Oshkosh Corporation JLG 150HAX Installation and user guide

Service and Maintenance Manual
Model
150HAX
P/N - 3120679
February 15, 2012
Courtesy of Crane.Market

Courtesy of Crane.Market

INTRODUCTION
3120679 – JLG Lift – A-1
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
AGENERAL
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per-
sonnel pay strict attention to these warnings and precau-
tions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT-
FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION
FROM THE MANUFACTURER.
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/OPERATOR.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pres-
sures. Every effort should be made to relieve any system
pressure 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 discon-
nected with minimal fluid loss.
CMAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL 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.
Courtesy of Crane.Market

INTRODUCTION
A-2 – JLG Lift – 3120679
REVISON LOG
Original Issue - May 15, 1992
Revised - January 2, 2001
Revised - February 4, 2010
Revised - February 15, 2012
Courtesy of Crane.Market

3120679 – JLG Lift – i
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Drive/Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.6 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.8 Pressure Settings - PSI (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.10 Critical Stability weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.12 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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ii – JLG Lift – 3120679
TABLE OF CONTENTS (Continued)
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.5 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 3-19
To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Replacement and Devcon Application Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.7 Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.8 Swing Brake - Ausco - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.9 Swing Brake - Mico - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
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TABLE OF CONTENTS
3.10 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.11 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.12 PQ Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
TRIM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
RAMP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.13 Pump Coupling Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Lovejoy Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Hayes Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.14 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.15 Throttle Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
SECTION 4 - BOOM & PLATFORM
4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Boom Mounted Limit Switches and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Tower Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Main Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Tower Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Tower Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Main Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Adjusting Procedures - Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4.4 Platform Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
SECTION 5 - HYDRAULICS
5.1 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Proportional Control Valves - Vickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
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TABLE OF CONTENTS (Continued)
5.3 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Cylinders w/o Counterbalance Valves - Front and Rear Steer Cylinders, Front and
Rear Frame Lift Cylinders, Upper Master Cylinder, Lower Master Cylinder, Front and
Rear Axle Extension Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cylinders w/Single Counterbalance Valves - Main Lift Cylinder,
Tower Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder,
Tower Lift Cylinder, Platform Slave Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Tower Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tower Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tower Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tower Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Main Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Main Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lower Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lower Master Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Upper Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Upper Master Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.5 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.6 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Low Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5 Stack Directional Control Valve (Internal Relief Adjustment) . . . . . . . . . . . . . . . . . . . . . . 5-11
5 Stack Directional Control Valve (External Relief Adjustment Screws) . . . . . . . . . . . . . . . . 5-12
Two Stack Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Three Stack Directional Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Four Stack Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.7 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Wear Guide for Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Recommended Start-up Procedure for New or Rebuilt Pump . . . . . . . . . . . . . . . . . . . . . . . 5-30
Recommended Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
SECTION 6 - SCHEMATICS
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
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LIST OF FIGURES
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
2-1. Engine Operating Temperature Specifications - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1. Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-3. Drive Brake - Mico (March 1992 to S/N 33746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3-4. Drive Brake - Mico (S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-19. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-18. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-20. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-21. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-22. Swing Brake - Ausco - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-23. Swing Brake - Mico - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-24. Swing Brake - Machines Built 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-25. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3-26. Lovejoy Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-27. Hayes Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-26. Tilt Switch Adjustment - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-27. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
3-28. Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
4-1. Boom Mounted Limit Switches and Valves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Main Boom Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-3. Main Boom Assembly - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-4. Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
5-1. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-2. Valve Locations - Turntable Mounted Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-3. Valve Locations - Frame Mounted Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-4. Recommended Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-5. Main Gear Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
6-1. Electrical Schematic - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-2. Electrical Schematic - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-3. Electrical Schematic - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-4. Electrical Schematic - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
6-5. Electrical Schematic - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-6. Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
6-7. Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
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vi – JLG Lift – 3120679
LIST OF TABLES
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Engine Datas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Drive Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-10 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-11 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Pressure Settings - 5 Spool Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-13 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
4-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
5-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-3 Turntable - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-4 Chassis - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
3120679 – JLG Lift – 1-1
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES
1.2 ENGINE DATA
1.3 DRIVE/STEER SYSTEM
1.4 PERFORMANCE DATA
1.5 FUNCTION SPEEDS
Table 1-1. Capacities
Fuel Tank 68 gallons (257 liters)
Hydraulic Oil Tank Approx. 124 gallons (469 liters)
Hydraulic System Approx. 150 gallons (568 liters)
Drive - 90 ounces (2.7 liters) Drive - 90 ounces (2.7 liters)
Swing - 60 ounces (1.8 liters) Swing - 60 ounces (1.8 liters)
Engine Crankcase 10.0 quarts (9.5 liters) w/o filter
Cooling System
Syste m
Engine
Rad ia tor
21.4 quarts (20.2 liters)
7.4 quarts (7.0 liters)
14.0 quarts (13.2 liters)
*Torque hubs should be one half full of lubricant.
