JLG E45A-AJ Service Manual

Model

BS E N ISO 9001 CertificateN o. 6917

M45A
M45AJ
E45A
E45AJ

CORPORATE OFFICE

JLG INDUST RIES, INC.
1 JLG Drive
McConnellsburg, PA 17233-9533
USA
Telephone: [phone]
Fax: [phone]

Issued: August 5, 1999 PRINTED IN U.S.A. 3120884
Updated: Fe bruary 15, 2000

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)
Kilmartin Place,
T a nnoc hs ide Park,
Uddingston, Scotland, G71 5PH
Telephone: [phone]
Fax: [phone]

AUSTRALIAN OFFICE

JLG INDUSTRIES (AUSTRALIA)
P.0. Box 972
11 Bolwarra Road
Port MacQuarie
N.S.W. 44
Australia
Telephone: [phone]

SERVICE & MAINTENANCE

INTRODUCTION

SECTION A. INTRODUCT ION - MAINT ENA NCE SA FETY

PRECAUTIONS

A GENERAL

This section contains the general s afety precaution s
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 themsel ves 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 considerat ion
when engaging in the maintenance of equipment. Always
be conscious of weight. Never atte mpt 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 MAINTENANC E,
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 b e made to reli eve any s ystem
pressure prior to discon nectin g or removin g any portio n of
the system.

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 SECU RE AT ALL OTHER
TIMES.

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

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

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

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

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTED­DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

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

3120884 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

August 5, 1999 - Original Issue
2-40 - Updated 8-30-99
1-1 and 1-2 - Updated 10-7-99
2-50 - Updated 10-7-99
2-52 thru 2-54 - Updated 10-7-99
1-1 - Updated 2-15-00
3-1 - Updated 2-15-00
3-5 - Updated 2-15-00
3-16 - Updated 2-15-00

A-2 – JLG Lift – 3120884

TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRE CAU TIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

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

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

1.4 Function Speeds (M45A/E45A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Function Speeds (M45AJ/E45AJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

1.8 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.10 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.12 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - PROCEDURES

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

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

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

2.4 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.5 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.6 Cylinder Checking Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.7 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.8 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.9 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.10 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.11 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2.12 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2.13 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2.14 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2.15 Mid and Lower Lift Cylinder Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.16 Boom Synchronizing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.17 Dri v e Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.18 Drive Brake - Mico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

2.19 Pins and Gar-max Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2.20 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2.21 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2.22 Positrac/Tilt module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2.23 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

2.24 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2.25 Gene r ator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

2.26 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Troubleshooting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3120884 – JLG Lift – i

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

2-1. On Board Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4. Capscr e w Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-5. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-6. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-7. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-8. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-11. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2

2-13. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-14. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-15. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 3

2-16. Upper Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-17. Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-18. Lower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-19. Upper Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-20. Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-21. Platform Components and Attaching Hardware (M45A & E45A). . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-22. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

2-23. Rotator Assembly (Helac). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-24. Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-25. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-26. Removing Sleeve from Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-27. Actuator Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2-28. Boo m Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-29. Location of Component s - Articulating Ji b Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-30. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-32. Swi ng Bearing Tolerance Measuring Po in t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-31. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-33. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-34. Swi ng Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-35. Dri v e Hub - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

2-36. Drive Brake - Mico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-37. Speed Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

2-38. Frame Mounted Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

2-39. Steering Components and Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

2-40. Dri v e Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2-41. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

2-42. Jib Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-43. Brake/Steer Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-44. Mai n Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 4

2-45. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2-46. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2-47. Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2-48. Generator Componen t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

2-49. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

ii – JLG Lift – 3120884

TABLE OF CONTENTS

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO.

3-1. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 0

3-2. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-3. Platform Electrical Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-4. Platform Electrical Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-5. Turntable Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Frame Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. On Board Generator Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8. Hydraulic Schematic - M45A/E45A - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-9. Hydraulic Schematic - M45A/E45A - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-10. Hydraulic Schematic - M45AJ/E45AJ - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-11. Hydraulic Schematic - M45AJ/E45AJ - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-8 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

2-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-2 Cylinder Piston Nut Torque Specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-4 Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-4 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-5 Personality Ranges/Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

2-6 Machine Setup Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

2-7 JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

2-8 Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

2-9 DIAGNOSTICS - Menu Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

2-10 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

2-11 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-12 RBS Prestart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-13 RBS Startup Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-14 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-15 Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73

2-16 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

3-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-4 Chassis Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-5 Hydraulic System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6 Electrical System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3120884 – JLG Lift – iii

TABLE OF CONTENTS

This Page Left Blank Intentionally .

iv – JLG Lift – 3120884

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES
Hydraulic Oil Tank

19 liters (5 gallons)

Generator Fuel Ta nk

15.1 liters (4 gallons)

Drive Axle

Torque Hubs - 0.5 liters (19 oz.)

