JLG 40H Installation and user guide

Service and Maintenance Manual
ANSI
Model
40H
40H+6
3120240
October 11, 2001

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
3120240 – JLG Lift – a
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A.A GENERAL
This section contains the general safety precautions which
must be observed during maintenance of the aerial plat-
form. It is of utmost importance that maintenance person-
nel pay strict attention to these warnings and precautions
to avoid possible injury to themselves or others, or dam-
age 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 VIOLA-
TION.
The specific precautions to be observed during mainte-
nance 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 CON-
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER-
ATOR.
A.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 pres-
sure prior to disconnecting or removing any portion of the
system.
Relieve system pressure by cycling the applicable control
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be disconnected
with minimal fluid loss.
A.C MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
ING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
TIONS ON MACHINE AND IN SERVICEMANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

EFFECTIVITY CHANGES
b– JLG Lift – 3120240
REVISON LOG
Aug, 1985 -Original Issue
Nov. 1985 -Revised
Oct. 1998 -Revised
Aug. 1999 -Revised
October 11, 2001 -Revised

3120240 – JLG Lift – i
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
EFFECTIVITY CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III
SECTION 1 - SPECIFICATIONS
1.1 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Component Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Performance Data.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.4 Torque Requirements.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.8 Boom Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.9 Major Components Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.11 Serial Number Location (See Figure 1-4.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
SECTION 2 - PROCEDURES
2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Servicing And Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Lubrication Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.4 Cylinders - Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Valves - Theory Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.6 Boom Chains. (See Figure 2-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.7 Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.8 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.9 Cylinder Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.10 Cylinder Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.11 Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2.12 Tilt Alarm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2.13 Horizontal High Speed Cutout Switch Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
2.14 Governor Checks And Addco Adjustment, Ford. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2.15 Throttle Checks And Precision Governor Adjustments, Addco (See Figure 2-6.) . . . . . . . . . . . . .2-21
2.16 Electric Governor And Adjustments - Ford Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2.17 Throttle Checks And Adjustments - Deutz F2l511 Engine. (See Figure 2-8.) . . . . . . . . . . . . . . . .2-29
2.18 Throttle Checks And Adjustments Wisconsin Engine. (See Figure 2-9.) . . . . . . . . . . . . . . . . . . . .2-33
2.19 Throttle Checks And Adjustments - Deutz F3l912 Engine. (See Figure 2-10.) . . . . . . . . . . . . . . .2-35
2.20 Throttle Checks And Adjustments - Deutz Engine F3l1011. (See Figure 2-11.) . . . . . . . . . . . . . .2-35
2.21 Pressure Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
2.22 Racine Proportional Air Gap Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
2.23 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
2.24 Torque Hub, 2w/d. (See Figure 2-36.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
2.25 Torque Hub 4wd. (See Figure 2-37.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
2.26 Swing Drive Brake, Mico (Machines Built Prior To May 1992). (See Figure 2-39.) . . . . . . . . . . . .2-71
2.27 Drive Brake, Mico. (Machines Built Prior To May 1992)(See Figure 2-40.) . . . . . . . . . . . . . . . . . .2-72
2.28 Swing Drive Brake, Ausco (Machines Built Prior To May 1992). (See Figure 2-41.) . . . . . . . . . . .2-75
2.29 Drive Brake, Ausco. (Machines Built Prior To May 1992) (See Figure 2-43.). . . . . . . . . . . . . . . . .2-77
2.30 Drive Brake, Mico. (Machines Built From May 1992 To S/n 33476) (See Figure 2-44.) . . . . . . . .2-79
2.31 Swing Brake, Mico. (Machines Built From May 1992 To S/n 33476) (See Figure 2-45.). . . . . . . .2-81

