JLG 10msp Installation and user guide

SerSer
vice and Maintenance Mavice and Maintenance Ma
nualnual
ANSIANSI
ModelModel
10MSP10MSP
VV
ertical Liftertical Lift
P/N - 3121228P/N - 3121228
April 29, 2April 29, 2
013013
®®

NOTES:NOTES:

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSINTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
33
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MAINTENANCE SAFETY PRECAUTIONSMAINTENANCE SAFETY PRECAUTIONS
AA
..
GG
EE
NN
EE
RR
AA
LL
This section contains the general safety precautionsThis section contains the general safety precautions
which must be observed during maintenance of the aerialwhich must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per-platform. It is of utmost importance that maintenance per-
sonnel pay strict attention to these warnings and precau-sonnel pay strict attention to these warnings and precau-
tions to avoid possible injury to themselves or others ortions to avoid possible injury to themselves or others or
damage to the equipment. A maintenance program mustdamage to the equipment. A maintenance program must
be established by a qualified person and must be followedbe established by a qualified person and must be followed
to ensure that the machine is safe to operate.to ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT MODIFICATION OF THE MACHINE WITHOUT
CERTIFICATCERTIFICAT
ION BYION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEASTA RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA-
TION.TION.
The specific precautions to be observed during machineThe specific precautions to be observed during machine
maintenance are inserted at the appropriate point in themaintenance are inserted at the appropriate point in the
manual. These precautions are, for the most part, thosemanual. These precautions are, for the most part, those
that apply when servicing hydraulic and larger machinethat apply when servicing hydraulic and larger machine
component parts.component parts.
Your safeYour safe
ty, and ty, and
that that
of oof o
thersthers
, i, i
s ts t
he he
first first
considconsid
eratierati
onon
when engaging in the maintenance of equipment. Alwayswhen engaging in the maintenance of equipment. Always
be conscious of component weight and never attempt tobe conscious of component weight and never attempt to
move heavy parts without the aid of a mechanical device.move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to Do not allow heavy objects to
rest in an unstable position.rest in an unstable position.
When raising a portion of the equipment, ensure that When raising a portion of the equipment, ensure that
ade-ade-
quate support is provided.quate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.OPERATOR.
B.B.
HYDHYD
RARA
ULIULI
C SC S
YSTYST
EM EM
SAFSAF
ETYETY
1.1.
It shIt sh
ould ould
be pbe p
articuarticu
larly larly
noted noted
that that
the the
machimachi
nesnes
hydraulic systems operate at extremely high andhydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort shouldpotentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to dis-be made to relieve any system pressure prior to dis-
connecting or removing any portion of the system.connecting or removing any portion of the system.
2.2.
RelievReliev
e syse sys
tem ptem p
ressuressu
re by re by
lowerlower
ing ing
the pthe p
latfolatfo
rmrm
completely to direct any line pressure back into thecompletely to direct any line pressure back into the
return line to the reservoir. Pressure feed lines toreturn line to the reservoir. Pressure feed lines to
system components can then be disconnected withsystem components can then be disconnected with
minimal fluid loss.minimal fluid loss.
C.C.
MAMA
ININ
TETE
NANA
NCNC
EE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED INFAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
••
REMOVE REMOVE
ALL RINGS, ALL RINGS,
WATCHEWATCHE
S, AND JS, AND J
EWELRYEWELRY
WHEN PERFORMING ANY MAINTENANCE.WHEN PERFORMING ANY MAINTENANCE.
••
DO NOT DO NOT
WEAR LWEAR L
ONG HAIR ONG HAIR
UNRESTRAINED, UNRESTRAINED,
OROR
LOOSE FITTING CLOTHING AND NECKTIES WHICHLOOSE FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLEDARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIIN EQUI
PMENTPMENT
..
••
OBSERVE AND OBSERVE AND
OBEY ALL OBEY ALL
DANGER, WDANGER, W
ARNING, CAU-ARNING, CAU-
TION AND OTHER INSTRUCTIONS ON MACHINETION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.AND IN SERVICE MANUAL.
••
KEEP STKEEP ST
ANDING SURFANDING SURF
ACES AND HAND ACES AND HAND
HOLDSHOLDS
FREE OF OIL, GREASE, WATER, ETC.FREE OF OIL, GREASE, WATER, ETC.
••
NEVER WORK NEVER WORK
UNDER AN ELEUNDER AN ELE
VATED VATED
PLATFORMPLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINEDUNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVER-FROM ANY MOVEMENT BY BLOCKING OR OVER-
HEAD SLING.HEAD SLING.
••
BEFORE BEFORE
MAKING ADJUSMAKING ADJUS
TMENTS, LTMENTS, L
UBRICATING UBRICATING
OROR
PERFORMING ANY OTHER MAINTENANCE, SHUTPERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.OFF ALL POWER CONTROLS.
••
BATTERY SHOULBATTERY SHOUL
D ALWAD ALWA
YS BE DISCYS BE DISC
ONNECTEDONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPO-DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.NENTS.
••
KEEP ALL KEEP ALL
SUPPORT EQSUPPORT EQ
UIPMENT AND AUIPMENT AND A
TTACH-TTACH-
MENTS STOWED IN THEIR PROPER PLACE.MENTS STOWED IN THEIR PROPER PLACE.
••
USE ONLUSE ONL
Y APPROVEDY APPROVED
, NONFLAMMABLE C, NONFLAMMABLE C
LEANINGLEANING
SOLVENTS.SOLVENTS.

INTRODUCTION - REVISION LOG
b
– JLG Lift –
3121228
REVISION LOG
Original Issue of
Manual
. . . . . . . . .
. . . .
December 23, 2005
Manual Revised. . . . . .
. . . . . . . . . . . . . .
January 2, 2005
Manual Revised. . . . . .
. . . . . . . . . . . . . .
January 6, 2005
Manual Revised. . . . . . . . . . . . .
. . . . . . .
May 23, 2006
Manual Revised. . . . .
. . . . . . . . . . . . . . .
October 4, 2006
Manual Revised. . . . . . . . . . . . .
. . . . . . .
December 5, 2007
Manual Revised. . . . .
. . . . . . . . . . . . . . .
September 18, 2008
Manual Revised. . . . . .
. . . . . . . . . . . . . .
February 4, 2011
Manual Revised. . . . . . .
. . . . . . . . . . . . .
April 29, 2013

