JLG T500J Service Manual

Service & Maintenance Manual

Model

T500J

3121200

January 9, 2013

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

C MAINTENANCE

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

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

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

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

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

B HYDRAULIC SYSTEM SAFETY

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

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

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

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

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

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

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

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

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

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

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

•BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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A-1

INTRODUCTION

	REVISON LOG
Original Issue	- January 15, 2005
Revised	- July 15, 2005
Revised	- August 26, 2005
Revised	- December 12, 2005
Revised	- February 24, 2006
Revised	- May 1, 2007
Revised	- September 28, 2011
Revised	- January 9, 2013

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TABLE OF CONTENTS

SECTION NO.

TITLE

PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

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

1.3 Electric Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

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

1.7 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.9 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.10 Operator Maintenance & 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 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

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

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

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2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6

SECTION 3 - CHASSIS & TURNTABLE

3.1 Breaking-in a New Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Retighten Lug Nuts at First 10, 25 & 50 Miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Adjust Brake Shoes at First 200 Miles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Synchronizing the Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Trailer inspection and Service Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Fasteners and Frame Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Brake Shoes and Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Manually Adjusting Brake Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Electric Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Brake Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Brake Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Shoes and Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Hydraulic (Surge) Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Self Adjusting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 Hubs, Drums, Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Brake Drum Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Bearing Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Seal Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.6 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Lug Nuts (Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.7 Hydraulic brake Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Backing Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Extended Storage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Proper Towing Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.8 Combination Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Servicing the Emergency Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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3.9 Hitch Coupler & Axle (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 Ball Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Coupling Head Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Damper Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Adjustment and Readjustment of the Overrun Braking System . . . . . . . . . . . . . . . . . . . . . . 3-24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10 Coupler Assembly (S/N 0030002099 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 Engaging Manual Lockout Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Servicing the Breakaway Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Actuator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Coupler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11 Trailer Jack (Solid wheels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.12 Swing Motor (Prior to S/N 0030000960) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Shaft Timing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3.13 Swing Motor (S/N 0030001050 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3.14 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51 Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3.15 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56 Throttle & Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Fuel Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Checking RPM Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Choke Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Checking Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3.16 Outrigger cylinder and Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

3.17 Outrigger Limit SwitchEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63 3.18 Procedure For Retracting Outriggers Using Service Harness (Optional) . . . . . . . . . . . . . . . . . . .3-63

3.19 Leveling, Tilt sensor calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64 When Machine Is on a Firm Level Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure: . . . . . . . . 3-65

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3.20 Drive & Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66

Drive & Set Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

3.21 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71

Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

3.22 Batteries (Electric Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Quarterly Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

3.23 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

Shunt Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

Interlock Relay Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

SCR Rectifier Replacement (Either Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

AC Circuit Breaker Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

DC Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

3.24 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-95

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

Battery Charger Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

SECTION 4 - BOOM & PLATFORM

4.1 Boom and Cylinder AssemblY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

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

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

4.4 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

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

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

4.6 Boom Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Boom Elevation Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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SECTION 5 - HYDRAULICS

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

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

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

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

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

5.2 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.3 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Telescope In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Telescope Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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

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

Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Outrigger Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.4 Hydraulic Oil Fill at Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5.5 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5.6 Hydraulic Filter and Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

SECTION 6 - JLG CONTROL SYSTEM

6.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-1
6.2	To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-2
6.3	Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-2
6.4	Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-3
6.5	Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-4
6.6	Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-5
6.7	System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-9
	Platform Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-9
	Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-11
6.8	User Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-12
6.9	Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-23
	Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-23

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PAGE NO.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 Basic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Switch Wiring - Low Side, High Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-4 7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

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LIST OF FIGURES

FIGURE NO.

TITLE

PAGE NO.

1-1. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 3-1. Electric Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 3-2. Hydraulic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 3-3. Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 3-4. Spare Tire (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 3-5. Hydraulic Brake Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 3-6. Combination Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 3-7. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 3-8. Overrun Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 3-9. Coupler Assembly - S/N 0030002099 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 3-10. Seal Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32 3-11. Notch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 3-12. Timing Mark. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34 3-13. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35 3-14. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37 3-15. Swing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51 3-16. Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52 3-17. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53 3-18. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55 3-19. Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59 3-20. Outrigger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62 3-21. Drive and Set - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68 3-22. Drive and Set - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69 3-23. Drive and Set Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70 3-24. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72 3-25. Battery and Contactor Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-87 3-25. Battery and Contactor Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88 3-25. Battery Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89 3-26. Battery Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-93 3-27. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94 4-1. Boom and Cylinders Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 5-1. Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 5-2. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 5-3. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5-4. Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 5-5. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 5-6. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 5-7. Hydraulic Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 5-8. Control Valve Torque Values - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 5-8. Control Valve Torque Values - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 5-8. Drive Directional Valve Identification - Drive & Set Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 5-9. Drive Directional Valve Torque Values - Drive & Set Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 5-10. Drive Enable Valve Identification - Drive & Set Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 5-11. Hydraulic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-2. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 6-3. Analyzer Flow Chart - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 6-4. Analyzer Flow Chart - Personalties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 6-5. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 6-6. System Test Flow Chart - Ground Station Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

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LIST OF FIGURES

FIGURE NO.