ii – JLG Lift – 3120240
TABLE OF CONTENTS (Continued)
2.32 Drive Brake, Mico. (Machines Built From S/n 33476 To Present) (See Figure 2-46.) . . . . . . . . . . 2-83
2.33 Swing Brake, Mico.(Machines Built From S/n 33476 To Present) (See Figure 2-46.) . . . . . . . . . .2-85
2.34 Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
2.35 Oscillating Axle Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
2.36 Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
2.37 Basket Rotator Brake. (See Figure 2-48.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
2.38 Free Wheeling Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
2.39 Spark Arrestor Mufflers.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
2.40 Footswitch Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
2.41 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
2.42 Dual Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
2.43 Preventive Maintenance And Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2.44 Capacity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92
SECTION 3 - TROUBLESHOOTING
3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-2. Lubrication Chart. (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-2. Lubrication Chart. (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-3. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
2-1. Typical Three Section Boom Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-2. Boom Positioning and Support, Cylinder Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-3. Poly-Pak Seal Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-4. Governor Adjustment, Ford with Addco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2-5. Addco Adjustment, Ford. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
2-6. Precision Governor Adjustment, Ford. (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
2-7. Precision governor Adjustment, Ford. (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-8. Addco Actuator Adjustments, F2L511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2-9. Addco Actuator Adjustments, VG4D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
2-10. Addco Actuator Adjustments, F3L912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
2-11. Addco Actuator Adjustments, F3L1011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
2-12. Racine Proportional Valve Pressure Setting.(Machines Built Prior To Mid 1987) (Sheet 1 of 2). .2-39
2-13. Racine Proportional Valve Setting.(Machines Built Prior To Mid 1967) (Sheet 2 of 2) . . . . . . . . .2-40
2-14. Vickers Proportional Valve Pressure Setting, Machines Built To Present (Sheet 1 of 4) . . . . . . . .2-41
2-15. Vickers Proportional Valve Pressure Setting, Machines Built To Present. (Sheet2 of 4) . . . . . . . .2-42
2-16. Vickers Proportional Valve Pressure Setting, Machines Built To Present. (Sheet 3 Of 4) . . . . . . .2-43
2-17. Vickers Proportional Valve Pressure Setting, Machines Built To Present. (Sheet 4 of 4) . . . . . . .2-44
2-18. Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve. (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . .2-45
2-19. Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve. (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . 2-46
2-20. Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve. (Sheet 3 Of 4) . . . . . . . . . . . . . . . . . . . . . . .2-47
2-21. Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessary Valve. (Sheet 4 Of 4) . . . . . . . . . . . . . . . . . . . . . . . 2-48
2-22. Solenoid Valve Pressure Settings. (Machines Built Prior To 1992 With Steering Wheel) . . . . . . . 2-49
2-23. Pressure And Flow Settings (Machines Built Prior To May 1992 With Steering Wheel).. . . . . . . . 2-50
2-24. Vickers All Hydraulic Machines Pressure Settings (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . .2-51

3120240 – JLG Lift – iii
TABLE OF CONTENTS
2-25. Vickers All Hydraulic Machines Pressure Settings (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . .2-52
2-26. Vickers All Hydraulic Machines Pressure Settings (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . .2-53
2-27. Vickers All Hydraulic Machines Pressure Settings (Sheet 4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . .2-54
2-28. Solenoid Valve Pressure Settings, Machines Built Before 1995. (Sheet 1 of 2) . . . . . . . . . . . . . .2-55
2-29. Solenoid Valve Pressure Settings, Machines Built from 1995 To Present. (Sheet 2 of 2) . . . . . . .2-56
2-30. Extend-A-Reach Valve Pressure and Speed Settings Model 40+6. . . . . . . . . . . . . . . . . . . . . . . .2-57
2-31. Racine Proportional Air Gap Adjustment, Machines Built Prior To Mid 1987. . . . . . . . . . . . . . . . .2-58
2-32. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
2-33. Swing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
2-34. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
2-35. Swing Bearing Torquing Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
2-36. Torque Hub Assembly, 2/WD.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
2-37. Torque Hub 4/WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
2-38. Torque Hub Carrier Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
2-39. Swing Brake Assembly - Mico (Machines Built Prior To May 1992). . . . . . . . . . . . . . . . . . . . . . . .2-71
2-40. Drive Brake Assembly - Mico (Machines Built Prior To May 1992). . . . . . . . . . . . . . . . . . . . . . . . .2-73
2-41. Swing Brake Assembly - Ausco (Machines Built Prior to May 1992). . . . . . . . . . . . . . . . . . . . . . .2-76
2-42. Drive Brake, (machines Built Prior to May 1992). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
2-43. Drive Brake, Mico. (Machines Built From May 1992 To Machine S/N 33476) . . . . . . . . . . . . . . . .2-80
2-44. Swing Brake, Mico. (Machines Built From May 1992 To Machine S/N 33476) . . . . . . . . . . . . . . .2-82
2-45. Drive Brake, Mico. (Machines Built From S/N 33476 To Present) . . . . . . . . . . . . . . . . . . . . . . . . .2-84
2-46. Swing Brake, Mico. (Machines Built From S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . .2-86
2-47. Basket Rotator Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
2-48. Boom Tape Replacement Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92
2-49. Capacity Indicator Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92
3-1. Wiring Diagram - Dual Fuel (Ford Or Wisconsin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-2. Wiring Diagram - 110v Generator (Ford). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-3. Wiring Diagram - 110v Generator (Deutz). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-4. Wiring Diagram - Platform Console (W/all Hydraulic Controls).. . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-5. Wiring Diagram - Platform Console Standard (Sheet 1 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-6. Wiring Diagram - Platform Console Standard (Sheet 2 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-7. Wiring Diagram - Standard (Deutz F2l511/f3l912 & Wisconsin
Engine W/ Standard Controls) (Sheet 1 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-8. Wiring Diagram - Standard (Deutz F2l4511/f3l912 & Wisconsin
Engine W/ Standard Controls) (Sheet 2 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-9. Wiring Diagram - Standard (Deutz F2l511/f3l912 &
Engine W/ Hydraulic Controls) (Sheet 1 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-10. Wiring Diagram - Standard (Deutz F2l511/f3l912 & Wisconsin
Engine W/ Hydraulic Controls) (Sheet 2 Of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-11. Wiring Diagram - Standard (Deutz F3l1011 Engine W/ Standard Controls) (Sheet 1 Of 2). . . . . .3-30
3-12. Wiring Diagram - Standard (Deutz F3l1011 Engine W/ Standard Controls) (Sheet 2 Of 2). . . . . .3-31
3-13. Wiring Diagram - Standard (Deutz F3l1011 Engine W/ Hydraulic Controls) (Sheet 1 Of 2). . . . . .3-32
3-14. Wiring Diagram - Standard (Deutz F3l1011 Engine W/ Hydraulic Controls) (Sheet 2 Of 2). . . . . .3-33
3-15. Wiring Diagram - Standard (Ford Lrg425 Dis Engine W/ Standard Controls) (Sheet 1 Of 2).. . . .3-34
3-16. Wiring Diagram - Standard (Ford Lrg425 Dis Engine W/ Standard Controls) (Sheet 2 Of 2).. . . .3-35
3-17. Wiring Diagram - Standard (Ford Dis Engine W/ Hydraulic Controls) (Sheet 1 Of 2).. . . . . . . . . .3-36
3-18. Wiring Diagram - Standard (Ford Dis Engine W/ Hydraulic Controls) (Sheet 2 Of 2).. . . . . . . . . .3-37
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
2-1 Chain Stretch Tolerance.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-2 Cylinder Piston Nut Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-3 Holding Valve Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-4 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
3-1 Platform Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