1.2 COMPONENT DATA
Battery Charger

Input, 110 VAC,60 HZ
Output, 48 VDC (25 Amps)
Batteries (8)
6 Volt, 370 AmpHour (20 hour rate)

Drive System

Drive Motor - 48 VDC, 12.5 H.P. @ 3200 rpm. continuous,
rotation - reversible

Drive Brake- spring-applied, hydraulic all y release d
Tires - IN240/55-17.5 pneumatic or foam filled
Tire Pressure - 6.2 Bar (90 psi)

1.3 PERFORMANCE DATA
Travel Speed

5.2 kph (3.2 mph)

Gradeability

30% (16.7 degrees)

Turning Radius (Inside)

0.61 m (2ft. 0 in.)

Turning Radius (Curb to Curb)

3.15 m (10 ft. 4 in.)

Tail Swing (Any Position)

0

Upper Boom Speed

Lift Up - 27 seconds
Lift Down - 26 seconds

Lower Boom Speed

Lift Up - 30 seconds
Lift Down - 24 seconds.

Swing Speed - 360 Degrees

90 seconds / rev.

Hydraulic Pump/Electric Motor Assembly

Motor - 48 VDC, 2.14 H.P. @ 2700 rpm.
Pump - 1.6 cm[3]/rev. (0.098 in.[3]/rev.)
Pump Output - 11.2 lpm (2.96 gpm) @ 222 Bar (3200 psi)

Machine Weight

E45A - 5,811 kg (12,800 lb.)
M45A - 5,811 kg (12,800 lb.)
E45AJ - 6690 kg (14,750 lb.)
M45AJ - 6690 kg (14,750.)

Max. Tire Load

M45A, E45A - 2,767 kg (6100 lbs.).
M45AJ, E45AJ - 3,130 kg (6900 lbs.)

Updated 2-15-00

3120884 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Ground Bearing Pressure

M45A, E45A - 6.2 Bar (95 psi)
M45AJ, E45AJ - 7.6 Bar (110 psi)

Machine Height (stowed)

M45A, E45A - 1.99 m (6 ft. 6.25 in.)
M45AJ, E45AJ - 2.0 m (6ft. 7 in.)

Machine Length (stowed)

M45A, E45A - 5.69 m (18 ft. 8.0 in.)
M45AJ, E45AJ - 6.45 m (21 ft. 2 in.)

Up and Over Platform Height

M45A, E45A - 7.49 m (24 ft. 7 in.)
M45AJ, E45AJ - 7.7 m (25 ft. 3in.)

Horizontal Reach @ Maximum Up and Over

M45 A, E45A - 7.0 m (23 ft. 1 in.)
M45AJ, E45AJ - 7.24 m (23 ft. 9 in.)

Machine Width

1.75 m (5 ft. 9 in.)

Wheel Base

2.00 m (6 ft. 7.0 in.)

Working Height

15.54 m (51 ft. 0 in.)

1.4 FUNCTION SPEEDS (M45A/E45A)

Lift Up - 30-24 seconds
Lift Down - 29-23 seconds
Tower Lift Up - 33-27 seconds
Tower Lift Down - 26-22 seconds
Telescope Out - 18-14 seconds
Telescope In - 28-23 seconds

Swing Left 360° - 81-67 seconds*
Swing Right 360° - 81-67 seconds*
Rotate Left 180° - 17-14 seconds
Rotate Right 180° - 18-15 seconds
High Drive - Fwd. & Rev. (60.9 m) - 42-44 seconds**

above Horiz. - Fwd. & Rev. (15.2 m) - 67-71 seconds**

Drive

*Swing Left to Swing Right should be within 10% of each other.
**Drive Forward to Drive Reverse should be within 10% of each

other.

1.5 FUNCTION SPEEDS (M45AJ/E45AJ)

Lift Up - 30-24 seconds
Lift Down - 29-23 seconds
Tower Lift Up - 33-27 seconds
Tower Lift Down - 26-22 seconds

Platform Height

13.72 m (45 ft. 0 in.)

Track Width

1.51 m (5 ft. 0 in.)

Ground Clearance

M45, E45 - 0.22 m (8.5 in.)
M45AJ, E45AJ - 0.20 m (8 in.)