3
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TABLE OF CONTENTS
TABLE OF CONTENTS
S
U
B
J
E
C
T
-
S
E
C
T
I
O
N
,
P
A
R
A
G
R
A
P
H
P
A
G
E
N
O
.
MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
A
GENERAL
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
A
B
HYD
RAUL
IC S
YST
EM S
AFE
TY
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . A
C
MAI
NTE
NAN
CE
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . A
REVISION LOG
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
B
SE
CT
IO
N
1
- MAC
HI
NE SPE
CI
FI
CA
TI
ON
S
1.1
CAPAC
ITIES
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .
. . . . . . . . .1-2
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Drive Motor GearBox (Gear Oil)
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
1-2
1.2
COMP
ONEN
T DATA
. . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .
. .
1-2
Hydraulic Pump/Pump Moto
r Assembly
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . .
1-2
Rear Wheel Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Batteries/Battery Charger
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
1-2
1.3
PERFO
RMANC
E DATA
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . .1-2
Platform Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Material Tray Size
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
1-2
Platform Height - (Fully Elevated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Platform Maximum (Working) Height
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . .
1-2
Machine Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Overall
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
.
1-3
Platform Entry Height (Floor to Platform Floor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Machine Ground Clearance
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
1-3
Machine Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.4
TORQ
UE REQ
UIREME
NTS . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . .1-3
1.5
CYLIN
DER S
PECIF
ICATIO
NS
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .
. .
1-3
1.6
SERIA
L NUMBE
R LOC
ATION
S . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . .1-3
1.7
LUBRIC
ATION
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . .1-3
Hydraulic Oil
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
.
1-3
Lubrication Specific
ations
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
1-3
1.8
TORQ
UE SPS
CIFIC
ATION
S. . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . .1-5
SEC
TIO
N
2
- G
ENE
RAL
SER
VIC
E I
NFO
RMA
TIO
N
2.1
MACHI
NE PREP
ARATIO
N, INSP
ECTIO
N, AND MAI
NTEN
ANCE . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preparation, Inspection, and Main
tenance
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
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
PREV
ENTIV
E MAINT
ENANC
E AND INS
PECT
ION SC
HEDUL
E . . . . .
. . . . . . . . . . . . . . . . . . . .
. .
2-2
Maintenance and Inspection Tab
le Codes:
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
2-4
Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.3
SERVI
CING
AND MAIN
TENAN
CE GU
IDELI
NES. . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Safety and Workmanship
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

ii
– JLG Lift –
3121228
TABLE OF CONTENTS
Components Removal and Installati
on
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . .
2-5
Component Disassembly and
Reassembly
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
.
2-5
Pressure-Fit Parts
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
2-5
Bearings
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . .
2-5
Gaskets
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . .
2-5
Bolt Usage and Torque Applicati
on
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . .
2-6
Hydraulic Lines and Electrical Wiri
ng . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
2-6
Hydraulic System. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
2-6
Lubrication and Servicing . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
2-6
Batteries
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . .
2-6
Mast Chain Inspection Procedure. . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
2-6
2.4
LUBRIC
ATION I
NFOR
MATION
. . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .
. .
2-8
Hydraulic System. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
2-8
Hydraulic Oil
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
2-8
Changing Hydraulic O
il
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
2-8
Lubrication Specificat
ions
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
2-8
SE
CT
IO
N
3
-
BA
SE
CO
MPO
NE
NT
S
3.1
BASE A
SSEMB
LY CO
MPONE
NTS . . . . . . . . . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .3-1
3.2
BASE F
RAME C
OVER
S
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . .3-2
Carry Deck Support Frame - Installatio
n
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
.
3-2
Rear Bumper Cover - Installation
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-3
Drive Motor Cover - Installation
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
3-3
3.3
DRIVE
AND CA
STER W
HEEL
S . . . . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .
. .
3-4
Tire Wear and Damage . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
3-4
Wheel and Tire Replacement
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-4
Wheel Installation. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
3-4
(Front) Caster Wheel - Installation. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-4
3.4
DRIVE
/ELE
VATIO
N CUT-
OUT SWI
TCH IN
STALL
ATION. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . .3-5
3.5
WHEE
L DRIV
E ASSE
MBLY - S
ERVIC
ING . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . .
3-5
Roll and Leak Testing
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-5
Oil Type and Capacity
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-5
Drive Motor Brush Wear - Warning Indicatio
n. . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-6
Wheel Drive Assembly - Removal From Machine
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
3-6
Wheel Drive Disassembly - Main Components. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
3-8
Replacing Drive Motor Brushes. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
3-9
Gear Box Main Disassembly
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-11
Input Carrier Disassembly
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
3-12
Hub - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-13
Spindle Disassembly
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
3-14
Spindle Sub-Assembly
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
3-15
Hub Sub-Assembly . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . .
3-16
Input Carrier Sub-Assembly
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
3-17
Main Gear Box Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
3-18
Motor, Brake and Gear Box Assembly . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-19
3.6
PUMP-
MOTO
R ASSEM
BLY -
SERVI
CE PR
OCED
URE . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . .3-20
General
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. .
3-20
Hydraulic Pressure Settings and Ad
justment
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-20
Hydraulic Pressure Gauge Connect
ion. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . .
3-21
After Filter Pressure Check
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
3-21
Pump-Motor Assembly - Remove/Instal
l
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
3-22
Pump-Motor Assembly - Remove/Instal
l
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
3-22
Motor Assembly - Remove/Install - Reference Marks
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-22
Motor/Brush Cover - Remove/Install
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . .
3-23
Brush Carrier Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
3-24
Brush Assembly - Remove/Install . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
3-24

3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
iii
TABLE OF CONTENTS
Tank Remove/Install
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
3-24
Filter Screen Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Pump Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Pressure Adjust Valve Remove/Install
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. .
3-25
Pressure Check Valve - Remove/Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3.7
BATTE
RIES AN
D BATTE
RY CHAR
GER -SE
RVICE
PROC
EDURE
S . . . . . . . . .
. . . . . . . . . . . . . .
3-26
Battery Condition Testing
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . .
3-26
Battery Replacement
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
3-26
Battery - Installation (2-12
V Batteries)
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . .
3-26
Battery Installation - (4-6V Bat
teries) (OPTION)
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
3-27
Battery Charge LED Indicat
or on Platform Control Co
nsole
. . . . . . . . . . . . . . . .
. . . . . . . .
3-28
Battery Low Voltage Warning Indic
ators
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
3-28
Battery Charger General Information
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
3-29
Battery Charging Status Indic
ators
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. .
3-29
Battery Charger Maintenance Informatio
n
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
3-30
Battery Charger Check/Change Ch
arging Algorithm
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
3-30
Battery Charger Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
SE
CT
IO
N
4
- C
ON
TR
OL
CO
MP
ON
EN
TS
4.1
CONT
ROL C
OMPO
NENT
S OVE
RVIEW
. . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . .
. .
4-1
4.2
CONT
ROL C
OMPO
NENT
S - INST
ALLAT
ION . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . . . . . .
. . .4-2
Ground Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Traction Control Module . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . .
4-3
Platform Control Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Platform Junction Box - Inst
all/Remove
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
4-4
Junction Box to Ground Control Harness - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Platform Interlock Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.3
GROUN
D CON
TROL M
ODUL
E - SE
RVICE
PROC
EDURE . . . . . . .
. . . . . . . .
. . . . . . . . .
. . . . . . .4-7
Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Power Selector/EStop Switch Installat
ion
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
4-9
4.4
GROUN
D CON
TROL M
ODUL
E - PRO
GRAMMI
NG. . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . . . .4-10
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Programming Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Activating Programming Mo
de
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . .
4-10
Entering Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Programming Mode Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Selecting Programmable Item to Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Adjusting Programmable Setting
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . .
4-11
Service Programming Mode - (Level-2)
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
4-12
Operator Programming Mod
e - (Level-3)
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
.
4-12
4.5
PLATF
ORM CO
NTROL
CONS
OLE - SE
RVIC
E PROC
EDURE
S
. . . . . . . . . . . . . . . . .
. . . . . . . . .
4-15
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Remove Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Display/Controller Module Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Mounting Bracket - Install/Remove
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . .
4-16
Rear Cover - Install/Remove
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
4-16
Display/Controller Module - Install/Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Drive/Lift Mode Switch - Install/Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Horn Button Switch - Install/Remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Key Switch - Install/Remove
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
4-17
E-Stop/ShutDown Switch
- Install/Remove
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
4-18
Joystick Assembly - Install/Remove
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
.
4-18

