when
platform is at a height of 65 ft (20 m).

4. Adjust Cam 4 (8) to activate Max Height Limit Switch
(4) when platform exceeds a height of 68.9 ft (21 m).

NOTE: The limit switch plate can be removed by removing

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

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

STRAP

STRAP

Scissor Arm Assembly Removal

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

NOTE: It is recommended to remove the scissor arm

assembly as a whole unit.

1. Remove the platform from the scissor arm assembly
(refer to Figure 3-32., Platform Removal - 1 of 2
(Front of Platform) and Figure 3-33., Platform
Removal - 2 of 2 (Rear of Platform)).

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

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

NOTE: Scissor arm assembly weighs approximately 15,653

lbs (7100 kg). Straps and lifting device must be
capable of lifting the scissor assembly.

3121325 – JLG Lift – 3-39

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

1. Bolt, M16 x 140mm

2. Flatwasher, M16

3. Spacer

4. Locknut, M16 (not shown)

1
2

3

4

1. Bolt, M6 x 10mm

2. Lockwasher, M6

3. Coverplate

4. Pin

1

2

3

1. Bolt, M20 x 34mm

2. Lockwasher, M20

3. Pin

4. Remove one pin from the steering linkage to gain
access to the scissor arms pin behind the wheel.
(see Section 3-6., Steering Assembly).

5. Remove the cable from the ground control socket in
the valve compartment.Remove the hydraulic hoses
for the platform extension (Refer to Figure 4-37.,
Main Valve Block). Cap the fittings and secure the
cable and hoses to the arm stack with tape. As soon
as possible, brace the lift cylinder so that when it is
disconnected from the arm stack it will be secured
and will not fall.

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

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

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

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

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

3-40 – JLG Lift – 3121325

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

STRAP

1

2

3

4

324

1

STRAP

1. Lift Cylinder

2. Pin

3. Bolt, M20 x 35mm

4. Lockwasher, M20

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

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

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

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

3121325 – JLG Lift – 3-41

NOTE: Follow the removal steps in reverse order when

installing the arm assembly.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4

2

3

1

STRAP

1. Lift Cylinder

2. Bolt, M20 x 35mm

3. Lockwasher, M20

4. Pin

Figure 3-37. Lift Cylinder Removal

Lift Cylinder Removal

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

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

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

MAKE SURE THE FITTING ON THE LEAK OIL LINE IS CLOSED TO
PREVENT EXTENSION OF THE CYLINDER WHILE LIFTING FROM
THE MACHINE.

3. Place a strap, attached to an overhead lifting device,
through the top portion of the lift cylinder to secure
the cylinder.

4. Put the cylinder into a vertical position with the over­head lifting device.

5. Remove the Bolt (2) and Lockwasher (3). Pull the
Pin (4) out of the machine.

6. Carefully raise the Lift Cylinder (1) from the chassis
using an overhead crane or other suitable lifting
device..

NOTE: Follow the removal procedures in reverse order

when installing the lift cylinder.

3-42 – JLG Lift – 3121325

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1

2

3

4

1. Arm Pin (75mm, 90mm, 110mm, or 130mm)

2. Nut (80mm or 100mm)

3. Retaining Washer (60mm, 80mm, or 100mm)

4. Washer & Pin

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

1

2

3

3

2

4

1. Arm Pin (75mm, 90mm, 110mm, or 130mm)

2. Bushing (75 x 60mm, 90 x 60mm, 110 x 60mm, or
130 x 60mm)

3. Ball Thrust Bearing

4. Bushing (75 x 80mm, 90 x 100mm, 110 x 110mm,
or 130 x 100mm)

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

Scissor Arms Disassembly

INDIVIDUAL SCISSOR ARMS ARE HEAVY. USE CAUTION WHEN
REMOVING. USE APPROPRIATE LIFTING DEVICES.

1. Disconnect battery and shutoff flow of hydraulic fluid
by closing the shutoff levers on the hydraulic tank
(see Figure 3-20.).

2. Remove Platform (see Figure 3-32., Platform
Removal - 1 of 2 (Front of Platform) and Figure 3-33.,
Platform Removal - 2 of 2 (Rear of Platform)).

3. Hydraulic lines and electrical lines run through the
insides of the scissor arms. These hoses and wires
must be removed before removing the arm compo­nents.

4. Brace the Scissor Arm Assembly as well as the indi­vidual Scissor Arm(s) being removed.

NOTE: The below steps apply to each scissor arm pin.