TITLE

PAGE NO.

6-7. Ground Module - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 6-8. Ground Module - Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 6-9. Ground Module - Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 6-10. Ground Module - Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 6-11. Ground Module - Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18 7-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 7-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3 7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-18. Chassis Wiring Harness and Connectors - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 7-19. Chassis Wiring Harness and Connectors - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 7-20. Controller and Valve Body Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 7-21. Electrical Schematic (Boom Operations) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 7-22. Electrical Schematic (Boom Operations) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19 7-23. Electrical Schematic (Trailer) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 7-24. Electrical Schematic (Trailer) - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21 7-25. Electrical Schematic (Trailer) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 7-26. Hydraulic Schematic - Electric Machines - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24 7-27. Hydraulic Schematic - Electric Machines - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 7-28. Hydraulic Schematic - Gas Machines - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 7-29. Hydraulic Schematic - Gas Machines - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27 7-30. Hydraulic Schematic - Drive Option (Gas) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 7-31. Hydraulic Schematic - Drive Option (Gas) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29 7-32. Hydraulic Schematic - Drive Option (Electric) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 7-33. Hydraulic Schematic - Drive Option (Electric) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

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LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

1-1 Operating & Towing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1-3 Electric Power Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1-6 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-8 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-9 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-10 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

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

2-3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

3-1 Tire Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-2 Wheel Torque Chart - ANSI, ANSI Export, CSA, Aus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-3 Wheel Torque Chart - CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4 Surge Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-5 Malfunctions and Remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-25 Battery Charger Fault Codes (Delta-Q). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-95

5-1 Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-2 Control Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

6-1 User Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-2 Machine Model Adjustments and Speeds - ANSI & CSA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

6-3 Machine Model Adjustments and Speeds - CE Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-5 Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

7-1 Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

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LIST OF TABLES

TABLE NO.

TITLE

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SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1OPERATING SPECIFICATIONS

Table 1-1. Operating & Towing Specifications

	Tongue Weight (ANSI):	350 lbs.(154 kg)
	Maximum Allowable Tow Speed:	65 mph
	(Do NOT exceed legal speed limit)	(105 kph)
	Maximum Work Load (Capacity)	440 lbs.
	w/Rotator	(200 kg)
	Maximum Work Load (Capacity)	500 lbs.
	w/o Rotator	(230 kg)
	Maximum Work Load (Capacity)	320 lbs.
	w/Rotator & Panel Tray	(145 kg)
	Maximum Work Load (Capacity)	350 lbs.
	w/o Rotator & w/Panel Tray	(158 kg)
	Material Hook Capacity (Optional)	500 lbs.(230 kg)
	Accessory Tray Capacity	250 lbs.*(114 kg)
	Panel Tray Capacity (w/Rotator)	70 lbs. (32 kg)
	Panel Tray Capacity (w/o Rotator)	100 lbs.(45 kg)
	Swing	410° non-continuous
	Max.Vertical Platform Height (Unrestricted)	50 ft. (15.2 m)
	Vertical Reach (unrestricted)	50 ft. (15.2 m)
	Horizontal Reach
	(from centerline of machine)	31 ft. (9.45 m)
	(from outrigger pad edge)	25 ft. (7.62 m)
	Up and Over Clearance	18 ft. (5.49 m)
	Maximum Outrigger Load	2660 (1206.5 kg)
	Maximum Ground Bearing Pressure	30.7 psi (2.15 kg/cm2)
	Maximum Travel Gradeability - ANSI, CSA,	20%
	AUS
	Maximum Travel Gradeability - CE	15%
	Maximum Sideslope - ANSI, CSA, AUS	11°
	Maximum Sideslope - CE	8.5°
	Max. Hydraulic System Pressure	2950 psi (203 Bar)
	Maximum Operating Wind Speed	28 mph (12.5 m/s)
	Maximum Horizontal Manual Force	90 lb. force (400 N)
	Electrical System Voltage - Electric Machine	24 Volts
	Electrical System Voltage - Gas Machine	12 Volts
	Gross Machine Weight (Platform Empty)	4750 lbs. (2155 kg)
	ANSI Machines/CSA/AUS
	Gross Machine Weight (Platform Empty)	5776 lbs. (2620 kg)
	CE Machines

* DO NOT exceed axle rating or GVW rating.