SECTION 1 -
MACHINE SPECIFICATIONS
1-2
– JLG Lift –
3121228
1
.
1
C
A
P
A
C
I
T
I
E
S
System Voltage
24 Volt DC
Hydraulic System
5 qts. U.S. (4.7 L)
Drive Motor GearBox (Gear Oil)
10 oz. (296cc)
1.
2
CO
MP
ON
E
NT D
AT
A
Hydraulic Pump/Pump Motor Assembly
Pump Motor - 24 Volt DC motor, Standard Duty
Pump Displacement -
.098 cu. in./rev. (1.6cc/rev.)
Pump Output (Max.) - 2.25 gpm @ 1400 psi @ 24 volts
and 105 amps @ 43 centistrokes (200 SSU)
Reservoir Capacity - 1 Gallon (3.78 L)
Rear Wheel Drive Motors
Drive Motors - 24 Volt DC, Variable
Gear Box
-
3500 in.lb. (395
.5 Nm) - Continuous Outp
ut
7000 in.lb. (791 Nm) - Intermittent Output
30.68:1 Gear Ratio
Bra
kes -
Fr
ict
ion D
isk - S
pri
ng Ap
pli
ed - E
lec
tri
cal
ly
Released
Batteries/Battery Charger
Batteries - 12 Volt DC (2 in
series @ 24 volt)
6 Volt DC (4 in series @ 24 volt)
Nominal Capacity - 12V - 100 Amp Hour @ 20 Hr.
6V - 210 Amp Hour @ 20 Hr.
T
ype - M2
Marine Combination (AGM)/Valve Regulated/
Leak Proof/NonCorrosive/Maintenance Free
Weight
-12V - 65.7 lb. (29.8 Kg)
- Per Battery
6V
-
64
lb.
(29 K
g) -
Per
Battery
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC-
TORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG' S
AFTERMARKET P
ARTS DISTRIBUTION CEN-
TERS OR JLG' S AFTERMARKET PROGRAMS. FOR ASSISTANCE
WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT
YOUR LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM-
PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTER-
IES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE
ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES
NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES
ARISING FROM THE USE OF NON APPROVED BATTERIES.
Battery Charger -
Microprocessor Controlled/SCR Circuit Monitor
120/240 Vol
t A.C. Selectable
/ 50/60 Hz input
24 volt, 20 amp output -
with 2 amp finish
Reset Circuit Breaker
Automatic Charge Circui
t
Plug Interlock Circuit
NOTE:
The 10MSP batteries require approximately five (5)
hours to fully charge when drained to 80% discharge
- (Only the RED LEDS on platform console lit).
1.
3
P
ER
FO
RM
AN
CE
DA
TA
Platform Capacity
NOTE:
Distribute weight evenly in platform and
material tray
when loading. Reference the capacity decal located
on the machines mast cover in the operators plat-
form.
Maximum Horizontal Manual Side Force
(Platform fully extended with Maximum load)
ANSI/CSA:
100 Lb. (445 N)
CE/AUST/JPN:
45 Lb.
(200 N)
Platform Size
23 in.-
W x 19.5 in.-L
(58cm) x (49cm)
Material Tray Size
28.75 in.-
W x 25.68 in.-L
(73cm) x (65cm)
Platform Height - (Fully Elevated)
10 ft. (3.05m) - Standard (To floor of platform)
7 ft. (2.13m) - with
Height Limiter (T
o floor of platform)
Platform Maximum (Working) Height
(Platform fully elevated + Operator height)
16 ft. (4.92m) approximately
T
able
1-2.
Platform
Maximum
Capacity
SPECIFICATION
MAXIMUM CAPACITY
MAX. WIND
SPEED
Platform
Load
Material
Tray Load
Carry
Deck
ANSI/CSA
350 lb.
(160kg)
250 lb.
(115kg)
250 lb.
(115kg)
28 mph
(12 m/s)
CE
(Indoor Use Only)
0 m/s
Australia
(Indoor Use Only)
0 m/s

SECTION 1 -
MACHINE SPECIFICATIONS
3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
1-3
Machine Height
Platform Elevated - 13.74
ft. (4.19m)(T
op of platform rails)
Platform Stowed - 57 in.
(1.44m)
Machine Overall
Length - 61 in. (1.55m)
Wid
th -
29.
5 in. (
75c
m) st
and
ard
32.5 in. (82.5cm) with bumpers
35.0 in. (89cm) with roller guides
Platform Entry Height (Floor to Platform Floor)
13.75 in. (34.9cm)
Machine Ground Clearance
Front - 0.872 in. (22mm)
Center - 1.872 in. (47.5mm)
Rear - 0.622 in. (16mm)
Machine Turning Radius (Outside)
106 in. (269cm)
1.
4
T
OR
QU
E
RE
QU
IRE
ME
NT
S
When maintenance becomes necessary or a fastener has
loosened, refer to the applicable Torque Chart in this sec-
tion of the manual to
determine proper torque values for
various size fasteners.
1.
5
CY
LIN
DE
R S
PE
CI
FIC
AT
ION
S
NOTE:
All dimensions are given in inches (in), with the
met-
ric equivalent, centimeters (cm), given in parenthe-
ses.
1.
6
SE
RI
AL
NU
MB
ER
LOC
AT
ION
S
For machine identification, a serial number plate is affixed
to the machine. The plate is
mounted on the base frame
between the front caster wheels
under the front cover
. The
serial number is also stamped on the front of the
mast
assembly near the amber beacon.
1.
7
LU
BR
IC
A
TI
ON
Hydraulic Oil
Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stabil-
ity for mobile hydraulic system service. JLG Industries,
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity of 10W-30 and a viscosity index of 152.
For cold weather applications, i.e. when temperatures
remain consistently below +20°F (–7°C) JLG recom-
mends using Mobil DTE 13 hydraulic oil.
Aside
from
JLG r
ecomme
ndation
s,
it is
not
advisa
ble
to
mix oils of different brands or types, as they may not con-
tain the same required additives or be of comparable vis-
cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda-
tions.
Lubrication Specifications
T
able 1-3.
Cylinder Specifications
DESCRIPTION
BORE
in./(cm)
STROKE
in./(cm)
ROD DIA.
in./(cm)
10MSP -
Lift Cylinder
1.63
(4.10)
41.50
(105.4)
1.375
(3.49)
Table 1-4. Hydraulic Oil Operating Range
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
T
able 1-5.
Lubrication Specifications
K
E
Y
S
P
E
C
I
F
I
C
A
T
I
O
N
S
MPG -
Multipurpose Grease having a minimum dripping
point of 350°
F
. Excellent water re
sistance and
adhesive qualities, and being of extreme pressure
type.
(Timken
OK
40
pounds
minimum.)
EPGL -
Extreme Pressure Gear Lube (oil) meeting API ser-
vice classi
ficatio
n GL-5
or MIL-Spec MIL-L
-2105.
HO
-
Hydraulic Oil. ISO-Vg grade 32, 46.
CL
-
Chain Lube. Use a good quality chain lubricant

