JLG Toucan 12E, Toucan 12E Plus, Toucan 32E Service And Maintenance Manual

Service and Maintenance Manual

Model

TOUCAN 12E

P/N - 31210149

December 18, 2013

 NOTES:

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SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

31210149 – JLG Lift – A-1

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

AGENERAL

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

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

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

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

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE 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.

CMAINTENANCE

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

• 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 DANGER, WARNING, CAU­TION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.

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

• NEVER WORK UNDER AN ELEVATED STRUCTURE
UNTIL STRUCTURE HAS BEEN SAFELY
RESTRAINED FROM ANY MOVEMENT BY BLOCKING
OR OVERHEAD SLING.

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

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

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

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

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A-2 – JLG Lift – 31210149

REVISON LOG

Original Issue - December 18, 2013

31210149 – JLG Lift – 1

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B HYDRAULIC SYSTEM SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

C MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - OPERATING SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 DIMENSIONAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 COMPONENTS DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Electric Pump / Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Platform Rotation Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 MAJOR COMPONENTS WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Lube Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.8 TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.9 SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

SECTION 2 - GENERAL SERVICE INFORMATION

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 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 SERVICING AND MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Care and Installation of Teflon Coated Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Welding on Work Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.5 PRESSURE RELIEF VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.6 HYDRAULIC CARTRIDGE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

SECTION 3 - THEORY OF OPERATION

2 – JLG Lift – 31210149

TABLE OF CONTENTS

3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Platform Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 CAN COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.4 JOYSTICKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.5 TRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.6 PUMP/STRUCTURE MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Lift Up/Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Telescope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Personality Settings and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

SECTION 4 - CHASSIS MOUNTED COMPONENTS

4.1 DRIVE MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Brake - Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Brake - Dust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Brake Disk Wear Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Drive Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Drive Motor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Oil Type & Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 STEERING LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Steering Linkage - Spindle/Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

SECTION 5 - TURNTABLE AND VERTICAL MAST

5.1 SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Swing Bearing Attach Bolts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Swing Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 SWING DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Swing Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Swing Drive Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Swing Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3 ROLLERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Mast Transversal Play/Mast Sections Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 LIFTING CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Safety Accessories and Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Lifting Chains Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Lifting Chains Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.5 PULLEY - PULLEY SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Pulley Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.6 MAST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Mast Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Mast Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

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Mast Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.7 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

SECTION 6 - TELESCOPIC BOOM AND PLATFORM

6.1 OVERLAOD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Overload System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Overload System Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Platform Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 PLATFORM SUPPORTS AND SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Platform Supports and Slave Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Slave Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Platform Supports and Slave Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4 TELESCOPIC BOOM, BOOM AND MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Boom and Cylinders Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Boom and Master Cylinders Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Boom and Cylinders Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.5 TELESCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Telescope Toucan 12E Plus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Telescope Sections and Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Telescope Dual Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Telescope Sections and Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Telescope Toucan 12E / Toucan 32E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Telescope Sections and Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Telescope Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Telescope Sections and Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

SECTION 7 - HYDRAULICS

7.1 HYDRAULIC LINES CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 HYDRAULIC POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Ports Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Proportional Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Check Valve 0.5 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Check Valve 4.5 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Adding Oil to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Tank Draining/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Tank Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.4 MAIN MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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

Inspection: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.5 SECONDARY MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

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

7.6 CYLINDERS HOLDING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Mast Cylinder Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Jib Cylinder Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Telescope Cylinder Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Slave Cylinder Holding Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.7 SWING MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7.8 CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

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Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

SECTION 8 - CONTROL COMPONENTS

8.1 CONTROL COMPONENTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

8.2 CONTROL COMPONENTS - SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Main Power Contactor Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Power Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Mast Elevation Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Jib Elevation Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Chain Slack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Overload Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Overload System Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Drive Orientation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Steering Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.3 TRACTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.4 POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.5 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16

Ground Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Membrane Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Printed Circuit Board (PCB) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.6 PLATFORM CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20

Printed Circuit Board (PCB) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Upper Control Box - Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Upper Control Box - Components Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

SECTION 9 - JLG CONTROL SYSTEM

9.1 HAND HELD ANALYZER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

Analyzer Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Hand Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Using the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.2 ANALYZER SCREEN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

9.3 MACHINE SETUP PROGRAMMING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8

9.4 CALIBRATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

9.5 CALIBRATING STEERING SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.6 CALIBRATING TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