5. On the left side of the machine, remove the Nut (2)
with a spanner wrench. Next remove the Retaining
Washer (3) and Washer and Pin (4).

6. Move to the right side of the machine. The Arm Pin
(1) can now be pulled out of the scissor arm stack.
Remove the four Bushings (2), two Ball Thrust Bear­ings (3), and two Bushings (4).

3121325 – JLG Lift – 3-43

7. Repeat steps 4 and 5 at each Arm Pin in order to
remove the individual scissor arm.

8. Carefully lift the arm from the assembly.

NOTE: Follow the removal steps in reverse order when

installing the scissor arms.

Tighten the Lock Nuts until there is zero clearance
between the arms and the bearings. Back off one
quarter of a revolution. Bend the lip on the corre­sponding Retaining Washer into the notch on the
lock nuts.

SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTES:

3-44 – JLG Lift – 3121325

SECTION 4. HYDRAULICS

SECTION 4 - HYDRAULICS

4.1 CYLINDERS - THEORY OF OPERATION

Deck Extension Cylinder:

The deck is extended and retracted by means of a double
acting cylinder controlled by the first section in the main
control valve (see Figure 4-37., Main Valve Block). The
service line relief valve in the control valve is set at 1160
psi ( 80 bar) for extend and 3046 psi (210 bar) for retract.

Lift Cylinder:

The lift cylinder is a single acting cylinder incorporating
dual solenoid holding valves and a pilot operated check
valve for emergency lowering. The lifting function is con-

trolled by the 3
speed is limited by flow from section 1 in the pump.

Lowering is operated by energizing the 2 solenoid holding

valves together with the 3rd section of the main control
valve. Descent speed is controlled by an adjustable line
mounted flow control valve.

To enable lowering at full speed when the engine is
stopped (i.e. there is no hydraulic power available to act
as a pilot supply for the electrical actuator), a pilot line is
connected to the auxiliary port "M" on the control valve via
a check valve. This provides the hydraulic power neces­sary to shift the lower valve section.

rd

section of the main control valve. Lift

Outrigger Cylinders:

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

Steer Cylinder:

directed through the valve body and returns to reservoir. A
typical control valve consists of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring­loaded to center position, therefore when the control is
released, the spool automatically returns to neutral, pro­hibiting any flow through the circuit.

Relief Valves

Main relief valves are installed at various points within the
hydraulic system to protect associated systems and com­ponents against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of
travel and the flow of pressurized fluid continues from the
system control. The relief valve provides an alternate path
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir­cuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pres­sure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actu­ator requires an operating pressure lower than that sup­plied to the system. When the circuit is activated and the
required pressure at the actuator is developed, the cross­over relief diverts excess pump flow to the reservoir. Indi­vidual, integral relief’s are provided for each side of the
circuit.

Steering is controlled by a double acting cylinder con-

nected to the 4

th

section of the main control valve.

4.2 VALVES - THEORY OF OPERATION

Proportional Valve

Flow is proportional to the amount of voltage supplied to
the valve coil. Voltage is gained by the machine controller
and determined by the position of the joystick.

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid
valves of the sliding spool design. When a circuit is acti­vated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to per­mit oil flow to the component in the selected circuit, with
the opposite work port opening to reservoir. Once the cir­cuit is deactivated (control returned to neutral), the valve
spool returns to neutral (center) and oil flow is then

3121325 – JLG Lift – 4-1

SECTION 4 - HYDRAULICS

Setscrews

Cylinder
Barrel

Valve
Block

Figure 4-1. Lift Cylinder Valve Block Removal

4.3 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system

component is replaced or when improper system
operation is suspected.

1. Using all applicable safety precautions, activate
engine and fully extend cylinder to be checked. Shut
down engine.

2. Carefully disconnect hydraulic hoses from retract
port of cylinder. There will be some initial weeping of
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be
no further drainage from the retract port.

3. Activate engine and extend cylinder.

4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repair must be
made.

5. With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.

6. Activate engine and retract cylinder. Check extend
port for leakage.

7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
then activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate of
6-8 drops per minute or more, cylinder repairs must
be made.

4.4 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted. Refer to
Figures 4-26 thru 4-30 for specific cylinder assembly
breakdowns and for specific parts references. Refer
to JLG Parts Manual 3121326 for seal kits and part
numbers.