iv – JLG Lift – 3120240
TABLE OF CONTENTS (Continued)
3-2 Boom Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3 Turntable Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-4 Chassis Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-5 Hydraulic Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3-6 Electrical Assembly Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
(INTENTIONAL BLANK PAGE)

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-1
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES.
Fuel Tank - 37 Gallons (140.2 L)
Hydraulic Oil Tank - 37 U.S. Gallons
(104.2 L).
Hydraulic System (Including Tank) - 70 U.S.
Gallons (264.95 L).
Torque Hub Drive - 2.5 Pints (1.18 L).
Torque Hub Swing - 2.0 Pints (1.18 L).
NOTE: Torque Hubs should be one - half full of lubricant.
(EPGL-90)
Engine Crankcase (Ford LSG423) w/Filter
5 quarts (4.73 L).
Engine Crankcase (Ford LRG423) w/Filter
5 quarts (4.73 L).
Engine Crankcase (Deutz F3L912) w/Filter
9.5 quarts (8.99 L).
Engine Crankcase (Deutz F3L1011) w/Filter
6.34 quarts (6 0 L).
Engine Crankcase (Deutz F2L511) w/Filter
3.5 quarts
Engine Crankcase (Wisconsin VG4D) w/Filter
5.0 quarts (4.73 L).
NOTE: Tolerance on all engine rpm settings is plus or minus
10%.
1.2 COMPONENT DATA.
Engine - Ford LSG423/Lrg423.
Oil capacity - 5 quarts (4.73 L) w/Filter, 4
quarts (3.79 L) w/o Filter.
Cooling System - 16 quarts (15.14 L).
Low RPM - 1000, no load.
Mid RPM - 1800, no load.
High RPM - 3000, no load.
Alternator - 40 Amp, belt drive.
Battery - 1000 cold cranking Amps, 210 min-
utes reserve capacity,12 VDC.
Fuel Consumption Low RPM - 2.03 GPH
(7.68 LPH).
Fuel Consumption High RPM - 2.73 GPH
(10.33 LPH).
Horsepower - 63 @ 2800 RPM, no load.
Engine -Ford LRG-425 D.I.S.
Oil Capacity.
4.50 Quarts (4.25 1) w/Filter.
3.50 Quarts (3.31 1) w/o Filter.
Idle RPM - 1000.
Low RPM - 1800.
High RPM - 2800.
Alternator - 95 Amp, Belt Drive.
Battery - 1000 Cold Cranking Amps, 210 minute reserve
Capacity, 12 VDC.
Fuel Consumption.
Low RPM - 3.45 GPH (13.06 lph).
High RPM - 4.60 GPH (17.41 lph).
Horsepower - 74 @ 3000 RPM, full load.
Cooling System - 16 Quarts (15.14 l.).
Engine - Deutz F3L912.
Oil capacity - 9.5 quarts (8.99L) w/Filter, 8.5
quarts (8.04 L) w/o Filter.
Low RPM 1800.
High RPM 2400.
Alternator - 85 Amp, belt drive.
Battery - 1000 cold cranking Amps, 210 minutes
reserve capacity, 12VDC.
Fuel Consumption Low RPM - 2.03 GPH
(7.68 LPH).
Fuel Consumption High RPM - 2.73 GPH
(10.33 LPH).
Horsepower - 47 @ 2800 RPM, no load.
Engine - Deutz F3L1011.
Oil Capacity - 6.34 quarts (6.0 L) w/Filter, 5.8
quarts (5.5 L) w/0 Filter.
Low RPM 2000.
High RPM 3000.
Alternator - 60 Amp, belt drive.

