Manual de Servicio JLG 110 HX

Service and Maintenance Manual
Model
100HX
100HX+10
110HX
P/N - 3120636
March 11, 2010

INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS
feed lines to system components can then be disconnected

A GENERAL
with minimal fluid loss.
This section contains the general safety precautions which
must be observed during maintenance of the aerial plat-
form. It is of utmost importance that maintenance person- C MAINTENANCE
nel pay strict attention to these warnings and precautions
to avoid possible injury to themselves or others, or dam-
age to the equipment. A maintenance program must be FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
followed to ensure that the machine is safe to operate. THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY ING ELECTRICAL STORMS. ENSURE THAT FUEL
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST CAP IS CLOSED AND SECURE AT ALL OTHER
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLA- TIMES.
TION. • REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
The specific precautions to be observed during mainte-
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
nance are inserted at the appropriate point in the manual.
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
These precautions are, for the most part, those that apply ARE APT TO BECOME CAUGHT ON OR ENTANGLED
when servicing hydraulic and larger machine component IN EQUIPMENT.
parts.
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
TIONS ON MACHINE AND IN SERVICEMANUAL.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
be conscious of weight. Never attempt to move heavy STANDING SURFACES AND HAND HOLDS.
parts without the aid of a mechanical device. Do not allow • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
heavy objects to rest in an unstable position. When raising IZED COOLANT SYSTEM.
a portion of the equipment, ensure that adequate support is
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
provided. BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, PERFORMING ANY OTHER MAINTENANCE, SHUT
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER- OFF ALL POWER CONTROLS.
ATOR. • BATTERY SHOULD ALWAYS BE DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
B HYDRAULIC SYSTEM SAFETY • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
It should be noted that the machines hydraulic systems MENTS STOWED IN THEIR PROPER PLACE.
operate at extremely high potentially dangerous pressures. • USE ONLY APPROVED, NONFLAMMABLE CLEANING
Every effort should be made to relieve any system pres- SOLVENTS.
sure prior to disconnecting or removing any portion of the
system.
Relieve system pressure by cycling the applicable control

several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
3120636 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
March, 1989 - Original Issue

October, 1994 - Revised
August, 1997 - Revised
January, 1999 - Revised
October 8, 1999 - Revised
May 20, 2002 - Revised
April 6, 2009 - Revised
March 11, 2010 - Revised
A-2 – JLG Lift – 3120636

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Engine - Ford LSG-423 & LRG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Ford LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Deutz F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Cummins 4B3.9C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Filter - Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Filter - Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Turning Radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Stowed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Stowed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Maximum Tire Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Ford LSG423 & LRG423 & LRG425 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Deutz F4L912 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Cummins 4B3.9C Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Accessory Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Extend-A-Reach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.8 Boom Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
With 4620038 Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
With 4620044 or 4620078 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.10 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
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3120636 – JLG Lift – i

TABLE OF CONTENTS (Continued)

SECTION 2 - PROCEDURES
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Manual Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Proportional Control Valves - Vickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Adjusting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2.8 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Cylinder w/o Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Cylinders w/Single Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Cylinders w/Dual Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Master Level Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
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ii – JLG Lift – 3120636

TABLE OF CONTENTS

2.12 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.13 Tilt Alarm Switch Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.14 Limit Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Horizontal Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.15 Throttle Checks and Adjustments - Deutz F4l-912 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2.16 Throttle Checks and Precision Governor Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . .2-32
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Automatic Choke Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Carburetor and Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.17 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Sequence Pressure (Prior to 1990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Sequence Pressure (1990 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Extend-A-Reach Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.18 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Bearing Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.19 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
2.20 Swing Torque hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.21 Swing Brake - Ausco - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
2.22 Swing Brake - Mico - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
2.23 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
2.24 Drive Brake - Ausco - Machines Built Prior To March 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2.25 Drive Brake - Mico - Machines Built March 1992 TO S/N 33476 . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
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3120636 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

2.26 Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
2.27 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 2-74
To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.28 OEM Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
THRESHOLD Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
HI RANGE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
IRS - RAMP RATE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
LO RANGE Adjustment (CREEP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.29 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
2.30 Boom Length/angle Sensor Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
1st and 2nd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
3rd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
2.31 Load Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86
Platform Position Indication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Overmoment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Overmoment Control Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
Load Management System Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
2.32 Load Management System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90
Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2.33 Turntable Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90
Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
2.34 Pump Coupling Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
Lovejoy Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Hayes Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
2.35 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-92
2.36 Platform Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93
2.37 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93
SECTION 3 - TROUBLESHOOTING
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
iv – JLG Lift – 3120636