SECTION 1 -
MACHINE SPECIFICATIONS
1-4
– JLG Lift –
3121228
Lubrication Points.
(See Table Below)
T
able 1-6.
Lubrication Intervals for Various Components
I
T
E
M
C
O
M
P
O
N
E
N
T
NO/TYPE
(a)
LUBE POINTS
LUBE/METHOD
INTERVAL
(b)
COMMENTS
3
MONTHS
6
MONTHS
1
YEAR
2
YEARS
1
H
y
d
r
a
u
l
i
c
O
i
l
Fill To Full Line on
Dipstick - 5 Qt.
Reservoir
HO - Check Hyd. Oil
 Level
HO - Change Hyd. Oil
✔
Check fluid level
every day.
(c)
Change
hydraulic oil every 2 years.
2
S
w
i
v
e
l
R
a
c
e
w
a
y
s
—
M
P
G
✔
Upper: Permanently Sealed.
Lower: Repack if Serviced.
3
M
a
s
t
C
h
a
i
n
s
2
-
P
e
r
S
e
c
t
i
o
n
C
L
-
B
r
u
s
h
o
r
S
p
r
a
y
✔
Inspect, lubricate if dry or rusting.
Key to Lubricants:
MPG
- Multipurpose Grease
HO
- Hydraulic Oil
- ISO-Vg grade 32, 46
GEAR OIL
- Good Quality Worm Gear Oil - SAE 90 - AGMA#5 - EP Compounded
CL
- Chain Lube. Use a good quality chain lubricant
Notes:
(a)
Be
certain
to
lubricate
like
items
on
each
side
of
the
machine.
(b)
Recommended
lubricating
intervals
are
based
on
normal
use. If
machine
is
subjected
to
severe
operating
conditions,
such
as
a
high
number
of
cycles,
location,
corrosive/dirty
environmen
t,
etc.,
user
must
adjust
lubricating
requirements
accordingly
.
(c)
Prior
to
checking
hydraulic
oil
level,
operate
machine
through
one
complete
cycle
of
lift
function
(full
up
and
down).
Failure
to
do
so
will result in incorrect oil level reading on
the hydraulic reservoir.

SECTION 1 -
MACHINE SPECIFICATIONS
3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
1-5
1.
8
T
OR
QU
E SP
EC
IFI
CA
TI
ON
S
Figure 1-1.
T
orque Chart (SAE Fasteners - Sheet 1 of 7)
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
J
L
G
P
/
N
L
o
c
t
i
t
e
®
P
/
N
N
D
I
n
d
u
s
t
r
i
e
s
P
/
N
Description
0100011
242
TM
Vibra-TITE
TM
121
Medium
Strength
(Blue)
0100019
271
TM
Vibra-TITE
TM
140
High Strength (Red)
0100071
262
TM
Vibra-TITE
TM
131
Medium - High Strength (Red)
S
i
z
e
T
P
I
B
o
l
t
D
i
a
Tensile
Stress Area
Clamp Load
I
n
S
q
I
n
L
B
I
N
-
L
B
[
N
.
m
]
I
N
-
L
B
[
N
.
m
]
I
N
-
L
B
[
N
.
m
]
I
N
-
L
B
[
N
.
m
]
4
4
0
0
.
1
1
2
0
0
.
0
0
6
0
4
3
8
0
8
0
.
9
6
0
.
7
4
8
0
.
1
1
2
0
0
.
0
0
6
6
1
4
2
0
9
1
.
0
7
0
.
8
6
3
2
0
.
1
3
8
0
0
.
0
0
9
0
9
5
8
0
1
6
1
.
8
1
2
1
.
4
4
0
0
.
1
3
8
0
0
.
0
1
0
1
5
6
1
0
1
8
2
.
0
1
3
1
.
5
8
3
2
0
.
1
6
4
0
0
.
0
1
4
0
0
9
0
0
3
0
3
.
4
2
2
2
.
5
3
6
0
.
1
6
4
0
0
.
0
1
4
7
4
9
4
0
3
1
3
.
5
2
3
2
.
6
1
0
2
4
0
.
1
9
0
0
0
.
0
1
7
5
0
1
1
2
0
4
3
4
.
8
3
2
3
.
5
3
2
0
.
1
9
0
0
0
.
0
2
0
0
0
1
2
8
5
4
9
5
.
5
3
6
4
1
/
4
2
0
0
.
2
5
0
0
0
.
0
3
1
8
2
0
2
0
9
6
1
0
.
8
7
5
9
1
0
5
1
2
2
8
0
.
2
5
0
0
0
.
0
3
6
4
2
3
2
0
1
2
0
1
3
.
5
8
6
1
0
1
3
5
1
5
I
n
S
q
I
n
L
B
F
T
-
L
B
[
N
.
m
]
F
T
-
L
B
[
N
.
m
]
F
T
-
L
B
[
N
.
m
]
F
T
-
L
B
[
N
.
m
]
5
/
1
6
1
8
0
.
3
1
2
5
0
.
0
5
2
4
3
3
4
0
1
7
2
3
1
3
1
8
1
9
2
6
1
6
2
2
2
4
0
.
3
1
2
5
0
.
0
5
8
0
3
7
0
0
1
9
2
6
1
4
1
9
2
1
2
9
1
7
2
3
3
/
8
1
6
0
.
3
7
5
0
0
.
0
7
7
5
4
9
4
0
3
0
4
1
2
3
3
1
3
5
4
8
2
8
3
8
2
4
0
.
3
7
5
0
0
.
0
8
7
8
5
6
0
0
3
5
4
7
2
5
3
4
4
0
5
4
3
2
4
3
7
/
1
6
1
4
0
.
4
3
7
5
0
.
1
0
6
3
6
8
0
0
5
0
6
8
3
5
4
7
5
5
7
5
4
5
6
1
2
0
0
.
4
3
7
5
0
.
1
1
8
7
7
5
5
0
5
5
7
5
4
0
5
4
6
0
8
2
5
0
6
8
1
/
2
1
3
0
.
5
0
0
0
0
.
1
4
1
9
9
0
5
0
7
5
1
0
2
5
5
7
5
8
5
1
1
6
6
8
9
2
2
0
0
.
5
0
0
0
0
.
1
5
9
9
1
0
7
0
0
9
0
1
2
2
6
5
8
8
1
0
0
1
3
6
8
0
1
0
8
9
/
1
6
1
2
0
.
5
6
2
5
0
.
1
8
2
0
1
1
6
0
0
1
1
0
1
4
9
8
0
1
0
8
1
2
0
1
6
3
9
8
1
3
3
1
8
0
.
5
6
2
5
0
.
2
0
3
0
1
2
9
5
0
1
2
0
1
6
3
9
0
1
2
2
1
3
5
1
8
4
1
0
9
1
4
8
5
/
8
1
1
0
.
6
2
5
0
0
.
2
2
6
0
1
4
4
0
0
1
5
0
2
0
3
1
1
0
1
4
9
1
6
5
2
2
4
1
3
5
1
8
3
1
8
0
.
6
2
5
0
0
.
2
5
6
0
1
6
3
0
0
1
7
0
2
3
0
1
3
0
1
7
6
1
9
0
2
5
8
1
5
3
2
0
7
3
/
4
1
0
0
.
7
5
0
0
0
.
3
3
4
0
2
1
3
0
0
2
6
0
3
5
3
2
0
0
2
7
1
2
8
5
3
8
8
2
4
0
3
2
5
1
6
0
.
7
5
0
0
0
.
3
7
3
0
2
3
8
0
0
3
0
0
4
0
7
2
2
0
2
9
8
3
3
0
4
4
9
2
6
8
3
6
3
7
/
8
9
0
.
8
7
5
0
0
.
4
6
2
0
2
9
4
0
0
4
3
0
5
8
3
3
2
0
4
3
4
4
7
5
6
4
6
3
8
6
5
2
3
1
4
0
.
8
7
5
0
0
.
5
0
9
0
3
2
4
0
0
4
7
0
6
3
7
3
5
0
4
7
5
5
2
0
7
0
7
4
2
5
5
7
6
1
8
1
.
0
0
0
0
0
.
6
0
6
0
3
8
6
0
0
6
4
0
8
6
8
4
8
0
6
5
1
6
7
5
9
1
8
5
7
9
7
8
5
1
2
1
.
0
0
0
0
0
.
6
6
3
0
4
2
2
0
0
7
0
0
9
4
9
5
3
0
7
1
9
7
3
5
1
0
0
0
6
3
3
8
5
8
1
1
/
8
7
1
.
1
2
5
0
0
.
7
6
3
0
4
2
3
0
0
8
0
0
1
0
8
5
6
0
0
8
1
3
8
4
0
1
1
4
2
7
1
4
9
6
8
1
2
1
.
1
2
5
0
0
.
8
5
6
0
4
7
5
0
0
8
8
0
1
1
9
3
6
6
0
8
9
5
9
2
5
1
2
5
8
8
0
2
1
0
8
7
1
1
/
4
7
1
.
2
5
0
0
0
.
9
6
9
0
5
3
8
0
0
1
1
2
0
1
5
1
8
8
4
0
1
1
3
9
1
1
7
5
1
5
9
8
1
0
0
9
1
3
6
8
1
2
1
.
2
5
0
0
1
.
0
7
3
0
5
9
6
0
0
1
2
4
0
1
6
8
1
9
2
0
1
2
4
7
1
3
0
0
1
7
6
8
1
1
1
8
1
5
1
6
1
3
/
8
6
1
.
3
7
5
0
1
.
1
5
5
0
6
4
1
0
0
1
4
6
0
1
9
7
9
1
1
0
0
1
4
9
1
1
5
2
5
2
0
7
4
1
3
2
2
1
7
9
2
1
2
1
.
3
7
5
0
1
.
3
1
5
0
7
3
0
0
0
1
6
8
0
2
2
7
8
1
2
6
0
1
7
0
8
1
7
5
0
2
3
8
0
1
5
0
6
2
0
4
2
1
1
/
2
6
1
.
5
0
0
0
1
.
4
0
5
0
7
8
0
0
0
1
9
4
0
2
6
3
0
1
4
6
0
1
9
7
9
2
0
2
5
2
7
5
4
1
7
5
5
2
3
7
9
1
2
1
.
5
0
0
0
1
.
5
8
0
0
8
7
7
0
0
2
2
0
0
2
9
8
3
1
6
4
0
2
2
2
4
2
3
0
0
3
1
2
8
1
9
7
4
2
6
7
6
NO.
50000
59
REV.
J
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Dry)
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
Torque
Lubricated
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140)
3. * ASSEMBLY USES HARDENED WASHER
NOTES:
1. THESE TORQUE
VALUES DO
NOT
APPLY
TO CADMIUM PLA
TED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER
STANDARD AUDIT METHODS TOLERANCE =
±10%