1.2CAPACITIES

Table 1-2. Capacities

Fuel Tank	1.6 Gal. (6.0 L)
Hydraulic Tank
Filling Volume	6.9 Gallon (26.1 Liters)
Usable Volume	6.3 Gallon (23.8 Liters)

1.3ELECTRIC POWER UNIT

Table 1-3. Electric Power Unit Specifications

		@ 740PSI	@1500PSI	@ 3000PSI
		(51 Bar)	(103 Bar)	(207 Bar)
Motor	Power	3.0 kW	3.0 kW	3.0 kW
	Voltage	24 VDC	24 VDC	24 VDC
	Amperage	90	140	230
	Speed	4000 rpm	3600 rpm	2900 rpm
	Short Term	9 minutes	6 minutes	2 minutes
	Operation
	Intermittent	28%	19%	10%
	Operation
Pump	Flow Rate	3.0 gpm	2.7 gpm	2.2 gpm
		(11.3 lpm)	(10.2 lpm)	(8.3 lpm)
	Displacement		0.192 cu.in.
			(3.15 cc)

1.4TIRES

Table 1-4. Tire Specifications

	(ANSI)	(CE)
Size	225-75-R15	225/75-R16
Load Rating	2540 lbs. @ 60 psi	3195 lbs. @ 83 psi
	(1152 kg @ 414 kPa)	(1449 kg @ 575 kPa)
Ply Rating/Load Range	6/D	10/E
Inflation Pressure	65 psi (448 kPa)	60 psi (414 kPa)
Wheel Nut Torque	221 ft. lbs.	90-120 ft. lbs.
	(300 Nm)	(122-164 Nm)

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SECTION 1 - SPECIFICATIONS

1.5ENGINE

Battery

Table 1-5. Battery Specifications

BCI Group Size	51R
Cranking Performance	550 amps @ 32°F (0°C)
	450 amps @ 0°F (-18°C)
Reserve Capacity	80 minutes @ 32°F (0°C)

1.6DIMENSIONAL DATA

Table 1-6. Dimensional Data

Overall Length
Surge Brake, 2" ball	26 ft 9.75 in (8.2 m)
Electric Brake	26 ft 8 in (8.1 m)
Surge Brake Combination	26 ft 10.25 in (8.2 m)
Overall Height ANSI	6 ft 7.25 in (2 m)
Overall Height CE	7 ft 0.5 in (2.1 m)
Overall Width - (outriggers up)	5ft 10.25 in (1.8 m)
Overall Width (outriggers down - ANSI)	12 ft 7.75 in (3.9 m)
Overall Width (outriggers down - CE)	13 ft 5.25 in (4.1 m)

1.7 LUBRICATION

Hydraulic Oil

Table 1-7. Hydraulic Oil

	Hydraulic System	S.A.E. Viscosity
	Operating
		Grade
	Temperature Range
	+0° to + 180° F	10W
	(-18° to +83° C)
	+0° to + 210° F	10W-20, 10W30
	(-18° to +99° C)
	+50° to + 210° F	20W-20
	(+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. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152.

NOTE: When temperatures remain consistently below 20° F. (-7° C.), JLG Industries recommends the use of Mobil DTE13.

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

Table 1-8. Mobilfluid 424 Specs

SAE Grade		10W30
Gravity, API		29.0
Density, Lb/Gal. 60°F		7.35
Pour Point, Max		-46°F (-43°C)
Flash Point, Min.		442°F (228°C)
Viscosity
Brookfield, cP at -18°C		2700
at 40° C		55 cSt
at 100° C		9.3 cSt
Viscosity Index		152

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SECTION 1 - SPECIFICATIONS

1.8MAJOR COMPONENT WEIGHTS

Table 1-9. Component Weights

Component	Pounds	Kilograms
Frame (bare)	597	271
Frame - CE, Aus (bare)	892	382
Turntable (bare)	262	119
Booms & Cylinders Assy.	1891	859
Main Boom	957	435
Engine Assy. (Incl. Tray)	116	53
Engine (bare)	57	26
Axle	221	100

1.9PRESSURE SETTINGS

Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within

± 5% of specified pressures.