SECTION 1 - SPECIFICATIONS
1-2 – JLG Lift – 3120240
Battery - 1000 cold cranking Amps, 210 min-
utes reserve capacity, 12VDC.
Fuel Consumption Low RPM - 1.9 GPH (7.19
LPH).
Fuel Consumption High RPM - 2.5 GPH (9.46
LPH).
Horsepower - 42@ 3000 RPM, no load.
Engine - Deutz F2L511.
Oil Capacity - 3.5 quarts (3.31 L) w/Filter, 3.0 quarts (2.84
L) w/o Filter.
Low RPM 1800.
High RPM 2500.
Alternator - 33 Amp, belt drive.
Battery - 1000 cold cranking Amps, 210 minutes
reserve capacity, 12 VDC.
Fuel Consumption Low RPM - 2.03 GPH (7.68 LPH).
Fuel Consumption High RPM - 2.73 GPH (10.34 LPH).
Horsepower - 47 @ 2300 RPM, full load.
Engine - Wisconsin VG4D.
Oil Capacity - 5 quarts (4.73 L) w/Filter, 4.5 quarts (4.26
L) w/o Filter.
Low RPM 1800, no load.
High RPM 2400, no load.
Alternator - 35 Amp, belt drive.
Battery - 1000 cold cranking Amps, 210 minutes
reserve capacity, 12 VDC.
Fuel Consumption Low RPM - 3.21 GPH (12.15 LPH).
Fuel Consumption High RPM - 3.89 GPH (14.72 LPH).
Horsepower - 37 @ 2500 RPM, full load.
Drive System.
Tires - 12.5 x 15, 12 ply rating, 72 PSI. (5 Bar) (4 WD
Same).
Tires - 14 x 17.5, 8 ply rating, 45 PSI. (3 Bar) (4 WD
Same).
Drive Motor Displacement - 2.48 in3/Rev.
Drive Hub Ratio - 49.29:1.
Steer System.
Tires - 12.5 x 15, 12 ply rating, 72 PSI. (5 Bar).
Toe-in, adjust for 1/4 in. (6.35 mm) overall.
Swing System.
Swing Motor - Displacement - 3.0 in3/Rev.
Swing Hub - Ratio - 69:1.
Swing Brake - Automatic spring applied, hydraulically
released disc brakes.
Hydraulic Pump.
Ford LSG423, Deutz F3L912, Wisconsin VG4D with
Racine Valves (Single Speed Drive Motors).
First Section to Proportional Valve-Drive, Lift, Swing -
14.5 GPM (54.88 LPM).
Second Section to High Drive - 9.5 GPM (35.96 LPM).
Third Section to Bang-Bang valve level, Telescope,
Steer, Rotate - 9.5 GPM (35.96 LPM).
Clockwise Rotation.
Ford LSG423, Deutz F3L912, Wisconsin VG4D with
Racine Valves (2 Speed Drive Motors).
First Section to Proportional Valve-Drive, Lift, Swing -
10.8 GPM (40.88 LPM).
Second Section to High Drive - 6.3 GPM (23.85 LPM).
Third Section to Bang-Bang valve level, Telescope,
Steer, Rotate - 6.3 GPM (23.85 LPM).
Clockwise Rotation.
Ford LSG423, Ford LRG423, Deutz F3L912, Deutz
F3L1011, Wisconsin VG4D with Vickers Valves (2 Speed
Drive Motors).
First Section to Proportional Valve-Drive, Lift, Swing -
15 GPM (56.78 LPM).
Second Section to High Drive - 9 GPM (34.07 LPM).
Third Section to Bang-Bang Valve Level, Telescope,
Steer, Rotate - 9 GPM (34.07 LPM).
Clockwise Rotation.
Auxiliary Power Pump.
Two section, 3.75 GPM (14.19 lpm) each section, 12
VDC motor, clockwise rotation.
Hydraulic Filter - Tank.
Return - Bypass Type.
10 Microns Nominal.
Hydraulic Filter - On-line (Racine Valve
Only).
Return - Non-Bypass Type.