9.7 CALIBRATING THE JOYSTICKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

9.8 CALIBRATING THE PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9.9 MACHINE PERSONALITY - ADJUSTMENT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

9.10 SYSTEM TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17

SECTION 10 - DIAGNOSTIC TROUBLE CODES

10.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

10.2 DTC INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.3 DTC CHECK TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

SECTION 11 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

11.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

11.2 MULTIMETER BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

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Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.3 CHECKING SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3

Basic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.4 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS . . . . . . . . .11-4

11.5 AMP CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5

Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 11-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

11.6 DEUTSCH CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

11.7 CONNECTORS IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11

11.8 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

11.9 HYDRAULIC SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-20

TABLE OF CONTENTS

6 – JLG Lift – 31210149

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-2. Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

3-1. Drive Motor Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Hydraulic Pump Electric Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3. Mast Lift System - Basic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-4. Jib Lift System - Basic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-5. Swing System - Basic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-6. Steer System - Basic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-7. Telescope System - Basic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-8. Platform Level System - Basic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

4-1. Dust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3. Brake Disk Wear Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-4. Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-5. Drive Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-6. Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-7. Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-8. Wheel Lug Nut Tightening Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-9. Steering Linkage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-10. Steering Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

5-1. Access Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-2. Torque Sequence Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-3. Swing Bearing Race Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-4. Swing Bearing Teeth Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5-5. Swing Bearing Removal - 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-6. Swing Bearing Removal - 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-7. Swing Bearing Removal - 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-8. Swing Bearing Removal - 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-9. Swing Bearing Removal - 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-10. Swing Bearing Removal - 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-11. Swing Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-12. Swing Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-13. Swing Drive Disassembly - 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-14. Swing Drive Disassembly - 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-15. Swing Drive Disassembly - 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-16. Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-17. Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-18. Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-19. Mast Sections Vertical Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-20. Long Hollow Body Socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-21. Cracked Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-22. Turned Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-23. Worn Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-24. Chains Stages and Attachments Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-25. First Chain Stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-26. Second Chain Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-27. Third Chain Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-28. Fourth Chain Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-29. First Chains Stage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-30. Second Chains Stage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-31. Third Chains Stage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .5-14

5-32. Fourth Chains Stage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-33. Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-34. Chains Tension Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-35. Slantwise Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-36. Pulley Assembly Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-37. Pulley Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-38. Mast Cylinder Removal - 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

TABLE OF CONTENTS

31210149 – JLG Lift – 7

5-39. Mast Cylinder Removal - 2 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-40. Mast Cylinder Removal - 3 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-41. Mast Cylinder Removal - 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-42. Mast Cylinder Removal - 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-43. Mast Cylinder Removal - 6 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-44. Mast Cylinder Removal - 7 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-45. Mast Cylinder Removal - 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-46. Counterweight Removal - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-47. Counterweight Removal - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

6-1. Platform Removal-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2. Platform Support and Slave Cylinder Removal - 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3. Platform Rotation Option (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4. Platform Support and Slave Cylinder Removal - 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5. Platform Support and Slave Cylinder Removal - 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-6. Platform Support and Slave Cylinder Removal - 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-7. Boom and Cylinder Removal - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-8. Boom and Cylinder Removal - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-9. Telescope and Cylinder Removal - 1of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-10. Telescope and Cylinder Removal - 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-11. Telescope and Cylinder Removal - 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-12. Telescope and Cylinder Removal - 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-13. Telescope and Cylinder Removal - 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-14. Telescope and Cylinder Removal - 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-15. Telescope and Cylinder Removal - 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-16. Telescope and Cylinder Removal - 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

7-1. Hydraulic Lines Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-2. Hydraulic Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Ports Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-4. Dust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7-5. Moving Hydraulic Power Unit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

7-6. Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-7. Hydraulic Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-8. Tank Draining/Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-9. Main Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-10. Manifold Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7-11. Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-12. Secondary Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7-13. Secondary Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-14. Mast Cylinder Holding Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-15. Mast Cylinder Holding Valve - Schematic/Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-16. Jib Cylinder Holding Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-17. Jib Cylinder Holding Valve - Schematic/Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-18. Telescope Cylinder Holding Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7-19. Slave Cylinder Holding Valve - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7-20. Adjustment Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7-21. Air Bleeding From Rod Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7-22. Air Bleeding From Piston Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-23. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-24. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-25. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-26. Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-27. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-28. Mast Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-29. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-30. Telescope Plus Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