System Voltage

48 volts

Battery Life per Charge

7 hours continuous

Jib Up - 25-26 seconds
Jib Down - 24-25 seconds
Telescope Out - 12-9 seconds
Telescope In - 19-15 seconds
Swing Left 360° - 81-67 seconds*
Swing Right 360° - 81-67 seconds*
Rotate Left 180° - 17-14 seconds
Rotate Right 180° - 18-15 seconds
High Drive - Fwd. & Rev. (60.9 m) - 42-44 seconds**

above Horiz. - Fwd. & Rev. (15.2 m) - 107-112 seconds**

Drive

*Swing Left to Swing Right should be within 10% of each other.
**Drive Forward to Drive Reverse should be within 10% of each

other.

Battery Recharge Time

Charger - 17 hours from full discharg e
Generator - 6.2 hours

Updated 10-7-99

1-2 – JLG Lift – 3120884

SECTION 1 - SPECIFICATIONS

1.6 TORQUE SPECIFICATIONS

Table 1-1.Torque Requirements

Description Torque V alue Interval Hours

Wheel Lugs 170 ft. lbs.

(230 Nm)

Swing Bearing

(Dry)

Swing Bearing

((Loctite)

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

220 ft. lbs.

(298 Nm)

240 ft. lbs.

(326 Nm)

150

50/600*

50/600*

1.7 LUBRICATION
Hydraulic Oil

Table 1-2.Hydraulic Oil

Hydraulic System

Operating

Temperature Range

+0 to + 180 F

(-18 to +83 C)

+0 to + 210 F

(-18 to +99 C)

+50 to + 210 F

(+10 to +99 C

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

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice.

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 viscos ities. If use of hydraulic oil ot her
than Mobil DTE 11M is desired, contact JLG Indus­tries for proper recommendations.

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

Lubrication Specifications

Table 1-3.Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of

350 degrees F. Excellent water resistance and adhesive
qualities; and being of extreme pressure type (Timken OK
40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service

Classification GL-5 or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Com-

pound. (JLG Part No. 3020027)

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG

Part No. 3020022)

EO Engine (crankca se) Oil. Gas - API SF/SG cl ass, MIL-L-

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

*MPG may be substituted for these lubricants, if neces­sary, but service intervals will be reduced.

NOTE: Refer to Lubrication Chart, Figure1-2, for specific

lubrication procedures.

Table 1-4. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Poi nt, Max -40 F (-40 C)

Flash Point, Min. 330 F (166 C)

Viscosity

at 40° C 15 cSt
at 100° C 4.1 cSt
at 100° F 80 SUS
at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

3120884 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Table 1-5.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Upper Lift
Cylinder

3.00

(76.2)

28.3125
(719.1)

1.50

(38.1)

Mid Lift Cylinder 3.00

(76.2)

21.25

(539.7)

1.50

(38.1)

Lower Lift Cylinder 4.00

(101.6)

23.25

(590.5)

2.25

(57.1)

T elescope Cylinder 2.00

(50.8)

92

(2337)

1.25

(31.8)

Master Cylinder 2.00

(50.8)

9.375

(238.1)

1.00

(25.4)

Slave Cylinder 2.00

(50.8)

9.375

(238.1)

1.00

(25.4)

Rotator Cylinder 1.875

(47.6)

15.250
(387.3)

1.00

(25.4)

Steer Cylinder
(Double Rod)

2.50

(63.5)

4.06

(103.1)

1.75

(44.5)

1.8 PRESSURE SETTINGS
Main Valve

Upper Lift Down Relief - 38 bar (550 psi)
Mid/Lower Lift Down Relief - 117 bar (1700 psi)
Telescope In Relief - 148 bar (2150 psi)
Platform Level Up Relief - 172 bar (2500 psi)
Platform Level Down Relief - 83 bar (1200 psi)

Steer/Brake Valve

Steer Relief - 159 bar (2300 psi)
Main Relief - 221 bar (3200 psi)

Jib Valve

Jib Relief (Up and Down) - 103 bar (1500 psi)

1.9 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in.), with the met-

ric equivalent, millimeters (mm), given in parenthe­ses.

1.10 MAJOR COMPONENT WEIGHTS

Table 1-6.Major Component Weights

Component LB. KG.

Platform and Support 215 97.5
Upper Boom Complete 810 367
Mid Boom Complete 550 249
Lower Boom Complete 550 249
Upper Lift Cylinder 89 40
Mid Lift Cylinder 95 43
Lower Lift Cylinder 110 50
T elescope Cy linder 85 38 .5
Upper Upright 225 102
Lower Uprig ht 97 44
Turntable 948 430
Battery Box (incl. batteries) 600 272
Chassis (w/ pneu. tires) 4,295 1948
Chassis (w/ foam-filled tires) 4,695 2130
Counterweight 3850 1746
Machine Complete (E45A) 14,000 6356
Machine Complete (M45A) 14,300 6492

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF
SAFELY SUPPORTING WEIGHT.