SECTION 2 - SECTION 2 -
GENERAL SERVICE INFORMATIONGENERAL SERVICE INFORMATION
2-22-2
– JLG Lift –– JLG Lift –
31212283121228
2.22.2
PREPRE
VENVEN
TIVTIV
E E
MAINMAIN
TENTEN
ANCANC
E E
ANDAND
INSPECTION SCHEDULEINSPECTION SCHEDULE
(See(See
Table 2-2Table 2-2
.).)
The preventive maintenance and inspection checks areThe preventive maintenance and inspection checks are
listed and defined in the following table. This table islisted and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspecteddivided into two basic parts, the “AREA” to be inspected
and the “INTERVALand the “INTERVAL
” at which ” at which
the inspection is the inspection is
to taketo take
place. Under the “AREA” portion of the table, the variousplace. Under the “AREA” portion of the table, the various
systems along with the components that make up thatsystems along with the components that make up that
system are system are
listed. The “Ilisted. The “I
NTERVALNTERVAL
” portion of the tab” portion of the tab
le isle is
divided into five columns representing the various inspec-divided into five columns representing the various inspec-
tion time periods. The numbers listed within the intervaltion time periods. The numbers listed within the interval
column represent the applicable inspection code forcolumn represent the applicable inspection code for
which that component is to be which that component is to be
checked.checked.
The checks and services listed in this schedule are notThe checks and services listed in this schedule are not
intended to replace any local or regional regulations thatintended to replace any local or regional regulations that
may pertain to this type of equipment nor should the listsmay pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval timesbe considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depend-may occur due to climate and/or conditions and depend-
ing on the location and use of the machine.ing on the location and use of the machine.
TT
able 2-1. Maable 2-1. Ma
intenance and Inspection intenance and Inspection
Requirements.Requirements.
TT
yy
pp
ee
FF
rr
ee
qq
uu
ee
nn
cc
yy
PrimaryPrimary
ResponsibilityResponsibility
ServiceService
QualificationQualification
ReferenceReference
Pre-StartPre-Start
InspectionInspection
Prior to use each day; orPrior to use each day; or
At each Operator change.At each Operator change.
UU
ss
ee
r r
oo
r r
OO
pp
ee
rr
aa
tt
oo
rr
UU
ss
ee
r r
oo
r r
OO
pp
ee
rr
aa
tt
oo
rr
OO
pp
ee
rr
aa
tt
oo
r r
aa
nn
d d
SS
aa
ff
ee
tt
y y
MM
aa
nn
uu
aa
ll
Pre-DeliveryPre-Delivery
InspectionInspection
Prior to each sale, lease, orPrior to each sale, lease, or
rental deliverrental deliver
yy
..
OwnerOwner
, ,
DealerDealer
, ,
or or
User User
Qualified Qualified
JLGJLG
MechanicMechanic
Service and Maintenance Man-Service and Maintenance Man-
ual and applicable JLG inspec-ual and applicable JLG inspec-
tion tion
form.form.
FrequentFrequent
InspectionInspection
In service for 3 months; or Out of serviceIn service for 3 months; or Out of service
for a period of more than for a period of more than
3 months; or Pur-3 months; or Pur-
chased used.chased used.
OO
ww
nn
ee
rr
, ,
DD
ee
aa
ll
ee
rr
, o, o
r Ur U
ss
ee
rr
QQ
uu
aa
lili
ff
ii
ed ed
JJ
LL
GG
MechanicMechanic
Service and Maintenance Man-Service and Maintenance Man-
ual and applicable JLG inspec-ual and applicable JLG inspec-
tion tion
form.form.
AnnualAnnual
MachineMachine
InspectionInspection
AnnuallyAnnually
, no later than 13 , no later than 13
months from themonths from the
date of the prior inspection.date of the prior inspection.
OO
ww
nn
ee
rr
, ,
DD
ee
aa
ll
ee
rr
, o, o
r Ur U
ss
ee
rr
QQ
uu
aa
lili
ff
ii
ed ed
JJ
LL
GG
MechanicMechanic
Service and Maintenance Man-Service and Maintenance Man-
ual and applicable JLG inspec-ual and applicable JLG inspec-
tion tion
form.form.
PreventativePreventative
MaintenanceMaintenance
At intervals as specified in the Service andAt intervals as specified in the Service and
Maintenance Manual.Maintenance Manual.
OO
ww
nn
ee
rr
, ,
DD
ee
aa
ll
ee
rr
, o, o
r Ur U
ss
ee
rr
QQ
uu
aa
lili
ff
ii
ed ed
JJ
LL
GG
MechanicMechanic
Service and Maintenance Man-Service and Maintenance Man-
ualual