Disassembly

BEFORE REMOVING CYLINDERS FROM THE MACHINE, BE SURE
TO SUPPORT THE MACHINE AND SCISSOR ARMS/PLATFORM
WITH SAFETY PROPS, FORKLIFTS, OR OVERHEAD CRANE TO
PREVENT RELEVANT COMPONENTS FROM COLLAPSING AND
CAUSING SERIOUS INJURY OR DEATH. (SEE FIGURE 4-31.)

DISCONNECT THE BATTERIES BEFORE REMOVING ANY COM­PONENTS FROM THE CYLINDER ASSEMBLY.

1. Remove cylinder(s) from the machine by first dis­connecting all hoses and/or wires and any valves.
Next, unscrew bolts connecting cylinder(s) to the
machine. If applicable, remove any pins connecting
the cylinders to the machine.

NOTE: Step 2 applies only to the Lift Cylinder.

2. To prevent damage, remove the valve block from the
lift cylinder barrel by unscrewing the 4 set screws.

4-2 – JLG Lift – 3121325

NOTE: Step 3 applies only to the Axle Lockout Cylinder.

Cylinder
Barrel

Load Check
Valve

Figure 4-2. Load Check Valve Romoval

Outrigger
Cylinder

Safety Valve

Limit Switch

Figure 4-3. Safety Valve and Limit Switch Removal

Figure 4-4. Cylinder Barrel Support

SECTION 4 - HYDRAULICS

3. To prevent damage, remove the load check valve
from the barrel.

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

5. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES­SURE.

6. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source.

7. Adequately support the cylinder rod, if applicable.

8. Place the cylinder barrel into a suitable holding fix­ture.

NOTE: Step 4 applies only to the Outrigger Cylinders.

4. To prevent damage, remove the safety valve and
limit switch from the top of the outrigger cylinders.

3121325 – JLG Lift – 4-3

SECTION 4 - HYDRAULICS

Cylinder
Head

Barrel

Cylinder
Rod

Figure 4-5. Cylinder Head Removal

Figure 4-6. Cylinder Rod Support

Pistons

Setscrews

Figure 4-7. Piston Setscrew Removal

Piston

Cylinder
Rod

Figure 4-8. Piston Removal

9. Using a spanner wrench, loosen and remove the
cylinder head from the barrel.

11. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.

12. If applicable, loosen and remove the setscrew which
attaches the piston to the rod, and remove the pis­ton.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL­INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF­CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.

10. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.

.

13. If applicable, unscrew the piston counter-clock-wise,
by hand, and remove the piston from the cylinder
rod.

4-4 – JLG Lift – 3121325

SECTION 4 - HYDRAULICS

O-Ring

Piston

Piston
Seal

Snap Ring
(Outrigger Cylinder
Only)

Figure 4-9. Piston Seals

Spacer

Cylinder
Rod

Figure 4-10. Spacer Removal

Cylinder
Rod

Cylinder
Head

Figure 4-11. Cylinder Head Removal

O-Ring

Head
Seal

Wiper

O-Ring

Rod
Seal

Cylinder

Head

Snap Ring

(Outrigger Cylinder Only)

Backup Ring
(Outrigger and Axle
Lockout Cylinders Only)

Figure 4-12. Cylinder Head Seals

14. Remove and discard the piston o-rings, seal rings,
and, if applicable, the snap ring.

15. If applicable, remove the spacer from the rod.

17. Remove the cylinder head from the cylinder rod.

18. If applicable, remove and discard the cylinder head
seal, rod seal, wiper, o-ring(s), back-up ring, and
snap ring.

3121325 – JLG Lift – 4-5

16. Remove the rod from the holding fixture.

SECTION 4 - HYDRAULICS

Bushing

Arbor
To ol

Bushing
Housing

Figure 4-13. Bushing Installation

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive dam­age. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scor­ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.

6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.

7. If applicable, inspect threaded portion of piston for
damage. Dress threads as necessary.

d. Using an arbor of the correct size, carefully

press the bushing(s) into bushing housing on
the cylinder rod and cylinder barrel, if applica­ble.

8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.

10. Inspect threaded portion of head for damage. Dress
threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.

13. If applicable, inspect rod and barrel bushings for
signs of excessive wear or damage. Replace as nec­essary.

a. Thoroughly clean bushing housing, of burrs, dirt

etc. to facilitate bearing installation.

b. Inspect bushing housing for wear or other dam-

age. If the bushing housing is worn or damaged,
rod/barrel must be replaced.