1.11 CRITICAL STABILITY WEIGHTS

Table 1-7.Critical Stability Weights

Component LB. KG.

Counterweight 3850 1746
Tire & Wheel (foam-filled) 207 94
Platform (4ft [1.2 m]) 90 41

1-4 – JLG Lift – 3120884

Platform (5 ft. [1.5 m]) 100 45
Battery (each) 120 54

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

SECTION 1 - SPECIFICATIONS

1.12 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed
to the left rear of frame, in front of left rear wheel. If the
serial number plate is damaged or missi ng, the machine

serial number is stamped on the top left side of the frame
and the top left side of the turntable. In addition, the serial
number is stamped on top of the end of the upper boom,
mid boom, and lower boom at the left rear of the booms.

Figure 1-1. Serial Number Locations

3120884 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

1-6 – JLG Lift – 3120884

Table 1-8. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

Components

Number/Type

Lube Points

Capacity Lube

Lubrication

Swing Bearing

1

Swing Bearing /

2

Worm Gear Teeth*

Hydraulic Fluid (Oil)

3

Hydraulic Filter

4

Wheel Drive Hub

5

Wheel Bearing

6

Spindles/Bushing

7

Boom Pivot Pins/

8

Bushing

Engine

9

NOTES: KEY TO LUBRIC ANTS

Lubrication intervals are base d on machine operation under nor mal conditions. For machines used in multi shift operations and/or ex posed to hostile
environments or conditions, l ubrication frequencies must be increased accordingly .

* If necessary install grease fitt ings into worm gear housing and grease bea rings.

1 Grease Fittin g or by

brush

Spray On A/R Mobiltac

Fill Cap 15 liters (tank) HO X Check o il every 10 hou rs of operation.

N/A N/A N/A X Replace filter element after first 50 hours and

Fill Plug/Hal f Full 0.5 liter (1/2 Full) EPGL X Check o il level at side plug on hub dail y.

Repack A/R MPG X

N/A A/R LL At Spindle/Bushing Repl acement Coat I.D. of bushings pri or to installin g king

N/A A/R LL At boom pivot pin s/bushing re placement Coat I.D. of bushi ngs prior to in stalling pins.

Fill Cap R efer to Engi ne

A/R MPG X More freq uent lubricati on intervals may b e

X More freq uent lubricati on intervals may be

375NC

EO Check daily . Change in acco rdance with

Manual

EPGL

required

required.

Change oil every 1 200 hours of opera tion.

every 300 hours t hereafter .**

Change after fir st 150 hours then e very 1200
hours of operatio n.

pins.

engine manual.

EO

Engine Oil
Extreme Pressure Ge ar Lube

HO

Hydraulic Fluid (Mobil DTE-11M)

MPG

Multi-Purpose Gre ase
Synthetic Lithiu m Lubricant

LL

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN
BLOWING OUTER SEAL IN HOUSING.

** Under certain conditions, it may be necessary to replace the h ydraulic filter on a more frequent basis. A common symptom of a dirty filter is sluggish­ness experienced in hydraulic func tions.

3120884 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart

1-8 – JLG Lift – 3120884

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

This section provides information necessary to per form
maintenance on the aerial platform. Descriptions, tech­niques and specific procedures are designed to provide
the safest and most efficient maintenance for use by per­sonnel responsible for ensuring the correct installation
and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK
IS RESUMED.

The maintenance procedures included consist of servic­ing and component rem oval and installation, disassembly,
and assembly, inspection, lubrication and cleaning. Infor­mation on any special tools or test equipment is also pro­vided where applicable.

2.2 SERVICING AND MAINTENANCE
GUIDELINES

General

The following inf ormation is prov ided to a ssist you in t he
use and application of servicing and maintenance proce­dures contained in this chapter.

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 atte mpt 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.

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.

Component 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 perpend icular as possibl e to top of par t being
lifted.

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

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

Component Disassembly and Reassembly

When disassembling or r e assembling a compon ent, com­plete the procedural steps in sequence. Do not part ially
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, ot her than
those recommended, without obtaining proper approval.

Pressure Fit Parts

When assembling pressure fit parts, use an “anti-seize” or
molybdenum disulfid e base co mpound to l ubricate the
mating surface.

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 oil supplies clean; however, these items must
be maintained on a s chedu led ba sis i n o rder to func ­tion properly.

2. At any time when hydraulic oil lines are discon­nected, clear adjacent areas as well as the openings

3120884 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

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 bea ring.

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 be installed.

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 in sta lled on a sh aft, apply pres su re 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.

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when discon nec ting 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 i n 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 man ual, at
the specified interval. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.