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-3
10 Microns Nominal.
1.3 PERFORMANCE DATA.
Travel Speed.
2WD- 4.5 MPH (7.2 KM/HR).
4WD - 4.0 MPH (6.4 KM/HR).
Gradeability.
2WD- 25% or 14°slope, hard surface.
4WD - 40% or 22°slope, hard surface.
Turning Radius.
2WS/2WD- 16 ft. 6 in. (5.1 m).
2WS/4WD - 16 ft. 6 in. (5.1 m).
Boom Speed Lift.
Up 25 - 40 Seconds.
Down 20 - 30 Seconds.
Telescope Speed.
Extend 50 - 80 Seconds.
Retract 40 - 60 Seconds.
Swing Speed 360°.
Left 61 - 92 Seconds.
Right 61 - 92 Seconds.
Boom Elevation.
+74° (above horizontal).
-22° (below horizontal).
Model 40H+6.
74° +15° ART. (above horizontal)
-22° -80° ART. (below horizontal)
Machine Weight.
Model 40H (2WD) - 11,600 LBS. (5,266 KG.).
Model 40H (4WD) - 12,000 LBS. (5,448 KG.).
Model 40H+6 - 13,350 LBS. (6,005 KG.).
Machine Stowed Height.
Model 40H (2WD) - 7 ft., 10 in. (2.39 M).
Model 40H (4WD) - 7 ft., 10 in. (2.39 M).
Machine Stowed Length.
Model 40H (2WD) - 25 ft.,2 in. (7.67 M).
Model 40H (4WD) - 25 ft.,2 in. (7.67 M).
Model 40H+6 (4WD) - 26 ft., 10 in. (8.18 M).
Machine Width.
Model 40H/40H+6(2WD/4WD) - 7 ft.,11 in. (2.41 M).
Wheelbase.
Model 40H/40H+6 (2WD/4WD) - 92 in. (2.34 M).
1.4 TORQUE REQUIREMENTS.
NOTE: *Retorque after first 200 hours of operation and
every 500 hours thereafter.
NOTE: See Procedure Section for tightening sequence of
turntable bearing bolts.
NOTE: When maintenance becomes necessary or a fas-
tener has loosened, refer to the Torque Chart to
determine proper torque value.
1.5 LUBRICATION.
Ford LSG423/LRG423/LRG425 Engine.
Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).
Description Torque
Value (Dry)
Inter-
val
Hours
A. Bearing To Chas-
sis
110 lbs.
(149 Nm)
*200/500
B. Bearing To Turn-
table
220 lbs.
(298 Nm)
*200/500
C. Wheel Lugs 90 lbs.
(122 Nm)
100
D. Drive Hub 150 lbs.
(204 Nm)
*200/500
E. Swing Hub 110 lbs.
(149 Nm)
*200/500
When Outside Temp is
Consistently
Use SAE
Viscosity Number