NOTE: Step 14 applies only to the Lift Cylinder and Axle

Lockout Cylinder.

14. Inspect lift/lower valve and load check valve.
Replace as necessary.

15. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

16. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

c. Lubricate inside of bushing housing with WD40

prior to bushing installation.

4-6 – JLG Lift – 3121325

Assembly

ROD
SEAL

Figure 4-14. Rod Seal Installation

O-Ring

Head
Seal

Wiper

O-Ring

Rod
Seal

Cylinder

Head

Snap Ring

(Outrigger Cylinder Only)

Backup Ring
(Outrigger and Axle
Lockout Cylinders Only)

Figure 4-15. Cylinder Head Seal Installation

Cylinder
Rod

Cylinder
Head

Figure 4-16. Cylinder Head Installation

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used. See your JLG Parts Manual

3121326. Always replace seals when servicing cylin­ders.

Apply a light film of hydraulic oil to all components prior to
assembly.

1. A special tool is used to install a new rod seal into
the applicable cylinder head gland groove.

SECTION 4 - HYDRAULICS

4. Carefully install the cylinder head on the rod, ensur­ing that the wiper, o-ring, and rod seals are not dam­aged or dislodged. Push the head along the rod to
the rod end, as applicable.

WHEN INSTALLING PISTON SEALS, ENSURE SEALS ARE
INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION COULD
RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER
OPERATION.

WHEN INSTALLING THE WIPER SEAL, APPLY LOCTITE #609 ON
THE WIPER SEAL IN THREE EVENLY SPACED PLACES TO AID IN
RETENTION OF THE SEAL.

2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
rod seal into the applicable cylinder head gland­groove.

3. Install a new head seal, new o-rings, and, if applica­ble, a new backup ring, in the appropriate outside
diameter groove of the cylinder head.

3121325 – JLG Lift – 4-7

SECTION 4 - HYDRAULICS

Spacer

Cylinder
Rod

Figure 4-17. Spacer Installation

O-Ring

Piston

Piston
Seal

Snap Ring
(Outrigger Cylinder
Only)

Figure 4-18. Piston Seal Installation

Piston

Spacer

Cylinder
Rod

Figure 4-19. Piston Installation

Pistons

Setscrews

Figure 4-20. Piston Setscrew Installation

5. Carefully slide the piston spacer onto the cylinder­rod.

6. If applicable, correctly install new o-ring and snap
ring in the inner piston diameter groove.

9. If applicable, carefully thread the piston clock-wise
on the cylinder rod hand tight until it abuts the
spacer, ensuring that the o-ring, snap ring, and pis­ton seals are not damaged or dislodged.

7. If applicable, correctly place new seals in the outer
piston diameter groove(s). (A tube, with an inner
diameter slightly larger than the outer diameter of
the piston is recommended to install the solid seal.)

8. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.

10. If applicable, insert the setscrews on the piston and
tighten to lock piston in place on cylinder rod.

11. Remove the cylinder rod from the holding fixture.

12. Position the cylinder barrel in a suitable holding fix­ture.

4-8 – JLG Lift – 3121325

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

Cylinder
Head

Cylinder
Rod

Piston

Cylinder
Barrel

Figure 4-21. Rod Installation

Cylinder
Head

Barrel

Cylinder
Rod

Figure 4-22. Rod Assembly Installation

Setscrews

Cylinder
Barrel

Valve
Block

Figure 4-23. Valve Block Installation

NOTE: Lift Cylinder only.

CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.

13. With the barrel clamped securely, and while ade­quately supporting the rod, insert the piston end into
the barrel cylinder. Ensure that the piston loading o­ring and seal ring are not damaged or dislodged.

SECTION 4 - HYDRAULICS

14. Continue pushing the rod into the barrel until the cyl­inder head can be inserted into the barrel cylinder.

15. Using a spanner wrench, tighten the cylinder head
onto the barrel.

NOTE: Steps 16 applies only the Lift and Axle Lockout Cyl-

inders.

16. If applicable, after the cylinder has been reassem­bled, the rod should be pushed all the way in (fully
retracted) prior to the reinstallation of any valve
block, load check valve, or safety valve.

3121325 – JLG Lift – 4-9

SECTION 4 - HYDRAULICS

Cylinder
Barrel

Load Check
Valve

Figure 4-24. Load Check Valve Installation

NOTE: Axle Lockout Cylinder only.