Batteries

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

Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in Lubricati on Chart.

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.

2-2 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

2.3 LUBRICATION INFORMATION
Hydraulic System

1. The primary enemy of a hydraulic system is contam­ination. Contaminants enter the system by various
means, e.g.; inadequate hydr aulic oil, allowi ng mois­ture, grease, filings, sealing componen ts, sand, etc.
to enter when performing maintenance, or by per­mitting the pump to cavitate due to insufficient sys­tem warm-up.

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 at the specified intervals
required in Section 1. Always examine filters for evi­dence of metal particles.

3. Cloudy oils indicate a high moisture content which
permits organic gr ow t h, res ulting in oxidation or cor­rosion. If this conditi on occurs, the system mu st be
drained, flushed, and refilled with clean oil.

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

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

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

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

2. JLG recommends Mobil DTE-11 Hydra ulic O il, wh ich
has an SAE viscosity of 10W and a viscosity index of

140.

NOTE: Start-up of hydraulic system with oil temperatures

below -29 degrees C. is not recommended. If it is
necessar y to sta r t the sy ste m in a sub- zero envi ron ­ment, it will be necessary to heat the oil with a low
density 100VAC heater to a minimum temperature of

-29 degrees C.

sesses the same antiwear and rust protection ch ar­acteristics as mineral oils, but will not adversely
affect ground water or the environment when spilled
or leaked in small amounts. Mobil EAL224H has a

viscosity of 34 cST at 40° C and a viscosity index of

213. The operating range of this oil is -18° C to +83°
C.

IT IS RECOMMENDED THAT MOBIL EAL224H HYDRAULIC OIL BE
STORED ABOVE FREEZING (0 C) AS THE OIL MAY APPEAR

CLOUDY AFTER EXPOSURE TO LOW TEMPERATURES FOR
EXTENDED PERIODS OF TIME. THE CLOUDINESS WILL DISAPPEAR
WHEN THE OIL IS WARME D TO AT L EAST 1 0 C AND AG ITATED. DO
NOT ATTEMPT TO "THIN" THE OIL WITH NO.2 DIESEL FUEL. FOR
BEST RESULTS, STORE THE OIL ABOVE FREEZING.

NOTE: Accidentally mixing Mobil EAL224 H hydraulic oil wi th

other mineral oils will cause no loss of performance
characteristics. However, biodegradability may be
reduced and toxicity may be increased, depending
on the oil and level of contamination.

Changing Hydraulic Oil

1. Use of any of the recommended hydraulic oils elimi­nates the need for changing the oil on a regular
basis. However, filter elements must be changed
after the first 50 hours of operation and every 300
hours thereafter. If it is necessary to change the oil,
use only those oils meeting or ex ceeding 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 ch an g­ing the hydraulic oil every two years.

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

3. While the unit is shut dow n, 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.

3. Some machines may be specially equipped with
Mobil EAL224H biodegradable and non-toxic
hydraulic oil. This oil is vegetable oil based and pos-

3120884 – JLG Lift – 2-3

SECTION 2 - PROCEDURES

Lubrication Specifications

Specified lubricants, as recommended by the component
manufacturers, are always th e best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose requirements. Should
any question arise regarding the use of greases in mainte­nance stock, consul t your local supp lier for eval uation.
Refer to Section 1 for an expl anation of the lub ricant ke y
designations appearing in the Lubrication Chart.

2.4 BATTERY MAINTENANCE AND
CHARGING

Battery Maintenance, Qu arterly

1. Open battery compartment cover to allow access to
battery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELEC­TROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES
UNLESS ELECTROLYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries , no n-metalli c

containers and/or funnels must be used.
To avoid electrolyte overflow, add distilled water to

batteries after charging.
When adding water to the battery, fill only to level

indicated or 9.5 mm above separators.

3. Remove battery cables from each battery post one
at a time, negative first. Clean cables with acid neu­tralizing solution (e.g. baking soda and water or
ammonia) and wire brush. Replace cables and/or
cable clamp bolts as re quired.

4. Clean battery post with wire brush then re-connect
cable to post. Coat non-contact surfaces with min­eral grease or petroleum jelly.

5. When all cables and terminal posts have been
cleaned, ensure all cables are properly positioned
and do not get pinched. Close battery compartment
cover.

6. Start hydraulic system and ensure that it functions
properly.

Optional On Board Generator

EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VEN­TILATED AREA ONLY.