8-1. Control Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . .8-1

8-2. Battery filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8-3. Draining the water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

8-4. Measuring Electrolyte Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

8-5. Main Power Contactor Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-6. Power Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-7. Mast Elevation Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

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8 – JLG Lift – 31210149

8-8. Actuators Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-9. Jib Elevation Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-10. Jib Actuators Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-11. Main Jib Switch Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-12. Chain Slack Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-13. Overload Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-14. Overload Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-15. Overload System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-16. Drive Orientation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

8-17. Steering Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

8-18. Wheel Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-19. Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-20. Tilt Sensor Calibration Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-21. Main Electrical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11

8-22. Power Module Removal - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-23. Power Module Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8-24. Cables on Power Module Post Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13

8-25. Ground Control Station Connectors - 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16

8-26. Ground Control Station Connectors - 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

8-27. Ground Control Station Connectors - 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18

8-28. Ground Control Box Circuit Board - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19

8-29. Upper Control Box Circuit Board - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-30. Joystick Controls - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20

8-31. Enable/Emergency Stop Switches - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-21

9-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

9-2. Hand Held Analyzer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-3. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9-4. Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9-5. Wheel Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9-6. System Test Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17

10-1. DTCs Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

11-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2

11-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3

11-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5

11-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6

11-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6

11-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6

11-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

11-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

11-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

11-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

11-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10

11-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10

11-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

11-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

11-18. Wiring Harness and Connectors - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11

11-19. Wiring Harness and Connectors - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-12

11-20. Wiring harness and Connectors - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.11-13

11-21. Electrical schematic - Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14

11-22. Electrical Schematic - Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15

11-23. Electrical Schematic - Lower Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16

11-24. Electrical Schematic - Mast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-17

11-25. Electrical Schematic - Platform Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18

11-26. Electrical Schematic - Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-19

11-27. Hydraulic schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-20

TABLE OF CONTENTS

31210149 – JLG Lift – 9

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-6 Hydraulic Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-7 Drive Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-8 Swing Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-9 Platform Rotation Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-10 Cylinders Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-11 Tires Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-12 Major Components Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-13 Hydraulic Oil Specifications (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-14 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-15 Lube Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-16 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

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

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

4-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

8-1 Battery Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-2 Mast Limit Switch Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-3 End Of Stroke Jib Limit Switch Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

8-4 Slack Chain Connection (x295) Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-5 Sensor Connections Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8

8-6 Sensor Connections Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10

8-7 Joysticks wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

9-1 Machine Setup Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-2 Acceptable Pressure Values - T12E/T32E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9-3 Acceptable Pressure Values - T12E Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

9-4 Machine Personality Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

TABLE OF CONTENTS

10 – JLG Lift – 31210149

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_______________________________________ _______________________________________
_______________________________________ _______________________________________
_______________________________________ _______________________________________
_______________________________________ _______________________________________

SECTION 1 - OPERATING SPECIFICATIONS

31210149 – JLG Lift – 1-1

SECTION 1. OPERATING SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

1.2 DIMENSIONAL DATA

Table 1-1. Operating Specifications

Description Model Toucan 12E Model Toucan 12E Plus Model Toucan 32E

Maximum Work Load 200 kg 500 lbs

Maximum Persons 2

Maximum Horizontal Side Force 400 N 100 lbs

Maximum Operating Wind Speed 12.5 m/s (45 km/h) 28 mph

Maximum Stowed Travel Grade (Gradeability) 25% (14°)

Maximum Stowed Travel Grade (Side slope) 8.7% (5°)

Tilt Alarm Triggering Angle Value 3°

Maximum Tire Load (per wheel) 2 280 kg 2 680 kg 5 030 lbs

Approximate Gross Machine Weight - Global 4 300 kg 4 900 kg 9 480 lbs

Table 1-2. Dimensions

Description Models Toucan 12E - Toucan 12E Plus Model Toucan 32E

Overall Stowed Machine Height 1.99 m 6.5’

Overall Machine Length 3.65 m 11.8’

Overall Machine Width 1.20 m 3.9’

Platform Size - Length (Platform base) 0.70 m 27.6"

Platform Size - Width - (Platform base) 1.05 m 41.3"