Table 1-2. Engine Datas
Model Cummins 4B3.9C
Low RPM 1800
High RPM 2500
Alternator 60 Amp, belt driven
Battery 85 Amphour, 550 CCA, 12 volts
Horsepower 76 @ 2500 RPM, no load
Table 1-3. Drive Steer System
Drive Hub Gear Ratio - 93.7:1
Drive Brake Automatic spring applied, hydrau-
lically released. Release pressure
150 psi (10.3 Bar) initial, 170 psi
(11.7 Bar) full.
Tires Size - 445/65R22.5, foam-filled
Table 1-4. Performance Data
Maximum Drive Speed 2.7 mph (4.3 kph) @ Max RPM
Maximum Travel Grade (Grade-
ability)
31%
Turning Radius (Outside) 24 ft. 2 in. (7.4 meters) w/axles
retracted
27 ft. 2 in. (8.3 meters) w/axles
extended
Gross Machine Weight 57,000 lbs. (25,855 kg)
Length Stowed 39 ft. 5 in. (12.0 meters) w/main
boom fully retracted and platform
in normal position.
41 ft. 7 in. (12.7 meters) w/main
boom telescoped out and plat-
form tilted to stow at minimum
height.
Machine Width 11 ft. 6 in. (3.5 meters) w/axles
retracted
18 ft. 0 in. (5.5 meters) w/axles
extended
Wheelbase 18 ft. 0 in. (5.5 meters)
Platform Capacity 500 lb. (230 kg) unrestricted
1000 lb. (450 kg) restricted
Table 1-5. Function Speeds
Function Speed - In Seconds
Lift Up 115-190
Lift Down 140-160
Tower Lift Up 89-103
Tower Telescope Out 125-160
Tower Telescope In 65-90
Tower Lift Down 61-83
Swing Right & Left 72-84
Telescope Out 46-50
Telescope In 46-50
Platform Rotate Left & Right 24-26
Jib Up 25-27
Jib Down 21-23
High Drive (200 ft.) 42-46 (3.0 mph)
Drive above Horizontal (50 ft.) 65-71 (0.5 mph)
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
1-2 – JLG Lift – 3120679
1.6 LUBRICATION
.
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 index of
152 .
NOTE: When temperatures remain consistently below 20
degrees F (-7 degrees C.), JLG Industries recom-
mends the use of Mobil DTE11.
NOTE: Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities. If use of hydraulic oil other
than Mobilfluid 424 is desired, contact JLG Indus-
tries for proper recommendations.
Table 1-6.Hydraulic Oil
Hydraulic System Operating
Temperature Range
SAE Viscosity
Grade
0° to +23° F(-18° to -5° C) 10W
0° to +210° F(-18° to +100° C) 10W-20, 10W-30
+50° to +210° F(+10° to +99° C) 20W-20
Table 1-7. Mobilfluid 424 Specs
SAE Grade 10W30
Gravity, API 29.0
Density, Lb/Gal. 60°F 7.35
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
Table 1-8. Mobil EAL 224 H Specs
Typ e Biodegradable Vegetable Oil
ISO Viscosity Grade 32/46
Specific Gravity .922
Pour Point, Max -25°F (-32°C)
Flash Point, Min. 428°F (220°C)
Weight 7.64 lb. per gal.