Table 1-10. Pressure Settings

Circuit	PSI	Bar
Main Relief	2950	203.5
Telescope In	2850	196.5
Telescope Out	2400	166
Platform Level Up	2800	193
Platform Level Down	2000	138
Swing Right	600-800	41-55
Swing Left	600-800	41-55
Outrigger Up	2500	172.5

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SECTION 1 - SPECIFICATIONS

1.	Wheel Bearings	5.	Swing Bearing Teeth	9.	Trailer Jack
2.	Hydraulic Oil	6.	Swing Drive	10.	Surge Brake
3.	Hydraulic Filter & Breather	7.	Engine	11.	Coupler & Hitch Ball
4.	Swing Bearing	8.	Fuel Tank	12.	Jockey Wheel Bearing

Figure 1-1. Operator Maintenance & Lubrication Diagram

1.10OPERATOR MAINTENANCE & LUBRICATION

NOTE: Lubrication intervals are based on machine operation under normal conditions. For machines used in multi shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

	Table 1-11.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. API Service Classification GL-3, SAE
		10W-20, Viscosity Index 152, e.g. Mobilfluid 424.
EO		Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-
		2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-
		2104C.
OGL		Open Gear Lubricant - Mobiltac 375 or equivalent.

1. Wheel Bearings

Lube - MPG

Interval - every 12 months or 12,000 miles Comments - Refer to Section 3.5, Hubs, Drums, Wheel Bearings

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SECTION 1 - SPECIFICATIONS

2. Hydraulic Oil

Lube Point(s) - Fill Cap Capacity - 4 gal. (15.1 L) Lube - HO

Interval - Check oil daily, change after, then every 1200 hours of operation.

3. Hydraulic Filter & Breather

4. Swing Bearing

Lube Point(s) - 1 Grease Fitting Capacity - As Required

Lube - MPG

Interval - Every month or 50 hours

Comments - Rotate the bearing back and forth

to ensure grease is distributed evenly the whole way around the bearing.

5.Swing Bearing Teeth

Lube Point(s) - Spray On Capacity - As Required Lube - OGL

Interval - Every month or 50 hours

Comments - More frequent lubrication intervals may be required.

6.Swing Drive

NOTE: The cap securing the filter must be torqued 154 to 170 ft.lbs. (209 to 230.5 Nm).

Interval - 100 hours

Comments - Change after the first 20 hours, then every 100 hours of operation.

Lube Point(s) - 2 Grease Fittings

Capacity - As Required

Lube - MPG

Interval - As Required

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

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SECTION 1 - SPECIFICATIONS

7. Engine

Capacity - See Engine Manual. Lube - EO, 10W30 API SJ

Interval - Check level daily; change per manufacturer’s engine manual.

Comments - Adjust final oil level by mark on dipstick 8. Fuel Tank

Capacity - 1.6 Gal. (6.0 L) Fuel - Gasoline

Interval - Check periodically during each shift 9. Trailer Jack

OIL

GREASE

Capacity - As necessary

Lube - MPG & EO

Interval - As necessary

10. Surge Brake

Lube Point(s) - Fill Cap

Capacity - No more than 1/2" (13 mm) from top of reservoir

Lube - DOT 3 or 4 Brake Fluid

Interval - Check before each tow. Flush the system yearly or when system is known to be contaminated