Wheel Base (Wheels straightened) 1.60 m 5.3’

Ground Clearance (chassis base plate) 10 cm 3.9"

SECTION 1 - OPERATING SPECIFICATIONS

1-2 – JLG Lift – 31210149

1.3 PERFORMANCE DATA

1.4 CAPACITIES

Table 1-3. Performances

Description Model Toucan 12E Model Toucan 12E Plus Model Toucan 32E

Platform Height - Stowed (Platform floor to ground) 0.35 m 1.1 ft

Platform Height - Elevated (Platform floor to ground) 9.83 m 10.65 m 32.3 ft

Platform Height - Mast Elevated / Jib Horizontal (Platform floor to ground ) 7.12 m 23.4 ft

Up and Over clearance - Jib Horizontal 6.95 m 22.8 ft

Maximum Horizontal Reach (from centreline) 4.60 m 5.55 m 14.9 ft

Maximum Horizontal Reach (from side edge of chassis) 4.00 m 4.95 m 13.0 ft

Maximum Horizontal Reach (from rear edge of chassis) 3.57 m 4.52 m 11.5 ft

Swinging Angle 345° (not continuous)

Inside Turning Radius 0.75 m 2.5 ft

Outside Turning Radius 2.60 m 8.5 ft

Gradeability 25% (14°)

Elevating

Mast Lift Up Time - W/one person (approx. 80kg) 22 to 26 seconds

Mast Lift Down Time - W/one person (approx. 80kg) 25 to 29 seconds

Jib Lift Up Time - W/one person (approx. 80k g) 15 to 21 seconds

Jib Lift Down Time - W/one person (Approx. 80kg) 18 to 24 seconds

Swinging

Swinging Time - From rest to rest - Mast stowed 53 to 63 seconds

Swinging Time - From rest to rest - Mast elevated 83 to 99 seconds

Driving

M ax im u m D r iv e S p ee d

Stowed

Ma s t e le v at e d

5.50 km/h

0.75 km/h

Table 1-4. Capacities

Component Models Toucan 12E - Toucan 32E Model Toucan 12E Plus

Hydraulic Tank 15l (11.5 l usable) - 3.96 gal (3.04 gal usable)

Hydraulic System (Including Tank) Approx. 20 l - (5.28 gal) Approx. 21.5 l - (5.3 gal)

SECTION 1 - OPERATING SPECIFICATIONS

31210149 – JLG Lift – 1-3

1.5 COMPONENTS DATA

Batteries

Electric Pump / Electric Motor Assembly

Drive Motor Assembly

Table 1-5. Battery Specifications

Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E

Voltage (48VSystem - Series) 8 Packs of 6 Volts (semitraction)

Amp Hour (Standard battery) 260 Amp Hour @ 20 HR. Rate

215 Amp Hour @ 5 HR. Rate

Life Cycle Rating 800 Cycles

Weight - Approx 265 kg 584 lbs

Table 1-6. Hydraulic Unit Specifications

Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E

Motor

Voltage 48 VDC

Powe r 3 .5 kW

Pump (Gear pump)

Displacement 4.2 cc/rev (0.26 cu.in/rev)

Flow rate

11.5 l/mn @ 13 MPa

(3.84 gal/mn@1900 psi)

Max. Operating Pressure 18 MPa (2 600 psi)

Table 1-7. Drive Motor Specifications

Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E

Motor

Vol tage 48 VDC

Power 3.5 kW

Brake Supply Voltage 24 VDC (Nominal)

Sensor Bearing 64 Impulses per rev.

SECTION 1 - OPERATING SPECIFICATIONS

1-4 – JLG Lift – 31210149

Swing Drive

Platform Rotation Drive

Cylinders

Tires

Table 1-8. Swing Drive Specifications

Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E

Motor Type Orbital

Displacement 20 cc

Gear Reducer Wheel and Worm. Ratio 1/50

Table 1-9. Platform Rotation Drive Specifications

Description Model Toucan 12E - Toucan 12E Plus - Toucan 32E

Electrical Cylinder

Vol tage 48 VDC

Stroke 150 mm

Table 1-10. Cylinders Specifications

Description Bore DIA. Stroke Rod DIA.