(0.9 kg per liter)
Viscosity
at 104° F (40° C) 37 cSt
at 212° F (100° C) 8.4 cSt
Viscosity Index 213
Operating Temp 0-180° F (-17 - -162°C)
Note: Must be stored above 32° F (14° C)
Table 1-9. Mobil DTE 13M Specs
ISO Viscosity Grade #32
Specific Gravity 0.877
Pour Point, Max -40°F (-40°C)
Flash Point, Min. 330°F (166°C)
Viscosity
at 40° C 33cSt
at 100° C 6.6 cSt
at 100° F 169 SUS
at 210° F 48 SUS
cp at -20° F 6,200
Viscosity Index 140
Table 1-10. Exxon Univis HVI 26 Specs
Specific Gravity 32.1
Pour Point -76°F (-60°C)
Flash Point 217°F (103°C)
Viscosity
at 40° C 25.8 cSt
at 100° C 9.3 cSt
Viscosity Index 376
NOTE: Mobil/Exxon recommends that this oil be
checked on a yearly basis for viscosity.
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
3120679 – JLG Lift – 1-3
1.7 TORQUE REQUIREMENTS 1.8 PRESSURE SETTINGS - PSI (BAR)
Table 1-11. Torque Requirements
Description To r q u e Va l u e
(Dry)
Interval
Hours
Bearing To Chassis 545 ft. lbs.
(740 Nm)
50/600*
Bearing To Turntable 545 ft. lbs.
(740 Nm)
50/600*
Wheel Lugs 300 ft. lbs.
(407 Nm)
150
Drive Torque Hub to Spin-
dle
260 ft. lbs.
(353 Nm)
200
Main Boom Chains 50 ft. lbs.
(68 Nm)
200
Swing Motor to Swing
Brake
110 ft. lbs.
(149 Nm)
500
Torque H ub t o Tu rntable
Mounting Plate
340 ft. lbs.
(461 Nm)
500
Platform Rotator Brake
Bolt
140 ft. lbs.
(190 Nm)
500
*Check swing bearing bolts for security after first 50 hours of
operation and every 600 hours thereafter. (See Swing Bearing in
Section 2)
NOTE: When maintenance becomes necessary or a
fastener has loosened, refer to the Torque
Chart to determine proper torque value.
Table 1-12. Pressure Settings - 5 Spool Proportional
Valve
PSI BAR
5 Spool Proportional Valve
Main Relief 3800 262
Main Tele Out Relief 2000 138
Main Tele In Relief 3300 228
Main Lift Up Relief 3000 207
Main Lift Down Relief 1850 128
Tower Tele Out Relief 3000 207
Tower Tele In Relief 2600 179
Tower Lift Up Relief 3700 255
Tower Lift Down Relief 3000 207
Swing Relief 1700 117
2 Spool Solenoid Valve
Main Relief 2750 190
Rotate Relief 2500 172
Level Reliefs 2500 172
3 Spool Solenoid Valve
Steer Reliefs 2000 138
4 Spool Solenoid Valve
Extension Cylinder Reliefs 2000 138
Low Drive System
Sequence Valve 450 31
Main Relief on E xt er n al Relief Valve 3200 2 21
Proportional Drive Valve Section Relief -
Factory set, does not normally need to
be adjusted
3200 221
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SECTION 1 - SPECIFICATIONS
1-4 – JLG Lift – 3120679
1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS
1.11 SERIAL NUMBER LOCATIONS
For machine identification, a serial number plate is affixed
to the machine. The plate is located on the left side of the
turntable, just behind the fuel tank. If the serial number
plate is missing, the machine serial number is stamped on
the left side of the frame, below the turntable bearing. In
addition, the last five digits of the serial number are
stamped on the top of the fly end of each of the tower
boom and main boom sections.
Table 1-13. Major Component Weights
LB. KG.
36 x 96 Platform 420 191
Platform Level Cylinder 80 36
Main Boom 6350 2880
Main Lift Cylinder 830 377
Master Level Cylinder (each) 60 27
Tower Boom 14700 6668
Tower Lift Cylinder 1100 499
Turntable Complete (includes swing
bearing)
14200 6441
Frame Complete 19200 8709
Complete Machine 57000 25855
Table 1-14. Critical Stability Weights
LB. KG.
Counterweight 3285 1490
Tire & Wheel Assembly 1020 494
Engine 680 308
8 ft. Platform 295 134
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
3120679 – JLG Lift – 1-5
1.12 OPERATOR MAINTENANCE
NOTE: The following numbers correspond to those in Fig-
ure 1-1., Operator Maintenance & Lubrication Dia-
gram.