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
2-1. Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-2. Boom Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-3. Typical Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-4. Boom Positioning and Support - Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2-5. Typical Hydraulic Cylinders - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
2-6. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2-7. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
2-8. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-9. Boom Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2-10. Boom Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
2-11. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
2-12. Tilt Switch Adjustment - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
2-13. Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
2-15. Precision Governor Adjustment - Ford Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
2-14. Precision Governor Adjustment - Ford Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
2-16. Pressure Setting Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
2-17. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
2-18. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
2-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
2-20. Swing Bearing Bolt Torquing Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
2-21. Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
2-22. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
2-23. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
2-24. Swing Brake - Ausco - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
2-25. Swing Brake - Mico - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
2-26. Swing Brake - Machines Built 1992 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
2-27. Drive Brake - Ausco (Prior to March 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
2-28. Drive Brake - Mico (March 1992 to S/N 33746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
2-29. Drive Brake - Mico (S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72
2-30. Spring Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73
2-31. Boom Marking Tape Installation - 100HX+10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
2-32. Boom Marking Tape Installation - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
2-33. Load Radius Card Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79
2-34. Boom Length/Angle Sensor Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
2-35. Load Radius Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81
2-36. Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
2-37. Load Moment Limiting System Monitoring Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
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3120636 – JLG Lift – v

LIST OF FIGURES (Continued)
FIGURE NO. TITLE PAGE NO.

3-1. Wiring Diagram - Boom Indicator Pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-2. Wiring Diagram - Dual Fuel (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-3. Wiring Diagram - Generator (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-4. Wiring Diagram - Generator (Ford) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
3-5. Wiring Diagram - Platform (100HX & 110HX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3-6. Wiring Diagram - Platform (100HX+10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-10. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-17. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
vi – JLG Lift – 3120636

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Maximum Tire Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-4 Mobil EAL Envirosyn H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-5 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-6 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-7 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-8 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
2-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-2 Cylinder Piston Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
2-4 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76
2-5 Card Adjustment - 1st and 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
2-6 Card Adjustment - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
2-7 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94
3-1 Platform Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3 Turntable Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3120636 – JLG Lift – vii

LIST OF TABLES (Continued)
TABLE NO. TITLE PAGE NO.
This page left blank intentionally.
viii – JLG Lift – 3120636

SECTION 1. SPECIFICATIONS
Engine - Deutz F4L912

1.1 CAPACITIES
Fuel - Diesel
Fuel Tank - 28 gallons (98 liters).
Oil Capacity - 12.7 quarts (12 liters)
Hydraulic Oil Tank - 55 gallons (208 liters).
Low (Mid) RPM - 1800
Hydraulic System (Including Tank) - 65 gallons (246 liters).
High RPM - 2400
Torque Hub, Drive - 90 oz. (2.7 liters).
Alternator -
Torque Hub, Swing - 17 oz. (0.5 liters).
Prior to Oct. 91 85 Amp
NOTE: Torque Hubs should be one-half full of lubricant.
Oct 91 to Present 55 Amp
(EPGL-90)
Battery - 1000 cold cranking Amps, 210 minutes reserve
Engine Crankcase capacity, 12 VDC
Ford LSG423 & LRG423 w/Filter - 5 quarts (4.7 liters)
Fuel Consumption
Ford LRG425 w/Filter - 4.5 quarts (4.25 liters)
Deutz F4L912 w/Filter - 11 liters. Low RPM - 2.4 gph (9.1 lph)
High RPM - 3.8 gph (14.2 lph)
1.2 COMPONENT DATA Horsepower - 70 @ 2400 RPM, no load
NOTE: Tolerance on all engine rpm settings is plus or minus Engine - Cummins 4B3.9C
10%.
Fuel - Diesel
Engine - Ford LSG-423 & LRG-423 Oil Capacity - 10 quarts (9.5 liters) w/o Filter
Fuel - Gasoline Cooling System Capacity - 21.4 quarts (20.2 liters)
Engine Capacity - 7.4 quarts (7 liters)
Oil Capacity - 5 quarts (4.7 liters) w/Filter, 4 quarts (3.8
Radiator capacity - 14 quarts (13.2 liters)
liters) w/o Filter
Low (Mid) RPM - 1800
Cooling System - 16 quarts (15 liters)
High RPM - 2400.
Idle RPM - 850 no load
Alternator - 60 Amp.
Low (Mid) RPM - 1800 no load
Battery - 1000 CCA, 210 minutes reserve capacity, 
High RPM - 3000 no load 12 VDC.
Alternator - 40 Amp Horsepower - 76 @ 2400 RPM, no load.
Battery - 1000 CCA, 210 minutes reserve capacity, 12VDC
Fuel Consumption
LSG-423 - 4.6gph (17.4 lph)
LRG-423 - 4.3gph (16.2 lph)
Horsepower
LSG-423 - 54 @ 3000 RPM, no load
LRG-425 - 66 @ 3000 RPM, no load
Engine - Ford LRG-425

Fuel - Gasoline
No. of Cylinders - 4
BHP at Max. RPM - 70
RPM Setting (No Load) - Mid - 1500
3120636 – JLG Lift – 1-1

Drive System Hydraulic Filter - Tank

Tires. Return - Bypass Type
Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam 10 Microns Nominal

filled.
Hydraulic Filter - Inline
After March, 1993 - 385/65R22.5, 18 ply rating, foam
filled. Return - Non-Bypass Type
10 Microns Nominal
Drive Motor - 2.5 in3 (6.4 cm3) /rev. displacement.
Drive Hub - 93.7:1 ratio.