Outrigger
Cylinder

Safety Valve

Limit Switch

Figure 4-25. Safety Valve and Limit Switch Installation

NOTE: Outrigger Cylinders only.

NOTE: Refer to Figure 1-3., Torque Chart (SAE Fasteners -

Sheet 1 of 3) to Figure 1-8., Torque Chart (METRIC
Fasteners - Sheet 3 of 3) for setscrew torques.

4-10 – JLG Lift – 3121325

SECTION 4 - HYDRAULICS

2

2

1

9

8

7

10

5

3

6

4

11

2

2

18

13

141716

13

15

12

1. Piston Rod

2. Bushing

3. Piston

4. Piston Seal

5. O-Ring

6. Setscrew

7. Cylinder Head

8. Wiper

9. Rod Seal

10. O-Ring

11. Cylinder Barrel

12. Lift/Lower Valve

13. Solenoid Valve

14. Check Valve

15. Capscrew (M8 x 120mm)

16. Hydraulic Block

17. Pressure Sensor

18. O-Ring

Figure 4-26. Lifting Cylinder Assembly

3121325 – JLG Lift – 4-11

SECTION 4 - HYDRAULICS

1

2

3

4

5

6

7

8

11

10

9

12

2

1. Barrel

2. Bushing

3. Piston

4. Piston Seal

5. Setscrew

6. Spacer

7. Head

8. Head Seal

9. Rod Seal

10. Wiper

11. O-Ring

12. Rod

Figure 4-27. Steering Cylinder Assembly

Table 4-1. Steer Cylinder Specs

Max Working Pressure

P is to n He ad To rqu e (A pp l y L oc t it e 2 4 2 b ef o re t ig ht e ni ng )

Max Speed

Max Operating Temperature

-4°F to 176°F

(-20°C to 80°C)

3045.7 psi
(210 bar)

191.8 lb ft
(260 Nm)

1.6 ft/sec

(0.5 m/sec)

4-12 – JLG Lift – 3121325

SECTION 4 - HYDRAULICS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

1. Barrel

2. O-Ring

3. Cap

4. Mounting Flange

5. Stop

6. Piston

7. Snap Ring

8. Piston Seal

9. Spacer

10. O-Ring

11. O-Ring

12. Back-up Ring

13. Head

14. Rod Seal

15. Wiper

16. Snap Ring

17. O-Ring

18. Rod Assembly

Figure 4-28. Outrigger Cylinder Assembly

Max Working Pressure

Table 4-2. Outrigger Cylinder Specs

Piston Head Torque (Apply Loctite 243 prior to tightening)(torque with Rod End)

Cap To rque (Apply Circlip behind Piston Head prior)

Max Speed 0.5 m/sec

Max Operating Temperature

2683.1 psi
(185 bar)

737.6 lb ft

(1000 Nm)

958.8 lb ft

(1300 Nm)

-22°F to 212°F

(-30°C to 100°C)

3121325 – JLG Lift – 4-13

SECTION 4 - HYDRAULICS

1

2

2

3

4

5

6

7

8

9

10

11

12

14

13

2

2

1. Barrel

2. Bushing

3. Load Check Valve

4. Piston

5. Piston Seal

6. Setscrew

7. Head Seal

8. Backup Ring

9. O-Ring

10. Head

11. Rod Seal

12. Wiper

13. Rod

14. O-Ring

Figure 4-29. Axle Locking Cylinder Assembly

Max Working Pressure

P is t on H e ad To rq u e (A p pl y Lo c ti t e 24 2 to P is t o n H e ad b e fo r e t i gh t en i n g

Max Speed 0.5 m/sec.

Max Operating Temperature

Table 4-3. Axle Locking Cylinder Specs

2900.7 psi
(200 bar)

737.8 lb ft

(1000 Nm)

-22°F to 212°F

(-30°C to 100°C)

4-14 – JLG Lift – 3121325

SECTION 4 - HYDRAULICS

1

2

3

4

5

6

7

8

9

10

11

12

13

1. Barrel

2. Piston

3. Setscrew

4. Piston Seal

5. Spacer

6. Head

7. O-Ring

8. Wiper

9. O-Ring

10. Wiper

11. Head Seal

12. Rod

13. Bushing

Figure 4-30. Extension Cylinder Assembly

Table 4-4. Deck Extension Cylinder Specs

Max Working Pressure

Full Bore Relief Pressure

P is t on To r qu e (A p pl y L oc t it e 24 2 t o P i st o n T h r ea d be f or e t ig h te n in g )