WHEN THE GENERATOR EN ABLE CONTROL LOCATED IN T HE
PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE
GROUND EMERGENCY STOP SWITCH IS ON (PULLED OUT), THE
GENERATOR WILL START AUTOMATICALLY WHEN THE BAT­TERIES REACH A LOW-CHARGE STATE, AUTOMATICALLY
CHARGING THE BATTERIES. THE GENERATOR WILL A LSO
AUTOMATICALLY STAR T IF THE G ENERATOR ST ART BATTERY
IS LOW.

2. Remove all vent caps and inspect electrolyte level of
each cell. Electrolyte level should be to the ring
approximately one inch from top of battery. Fill bat­teries with distilled water only. Replace and secure
all vent caps.

2-4 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-1. On Board Generator

3120884 – JLG Lift – 2-5

SECTION 2 - PROCEDURES

NOTE: The engine will automatically shut down under the

following conditions:
High Engine Oil Temperature

Low Engine Oil Pressure
Engine Overspeed
Generator Overvoltage
Batteries fully charged

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR
ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC­ING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER­VICING BATTERIES.

Battery Charging (On Board Charger)

1. For maximum battery life:

a. Avoid completely discharging the batteries.
b. Fully charge the batteries each day the machine

is used.

c. Charge the batteries at available times between

charging.

d. Be sure the battery fluid covers the battery

plates before charging, but to avoid overflow, do
not top off the fluid level until charging.

2. To charge the batteries, connect the charger to a
115 volt source with a 15 amp minimum capacity.

3. The Charger will shut off automatically when the bat­teries are fully charged.

4. The charge cycle is complete when the ammeter
reads 0 amps. Any reading indicates the charge
cycle is not complete.

5. Depleted batteries will take approximately 17 hours
to charge.

2.5 CYLINDERS - THEORY OF OPERATION
Upper Boom Lift, Mid Boom Lift, Lower

Boom Lift, T e lescope, Slave, Master , Rotator,
and Steer

A double acting cylinder is one that requires oil flow to
operate the cylinder rod in both directions. Directing oil
(by actuating the corresponding control valve to the pis­ton side of the cylinder) forces the piston to travel toward
the rod end of the barrel, extending the cylinder rod (pis­ton attached to rod). When the oil flow is stopped, move­ment of the rod will stop. By directing oil to the rod side of
the cylinder, the piston will be forced in the opposite direc­tion and the cylinder rod will retract.

Figure 2-2. Batteries and Battery Charger

2-6 – JLG Lift – 3120884

Holding valves are used in the Lift circuits to prevent
retraction of the cylin der rod should a hydr aulic line rup­ture or leak develop between t he cylin der and it s relat ed
control valve.

2.6 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is repl ac ed o r wh en im pro pe r syste m
operation is suspected.

Cylinder Without Counterbalance Valves
(Steer, Master, and Rotate)

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

2. Carefully disconnect hydraulic ho se from retra ct port
of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container.
After initial discharge, there should be no further
leakage from the retract port.

3. Activate hydraulic system, and activate cylinder
extend function.

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

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

6. Activate hydraulic system and activate cylinder
retract function. 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.

Cylinders With Single Counterbalanc e Valve
(Upper Lift Cylinder)

SECTION 2 - PROCEDURES

WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE
THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
APPROXIMATELY 2.5 CM BELOW THE MAIN BOOM. IF WORKING
ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALF­WAY, FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD
CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING APPROXI­MATELY 2.5 CM OF SLACK IN CHAIN O R SLING FOR TEST PUR­POSES.

2. After completing the above, shut down hydraulic
system and allow machine to si t for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appro­priate cylinder port block.

3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.

4. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.

5. Remove boom prop/overhead crane, activate
hydraulic sy s t e m and run cyl inder throug h complete
cycle to check for leaks and operation.

Cylinders With Dual Counterb alance Valve
(Lower Lift, Mid Lift, Telescope, and Sla ve
Cylinders)

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

1. Using all applicable safety precautions, activate
hydraulic system.

WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
ONLY.

1. Using all applicable safety precautions, activate
hydraulic system.

APPROXIMATELY 2.5 CM BELOW THE MAIN BOOM. IF WORKING
ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALF­WAY, FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD
CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING APPROXI­MATELY 2.5 CM OF SLACK IN CHAIN O R SLING FOR TEST PUR­POSES.

3120884 – JLG Lift – 2-7

SECTION 2 - PROCEDURES

2. When working on the platform slave cylinder, stroke
platform slave level cylinder forward until platform
sits at a 45 degree angle.

3. After completing the above, shut down hydraulic
system and allow machine to sit f or 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appro­priate cylinder port block.

4. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.

5. To check piston seals, carefully remove the counter­balance valve from the retract port. After initial dis­charge there should not be any further leakage from
the ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.

6. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.