11. Coupler & Hitch Ball

Capacity - Coupler 2 Grease Fittings (CE Only); Hitch Ball

As necessary Lube - MPG

Interval - As necessary

12. Jockey Wheel Bearing (Drive and Set Option Only)

Lube Point(s) - 1 Grease Fittings

Capacity - As Required

Lube - MPG

Interval - As Required

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3121200

SECTION 1 - SPECIFICATIONS

				Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
						SAE GRADE 5 BOLTS & GRADE 2 NUTS
											Torque				Torque
			Tensile		Torque			Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia		Clamp Load												TM	or Vibra-
			Stress Area			(Dry)		Lubricated			OR Vibra-TITE		TM	111 or	(Loctite® 262
															TITETM 131)
											140)
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]		IN-LB		[N.m]
4	40	0.1120	0.00604	380	8		0.9	6		0.7
	48	0.1120	0.00661	420	9		1.0	7		0.8
6	32	0.1380	0.00909	580	16		1.8	12		1.4
	40	0.1380	0.01015	610	18		2.0	13		1.5
8	32	0.1640	0.01400	900	30		3.4	22		2.5
	36	0.1640	0.01474	940	31		3.5	23		2.6
10	24	0.1900	0.01750	1120	43		4.8	32		3.5
	32	0.1900	0.02000	1285	49		5.5	36		4
1/4	20	0.2500	0.0318	2020	96		10.8	75		9	105		12
	28	0.2500	0.0364	2320	120		13.5	86		10	135		15
		In	Sq In	LB	FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m]		FT-LB		[N.m]
5/16	18	0.3125	0.0524	3340	17		23	13		18	19		26		16		22
	24	0.3125	0.0580	3700	19		26	14		19	21		29		17		23
3/8	16	0.3750	0.0775	4940	30		41	23		31	35		48		28		38
	24	0.3750	0.0878	5600	35		47	25		34	40		54		32		43
7/16	14	0.4375	0.1063	6800	50		68	35		47	55		75		45		61
	20	0.4375	0.1187	7550	55		75	40		54	60		82		50		68
1/2	13	0.5000	0.1419	9050	75		102	55		75	85		116		68		92
	20	0.5000	0.1599	10700	90		122	65		88	100		136		80		108
9/16	12	0.5625	0.1820	11600	110		149	80		108	120		163		98		133
	18	0.5625	0.2030	12950	120		163	90		122	135		184		109		148
5/8	11	0.6250	0.2260	14400	150		203	110		149	165		224		135		183
	18	0.6250	0.2560	16300	170		230	130		176	190		258		153		207
3/4	10	0.7500	0.3340	21300	260		353	200		271	285		388		240		325
	16	0.7500	0.3730	23800	300		407	220		298	330		449		268		363
7/8	9	0.8750	0.4620	29400	430		583	320		434	475		646		386		523
	14	0.8750	0.5090	32400	470		637	350		475	520		707		425		576
1	8	1.0000	0.6060	38600	640		868	480		651	675		918		579		785
	12	1.0000	0.6630	42200	700		949	530		719	735		1000		633		858
1 1/8	7	1.1250	0.7630	42300	800		1085	600		813	840		1142		714		968
	12	1.1250	0.8560	47500	880		1193	660		895	925		1258		802		1087
1 1/4	7	1.2500	0.9690	53800	1120		1518	840		1139	1175		1598		1009		1368
	12	1.2500	1.0730	59600	1240		1681	920		1247	1300		1768		1118		1516
1 3/8	6	1.3750	1.1550	64100	1460		1979	1100		1491	1525		2074		1322		1792
	12	1.3750	1.3150	73000	1680		2278	1260		1708	1750		2380		1506		2042
1 1/2	6	1.5000	1.4050	78000	1940		2630	1460		1979	2025		2754		1755		2379
	12	1.5000	1.5800	87700	2200		2983	1640		2224	2300		3128		1974		2676
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS														NO. 5000059		REV. J

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3.* ASSEMBLY USES HARDENED WASHER

	REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N	Loctite® P/N		ND Industries P/N	Description
0100011	242TM		Vibra-TITETM 121	Medium Strength (Blue)
0100019	271TM		Vibra-TITETM 140	High Strength (Red)
0100071	262TM		Vibra-TITETM 131	Medium - High Strength (Red)

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

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SECTION 1 - SPECIFICATIONS

				SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
						Torque			Torque			Torque
			Tensile						(Loctite® 242TM or 271TM			(Loctite® 262TM or Vibra-
Size	TPI	Bolt Dia	Stress Area	Clamp Load		(Dry or Loctite® 263)			OR Vibra-TITETM 111 or			TITETM 131)
						K= 0.20			140)		K=.18	K=0.15
		In	Sq In		LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]
4	40	0.1120	0.00604
	48	0.1120	0.00661
6	32	0.1380	0.00909
	40	0.1380	0.01015
8	32	0.1640	0.01400
	36	0.1640	0.01474	1320		43		5
10	24	0.1900	0.01750	1580		60		7
	32	0.1900	0.02000	1800		68		8
1/4	20	0.2500	0.0318	2860		143		16	129		15
	28	0.2500	0.0364	3280		164		19	148		17
		In	Sq In	LB		FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m
5/16	18	0.3125	0.0524	4720		25		35	20		25	20		25
	24	0.3125	0.0580	5220		25		35	25		35	20		25
3/8	16	0.3750	0.0775	7000		45		60	40		55	35		50
	24	0.3750	0.0878	7900		50		70	45		60	35		50
7/16	14	0.4375	0.1063	9550		70		95	65		90	50		70
	20	0.4375	0.1187	10700		80		110	70		95	60		80
1/2	13	0.5000	0.1419	12750		105		145	95		130	80		110
	20	0.5000	0.1599	14400		120		165	110		150	90		120
9/16	12	0.5625	0.1820	16400		155		210	140		190	115		155
	18	0.5625	0.2030	18250		170		230	155		210	130		175
5/8	11	0.6250	0.2260	20350		210		285	190		260	160		220
	18	0.6250	0.2560	23000		240		325	215		290	180		245
3/4	10	0.7500	0.3340	30100		375		510	340		460	280		380
	16	0.7500	0.3730	33600		420		570	380		515	315		430
7/8	9	0.8750	0.4620	41600		605		825	545		740	455		620
	14	0.8750	0.5090	45800		670		910	600		815	500		680
1	8	1.0000	0.6060	51500		860		1170	770		1045	645		875
	12	1.0000	0.6630	59700		995		1355	895		1215	745		1015
1 1/8	7	1.1250	0.7630	68700		1290		1755	1160		1580	965		1310
	12	1.1250	0.8560	77000		1445		1965	1300		1770	1085		1475
1 1/4	7	1.2500	0.9690	87200		1815		2470	1635		2225	1365		1855
	12	1.2500	1.0730	96600		2015		2740	1810		2460	1510		2055
1 3/8	6	1.3750	1.1550	104000		2385		3245	2145		2915	1785		2430
	12	1.3750	1.3150	118100		2705		3680	2435		3310	2030		2760
1 1/2	6	1.5000	1.4050	126500		3165		4305	2845		3870	2370		3225
	12	1.5000	1.5800	142200		3555		4835	3200		4350	2665		3625
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS											NO. 5000059		REV. J