1.3 PERFORMANCE DATA
Drive Brake - Automatic spring applied, hydraulically
released. Travel Speed
Steer System 2.8 mph (4.5 kmh)
Tires. Gradeability
Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam 25% or 14° slope, hard surface.
filled.
Turning Radius
After March, 1993 - 385/65R22.5, 18 ply rating, foam
filled. Outside - 22ft. 10 1/4 in. (7.1 m) w/axles extended.
Toe-In - Adjust for 1/4in. (6.4 mm) overall. Boom Speed

Extend - 128-156 Seconds.
Swing System
Retract - 93-113 Seconds.
Swing Motor - 10.3 in3 (26.2 cm3)/rev. displacement.
Lift Up - 65-80 Seconds
Swing Hub - 69.5:1 ratio.
Lift Down - 52-64 Seconds.
Swing Brake - Automatic spring applied, hydraulically
released. Swing Speed
Hydraulic Pump 360° - 260-350 Seconds
1st Section - 15.0 gpm (56.8 lpm) Boom Elevation

2nd Section - 9.0 gpm (34.1 lpm) Models 100HX/110HX
3rd Section - 9.0 gpm (34.1 lpm) +75° (above horizontal) to -21° (below horizontal)
Model 100HX+10
Auxiliary Power Pump
Main Boom - +75° (above horizontal) to -21° (below
18.0 lpm horizontal)
12 Volts DC motor Extend-a-Reach - +15° (above horizontal) to -80°
(below horizontal)
Clockwise rotation 
 
 
 
 
 
 
 
 
 
 
1-2 – JLG Lift – 3120636

Machine Weight
1.4 TORQUE REQUIREMENTS
100HX - 36,400 lbs. (16,511 kg)
110HX - 40,410 lbs. (18,330 kg) Table 1-2.Torque Requirements
100HX+10 - 39,685 lbs. (18,001 kg) Torque Value Interval
Description
Ft. Lbs. Nm Hours
Machine Stowed Height
Bearing to Chassis 220 298 50/600*
9 ft. 10 in. (3.0 m)
Bearing to Turntable 220 298 50/600*
Machine Stowed Length Wheel Lugs 300 407 100
100HX - 36 ft. in. (11.0 m) Turntable Springs 75 102 200
110HX - 38 ft. 7 in. (11.8 m) Boom Chains 59 80 500

Platform Rotator Bolt 140 190 500
100HX+10 - 44 ft. 2 in. (13.5 m)
* Check swing bearing bolts for security after first 50 hours of
operation and every 600 hours thereafter.
Machine Width
With axles retracted - 8 ft. 6 in. (2.6 m) NOTE: See Procedure Section for tightening sequence of
With axles extended - 10 ft. 10 in. (3.3 m) turntable bearing bolts.
Wheelbase NOTE: When maintenance becomes necessary or a fas-

11 ft. (3.4 m) tener has loosened, refer to the Torque Chart to
determine proper torque value.
Maximum Tire Loads

Table 1-1.Maximum Tire Loads 1.5 LUBRICATION
Max. Load Max Bearing Pressure
Ford LSG423 & LRG423 & LRG425 Engines
Description Lbs. Kg PSI kg/cm2
Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD)
100HX 19900 9027 145 10
100HX+10 23740 10769 172 11.8
Use SAE Viscosity
110HX 21540 9771 156 10.7 When Outside Temp is Consistently
Number
 -10° to +60° F (-24° to +16° C) *10W
 +10° to +90° F (-12° C to +32° C) 20W-20