7. Remove boom prop/overhead crane, activate
hydraulic system and run cylinder through complete
cycle to check for leaks and operation.

source. Adequa te ly s upport the cylinder rod, if appli­cable.

3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis­card o-rings.

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

Figure 2-3. Cylinder Barrel Support

5. Mark cylinder head and barrel with a center punch
for easy realignment. Using an allen wrench, loosen
the cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.

2.7 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the c ylinde rs on th is mac hine. Pr ocedur es that
apply to a specific cylinder will be so noted.

Disassembly

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

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

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

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

NOTE: St eps 6 applies only t o the lower lift and tele scope

6. Using a spanner wrench, loosen the end cap or

7. Attach a suitable pulling device to the cylinder rod

2-8 – JLG Lift – 3120884

Figure 2-4. Capscrew Removal

cylinders.

head retainer, and remove from cylinder barrel.

port block end or cylinder rod end, as applicable.

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

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

SECTION 2 - PROCEDURES

12. Remove the bushing from the piston.

Figure 2-6. Tapered Bushing Removal

13. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.

14. Remove and discard the piston o-rings, seal rings,
and backup rings.

Figure 2-5. Cylinder Rod S upport

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

10. Loosen and remove the cap screw(s), i f applicable,
which attach the tapered bushing to the piston.

11. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.

15. Remove piston spa cer, if applicable, from the rod.

16. Remove the rod from the holding fixture. Remove
the cylinder head gland an d retainer plate, if app lica­ble. Discard the o-rings, back-up rings, rod seals,
and wiper seals.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.

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 b arrel fo r dam age. Dress
threads as necessary.

6. Inspect pist on surface f or damage and s coring and
for distortion. Dress piston surface or replace piston
as necessary.

7. Inspect threaded portion of piston for damage.
Dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

3120884 – JLG Lift – 2-9

SECTION 2 - PROCEDURES

Figure 2-7. Gar-Max Bearing Installation

9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.

10. Inspect threaded portion of head for damage. Dress
threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec­essary.

12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.

13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs,

dirt etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other damage.

If steel bushing is worn o r damaged, rod/bar rel
must be replaced.

c. Lubricate inside of the steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is us ed . Se e your JLG Parts Manua l.
Apply a light film of hydraulic oil to all components

prior to assembly.

1. A speci al tool is use d to install a new rod seal into
the applicable cylinder head gland groove.

NOTE: Install pin into the Gar-Max bearing dry. Lubrication

is not required with nickel plated pins and bearings.

14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.

15. If applic able, inspect port block fitt ings and holdi ng
valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other
damage. Replace as nece s sa ry.

Figure 2-8. Rod Seal Installation

WHEN INSTALLING "POLY-PAK" PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA­TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.

2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland
groove.

Figure 2-9. Wiper Seal Installation

2-10 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

3. Place a new o-ring and back-up seal in the applica­ble outside diameter groove of the cylinder head.

Figure 2-10. Installation of Head Seal Kit

4. Install washer ring onto rod, careful ly instal l the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod.

6. If applicable, correctly place new o-ring in the inner
piston diameter gr oove. (The backup ring side fac­ing the O-ring is grooved.)

7. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D.of the pis­ton is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on

one side. This side faces the solid seal.(See magni­fied insert in Figure 2-11.)The split of seals and
backup rings are to be positioned so as not to be in
alignment with each other.

Figure 2-11. Piston Seal Kit Installation

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

9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.

10. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.

NOTE: When installing the tapered bushing, piston and ma t-

ing end of rod must be free of oil.

WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER,
OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED
BUSHING BOLTS, THEN TIGHTEN SECURELY.

3120884 – JLG Lift – 2-11

SECTION 2 - PROCEDURES

Figure 2-12. Tapered Bushing Installation

11. Assemble the tapered bushing loosely into the pis­ton and insert JLG capscrews (not vendor cap­screws) through the drilled holes in the bushing and
into the tapped holes in the piston.

12. Tighten the capscrews evenly and progressively in
rotation to the specified torque value. (See T able 2-1,
Cylinder Head and Tapered Bushing Torque Specifi­cations.)

13. After the screws have been torqued, tap the tapered
bushing with a hammer (500 to 750 gram) and brass
shaft (approximately 19 mm in diameter) as follows;

b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces
between the capscrews.

Figure 2-13. Seating the Tapered Bearing

14. Retorque the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 2-1,
Cylinder Hea d an d Tapered Bushing Torque Specifi­cations.)

15. Remove the cylinder rod from the holding fixture.

16. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 2-11., Piston Seal Kit Installation)

a. Place the shaf t against the cylinder rod and in

contact with the bushing in the spaces between
the capscrews.