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3.* ASSEMBLY USES HARDENED WASHER

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

1-8

– JLG Lift –

3121200

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
					Magni Coating (Ref 4150701)*
							Torque			Torque
							(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load	Torque					(Loctite® 262TM
			Stress Area	See Note 4	(Dry)	K = .17	OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
							140 OR Precoat 85®
										K=0.15
							K=0.16
		In	Sq In	LB	IN-LB	[N.m]	IN-LB		[N.m]	IN-LB		[N.m]
4	40	0.1120	0.00604
	48	0.1120	0.00661
6	32	0.1380	0.00909
	40	0.1380	0.01015
8	32	0.1640	0.01400
	36	0.1640	0.01474
10	24	0.1900	0.01750
	32	0.1900	0.02000
1/4	20	0.2500	0.0318	2860	122	14	114		13
	28	0.2500	0.0364	3280	139	16	131		15
		In	Sq In	LB	FT-LB	[N.m]	FT-LB		[N.m]	FT-LB		[N.m]
5/16	18	0.3125	0.0524	4720	20	25	20		25	20		25
	24	0.3125	0.0580	5220	25	35	20		25	20		25
3/8	16	0.3750	0.0775	7000	35	50	35		50	35		50
	24	0.3750	0.0878	7900	40	55	40		55	35		50
7/16	14	0.4375	0.1063	9550	60	80	55		75	50		70
	20	0.4375	0.1187	10700	65	90	60		80	60		80
1/2	13	0.5000	0.1419	12750	90	120	85		115	80		110
	20	0.5000	0.1599	14400	100	135	95		130	90		120
9/16	12	0.5625	0.1820	16400	130	175	125		170	115		155
	18	0.5625	0.2030	18250	145	195	135		185	130		175
5/8	11	0.6250	0.2260	20350	180	245	170		230	160		220
	18	0.6250	0.2560	23000	205	280	190		260	180		245
3/4	10	0.7500	0.3340	30100	320	435	300		410	280		380
	16	0.7500	0.3730	33600	355	485	335		455	315		430
7/8	9	0.8750	0.4620	41600	515	700	485		660	455		620
	14	0.8750	0.5090	45800	570	775	535		730	500		680
1	8	1.0000	0.6060	51500	730	995	685		930	645		875
	12	1.0000	0.6630	59700	845	1150	795		1080	745		1015
1 1/8	7	1.1250	0.7630	68700	1095	1490	1030		1400	965		1310
	12	1.1250	0.8560	77000	1225	1665	1155		1570	1085		1475
1 1/4	7	1.2500	0.9690	87200	1545	2100	1455		1980	1365		1855
	12	1.2500	1.0730	96600	1710	2325	1610		2190	1510		2055
1 3/8	6	1.3750	1.1550	104000	2025	2755	1905		2590	1785		2430
	12	1.3750	1.3150	118100	2300	3130	2165		2945	2030		2760
1 1/2	6	1.5000	1.4050	126500	2690	3660	2530		3440	2370		3225
	12	1.5000	1.5800	142200	3020	4105	2845		3870	2665		3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)