Above +32° F (0° C) 30

Above +50° F (+10° C) 40
Multi-Viscosity Oils (CD-SE, CD-SF)
Use SAE Viscosity

When Outside Temp is Consistently
Number
Below +10° F(-12° C) *5W-20
(Synthetic)
Below +60° F(+16° C) 5W-30
-10° to +90° F(-24° to +32° C) 10W-30
Above -10° F(-24° C) 10W-40 or 10W-50
Above +20° F( -7° C) 20W-40 or 20W-50
* This viscosity can be used at colder temperatures only

with engine oil preheating.
3120636 – JLG Lift – 1-3

Deutz F4L912 Engine Table 1-3.Hydraulic Oil
Single Viscosity Oils (CD-SE, CD-SF) Hydraulic System Operating SAE Viscosity
Temperature Range Grade
Use SAE Viscosity 0° to +23° F(-18° to -5° C) 10W
Number 0° to +210° F(-18° to +100° C) 10W-20, 10W-30
-20° to +25° F (-29° to -4° C) *10W +50° to +210° F(+10° to +99° C) 20W-20
+15° to +50° F (-10° C to +10° C) 20W-20
+40° to +85° F (+4° to +30° C) 30 NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
Above 75° F (+24° C) 40
chemical stability for mobile hydraulic system ser-
vice. JLG Industries recommends Mobilfluid 424
Multi-Viscosity Oils (CD-SE, CD-SF) hydraulic oil, which has an SAE viscosity index of
152 .
Use SAE Viscosity
When Outside Temp is Consistently NOTE: When temperatures remain consistently below 20
Number
degrees F (-7 degrees C.), JLG Industries recom-
-40° to +75° F(-40° to +24° C) *5W-20 mends the use of Mobil DTE11.
(Synthetic)
-5° to +70° F(-21° to +21° C) 10W-30 NOTE: Aside from JLG recommendations, it is not advisable
-5° to +85° F(-21° to +30° C) 10W-40 to mix oils of different brands or types, as they may
not contain the same required additives or be of
+15° to +75° F(-10° to +24° C) 15W-30
comparable viscosities. If use of hydraulic oil other
Above +15° F(-10° C) 15W-40 than Mobilfluid 424 is desired, contact JLG Indus-
tries for proper recommendations.
* This viscosity can be used at colder temperatures only
with engine oil preheating.
Cummins 4B3.9C Engine

Single Viscosity Oils
Use SAE Viscosity

Number
-22° to +23° F (-30° to -5° C) 10W
+14° to +50° F (-10° C to +10° C) 20W-20
+41° to +86° F (+5° to +30° C) 30
Above 77° F (+25° C) 40
Multi-Viscosity Oils (MS, SD, SE).
Use SAE Viscosity

Number
-40° to +77° F(-40° to +25° C) 5W-20
(Synthetic)
-4° to +68° F(-20° to +20° C) 10W-30
-4° to +86° F(-20° to +30° C) 10W-40
+14° to +77° F(-10° to +25° C) 15W-30
Above +14° F(-10° C) 15W-40
NOTE: Crankcase oil should meet one of the following API

classification grades: SE/CC, SE/CD, SF/CC, SF/
CD.
1-4 – JLG Lift – 3120636

Table 1-4. Mobil EAL Envirosyn H 46 Specs Table 1-6. Mobil DTE 13M Specs
Type Synthetic Biodegradable Type Petroleum Base

ISO Viscosity Grade 46 ISO Viscosity Grade 32
Specific Gravity .910 Specific Gravity .877
Pour Point, Max -44°F (-44°C) Pour Point, Max -40°F (-40°C)
Flash Point, Min. 500°F (260°C) Flash Point, Min. 330°F (166°C)
7.64 lb. per gal. Viscosity
Weight
(0.9 kg per liter) at 104° F (40° C) 33 cSt
Viscosity at 212° F (100° C) 6.5 cSt
at 104° F (40° C) 45 cSt Viscosity Index 140
at 212° F (100° C) 8.0 cSt
Viscosity Index 153
Lubrication Specifications
Table 1-5. Mobil EAL 224 H Specs

Table 1-7.Lubrication Specifications
Type Biodegradable Vegetable Oil
KEY SPECIFICATIONS
ISO Viscosity Grade 32/46
MPG Multipurpose Grease having a minimum dripping point of 350
Specific Gravity .922 degrees F. Excellent water resistance and adhesive qualities;
-25°F (-32°C) and being of extreme pressure type (Timken OK 40 pounds
Pour Point, Max
minimum).
Flash Point, Min. 428°F (220°C)
EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classi-
7.64 lb. per gal. fication GL-5 or Mil-Spec Mil-L-2105.
Weight
(0.9 kg per liter) HO Hydraulic Oil. API Service Classification GL-3, SAE 10W-20,
Viscosity Viscosity Index 152.
at 104° F (40° C) 37 cSt EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
at 212° F (100° C) 8.4 cSt
Viscosity Index 213
Refer to Lubrication Chart for specific lubrication proce-
Operating Temp 0-180° F (-17 - -162°C) dures.
Note: Must be stored above 32° F (14° C)
3120636 – JLG Lift – 1-5