SECTION 1 - SPECIFICATIONS
1-4 – JLG Lift – 3120240
Multi-Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).
* Not recommended for severe service - including high
RPM operation.
Deutz F3L912/F3L1011 Engine.
Single Viscosity Oils (CD-SE, CD-SF).
Multi-Viscosity Oils (CD-SE, CD-SF).
* This viscosity can be used at colder temperatures only
with engine oil preheating.
Wisconsin VG4D Engine.
Single Viscosity Oils (MS or SD).
Multi-Viscosity Oils (MS, SD, SE).
NOTE: Crankcase oil should meet one of the following API
classification grades: SE/CC, SE/CD, SF/CC, SF/
CD.
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser-
vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity of 10W-30
and viscosity index of 152.
When temperatures remain consistently below +20°
F. (-7° C.), an amount of no. 2 diesel fuel, not to
exceed 20% of system capacity, may be added to
the hydraulic oil reservoir. This diesel fuel will “thin”
the hydraulic oil for easier cold weather operation,
and will almost completely dissipate from the hydrau-
lic system over a several month period of time. When
cold weather is past, it may be necessary to drain
and refill the hydraulic system to rid the system of
any remaining diesel fuel.
Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities. If use of hydraulic oil other
than Kendall Hyken 052 is desired or Mobilfluid 424,
contact JLG Industries for proper recommendations.
-10° F - +60° F.
(-24°C. to +16°C.)
*10W
+10° F - + 90° F.
(+12°C. to +32°C.)
20W-20
Above +32° F. (+0°C.) 30
Above + 50° F. (+10°C.) 40
When Outside Temp
is Consistently
Use SAE
Viscosity Number
Below +10° F. (+12°C.) *5W-20
Below +60° F. (+16°C.) 5W-30
-10° F - +90° F.
(-23°C. to+32°C>)
10W-30
Above -10° F. (23°C.) 10W-40 or 10W-50
Above +20° F. (-23°C.) 20W-40 or 20W-50
When Outside Temp
is Consistently
Use SAE
Viscosity Number
-20° F - +25° F.
(-29°C. to +4°C.)
*10W
+5° F - + 50° F.
(+15°C. to +10°C.)
20W-20
+40° F - +85° F.
(+4°C. to +30°C.)
30
Above 75° F. (24°C.) 40
When Outside Temp
is Consistently
Use SAE
Viscosity Number
-40° F - +75° F.
(-40°C, to +24°C.)
*5W-20 (Synthetic)
-15° F - +70° F.
(-26°C. to +21°C.)
10W-30
-15° F - +85° F.
(-26°C. to +30°C.)
10W-40
+5° F - +75° F.
(-21°C. to +24°C.)
15W-30
Above +5° F. (-21°C.) 15W-40
When Outside Temp
is Consistently
Use SAE
Viscosity Number
+15° F - 0° F. 10W
+40° F - + 15° F. 20-20W
+120° F - + 40° F. 30
When Outside Temp
is Consistently
Use SAE
Viscosity Number
Below Zero.( 5W-20
Table 1-1. Hydraulic Oil.
Hydraulic System
Operating
Temperature Range
SAE Viscosity
Grade
0° F to +180° F (-18°C. to 83°C.) 10W
0° F to +210° F (-18° C to 99° C) 10W-20/10W-30
50° F to 210° F (10° C to 99° C) 20W-20

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-5
Figure 1-1. Torque Chart.

SECTION 1 - SPECIFICATIONS
1-6 – JLG Lift – 3120240
Figure 1-2. Lubrication Chart. (Sheet 1 of 2)

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-7
*Check oil level after every 50 hours of operation. Change oil after every 2 years (1200 hrs.) of operation.
**Check oil level after every 10 hours of operation. Change oil after every 3 months (150 hrs.) of operation.
***Replace filter element after first 40 hours of operation, then after every 6 months (300 hrs.) of operation thereafter.
****Check oil level after every 10 hours of operation.Change oil after every 2 years(1200 hrs.) of operation.
*****It will be necessary to swing the boom over side of frame and remove the frame shield to gain access to
the grease fitting.
NOTE: Lubrication intervals are based on machine operations under normal conditions. for machines used in multi shift opera-
tions and /or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.
Figure 1-2. Lubrication Chart. (Sheet 2 of 2)
INDEX
NO.
COMPONENT NUMBER/TYPE
LUBE POINTS
LUBE & METHOD INTERVAL
(HOURS)
1. Wheel Drive Hub Fill Plug/1/2 Full EPGL (SAE - 90) *50/2 years
2. Slave Leveling Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150
3. Slave Leveling Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
4. Rotary Platform Control Stand (If Equipped)
Platform Pivot
2 Grease Fittings
1 Grease Fitting
MPG - Pressure Gun
MPG - Pressure Gun
150
150
5. Rotary Worm Gear (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
6. Platform Hinges 2 Grease Fittings MPG - Pressure Gun 150
7. Platform Latch & Control Handle Slide Locks N/A SAE 10 - Oil Can A/R
8. Telescope Cylinder Sheave (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
9. Swing Bearing (Remote Access) 2 Grease Fittings MPG - Pressure Gun 150
10. Lift Cylinder - Barrel End (Remote Access) 1 Grease Fitting MPG - Pressure Gun 150
11. Lift Cylinder - Rod End 2 Grease Fittings MPG - Pressure Gun 150
12. Master Level Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
13. Master Level Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150
14. Boom Pivot Bushings 2 Grease Fittings MPG - Pressure Gun 150
15. Engine Crankcase Fill Cap/Drain Plug EO (Refer to end. manual) **10/150
16. Lockout Cylinder - Barrel End
(If Equipped)
1 Grease Fittings MPG - Pressure Gun 100
17. Lockout Cylinder - Rod End (If Equipped) 2 Grease Fittings MPG - Pressure Gun 150
18. Oscillating Axle Pivot Pin (If Equipped) 1 Grease Fitting MPG - Pressure Gun *****150
19. Steer Cylinder 2 Grease Fittings MPG - Pressure Gun 150
20. Steer Spindle 2 Grease Fittings MPG - Pressure Gun 150
21. Steer Spindle - 4WD (If Equipped) 4 Grease Fittings MPG - Pressure Gun 150
22. Tie Rod Ends 2 Grease Fittings MPG - Pressure Gun 150
23. Tie Rods - Two Hitch (If Equipped) 4 Grease Fittings MPG - Pressure Gun 150
24. Towing Hitch (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
25. Wheel Bearings N/A MPG - Repack 500
26. Wheel Drive Hubs - 4WD (If Equipped) Fill Plug/1/2 Full EPGL (SAE - 90) *50/2 yrs.
27. Swing Hub Fill Plug EPGL (SAE - 90) *50/2 yrs.
28. Swing Bearing & Pinion Gear Teeth N/A MPG - Brush 100
29. Door & Access Panel Hinges N/A SAE 10 - Oil Can A/R
30. Hydraulic Filter Element, Return N/A Replacement Element ***40/300
31. Hydraulic Filter Element, Inline N/A Replacement Element ***40/300
32. Hydraulic Fluid (Oil) Fill Plug/1/2 Full HO ****10/2 yrs.
33. E.A.R. Pivot (If Equipped) 2 Grease Fittings MPG - Pressure Gun 150
34. E.A.R. Lift Cylinder Barrel End (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
35. E.A.R. Link Boom End (If Equipped) 2 Grease Fittings MPG - Pressure Gun 150
36. E.A.R. Lift Cylinder Rod End (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
37. E.A.R. Slave Cylinder Pivot Points
(If Equipped)
2 Grease Fittings MPG - Pressure Gun 150
38. E.A.R. Slave Cylinder Rod End
(If Equipped)
1 Grease Fitting MPG - Pressure Gun 150
39. E.A.R. Link Platform End (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150
40. E.A.R. Platform Pivot (If Equipped) 1 Grease Fitting MPG - Pressure Gun 150