SECTION 2 - SECTION 2 -
GENERAL SERVICE INFORMAGENERAL SERVICE INFORMA
TIONTION
33
11
22
11
22
22
88
– –
JJ
LL
G G
LL
ii
ff
t t
––
2-32-3
TT
able 2-2. 10MSP able 2-2. 10MSP
- Preventive Maintenance & - Preventive Maintenance &
Inspection Schedule.Inspection Schedule.
AREA ON MACHINEAREA ON MACHINE
INTERVALINTERVAL
PRE-START (a)PRE-START (a)
INSPECTIONINSPECTION
3 MONTH3 MONTH
PREVENTATIVEPREVENTATIVE
MAINTENANCEMAINTENANCE
6 MONTH6 MONTH
PREVENTATIVEPREVENTATIVE
MAINTENANCEMAINTENANCE
PRE-DELIVERY (b)PRE-DELIVERY (b)
OR FREQUENT (c)OR FREQUENT (c)
INSPECTIONINSPECTION
ANNUAL (d)ANNUAL (d)
(YEARLY)(YEARLY)
INSPECTIONINSPECTION
MAST MAST
ASSEMBLASSEMBL
YY
77
MM
aa
ss
t t
SS
ee
cc
tt
ii
oo
nn
ss
22
, ,
55
22
, ,
55
CC
hh
aa
ii
n n
SS
yy
ss
tt
ee
mm
ss
11
44
33
, ,
11
44
11
44
, ,
22
55
SS
ee
qq
uu
ee
nn
cc
e e
CC
aa
bb
ll
e e
SS
yy
ss
tt
ee
mm
ss
33
11
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PLATFORM ASSEMBLYPLATFORM ASSEMBLY
77
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CHASSIS CHASSIS
ASSEMBLASSEMBL
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——
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**
——
——
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FUNCTIONS/CONTROLSFUNCTIONS/CONTROLS
77
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POWER SYSTEMPOWER SYSTEM
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HYDRAULIC/ELECTRIC SYSTEMHYDRAULIC/ELECTRIC SYSTEM
99
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55

SECTION 2 - SECTION 2 -
GENERAL SERVICE INFORMATIONGENERAL SERVICE INFORMATION
2-42-4
– JLG Lift –– JLG Lift –
31212283121228
Maintenance and Inspection Table Codes:Maintenance and Inspection Table Codes:
1.1.
CheChe
ck for pck for p
roprop
er and seer and se
curcur
e inste inst
allall
atiati
on.on.
2.2.
VisuaVisua
l insl ins
pectipecti
on fon f
or daor da
mage, mage,
crackcrack
s, dis, di
stortstort
ion, ion,
oror
excessive wear.excessive wear.
3.3.
CheChe
ck ck
for for
propro
per per
adjadj
ustust
menmen
t.t.
4.4.
CheChe
ck fck f
or cor c
racrac
ked ked
or bor b
rokrok
en wen w
eldeld
s.s.
5.5.
OpOp
erer
atat
es es
prpr
opop
erer
lyly
..
6.6.
ReturnReturn
s to ns to n
eutraeutra
l or "l or "
off" off"
posiposi
tion tion
when rwhen r
eleaseelease
d.d.
7.7.
ClCl
eaea
n ann an
d frd fr
ee oee o
f def de
brbr
isis
..
8.8.
IntInt
erlerl
ockock
s fus fu
nctnct
ion ion
propro
perper
lyly
..
9.9.
ChCh
ecec
k fok fo
r sir si
gngn
s of ls of l
eaea
kaka
gege
..
10.10.
DecDec
als als
insins
taltal
led led
and and
legleg
ibib
le.le.
11.11.
CheChe
ck fck f
or or
propro
per per
fluflu
id lid l
eveeve
l.l.
12.12.
CheChe
ck fock fo
r chafr chaf
ing aing a
nd prnd pr
opeope
r rour rou
tintin
g.g.
13.13.
CheChe
ck ck
for for
propro
per per
toltol
eraera
ncence
s.s.
1414
..
PrPr
opop
erer
ly lly l
ubub
riri
caca
tete
d.d.
15.15.
TT
orqorq
ued to prued to pr
opeope
r specr spec
ifiifi
catcat
ionion
..
16.16.
No gNo g
ougesouges
, exc, exc
essivessiv
e weare wear
, or , or
cords cords
showinshowin
g.g.
17.17.
ProPro
perper
ly infly inf
latlat
ed and seed and se
ateate
d aroud arou
nd rimnd rim
..
1818
..
ProPro
per anper an
d autd aut
horhor
izeize
d comd com
ponpon
entent
s.s.
1919
..
FF
ulul
ly ly
chch
arar
gege
d.d.
20.20.
No lNo l
oose oose
connconn
ectioectio
ns, cns, c
orroorro
sion, sion,
or abor ab
rasiorasio
ns.ns.
22
11
..
VV
ee
rr
ii
ff
yy
..
22
22
..
PP
erer
ff
oo
rr
mm
..
2323
..
SeSe
alal
ed ed
prpr
opop
erer
lyly
..
24.24.
OveOve
rrirri
des des
PlaPla
tfotfo
rm crm c
ontont
rolrol
s.s.
25.25.
InspeInspe
cted cted
per per
ServiServi
ce ace a
nd Mnd M
ainteainte
nance nance
ManuaManua
l.l.
Footnotes:Footnotes:
(a) (a)
Prior to use each Prior to use each
day; or at eacday; or at eac
h Operator change.h Operator change.
(b) (b)
Prior to each sale, lease, Prior to each sale, lease,
or deliveryor delivery
..
(c) (c)
In service for 3 months; or Out oIn service for 3 months; or Out o
f service for 3 monthsf service for 3 months
or or
more; more;
or or
Purchased Purchased
used.used.
(d) (d)
AnnuallyAnnually
, no later than 13 months from the d, no later than 13 months from the d
ate of theate of the
prior prior
inspection.inspection.
GENERALGENERAL
OO
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22
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11
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22
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aa
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pp
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ii
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aa
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22
22
22
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uu
nn
cc
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n n
TT
ee
ss
t t
oo
f f
AA
ll
l l
SS
yy
ss
tt
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mm
ss
22
22
22
22
PP
aa
ii
nn
t t
aa
nn
d d
AA
pp
pp
ee
aa
rr
aa
nn
cc
ee
77
77
NN
oo
tt
ii
ff
y y
JJ
LL
G G
oo
f f
cc
hh
aa
nn
gg
e e
ii
n n
MM
aa
cc
hh
ii
nn
e e
OO
ww
nn
ee
rr
ss
hh
ii
pp
22
22
**
ChCh
anan
ge oge o
nlnl
y wy w
hehe
n sn s
erverv
icic
eded
, F, F
ilil
l hal ha
lf flf f
ulul
l.l.
****
RepRep
laclac
e after se after s
ystyst
em brusem brus
h wear ih wear i
ndindi
catcat
or waror war
ning ining i
s acts act
ivaiva
tedted
..
******
Drain Drain
and refand ref
ill witill wit
h fresh hh fresh h
ydrauydrau
lic flulic flu
id every tid every t
wo yeawo yea
rs.rs.
TT
able 2-2. 10MSP - Preventive Maintenance & Inspection Schedule. able 2-2. 10MSP - Preventive Maintenance & Inspection Schedule.
(Continued)(Continued)
AREA ON MACHINEAREA ON MACHINE
INTERVALINTERVAL
PRE-START (a)PRE-START (a)
INSPECTIONINSPECTION
3 MONTH3 MONTH
PREVENTATIVEPREVENTATIVE
MAINTENANCEMAINTENANCE
6 MONTH6 MONTH
PREVENTATIVEPREVENTATIVE
MAINTENANCEMAINTENANCE
PRE-DELIVERY (b)PRE-DELIVERY (b)
OR FREQUENT (c)OR FREQUENT (c)
INSPECTIONINSPECTION
ANNUAL (d)ANNUAL (d)
(YEARLY)(YEARLY)
INSPECTIONINSPECTION