3121200

– JLG Lift –

1-9

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
				Zinc Yellow Chromate Fasteners (Ref 4150707)*
								Torque			Torque
					Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load							(Loctite® 262TM
			Stress Area	See Note 4	(Dry)			OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
					K = .20			140 OR Precoat 85®
											K=0.15
								K=0.18
		In	Sq In	LB	IN-LB		[N.m]	IN-LB		[N.m]	IN-LB		[N.m]
4	40	0.1120	0.00604
	48	0.1120	0.00661
6	32	0.1380	0.00909
	40	0.1380	0.01015
8	32	0.1640	0.01400
	36	0.1640	0.01474
10	24	0.1900	0.01750
	32	0.1900	0.02000
1/4	20	0.2500	0.0318	2860	143		16	129		15
	28	0.2500	0.0364	3280	164		19	148		17
		In	Sq In	LB	FT-LB		[N.m]	FT-LB		[N.m]	FT-LB		[N.m]
5/16	18	0.3125	0.0524	4720	25		35	20		25	20		25
	24	0.3125	0.0580	5220	25		35	25		35	20		25
3/8	16	0.3750	0.0775	7000	45		60	40		55	35		50
	24	0.3750	0.0878	7900	50		70	45		60	35		50
7/16	14	0.4375	0.1063	9550	70		95	65		90	50		70
	20	0.4375	0.1187	10700	80		110	70		95	60		80
1/2	13	0.5000	0.1419	12750	105		145	95		130	80		110
	20	0.5000	0.1599	14400	120		165	110		150	90		120
9/16	12	0.5625	0.1820	16400	155		210	140		190	115		155
	18	0.5625	0.2030	18250	170		230	155		210	130		175
5/8	11	0.6250	0.2260	20350	210		285	190		260	160		220
	18	0.6250	0.2560	23000	240		325	215		290	180		245
3/4	10	0.7500	0.3340	30100	375		510	340		460	280		380
	16	0.7500	0.3730	33600	420		570	380		515	315		430
7/8	9	0.8750	0.4620	41600	605		825	545		740	455		620
	14	0.8750	0.5090	45800	670		910	600		815	500		680
1	8	1.0000	0.6060	51500	860		1170	775		1055	645		875
	12	1.0000	0.6630	59700	995		1355	895		1215	745		1015
1 1/8	7	1.1250	0.7630	68700	1290		1755	1160		1580	965		1310
	12	1.1250	0.8560	77000	1445		1965	1300		1770	1085		1475
1 1/4	7	1.2500	0.9690	87200	1815		2470	1635		2225	1365		1855
	12	1.2500	1.0730	96600	2015		2740	1810		2460	1510		2055
1 3/8	6	1.3750	1.1550	104000	2385		3245	2145		2915	1785		2430
	12	1.3750	1.3150	118100	2705		3680	2435		3310	2030		2760
1 1/2	6	1.5000	1.4050	126500	3165		4305	2845		3870	2370		3225
	12	1.5000	1.5800	142200	3555		4835	3200		4350	2665		3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)

1-10

– JLG Lift –

3121200

SECTION 1 - SPECIFICATIONS

					CLASS 8.8 METRIC BOLTS
					CLASS 8 METRIC NUTS
								Torque	Torque
		Tensile			Torque				(Loctite®
Size	PITCH		Clamp				Torque	(Loctite® 262TM	242TM or 271TM
		Stress	Load		(Dry or Loctite®		(Lub)	OR Vibra-	OR Vibra-
		Area			TM
					263 )			TITETM 131)	TITETM 111 or
									140)
		Sq mm		KN	[N.m]		[N.m]	[N.m]	[N.m]
3	0.5	5.03	2.19		1.3		1.0	1.2	1.4
3.5	0.6	6.78	2.95		2.1		1.6	1.9	2.3
4	0.7	8.78	3.82		3.1		2.3	2.8	3.4
5	0.8	14.20	6.18		6.2		4.6	5.6	6.8
6	1	20.10	8.74		11		7.9	9.4	12
7	1	28.90	12.6		18		13	16	19
8	1.25	36.60	15.9		26		19	23	28
10	1.5	58.00	25.2		50		38	45	55
12	1.75	84.30	36.7		88		66	79	97
14	2	115	50.0		140		105	126	154
16	2	157	68.3		219		164	197	241
18	2.5	192	83.5		301		226	271	331
20	2.5	245	106.5		426		320	383	469
22	2.5	303	132.0		581		436	523	639
24	3	353	153.5		737		553	663	811
27	3	459	199.5		1080		810	970	1130
30	3.5	561	244.0		1460		1100	1320	1530
33	3.5	694	302.0		1990		1490	1790	2090
36	4	817	355.5		2560		1920	2300	2690
42	4.5	1120	487.0		4090		3070	3680	4290
								NO. 5000059 REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