2 3
20
5 19
22 26, 27, 28
18, 20
17 22
17
21 21
23, 24
25
25
31
31 9
15 35
4 34
33
8
21
32 1, 5, 16
14 5
14
21
30 29
34
6, 7
Note
The lubrication intervals in this
chart are equivalent to the following:
150 hours = 3 months
300 hours = 6 months
600 hours = 1 year
1200 hours = 2 years
11 10
Figure 1-1. Lubrication Diagram
1-6 – JLG Lift – 3120636

Table 1-8. Lubrication Chart
Number/Type Interval
Components Lube & Method Comments
Lube Points Hours
1 Master Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150 Remote Access
2 Master Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
3 Boom Pivot Bushings 2 Grease Fittings MPG - Pressure Gun 150
4 Lift Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
5 Lift Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150 Remote Access
6 Slave Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
7 Slave Cylinder - Shaft End 1 Grease Fitting MPG - Pressure Gun 150
8 Extend-A-Reach Cylinder - Rod End 1 Grease Fitting MPG- Pressure Gun 150
9 Extend-A-Reach Cylinder - Attach Pin 2 Grease Fittings MPG - Pressure Gun 150
10 Platform Door Hinges 2 Grease Fittings MPG - Pressure Gun 150
11 Platform Door Latch N/A SAE10 - Oil Can 150
12 Rotary Platform Control Stand 2 Grease Fittings MPG - Pressure Gun 150
13 Platform Attach Pin and Rotary Worm 1 Grease Fitting Each MPG - Pressure Gun 150
Gear
14 Drive Hubs Fill Plug EPGL - SAE90 150/1200 Check every 150 hrs. /Change every 1200 hrs.
15 Swing Bearing Gear N/A MPG - Brush 150
16 Swing Bearing 1 Grease Fitting MPG - Pressure Gun 150
17 Steer Spindles 2 Grease Fittings MPG - Pressure Gun 150
18 Steer Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
19 Steer Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150
20 Tie Rod Ends 2 Grease Fittings MPG - Pressure Gun 150
21 Extending Axle Beams N/A MPG - Brush 150
22 Wheel Bearings N/A MPG - Repack 1200
23 Engine Crankcase Fill Cap EO-SAE30 10/300 Check daily/Change every 300 hrs.
24 Engine Oil Filter N/A Replaceable Cartridge 300
25 Door and Access Panel Hinges N/A SAE10 - Oil Can 150
26 Hydraulic Fluid Fill Cap HO 10/1200 Check daily/Change every 1200 hrs.
27 Hyd. Filter Element (Tank) N/A N/A 50/300 Replace filter after first 50 hrs. of operation,
then every 300 hrs. thereafter
28 Hyd. Filter Element (Inline) N/A N/A 50/300 Replace filter after first 50 hrs. of operation,
then every 300 hrs. thereafter
29 Telescope Cylinder Sheave 1 Grease Fitting MPG - Pressure Gun 150
30 Extend Chain Sheave 1 Grease Fitting MPG - Pressure Gun 150
31 Retract Chain Sheave 1 Grease Fitting MPG - Pressure Gun 150
3120636 – JLG Lift – 1-7

Table 1-8. Lubrication Chart
Number/Type Interval
Components Lube & Method Comments
Lube Points Hours
32 Boom Chains N/A Chain Lube/Hot Oil Dip 1200 Includes extend and retract chains
33 Turntable Pivot Pin 2 Grease Fittings MPG - Pressure Gun 150
34 Extend-A-Reach Link Attach Pin 1 Grease Fitting MPG - Pressure Gun 150
35 Extend-A-Reach Pivot Pin 2 Grease Fittings MPG - Pressure Gun 150
NOTES: Key to Lubricants:
EO Engine Oil
EPGL Extreme Pressure Gear Lube
HO Hydraulic Fluid (Mobil #424 or equivalent)
MPG t Multi-Purpose Grease
1.6 PRESSURE SETTINGS 1.7 CYLINDER SPECIFICATIONS

NOTE: All cylinder dimensions are given in inches (in), with
Proportional Valve the metric equivalent, centimeters (cm) in parenthe-
Drive - 3500 psi (241 bar) ses.
Table 1-9.Cylinder Specifications

Lift Up - 3000 psi (207 bar)
Cylinder Bore Stroke Rod Dia.
Lift Down - 1200 psi (83 bar)
Lift 9.0 43.375 4.0
Telescope In - 2500 psi (172 bar) (22.9) (120.3) (10.2)
Maser Level 2.5 14.5 1.25
Telescope Out - 1500 psi (103 bar)
(100HX, 110HX) (6.4) (36.8) (3.2)
Swing - 1200 psi (83 bar) Master Level 2.5 15.1 1.25
(100HX+10) (6.4) (38.4) (3.2)
Accessory Valve Slave Level 2.5 13.875 1.25
(100HX, 110HX) (6.4) (35.2) (3.2)
Main Relief - 3500 psi (241 bar)
Slave Level 3.5 6.94 1.75
Sequence Cartridge - 450 psi (31 bar) (100HX+10) (8.9) (17.6) (4.4)
Steer 3 10.31 1.5
Pressure Reducing Cartridge - 550 psi (38 bar) (7.6) (26.2) (3.8)
Telescope 5 247.81 3.5
Solenoid Valve (100HX, 100HX+10 (12.7) (629.4) (8.9)
Main Relief - 2500 psi (172 bar) Telescope 5 266 3.5