Steer Cylinder (Double Action) 50 mm (1.97 in) 171 mm (6.73 in) 25 mm (0.98 in)

Telescope Cylinder Toucan 12E
(Double Action)

50 mm (1.97 in) 1240 mm (48.82 in) 30 mm (1.18 in)

Telescope Cylinder Toucan 12E Plus
(Double Action)

50 mm (1.97 in) 171 mm (6.73 in) 25 mm (0.98 in)

Master Cylinder (Double Action) 55 mm (2.16 in) 265.5 mm (10.45 in) 35 mm (1.38 in)

Slave Cylinder (Double Action) 55 mm (2.16 in) 265.5 mm (10.45 in) 35 mm (1.38 in)

Mast Cylinder (Single Action) 90 mm (3.54 in) 1005 mm (39.57 in) 80 mm (3.15 in)

Jib Cylinder (Single Action) 70 mm (2.76 in) 755 mm (29.72 in) 65 mm (2.56 in)

Table 1-11. Tires Specifications

Description Models Toucan 12E/12E Plus Tou ca n 3 2E

Size 457 x 178 mm 18 x 7 in

Max. Allowable Tire Load 3 265 kg 7 200 lbs

Wheel Bolt Torque

250 Nm 185 ft lb

210 Nm 155 ft lb

SECTION 1 - OPERATING SPECIFICATIONS

31210149 – JLG Lift – 1-5

1.6 MAJOR COMPONENTS WEIGHTS

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

Table 1-12. Major Components Weights

Description Models Toucan 12E/12E Plus Tou ca n 3 2E

Platform (*) 54 kg 119 lbs

Platform Support (Without Rotation) 20 kg 44 lbs

Platform Support (Option Rotation) 11 kg 24 lbs

Level Correction Support (Option Rotatio n) 15 kg 33 lbs

Boom 54 kg 119 lbs

Telescope Mid Sec tion (Toucan 12E Plus) 28 kg 62 lbs

Telescope Inner Secti on (Toucan12E Plus) 22 kg 49 lbs

Telescope (Toucan 12E / Toucan 32E) 32 kg 71 lbs

Boom Cylinder 46 kg 101 lbs

Master Cylinder 11 kg 24 lbs

Slave Cylinder 12 kg 26 lbs

Telescope Cyl inder Toucan 12E Pl us 42 kg 93 lbs

Toucan 12E/Toucan 32E 26 kg 57 lbs

Mast Assembly (5 Mast Sections) 630 kg 1 390 lbs

Mast Cylinder 76 kg 168 lbs

Mast Section #1 290 kg 640 lbs

Swing Bearing 32 kg 71 lbs

Swing Drive 17 kg 37 lbs

Electric Pump 18 kg 40 lbs

Chassis 680 kg 1 500 lbs

Wheel and Tire (each) (*) 35 kg 77 lbs

Spindle Steering (each) (*) 19 kg 42 lbs

Drive Motor (each) (*) 90 kg 200 lbs

Battery Standard (each) (*) 33 kg 73 lbs

Counterweight Main (*) 1 395 kg 3 076 lbs

Additional (*) 575 kg 1 268 lbs

(*) Items critical for stability

SECTION 1 - OPERATING SPECIFICATIONS

1-6 – JLG Lift – 31210149

1.7 LUBRICATION

Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities and suffi-

cient chemical stability for mobile hydraulic system
service. It is not advisable to mix oil of different
brands or types, as they may not contain the same
required additive or be of comparable viscosities.

Table 1-13. Hydraulic Oil Specifications (Standard)

Specifications NERVOFLUID 15

ISO Viscosity Grade 15

Cinematic Viscosity @ -20°C [-4°F] 213.6 mm²/s (cSt)

Cinematic Viscosity @ 0°C [32°F] 68.1 mm²/s (cSt)

Cinematic Viscosity @ +40°C [104°F] 15.1 mm²/s (cSt)

Pour Point, Max. -40°C (-40°F)

Flash Point, Min. 175°C (347°F)

Viscosity Index 153

ISO 6743-4 Classification HV

SECTION 1 - OPERATING SPECIFICATIONS

31210149 – JLG Lift – 1-7

Lubrication Chart

Figure 1-1. Lubrication Chart

NOTE: Lubrication intervals are based on machine operation under normal condition. For machines used in multi shift opera-

tions and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

NOTE: Refer to the corresponding sections in this manual for specific lubrication procedures.