SECTION 2 -
GENERAL SERVICE INFORMA
TION
3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
2-5
2.
3
SE
RVI
CIN
G AN
D MA
INT
EN
AN
CE
GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance proce-
dures contained in this
chapter
.
Safety and Workmanship
Your safe
ty, and
that
of o
thers
, i
s t
he
first
consid
erati
on
when engaging in the maintenance of equipment. Always
be conscious of component 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
ade-
quate support is provided.
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-
FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT
BY BLOCKING OR OVERHEAD SLING.
Cleanliness
The most important single item in
preserving the long ser-
vice life of a machine is to keep dirt and foreign materials
out of 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 main-
tained on a scheduled basis
in order to function properly.
IT IS GOOD PRACTICE TO AVOID
PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS.
IN THE
EVENT PRES-
SURE-WASHING THE MACHINE IS NEEDED, ENSURE THE
MACHINE IS SHUT DOWN BEFORE
PRESSURE-WASHING.
SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS
CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG
INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF
750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5
CM) AWAY
FROM THESE
COMPONENTS.
IF ELECTRICAL/ELEC-
TRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY
SATURATION.
At
any
time
when
oil
lines
are
disconn
ected
, cl
ear
adja-
cent areas as well as the
openings and fitting
s them-
selves. As soon as a line or component is disconnected,
cap or cover all openings to prevent entry of foreign mat-
ter.
Clean and inspect all parts during servicing or mainte-
nance, 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 sim-
ilar 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, com-
plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your
work to assure
that nothing
has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper
approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use an
“anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.
Bearings
When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used
but do not spin the bearing.
Discard bearings if the races and balls
(or rollers)
are pit-
ted, 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 bearings until they are ready to install.
Lubricate new or used serviceable bearings before instal-
lation. When pressing a bearing into a retainer or bore,
apply pressure to the outer race. If the bearing is to be
installed on a shaft, apply pressure to the inner race.
Gaskets
Check that holes in gaskets
align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or
stock of equivalent material
and thickness. Be sure to
cut holes in the right location, as
blank gaskets can cause serious system damage.

SECTION 2 -
GENERAL SERVICE INFORMATION
2-6
– JLG Lift –
3121228
Bolt Usage and Torque Application
Use bolts of proper length. A bolt which is too long will
bottom before the head is tight against its related part. If a
bolt is too short, there will not be enough thread area to
engage and hold the part properly. When replacing bolts,
use only those having the
same specifications of the origi-
nal, or one which is equivalent.
Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
treated bolts, studs, and steel nuts, in accordance with
recommended shop practices or
the T
orque Chart Figures
in Section 1 of this Service Manual.
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles,
when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.
Hydraulic System
Keep the system clean. If evidence of metal or
rubber par-
ticles is found in the hydraulic system, drain and flush the
entire system.
Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components, as required, to aid assem-
bly.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart,
(See Section
1)
. Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds
the specifications listed.
Batteries
Clean batteries, using a non-metallic brush and a solution
of baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry batteries and coat terminals with
an anti-corrosion compound.
Mast Chain Inspection Procedure
Inspect mast chains for the
following conditions:
Wear:
Always inspect that segment
of chain that operates
over a sheave. As the chain flexes over the sheaves, joints
and plate edges very gradually wear. Chain “stretch” can
be measured using a manufacturers wear scale or steel
tape. When chains have elongated 3% they must be
removed and replaced. Refer to
T
able
2-3
for proper chain
specification
s and
allowable stretch tolerances. Peening
and wear of chain plate edges are caused by sliding over
a chain worn contact face of a sheave,
or unusually heavy
loads. All of the above require replacement of the chain
and correction of the cause. Chain side wear, noticeable
when pin heads and outside plates show a definite wear
pattern, is caused by misalignment of the sheave/chain
anchors and must be corrected promptly. Do not repair
chains; if a section of chain is damaged, replace the entire
chain set.
Rust and Corrosion:
Rust and corrosion will cause a
major reduction in the load carrying capacity of the chain,
because these are primary reasons for side plate crack-
ing. The initial lubrication at the factory is applied in a hot
dip tank to assure full penetration into the joint. Do not
steam clean or degrease chains. At time of chain installa-
tion, factory lube must be supplemented by a mainte-
nance program to provide a film of oil on the chains at all
times. If chains are corroded, they must be inspected,
especially the outside plates, for cracks in-line with the
pins. If cracks are found, replace the chain; if no cracks
are discovered, lubricate the chains by dipping in heated
oil, and reinstall on the
machine. Keep chains lubricated.
Fatigue Cracks:
Fatigue is a
phenomenon that affects
most metals, and is the most common cause of chain
plate failures. Fatigue cracks are found through the link
holes, perpendicular
(90 degrees)
from the pin in-line
position. Inspect chains carefully after long time use and
heavy loading for this type of crack. If any cracks are dis-
covered, replace all chains, as seemingly sound plates
Table 2-3. Chain Stretch Tolerance
Chain Size
Pin to Pin
Measurement
Allowable Stretch
.5
0"
pi
tc
h
12
"
or
24
pi
tc
he
s
.2
4
in
./
12
in
.
sp
an
.
6
2
5
p
i
t
c
h
1
5
"
o
r
2
4
p
i
t
c
h
e
s
.
3
0
i
n
.
/
1
5
i
n
.
s
p
a
n