(110HX) (12.7) (675.6) (8.9)
Rotate - 2500 psi (172 bar) Axle Extension 2.5 28.19 1.25
(6.4) (71.6) (3.2)
Level - 2500 psi (172 bar)
Extend-a-Reach 3.5 18.31 2.5
Steer - 2000 psi (138 bar) (100HX+10) (8.9 (46.5) (6.4)
Extend-A-Reach Valve
Extend (Up) - 2500 psi (172 bar)
Retract (Down) - 700 psi (48 bar)
NOTE: Refer to Section 2 for pressure setting procedures.
1-8 – JLG Lift – 3120636

100HX+10.
1.8 BOOM TAPE
Blue - 53 in. (134.6 cm)
With 4620038 Turntable
Yellow - Not used
110HX Single Capacity
Red - 87 in. (221.0 cm)
Blue - Not used
White - 138.5 in. (351.8 cm)
Yellow - Not used
Red - 119.5 in. (303.5 cm)
1.9 MAJOR COMPONENT WEIGHTS
White - 154.5 in. (392.4 cm)
110HX Dual Capacity Table 1-10.Major Component Weights
Blue - Not used
Component Lbs. KG.
Yellow - 82.5 in. (209.6 cm) Platform (36x48) w/o Control Box 150 68
Red - 119.5 in. (303.5 cm) Platform (36x60) w/o Control Box 165 75
White - 154.5 in. (392.4 cm) Platform (36x72) w/o Control Box 180 82
Platform (36x96) w/o Control Box 220 100
100HX+10
Boom - 100HX (Incl. Lift Cylinder) 9920 4.500
Blue - 50 in. (127 cm)
Boom - 110HX (Incl. Lift Cylinder) 10960 4,971
Yellow - Not used Boom - 100HX+10 (Incl. Lift Cylinder) 10680 4,844
Red - 84 in. (213.4 cm) Turntable (w/Ford Engine, Less Cwt.) 10300 4,672
Turntable (w/Deutz Engine, Less Cwt.) 10620 4,817
White - 135.5 in. (344.2 cm)
Turntable (w/Cummins Engine, Less Cwt.) 10455 4,742
With 4620044 or 4620078 Turntable Frame Complete (incl. Wheels and Tires) 13620 6,178
100HX Dual Capacity Complete Machine - 100HX 37000 16,783
Blue - Not used Complete Machine - 110HX 40500 18,371
Complete Machine - 100HX+10 38500 17,464
Yellow - 62 in. (157.5 cm)
Red - 90 in. (228.6 cm)
White- 118 in. (299.7 cm) 1.10 SERIAL NUMBER LOCATIONS
110HX Single Capacity For machine identification, a serial number plate is affixed
to the left side of the frame, below the battery compart-
Blue - Not used
ment. If the serial number plate is damaged or missing,
Yellow - Not used the machine serial number is stamped on the left side of
the frame between the front and rear wheels, below the
Red - 122.5 in. (311.2 cm) turntable bearing and on the right side of the turntable in
White - 157.5 in. (400.1 cm) the bottom of the valve compartment. In addition, the last
five digits of the serial number are stamped on top of the
110HX Dual Capacity fly end of the base boom section.
Blue - Not used 

Yellow - 85.5 in. (217.2 cm) 

Red - 122.5 in. (311.2 cm)

White - 160.5 in. (400.1 cm) 
 
 
 
 
 
3120636 – JLG Lift – 1-9

1.11 CRITICAL STABILITY WEIGHTS Table 1-11.Critical Stability Weights
Component 100HX 110HX 100HX+10

Counterweight 6150 lbs. 10,350 lbs. 9,850 lbs.
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS THE
(1.5:1) (2790 kg) (4695 kg) (4468 kg)
COUNTERWEIGHT OR FOAM-FILLED TIRES, WITH ITEMS OF DIF-
FERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN Counterweight N/A 10,350 lbs. 9,850 lbs.
ANY WAY TO AFFECT STABILITY. (2:1) (4695 kg) (4468 kg)
Foam-Filled Tires 700 lbs. 700 lbs. 700 lbs.
(each) (318 kg) (318 kg) (318 kg)
Ford Engine 525 lbs. 525 lbs. 525 lbs.
(238 kg) (238 kg) (238 kg)
Deutz Engine 837 lbs. 837 lbs. 837 lbs.
(380 kg) (380 kg) (380 kg)
Cummins Engine 680 lbs. 680 lbs. 680 lbs.
(308 kg) (308 kg) (308 kg)
36x48 Platform N/A N/A 150 lbs.
(68 kg)
36x60 Platform N/A N/A 165 lbs.
(75 kg)
36x72 Platform N/A N/A 180 lb.
(82 kg)
36x96 Platform (100 kg) (100 kg) (100 kg)
Serial Number - Stamped