Table 1-14. Lubrication Chart

Component

Number/Type

Lube Points

Lube

Interval Hours

Comments

125 250 1000

1 Swing Bearing Race 2 grease fittings A X

2 Swing Bearing Teeth By brush B X Remove old grease first

3 Lifting Chains

Spray on or by

brush

C X Lubricate before first 50 hours of operation

4 Hydraulic Oil

Fill through

reservoir cap

D X Check level daily. Change at least ever y 2 years

1. Swing bearing race

2. Swing bearing Teeth

3. Lifting Chains

4. Hydraulic Oil

SECTION 1 - OPERATING SPECIFICATIONS

1-8 – JLG Lift – 31210149

Lube Specifications

1.8 TORQUE REQUIREMENTS

Unless specific torque requirements are given within the
text, refer to the following torque chart to determine
proper torque values.

Table 1-15. Lube Specifications

Key Specifications E.g.

A Extreme Pressure - Multi Purpose Grease

MOBILUX EP2

COMPLEX EP2

B Open Gear Lube MOBILTAC 81

C Non Detergent Mineral Oil (*) MOBIL DTE 16M

D Hydraulic Oil NERVOFLUID 15

E Synthetic Chain Oil FUCHS VT800

(*) To be adapted to the machi ne’s operating conditions. Refer to the corresponding section in this manual.

Table 1-16. Torque Chart

Torque Values for Bolts, Nuts and Studs

Grade Unit M4x70 M5x80 M6x100 M8x125 M10x150 M12x175 M14x200 M16x200 M20x250 M24x300 M30x350

8.8

Nm

lbf.ft

2.7
2

5.2

3.8

9.1

6.7

22

16.2

44

32.5

76
56

121

89.2

189
139

370
272

637
469

1280

944

10.9

Nm

lbf.ft

3.9

2.9

7.7

5.7

13.4

9.9

32

23.6

64

47.2

111

81.9

178
131

278
205

544
408

936
690

1880
1386

12.9

Nm

lbf.ft

4.6

3.4

9

6.6

15.7

11.6

38
28

75

55.3

130

95.9

209
154

325
239

637
469

1095

807

2200
1622

Torque Values for Hydraulic Fittings

Ty pe Unit Torque

JIC 9/16"-18

Nm

lbf.ft3022.1

BSPP 1/4"-19

Nm

lbf.ft

14.8
109

BSPP 3/8"-19

Nm

lbf.ft3425.1

Metric M18x150

Nm

lbf.ft5137.6

SECTION 1 - OPERATING SPECIFICATIONS

31210149 – JLG Lift – 1-9

1.9 SERIAL NUMBER LOCATIONS

For machines identification, a serial number plate is
affixed at the front side of the chassis. If the serial number
plate is damaged or missing, the machine serial number is
stamped on the frame at location shown following.

Figure 1-2. Serial Number

SECTION 1 - OPERATING SPECIFICATIONS

1-10 – JLG Lift – 31210149

 NOTES:

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SECTION 2 - GENERAL SERVICE INFORMATION

31210149 – JLG Lift – 2-1

SECTION 2. GENERAL SERVICE INFORMATION

2.1 MACHINE PREPARATION, INSPECTION
AND MAINTENANCE

General

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

Preparation, Inspection and Maintenance

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

Pre-Start Inspection

It is the User's or Operator's primary responsibility to per­form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera­tion 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 perfor-

mance 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-Trained Service Technician on an annual basis, lo
later than thirteen (13) months from the date of the prior
Annual Machine Inspection. JLG Industries, Inc. recog­nizes a Factory-Trained 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 Preventive Maintenance and Inspection
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.

SECTION 2 - GENERAL SERVICE INFORMATION

2-2 – JLG Lift – 31210149

2.2 PREVENTIVE MAINTENANCE AND
INSPECTION SCHEDULE

The preventive maintenance and inspection checks are
listed and defined in Table 2-2. This table is divided into
two basic parts, the "AREA" to be inspected and the
"INTERVAL" at which the inspection is to take place. Under
the "AREA" portion of the table, the various systems along
with the components that make up that system are listed.
The "INTERVAL" portion of the table is divided into six col­umns representing the various inspection time periods.
The numbers listed within the interval column represent
the applicable inspection code for which that component
is to be checked.