Figure 2-14. Poly-Pak Piston Seal Installat ion

2-12 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

17. Position the cylinder barrel in a suitable holding fix­ture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, A ND PISTON. AVOID PULLING TH E ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.

18. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.

19. Continue pushing the rod into the barrel until the cyl­inder head gland can be inserted into the barrel cyl­inder.

20. Secure the cylinder head gland using the washer
ring and socket head bolts.

Table 2-1.Cylinder Head and Tapered Bushing Torque

Specifications

Description

E.A.R. Cylinder

Level Cylinder (M45AJ)

Master Cylinder

(M45AJ)

Table 2-2. Cylinder Piston Nut Torque Specifications)

Description

Upper
Lift Cylinder

Mid
Lift Cylinder

Head Torque V alue

(Wet)

30 ft. lbs
(41 Nm)

30 ft. lbs
(41 Nm)

30 ft. lbs.

(41 Nm)

Nut Torque
Valve (Wet)

200 ft. lbs.

(270 Nm)

400 ft. lbs.

(542 Nm)

Tapered Bushing

Torque Value (Wet)

5 ft. lbs.

(7 Nm)

5 ft. lbs.

(7 Nm)

5 ft. lbs.

(7 Nm)

Setscrew

Torque Value

(Dry)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

Figure 2-15. Rod Assembly Installation

21. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.

22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 2-3, Holding Valve Torque
Specifications).

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATIO N ON
THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE
EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR O THER
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD.

Lower
Lift Cylinder

Level Cylinder (M45 A) 80 ft. lbs.

Master Cylinder
(M45A)

Table 2-3. Holding Valve Torque Specificatio ns

Description Torque Value

SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

RACINE - 1 3/8 HEX 1 3/16 - 12 THDS. 75-80 ft. lbs.

400 ft. lbs.

(542 Nm)

(108 Nm)

80 ft. lbs.

(108 Nm)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

(41-48 Nm)

(61-68 Nm)

(204-217 Nm)

(68-75 Nm)

(102-109 Nm)

RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs.

(136-149 Nm)

3120884 – JLG Lift – 2-13

SECTION 2 - PROCEDURES

Figure 2-16. Upper Boom Lift Cy linder Removal

2.8 CYLINDER REMOVAL AND
INSTALLATION

Upper (Main) Boom Lift Cylinder Removal

1. Place the machine on a flat and level surface. Place
the Upper Boom in a horizontal position. Place
Lower and Mid Booms 5 degree above horizontal.
Shut down machine and prop boom.

2. Tag, disco nnec t a nd ca p th e up per boom lift cylind er
hydraulic lines and ports.

3. Remove the hardware securing the cylinder rod
attach pin #1 to the boom. Using a suitable brass
drift, drive out the cylinder rod attach pin #1.

3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.

4. With function speed switch at its slowest setting,
extend the cylinder rod until attach pin hole aligns
with those in boom. Using a suitable drift, drive the
cylinder rod attach pin #1 through the aligned
holes. Secure the pin in place with pin retaining
hardware.

5. Cycle cylinder completely to check for proper func­tioning. Place boom in stowed position. Check
hydraulic fluid level and adjust accordingly.

Mid Boom Lift Cylinder Removal

1. Place machine on flat and level surface. Place the
Upper Boom in a horizontal position. Place the Mid
Boom in a 10 degree elevated position. Support
Upper Boom with a prop. Support upright with an
overhead cran e.

2. Using slings, restrain the lower lift cylinder.

3. Remove the hardware securing the cylinder rod
attach pin #3 to the boom. Using an appropriate
brass drift, drive out the cylinder rod attach pin #3.

4. Secure the cylinder with suitable slings or supports
as required. Remove the hardware securing the bar­rel end attach pin #2. Using a suitable brass drift,
drive out the barrel end attach pin #2.

5. Remove the cylinder from the boom and place in a
suitable work area.

Upper (Main) Boom Lift Cylinder In stallation

NOTE: Coat I.D. of bushings with specified lubricant prior to

installing pins.

1. Install Lift Cylinder in place using suitable slings or
supports, aligning attach pin mounting holes on
upright.

2. Using a suitable drift, drive the barrel end attach pin
#2 through the mounting holes in the lift cylinder
and upright. Secure in place with pin retaining hard­ware.

Figure 2-17. Mid Boom Lift Cylinder Removal

4. Tag, disconnect and cap the lift cylinder hydraulic
lines and ports.

5. Remove the hardware securing the barrel end attac h
pin #4 to the boom. Using an appropriate brass
drift, drive out the cylinder barrel pin #4.

6. Carefully remove cylinder from boom. Place in a
suitable work area.

2-14 – JLG Lift – 3120884