NOTE: The lubrication intervals in Figure 1-1., Operator
Maintenance & Lubrication Diagram are equivalent
to the following:
150 hours = 3 months
300 hours = 6 months
600 hours = 1 year
1200 hours = 2 years
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION
UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-
SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON-
MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
NOTE: It is recommended as a good practice to replace all
filters at the same time.
Figure 1-1. Operator Maintenance & Lubrication Diagram
Table 1-15. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350°
F (177° C). 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 classifi-
cation GL-5 or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid
424.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-
2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
1-6 – JLG Lift – 3120679
1. To r q u e H u b s
Lube Point(s) - 1 Fill Plug per hub
Capacity -
Lube - EPGL
Interval - Check oil level at side plug on hub weekly.
Change after first 3 months or 150 hours then
every 2 years or 1200 hours of operation.
Comments - Place Fill port at 12 o’clock position
and pour lubricant into fill port until it just starts
to flow out of check port when it’s at the 3
o’clock position.
2. Steer Spindles
Lube Point(s) - 4 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
3. Tie Rod Center Pivot Links
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
4. Steer Cylinder Barrel Ends
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
5. Steer Cylinder Rod Ends
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
3120679 – JLG Lift – 1-7
6. Extending Axles
Lube Point(s) - N/A
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply by brush
7. Swing Bearing Gear
Lube Point(s) - N/A
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply by brush
8. Lower Master Cylinder Barrel End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Fitting on Left Rear of Turnta-
ble
9. Tower Boom Lift Cylinder Barrel End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Fitting on Left Rear of Turnta-
ble
10. Swing Bearing
Lube Point(s) - 2 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Fitting on Left Rear of Turnta-
ble
11. Lower Master Cylinder Rod End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments -
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
1-8 – JLG Lift – 3120679
12. Platform Hinges
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
13. Platform Door Latch
Lube Point(s) - N/A
Capacity - A/R
Lube - EO
Interval - Every 3 months or 150 hrs of operation
14. Platform Rotate Pivot/Rotator Worm Gear
Lube Point(s) - 2 Grease Fittings on pivot; 1 Grease
Fitting on worm gear
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
15. Platform Level Links
Lube Point(s) - 3 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
16. Level Cylinder Rod End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
17. Level Cylinder Barrel End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
18. Engine Crankcase
Lube Point(s) - Fill Cap/Drain Plug
Capacity - 10 quarts (9.5 L) w/o filter
Lube - EO
Comments - Check daily. Refer to Engine Manual for
Change interval.
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
3120679 – JLG Lift – 1-9
19. Engine Oil Filter
Lube Point(s) - N/A
Lube - EO
Comments - Refer to Engine Manual for Change
interval.
20. Main Boom Chains
Lube Point(s) - N/A
Capacity - N/A
Lube - Chain Lube
Interval - Every 2 years or 1200 hours of operation.
21. Main Boom Extend Chain Sheave
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Align access holes in mid and fly boom
22. Main Boom Lift Cylinder
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
23. Main Boom Retract Chain Sheave
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Align with access hole in base boom.
24. Main Boom Pivot Pin
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
25. Tower Boom Pivot Pin
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
26. Level Links
Lube Point(s) - 3 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments -
Courtesy of Crane.Market

SECTION 1 - SPECIFICATIONS
1-10 – JLG Lift – 3120679
27. Upper Master Cylinder Rod End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments -
28. Upper Master Cylinder Barrel End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments -
29. Tower Boom Lift Cylinder Rod End
Lube Point(s) - 1 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments -
30. Hydraulic Oil
Lube Point(s) - Fill Cap/Drain Plug
Capacity - A/R
Lube - HO
Interval - Check daily. Change every 2 years or 1200
hours
Comments - On new machines, those recently over-
hauled, or after changing hydraulic oil, operate
all systems a minimum of two complete cycles
and recheck oil level in reservoir.
31. Hydraulic Filter
Interval - Replace filter after first 50 hours of opera-
tion, then every 6 months or 300 hours thereaf-
ter.
32. Air Filter
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator
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