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

Table 2-1. Maintenance and Inspection Requirements

TYPE FREQUENCY

PRIMARY

RESPONSIBILITY

SERVICE

QUALIFICATION

REFERENCE

Pre-start Inspection

Prior to use each day; or
At each Operator change

User or Operator User or Operator Operator and Safety manual

Pre-delivery Inspection

Prior to each sale, lease or
rental delivery

Owner, Dealer or
User

Qualified JLG
Mechanic

Service and Maintenance
Manual and applicable JLG
inspection form

Frequent Inspection

In service for 3 months; or
Out of service for a period of
more than 3 months; or
Purchased used

Owner, Dealer or
User

Qualified JLG
Mechanic

Service and Maintenance
Manual and applicable JLG
inspection form

Annual Machine Inspection

Annually, no later than 13
months from the date of the
prior inspection

Owner, Dealer or
User

Factory-Trained
Service Technician
(Recommended)

Service and Maintenance
Manual and applicable JLG
inspection form

Preventive Maintenance

At intervals as specified in the
Service and Maintenance
manual

Owner, Dealer or
User

Qualified JLG
Mechanic

Service and Maintenance
Manual

SECTION 2 - GENERAL SERVICE INFORMATION

31210149 – JLG Lift – 2-3

Table 2-2. Inspection and Preventive Maintenance Schedule

AREA

INTERVAL

Pre-start1

Inspection

Weekly

preventive

maintenance

Monthly

preventive

Maintenance

Pre-delivery2
or Frequent

3

Inspection

Annual4

(Yearly)

Inspection

Every 2

Yea rs

PLATFORM ASSEMBLY

Platform 1-2 1-2

Railing 2 2

Gate 1-5 1-5

Floor 7 2

Lanyard Anchorage Points 2 2-9

Platform Support (Option Platform Rotation
Only)

2 1-2-4 1-2-4

Level Correction Support 2 1-2-4 1-2-4

TELESCOPIC BOOM ASSEMBLY

Boom and Telescope Weldment 2 1-2-4 1-2-4

Pivot Pins and Pins Retainers 1 1-2 1-2

Wear Pads 12 3-12

Hose, Cables Installation, Power Track 1-2-8-11 1-2-8-11

MAST ASSEMBLY

Mast Sections 2 2-4 2-3-4

Roller Pin, Plastic Wear Pad 12 3-12

Pulleys 22

Chains/Yokes 13 12-13 12-13

Hose, Cables Installation, Power Track 1-2-8-11 1-2-8-11

TURNTABLE

Swing Drive System 5 8 5-8 5-8

Swing Bearing Bolts 14

Hose, Cables Installation, Power Track 1-2-8-11 1-2-8-11

Hoods, Hood Props, Hood Latches 5 1-2-5

CHASSIS ASSEMBLY

Chassis Weldment 4

Tires 1-15 16 15-16-17 15-16-17

Wheel Bolts 1 14 14 14

Steering Spindles Weldments 2-4 2-4

SECTION 2 - GENERAL SERVICE INFORMATION

2-4 – JLG Lift – 31210149

Steering Knuckles Thrust Washers 12 12

Steer Components 1

Drive Motor Brakes 7-12

Drive Motor Gearbox 8 8

Hoods, Hood Props 5 1-2-5

FUNCTIONS/CONTROLS

Platform Controls 5-6-9 5-6-9 5-6-9

Ground Controls 5-6-9 5-6-9 5-6-9

Manual/Breakdown Controls 5-9 5-9 5-9

Emergency Stop Switches (Ground & Plat­form)