Setscrew Torque

Max Speed 0.5 m/sec

Max Operating Temperature

3045.7 psi
(210 bar)

1160.3 psi

(80 bar)

147.5 lb ft
(200 Nm)

14.8 lb ft
(20 Nm)

22°F to 176°F

(-30°C to 80°C)

3121325 – JLG Lift – 4-15

SECTION 4 - HYDRAULICS

STRAP

REMOVE ANY LOAD FROM PLATFORM. NEVER
WORK UNDER AN ELEVATED PLATFORM UNTIL IT
HAS BEEN RESTRAINED FROM MOVEMENT WITH
SAFETY PROPS, BLOCKING OR OVERHEAD SLING.

ARM SAFETY

PROP

STRAP

Figure 4-31. Arms and Platform Positioning and Support

4-16 – JLG Lift – 3121325

4.5 VALVES

1

2

3

4

1. Pressure Switch, Drive Enable
& Brake Valve

2. Drive Valve

3. Main Valve Block

4. Hand Pump

Figure 4-32. Valve/Hydraulic Compartment

Figure 4-33. Pressure Switch Adjustment

• Operate the lower function to retract the
jacks and adjust the switch (screw on the
top of the switch) to trip at 2683 psi
(185 bar)

Valve Compartment

SECTION 4 - HYDRAULICS

Pressure Switch, Drive Enable

3121325 – JLG Lift – 4-17

SECTION 4 - HYDRAULICS

1

2

VALVE SCHEMATIC

A

P

T

Figure 4-34. Brake Valve

1. Torque to 5 ft lbs (6.8 Nm)

2. Torque to 20 ft lbs (27.1 Nm)

• Operating Pressure: 3000 psi (207 bar)

• Voltage: 24VDC

Figure 4-35. Brake Valve Adjustment

• To achieve smooth deceleration when
the joystick is returned quickly from the
max forward or backward position to the
neutral position, completely close the
valve knob (shown to the left) then open
the knob 1/2 of a revolution.

Brake Valve

Brake Valve Adjustment:

4-18 – JLG Lift – 3121325

Drive Valve

C4 D4 C3 D3 C2

D2 C1

D1

C4

D4

C3

D3

C2

D2

C1

D1

B

PT

AB

PT

AB

B

B

A

P

T

A

B

PT

AB

B

B

PTABPT

AB

B

A

A

AAA

Passive

Parallel 4-Wheel Drive

Active

Fast 2-Wheel Drive

Active

Posi-trac 4-Wheel Drive

Rear Front Rear Front Rear Front

Drive 2
Valv e

Drive 1
Valv e

Drive 2

Valv e

Not Used

Drive 1 Valve

Active

Drive 2
Valv e

Drive 1
Valv e

SCHEMATIC

C4 D4 C3 D3 C2

D2 C1

D1

C4

D4

C3

D3

C2

D2

C1

D1

C4 D4 C3 D3 C2

D2 C1

D1

C4

D4

C3

D3

C2

D2

C1

D1

Figure 4-36. Drive Valve

SECTION 4 - HYDRAULICS

• With no power activating the Valve Coils (1 thru 4), the
machine is in 4 wheel drive low speed. A2 and A1
receive flow from both drive sections of the Main Valve
Block.

• With 24V on Coils 3 and 4, oil is forced through the flow
dividers as it enters the A1 and A2 ports of the mani­fold, splitting 50% of the oil to each axle resulting in Dif­ferential Lock Tractor Drive.

• With 24V on Coils 1 and 2, all oil from the pump will
give maximum oil flow through A1 section of the valve
to the front wheels resulting in High Speed 2 Wheel
Drive.

3121325 – JLG Lift – 4-19

SECTION 4 - HYDRAULICS

1

2

3

4

10

6

7

8

9

PLATFORM

DRIVE 2

LIFTING

STEERING

LEVELING

REAR RIGHT

LEVELING

REAR LEFT

LEVELING

FRONT RIGHT

DRIVE 1

VALVE SCHEMATIC

Figure 4-37. Main Valve Block

1. Main Pressure Block

2. Platform

3. Drive 2

4. Lift

5. Steer

6. Rear Right Jack

7. Rear Left Jack

8. Front Right Jack

9. Front Left Jack

10. Drive 1

Main Valve Block

4-20 – JLG Lift – 3121325