SECTION 1 - SPECIFICATIONS
1-8 – JLG Lift – 3120240
Lubrication Specifications.
NOTE: Refer to Lubrication Chart, Figure 1-2, for specific
lubrication procedures.
1.6 PRESSURE SETTINGS.
NOTE: All pressure are given in pounds per square inch
(psi), with the metric equivalent, Bar, in parentheses.
Racine Proportional Valve.
Racine.
Main Relief - 2800 psi. (193.06 Bar).
Drive - 2800 psi. (193.06 Bar).
Lift Up - 2800 psi. (193.06 Bar).
Lift Down - 1100 psi. (75.85 Bar).
Swing - 1000 psi. (68.95 Bar).
Vickers - Proportional Valve w/o Tele.
Vickers.
Drive - 3000 psi. (206.85 Bar).
Lift Up - 2500 psi. (172.38 Bar).
Lift Down - 1200 psi. (82.74 Bar).
Swing - 1100 psi. (75.85 Bar).
Accessory.
Main Relief - 3200 psi. (220.64 Bar).
Sequence Cartridge - 450 psi. (31.03 Bar).
Pressure Reducing - 600 psi. (41.37 Bar).
Solenoid Valve.
Main Relief - 2500 psi. (172.38 Bar).
Te l es c o p e I n .
a. 2 Section Boom - 2000 psi
(137.9 Bar).
b. 3 Section Boom - 2500 psi.
(172.38 Bar).
Telescope Out - 1500 psi (103.43 Bar).
Rotate - 2500 psi (172.38 Bar).
Level Up - 2500 psi (172.38 Bar).
Level Down - 1500 psi (103.43 Bar).
Steer.
a. Without Wheel - 1500 psi.(103.43 Bar).
b. Without Wheel - 2500 psi.(172.38 Bar).
Vickers Proportional Valve.
Vickers.
Drive - 3000 psi.(206.85 Bar).
Lift Up - 2500 psi.(172.38 Bar).
Lift Down - 1500 psi. (103.43 Bar).
Telescope In - 2500 psi. (172.38 Bar).
Telescope Out - 1500 psi. (103.43 Bar).
Swing - 1200 psi. (82.74 Bar).
Main Relief - 3200 psi (220.64 Bar).
Sequence Cartridge - 400 psi.
(27.58 Bar).
Pressure Reducing - 600 psi.
(41.37 Bar).
Table 1-2. Lubrication Specifications.
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum
dripping point of 350 degrees F. Excellent
water resistance and adhesive qualities;
and being of extreme pressure type
(Timken OK 40 pounds minimum).
EPGL Extreme Pressure Gear Lube (oil) meeting
API Service Classification GL-5 or Mil-Spec
Mil-L-2105.
HO Hydraulic Oil. API Service Classification
GL-3, SAE 10W-20, Viscosity Index 152,
e.g. Kendall Hyken 052 or Mobilfluid 424.
EO Engine (crankcase) Oil. Gas - API SF/SG
class, MIL-L-2104. Diesel - API CC/CD
class, MIL-L-2104B/MIL-L-2104C.