555

Functions Limit or Cutout Switch Systems 5 5 5

POWER SYSTEM

Batteries 18 18 1-19

Battery Fluid 10 10

Centralized Filling System 5 5 5-8

Battery Container Draining 22 22

Electrical Connections 1 20 20

Battery Charger 55

HYDRAULIC/ELECTRIC SYSTEM

Hydraulic Power Unit 8 1-8 1-8

Hydraulic Cylinders 8 1-7-8 2 1-2-8 1-2-8

Hydraulic Hoses, Lines and Fittings 8 1-8 11 1-2-8-11 1-2-8-11

Hydraulic Tank/Hydraulic Fluid 10

Hydraulic Fluid Replacement 22

Electrical Connections 1 20 20

Instruments, Switches 5 1 7-15

Lights, Horn 5 5

Electric Motor Brushes (Hyd. Power Unit) 7-12

GENERAL

Operation and Safety manuals in Storage
Box

21 21 21

Table 2-2. Inspection and Preventive Maintenance Schedule

AREA

INTERVAL

Pre-start1

Inspection

Weekly

preventive

maintenance

Monthly

preventive

Maintenance

Pre-delivery2
or Frequent

3

Inspection

Annual4

(Yearly)

Inspection

Every 2

Yea rs

SECTION 2 - GENERAL SERVICE INFORMATION

31210149 – JLG Lift – 2-5

Maintenance and Inspection Table Codes:

1. Check for proper and secure installation.

2. Visual inspection for damage, cracks, distortion and
excessive wear.

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

6. Returns to neutral or "off" position when released.

7. Clean and free of debris.

8. Check for sign of leakage.

9. Decals installed and legible.

10. Check for proper fluid level.

11. Check for chafing and proper routing.

12. Check for proper tolerances.

13. Properly lubricated.

14. Torqued to proper specification

15. No worn edges, excessive wear or distorted profiles.

16. Properly seated around the rim.

17. Proper and authorized components.

18. State of charge.

19. Check/record acid gravity and tension.

20. No loose connections, corrosion or abrasion.

21. Verify.

22. Perform.

Footnotes:

1

: Prior to use each day; or at each operator change.

2

: Prior to each sale, lease or delivery.

3

: In service for 3 months or 125 hours; or out of service

for 3 months or more; or purchased used.

4

: Annually, not later than 13 months from the date of prior

inspection.

ANSI and EMI Manuals/Handbooks
Installed

21

Capacity Decals Installed, Secure, Legible 21 21 21

All Decals/Placards installed, Secure, Legi­ble

21 21 21

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21 21

No Unauthorized Modifications or Additions 21 2 1

All Relevant Safety Publications Incorpo­rated

21 21

General Structural Condition and Welds 2-4 2-4

All Fasteners, Pins, Shields and Covers 1-2 1-2

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21 21-22

Paint and Appearance 7 7

Stamp Inspection Date on Mast Section #1 22

Notify JLG of Machine Ownership 22

Table 2-2. Inspection and Preventive Maintenance Schedule

AREA

INTERVAL

Pre-start1

Inspection

Weekly

preventive

maintenance

Monthly

preventive

Maintenance

Pre-delivery2
or Frequent

3

Inspection

Annual4

(Yearly)

Inspection

Every 2

Yea rs

SECTION 2 - GENERAL SERVICE INFORMATION

2-6 – JLG Lift – 31210149

2.3 SERVICING AND MAINTENANCE
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 object to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT­FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.

Cleanliness

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 the wheel bearings, mast sections
and oil supply clean; however, these items must be main­tained on a scheduled basis in order to function properly.

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

Contaminants in the hydraulic system will affect operation
and will result in serious damage to components working
parts. Every precaution must be taken to keep hydraulic
oil clean, including reserve oil in storage. If the oil must be
poured from the original container into another, be sure to
clean all contaminants from the service container.

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

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.

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.

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 reassembling a component, com­plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.

Always recheck your work to ensure that nothing has
been overlooked. Do not make any adjustments, other
than those recommended, without obtaining proper
approval.

Pressure-Fit Parts

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

Bearings

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

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

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 bearing until they are ready to be
installed.

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

Care and Installation of Teflon Coated
Bushings

Bushings:

No jiffy wheels or reaming of any kind can be used on tef­lon coated bushings.

Once the coating on the bushing is damaged, it cannot be
used any more and must be replaced.

Pins:

Any rough or damaged surface on a pin will cause the tef­lon coating of the bushing to be damaged.

All rust or masking residue must be cleaned from the pin
prior to assembly.

Never dry (black colored) "Arcor" treated pins (hot wash­ing, vapor...). This will reduce corrosion resistance prop­erty of pin coating.

Bushings and Pin:

1. Coat inside diameter of bushing with specified lubri­cant prior to pin installation.