(Boom Sections)
Serial Number - Stamped
(Turntable - Far Side)
Serial Number - Stamped Serial Number Plate

(Frame) (Frame)
Figure 1-2. Serial Number Locations
1-10 – JLG Lift – 3120636

UNPLATED
VALUES FOR ZINC PLATED BOLTS ONLY CAP SCREWS
3120636
SAE GRADE 5 BOLTS & GRADE 2 NUTS SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
BOLT THREAD SOCKET HEAD CAP SCREW
SIZE THD DIA. STRESS CLAMP TORQUE CLAMP TORQUE WITH LOC-WEL PATCH
(CM) AREA LOAD (DRY OR (LUB.) (LOCTITE (LOCTITE LOAD (DRY OR (LUB.) (LOCTITE (LOCTITE CLAMP LOAD TORQUE
(SQ. CM) 263) 262) 242 OR 271) 263) 262) 242 OR 271) (as received)
(KG) LOC.
NM NM NM NM
(KG) LOC.
NM NM NM NM (KG) NM
40 0.0153 172 1 1 245 2 1
4 0.2845
48 0.0168 191 1 1 272 2 1
32 0.0232 263 2 2 372 3 2
6 0.3505
40 0.0258 277 2 2 417 3 2
8 32 0.0356 408 4 3 572 5 4
0.4166
36 0.0374 426 4 3 599 5 4
10 24 0.0445 508 5 4 717 7 5
0.4826
32 0.0508 583 6 4 817 8 6
1/4 20 0.0808 916 11 9 12 1297 16 12 18 1442 18
0.6350
28 0.0925 1052 14 10 16 1488 19 14 21 1651 19
18 0.1331 1515 23 18 22 26 2141 34 25 30 41 2377 34
5/16 0.7938
24 0.1473 1678 26 19 23 29 2821 34 27 34 41 2631 37
16 0.1969 2241 41 31 38 48 3175 61 48 54 68 3493 61
3/8 0.9525
24 0.2230 2540 48 34 43 54 3583 68 48 61 75 3983 68
14 0.2700 3085 68 48 61 75 4332 95 75 85 109 4822 95
7/16 1.1112
20 0.3015 3425 75 68 68 81 4854 109 81 95 122 5384 102
13 0.3604 4105 102 75 92 115 5783 149 109 130 163 6437 149
1/2 1.2700
20 0.4061 4854 122 88 108 136 6532 163 122 146 183 7253 156
12 0.4623 5262 149 109 133 163 7539 204 149 188 224 8256 210
9/16 1.4288
– JLG Lift –
18 0.5156 5874 163 122 148 183 8278 231 176 209 258 9208 224
5/8 11 0.5740 6532 204 149 183 224 9231 298 231 244 326 10251 285
1.5875
18 0.6502 7394 231 176 207 258 10433 326 244 277 359 11612 298
Figure 1-3. Torque Chart

10 0.8484 9662 353 271 325 387 13653 515 380 408 570 15150 495
3/4 1.9050
16 0.9474 10796 407 298 363 448 15241 570 434 456 631 16919 542
9 1.1735 13336 583 434 523 644 18870 814 624 658 895 20956 793
7/8 2.2225
14 1.2929 14697 637 475 576 705 20775 895 678 724 983 23088 861
8 1.5392 17509 868 651 785 915 23360 1220 922 931 1342 27488 1173
1 2.5400
12 1.6840 19142 949 719 858 997 27080 1356 1003 1079 1492 30074 1241
7 1.9380 19187 1085 814 968 1139 31162 1736 1302 1396 1898 34610 1681
1-1/8 2.8575
12 2.1742 21546 1193 895 1087 1254 34927 1953 1464 1566 2136 38828 1871
7 2.4613 24404 1519 1139 1368 1593 38554 2468 1844 1970 2712 43954 2373
1-1/4 3.1750
12 2.7254 27035 1681 1247 1516 1762 43818 2712 2034 2183 2983 48671 2549
6 2.9337 29076 1980 1492 1792 2068 47174 3227 2413 2586 3559 52391 3145
1-1/2 3.4925
12 3.3401 33113 2278 1708 2042 2373 53570 3688 2766 2935 4068 59648 3308
6 3.5687 35381 2630 1980 2379 2746 57380 4284 3200 3430 4712 63731 4122
1-1/2 3.8100
12 4.0132 39781 2983 2224 2676 3118 142200 4827 3607 3856 5322 71669 4433
Note: These torque values do not apply to cadium plated fasteners.
SAE GRADE 5 SAE GRADE 8
1-11
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1-12 – JLG Lift – 3120636