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-9
3 Stack Racine Bang-Bang Valve.
Main Relief - 2500 psi. (172.38 Bar).
Steer - 2000 psi. (137.9 Bar).
4WD Steer Pressure - 2000 psi. (137.9 Bar).
Extend-A-Reach Racine Valve.
Extend Up - 2500 psi. (172.38 Bar).
Extend Down - 800 psi. (55.16 Bar).
NOTE: Refer to Section 2 for pressure setting procedures.
1.7 CYLINDER SPECIFICATIONS
1.8 BOOM TAPE
Two Section Boom (American Standard).
Red - 64 in. (162.56 cm).
Yellow - 41 in. (104.14 cm).
Blue - 71.50 in. (181.61 cm).
Three Section Boom (American Standard).
Red - 24.06 in. (61.11 cm).
Yellow - 20.50 in. (52.07 cm).
Blue - 70.75 in. (179.70 cm).
Two Section Boom (Canadian Standard).
Red - 70.75 in. (179.71 cm).
Yellow - 46.24 in. (117.47 cm).
Blue - 59.49 in. (151.12 cm).
Table 1-3. CYLINDER SPECIFICATIONS.
DESCRIPTION BORE STROKE R O D
DIA.
Master Level 2.50 15.25 1.25
Slave Level 2.50 15.21 1.25
Lift 6.00 23.50 2.50
Lockout
(Oscillating Axle)
3.00 4.56 1.25
Lock-
out
(4WD)
3.00 4.06 1.25
Te le s c o pe
(2 Section Boom)
3.00 174.18 2.00
Te le s c o pe
(3 Section Boom)
3.00 110.31 2.00
Steer (2WD) 3.00 8.06 1.25
Steer (4WD) 3.00 9.81 1.50
Extend-A-Reach
Lift 3.00 12.687 2.00
Slave 3.50 7.25 1.75

SECTION 1 - SPECIFICATIONS
1-10 – JLG Lift – 3120240
1.9 MAJOR COMPONENTS WEIGHTS
1.10 CRITICAL STABILITY WEIGHTS
1.11 SERIAL NUMBER LOCATION (SEE FIGURE 1-4.)
A serial number plate is affixed to the left rear front of the turntable. If the serial number plate is damaged or missing, the
machine serial number is stamped on the left side of the frame between front and rear wheels, below turntable bearing. In
addition, the last five digits of the serial number are stamped on top of the fly and base end of the boom and on the left side
of the turntable.
TABLE 1-4. COMPONENT WEIGHTS.
MODEL40H MODEL 40H+6
LBS. KG LBS. KG
Platform - 36" x 48" (91.4 cm x 122 cm)
w/Control Box.
170 78 170 78
Platform - 36" x 60" (91.4 cm x 152 cm)
w/Control Box.
185 84 185 84
Platform - 36" x 72" (91.4 cm x 182.88 cm)
w/Control Box.
200 90 200 90
Platform - 36" x 96" (91.4 cm x 243.84 cm)
w/Control Box.
240 109 - - - - - -
2 Section Boom (Includes Boom Lift
Cylinder, Rotator and Support).
1795 814 2165 982
3 Section Boom (Includes Boom Lift
Cylinder, Rotator and Support).
2275 1032 2645 1200
Turntable Complete. 4687 2126 5925 2688
Frame Complete (Includes Pneumatic Tires and Wheels).
(2WD)
5020 2277 5020 2277
Frame Complete (Includes Pneumatic Tires and Wheels).
(4WD)
5420 2458 5420 2458
Complete Machine - 2WD. 11,600 5,266 13,350 6,055
Complete Machine - 4WD. 12,000 5,448 13,750 6,237
TABLE 1-5.CRITICAL STABILITY WEIGHTS.
MODEL 40H MODEL 40H+6
LBS. KG LBS. KG
Counterweight
(If Removable)
1.5:1 910 412.8 2490 1129.5
2:1 1075 487.6 2690 1220.2
Tires
(ballasted Only)
sIZE 12.5L -15 12.5L -15
Weight 305 138.4 305 138.4
Engine Ford 525 238.1 525 238.1
Deutz 600 272.2 600 272.2
Wisconsin - - - - - - - - - - - -

SECTION 1 - SPECIFICATIONS
3120240 – JLG Lift – 1-11
Figure 1-3. Serial Number Locations.

SECTION 1 - SPECIFICATIONS
1-12 – JLG Lift – 3120240
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