3121200

– JLG Lift –

1-11

SECTION 1 - SPECIFICATIONS

					CLASS 10.9 METRIC BOLTS
					CLASS 10 METRIC NUTS
			CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
							Torque	Torque
		Tensile			Torque		(Lub OR Loctite®
Size	PITCH		Clamp		(Dry or Loctite®		242TM or 271TM OR	(Loctite® 262TM OR
		Stress	Load		263TM)		Vibra-TITETM 111 or	Vibra-TITETM 131)
		Area
					K = 0.20		140)	K=0.15
							K= 0.18
		Sq mm		KN	[N.m]		[N.m]	[N.m]
3	0.5	5.03	3.13
3.5	0.6	6.78	4.22
4	0.7	8.78	5.47
5	0.8	14.20	8.85
6	1	20.10	12.5
7	1	28.90	18.0		25.2		22.7	18.9
8	1.25	36.60	22.8		36.5		32.8	27.4
10	1.5	58.00	36.1		70		65	55
12	1.75	84.30	52.5		125		115	95
14	2	115	71.6		200		180	150
16	2	157	97.8		315		280	235
18	2.5	192	119.5		430		385	325
20	2.5	245	152.5		610		550	460
22	2.5	303	189.0		830		750	625
24	3	353	222.0		1065		960	800
27	3	459	286.0		1545		1390	1160
30	3.5	561	349.5		2095		1885	1575
33	3.5	694	432.5		2855		2570	2140
36	4	817	509.0		3665		3300	2750
42	4.5	1120	698.0		5865		5275	4395
							NO. 5000059 REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

1-12

– JLG Lift –

3121200

SECTION 1 - SPECIFICATIONS

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

					Torque	Torque
				Torque	(Lub OR Loctite®
		Tensile				(Loctite® 262TM
Size	PITCH		Clamp Load	(Dry or Loctite®	242TM or 271TM
		Stress	See Note 4	263TM)	OR Vibra-TITETM	OR Vibra-TITE	TM
		Area
				K = .17	111 or 140)	131)
						K = .15
					K = .16
		Sq mm	kN	[N.m]	[N.m]	[N.m]
3	0.5	5.03
3.5	0.6	6.78
4	0.7	8.78
5	0.8	14.20
6	1	20.10	12.5	13	12	11
7	1	28.90	18.0	21	20	19
8	1.25	36.60	22.8	31	29	27
10	1.5	58.00	36.1	61	58	54
12	1.75	84.30	52.5	105	100	95
14	2	115	71.6	170	160	150
16	2	157	97.8	265	250	235
18	2.5	192	119.5	365	345	325
20	2.5	245	152.5	520	490	460
22	2.5	303	189.0	705	665	625
24	3	353	220.0	900	845	790
27	3	459	286.0	1315	1235	1160
30	3.5	561	349.5	1780	1680	1575
33	3.5	694	432.5	2425	2285	2140
36	4	817	509.0	3115	2930	2750
42	4.5	1120	698.0	4985	4690	4395
					NO. 5000059 REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2.ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

4.CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

3121200

– JLG Lift –

1-13

SECTION 1 - SPECIFICATIONS

NOTES:

1-14

– JLG Lift –

3121200

SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

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

3121200

– JLG Lift –

2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start Inspection	Prior to use each day; or	User or Operator	User or Operator	Operator and Safety Manual
		At each Operator change.
	Pre-Delivery	Prior to each sale, lease, or	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	Inspection	rental delivery.		Mechanic	Manual and applicable JLG
					inspection form.
	Frequent Inspection	In service for 3 months or 150 hours, which-	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
		ever comes first; or		Mechanic	Manual and applicable JLG
		Out of service for a period of more than 3			inspection form.
		months; or
		Purchased used.
	Annual Machine	Annually, no later than 13 months from the	Owner, Dealer, or User	Factory-Certified	Service and Maintenance
	Inspection	date of the prior inspection.		Service Technician	Manual and applicable JLG
					inspection form.
	Preventative	At intervals as specified in the Service and	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	Maintenance	Maintenance Manual.		Mechanic	Manual

2.2SERVICE 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.

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.

Components Removal and Installation

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

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

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

2-2

– JLG Lift –

3121200