SECTION 2 -
GENERAL SERVICE INFORMA
TION
3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
2-7
are on the verge of cracking. Fatigue and ultimate
strength failures on JLG Lifts are incurred as a result of
severe abuse as design specs are
well within the rated lift-
ing capacity of these chains.
Tight Joints:
All joints in the leaf chain should flex freely.
On leaf chain, tight joints are
usually caused by rust/corro-
sion, or the inside
plates “walking” off the bushing. Limber
up rusty/corroded chains
(after inspecting care fully)
with
a heavy application of oil
(preferably a hot oil dip)
. Tap
inside “walking” plates inward; if “walking” persists,
replace the chain. This type of problem is accelerated by
poor lubrication maintenance practice, and most tight
joint
chains
have
been
operate
d wi
th li
ttle
or n
o lubr
ica-
tion. Tight joints on leaf chain are generally caused by:
a.
Ben
t p
ins
or
pla
tes
.
b.
Ru
st
y jo
in
ts
.
c.
Pe
ene
d p
lat
e ed
ges
.
Oil rusty chains, and replace chains with bent or peened
chain components. Keep chains
lubricated.
Protruding or
T
urned Pins:
Chains operating with inade-
quate lube generate tremendous friction between the pin
and plates (pin and bushing on leaf chain). In extreme
cases, this frictional torque can actually turn the pins in
the outside press-fit plates. Inspect for turned pins, which
can be easily spotted as the “V” flats on
the pin heads are
no longer in line. Replace all chains showing evidence of
turned or protruding pins. Keep chains lubricated.
Stress Corrosion Cracking:
The outside link plates,
which are heavily press-fitted to the pins, are particularly
susceptible to stress corrosion cracking. Like
fatigue
cracks, these initiate at the
point of highest stress (aper-
ture) but tend to extend in an arc-like
path, often parallel to
the rolling grain of the material.
Als
o,
mor
e
the
n
one
cra
ck
can
oft
en
app
ear
on
a
lin
k
plate. In addition to rusting, this condition can be caused
by exposure to an acidic or
caustic medium or atmo-
sphere. Stress corrosion is an environmentally assisted
failure. Two conditions must be present; corrosive agent
and static stress.
In the chain, static stress is present at the aperture due to
the press fit pin. No cycle motion is required and the
plates can crack during idle periods. The reactions of
many chemical agents (such as battery acid fumes) with
hardened metals liberate hydrogen which attacks and
weakens the metal grain structure.
Chain Anchors and Sheaves:
An inspection of the chain
must include a close examination of chain anchors and
sheaves. Check chain anchors for wear breakage and
misalignment. Anchors with worn or broken fingers should
be replaced. They should also be adjusted to eliminate
twisting the chain for an even
load distribution.
Inspect the sheaves, sheave bearings, sheave grooves
and pins for extreme wear, replace as necessary. A worn
sheave can mean several problems, as follows:
a.
Cha
ins
to
o t
igh
t.
b.
Sheav
e b
earing
s/pin
bad.
c.
Ben
t/m
isa
lig
ned cha
ins
.
TIGHT JOINTS
ABNORMAL PROTRUSION OR
TURNED PINS
ARC-LIKE CRACKED PLATES
(STRESS CORROSION)

SECTION 3 -
BASE COMPONENTS
3-6
– JLG Lift –
3121228
Oil Filling Instructions
10 oz of gearbox oil will fill the gearbox cavity approxi-
mately half full.
T
o check the oil level, rotate the wheel so
that the cover plugs
are at 12 o-clock and 3
o-clock.
Allow
the oil to
settle. Slowly loosen the 3 o-clock plug.
If oil
begins to come out then the oil l
evel is sufficient.
If no oil
is noticed at the 3 o-clock plug location, then remove both
plugs.
Slowly add oil at the
12 o-clock plug loc
ation until
oil begins to seep out of the 3 o-cl
ock plug location.
Rein-
stall and tighten plugs to 6-8 ft-lbs.
Drive Motor Brush Wear - Warning Indication
The machines drive motors include brush wear sensors
that activate a warning indicating the drive motor brushes
will require replacment soon. This warning protects the
drive motors from damage due to
extreme brush wear.
When the brush wear warning is activated the Ground
Control Station LCD screen will indicate a fault code of 6,
also the hourmeter is set to countdown 25 hours of
(DRIVE) operation remaining.
The Platform Control LEDs will indicate this warning with 8
flashing LEDs and an intermittent beep.
NOTE:
Only the drive function when used will affect the
hour meter count down once the warning has been
activated.
The
machine
will
operate
normally
until
the last 10 seconds of the
25 hour countdown.
During the last 10 seconds of the 25 hour (DRIVE) count-
down the machine will only drive in
creep/turtle drive
mode and platform lift up will be disabled. At this point
cycling power on/off will only repeat the final 10 second
mode cycle.
The machine will not operate normally until the drive
motor brushes are replaced
(repositioning the brush warn-
in
g
se
ns
or
s),
and the Ground Control Station is pro-
grammed to reset the Brush Wear - Warning Timer - see
Ground Control Module Programming in Section 4 of this
manual.
Wheel Drive Assembly - Removal
From Machine
The electric wheel drive assemblies are
mounted indepen-
tent of each other in the base frame at the rear of the
machine.
The wheel drive assembly consists of an 24V DC electric
motor driving a 30.68:1 ratio gear box, the assembly also
included a friction disk parking brake
assembly
. This
brake assembly is mounted internally on the drive assem-
bly between the drive
motor and the gear box
assembly
.
1.
Eleva
te th
e pla
tfor
m and
remove
the
wheel
drive
assembly cover and set aside, see
Section 3.2 on
page 3-2
.
2.
Disco
nnect
the p
osit
ive b
atter
y term
inals
from
the
left side battery.
3.
Raise
the r
ear dr
ive wh
eels o
f the
machi
ne of
f th
e
ground, use a fork truck or floor jack. Place a block
or safety stand under machine.
4.
Remov
e the
drive
wheel
mount
ing
lugs
and
remove
the wheel(s).
5.
Disco
nnect
the
power
harne
ss t
ermina
ls a
nd b
rake
harness connector(s) from the
drive motor.
6.
Rem
ove t
he si
x (6) he
x head c
ap sc
rew
s and wa
sh-
ers attaching the drive assembly to the frame.
7.
Caref
ully
slide
the d
rive m
otor
assemb
ly ou
t of
the
base frame assembly
for disassembly.

SECTION 3 -
BASE COMPONENTS
3
1
2
1
2
2
8
–
J
L
G
L
i
f
t
–
3-7
Wheel Drive Assembly - Installation (Right Side Shown)
1.
Wheel Drive Assembly
2.
Frame Mounting Surface
3.
Mounting Bolts/Washers (a)
4.
Drive Wheel
5.
Wheel Mounting Lugs (b)
NOTE:
Installation
same for left and
right drive motor
-
(a)
Apply Loctite #242 to
threads before tightening.
(b)
Tighten to 120 ft. lbs. (534
N-m)
1
2
3
4
5

SECTION 3 -
BASE COMPONENTS
3-8
– JLG Lift –
3121228
Wheel Drive Disassembly - Main Components
NOTE:
If
possible,
remove
the
wheel
drive
assembly
from
the
machine f
rame.
1.
Dr
ai
n t
he o
il f
ro
m t
he
Gearbox (1)
by removing the
cover plugs in the cover.
2.
Re
mo
ve
t
he
2
Drive Motor Bolts (6
) and slowly pull
the
Motor (2)
out of the gearbox.
3.
Obta
in an
d ins
tall
2 bo
lts (
M5 x
0.8
- 20
mm lo
ng)
into the brake cont
ainment holes.
This will keep the
brake housing in one piece.
4.
Cut t
he bl
ack wi
re tie
(not
shown
) from
the f
rame o
f
the motor.
5.
Re
m
ov
e
th
e
3
Brake Bolts (7)
.
6
.
R
e
m
o
v
e t
h
e
Brake Housing (B1)
and the
Spacers
(B4)
.
NOTE:
The brake wires will have some silicone sealant at the slot
through the motor flang
e.
It is okay to pull the wire out of the
motor flange slot.
The slot
will have to
be re-sealed during
reassembly
.
7
.
R
e
m
o
v
e t
h
e
Brake Disc (B2)
from the splined motor
shaft.
8
.
R
e
m
o
v
e t
h
e
Brake Friction Plate (B3)
 from the
motor flange.
Drive Motor Disassem
bly -
Main Components