SECTION 2. PROCEDURES
Cleanliness
2.1 GENERAL
NOTE: The JLG Models 100HX, 110HX and 100HX+10 1. The most important single item in preserving the
have been built with two different turntable configura- long service life of a machine is to keep dirt and for-
tions. Turntable number 4620044 is used on eign materials out of the vital components. Precau-
machines with serial numbers 11511, 12249, 12598, tions have been taken to safeguard against this.
12836, 12838 and higher through March, 1992. Shields, covers, seals, and filters are provided to
Turntable number 4620078 is used on machines keep air, fuel, and oil supplies clean; however, these
since March, 1992. Where differences between items must be maintained on a scheduled basis in
specifications on maintenance procedures exist, the order to function properly.
turntable number will be specified. Refer to the JLG 2. At any time when air, fuel, or oil lines are discon-
Illustrated Parts Manual for turntable illustrations. nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
This section provides information necessary to perform nent is disconnected, cap or cover all openings to
maintenance on the aerial platform. Descriptions, tech- prevent entry of foreign matter.
niques and specific procedures are designed to provide
the safest and most efficient maintenance for use by per- 3. Clean and inspect all parts during servicing or main-
sonnel responsible for ensuring the correct installation tenance, and assure that all passages and openings
and operation of machine components and systems. 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 contain-
ers until they are ready to be used.
WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE Components Removal and Installation
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK 1. Use adjustable lifting devices, whenever possible, if
IS RESUMED. mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
The maintenance procedures included consist of servic- near perpendicular as possible to top of part being
ing and component removal and installation, disassembly lifted.
and assembly, inspection, lubrication and cleaning. Infor-
mation on any special tools or test equipment is also pro- 2. Should it be necessary to remove a component on
vided where applicable. an angle, keep in mind that the capacity of an eye-
bolt or similar bracket lessens, as the angle between
the supporting structure and the component
2.2 SERVICING AND MAINTENANCE becomes less than 90 degrees.
GUIDELINES 3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc.,have been
General removed and that no adjacent parts are interfering.
The following information is provided to assist you in the
use and application of servicing and maintenance proce- Component Disassembly and Reassembly
dures contained in this chapter. When disassembling or reassembling a component, com-
plete the procedural steps in sequence. Do not partially
Safety and Workmanship disassemble or assemble one part, then start on another.
Your safety, and that of others, is the first consideration Always recheck your work to assure that nothing has been
when engaging in the maintenance of equipment. Always overlooked. Do not make any adjustments, other than
be conscious of weight. Never attempt to move heavy those recommended, without obtaining proper approval.
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising Pressure-Fit Parts
a portion of the equipment, ensure that adequate support When assembling pressure-fit parts, use an “anti-seize” or
is provided. molybdenum disulfide base compound to lubricate the
mating surface.
3120636 – JLG Lift – 2-1

Bearings cleaning solvent. Lubricate components, as

required, to aid assembly.
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable Lubrication
cleaning solvent and allow to drip dry. Compressed Service applicable components with the amount, type,
air can be used but do not spin the bearing. and grade of lubricant recommended in this manual, at
2. Discard bearings if the races and balls (or rollers) the specified intervals. When recommended lubricants are
are pitted, scored, or burned. not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not Battery
unwrap reusable or new bearings until they are
ready to install. Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
4. Lubricate new or used serviceable bearings before cleaning, thoroughly dry battery and coat terminals with
installation. When pressing a bearing into a retainer an anti-corrosion compound.
or bore, apply pressure to the outer race. If the bear-
ing is to be installed on a shaft, apply pressure to the Lubrication and Servicing
inner race.
Components and assemblies requiring lubrication and
Gaskets servicing are shown in the Lubrication Chart in Section 1.
Check that holes in gaskets align with openings in the

mating parts. If it becomes necessary to hand-fabricate a 2.3 LUBRICATION INFORMATION
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as Hydraulic System
blank gaskets can cause serious system damage.
1. The primary enemy of a hydraulic system is contam-
Bolt Usage and Torque Application ination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
1. Use bolts of proper length. A bolt which is too long moisture, grease, filings, sealing components, sand,
will bottom before the head is tight against its related etc., to enter when performing maintenance, or by
part. If a bolt is too short, there will not be enough permitting the pump to cavitate due to insufficient
thread area to engage and hold the part properly. system warm-up or leaks in the pump supply (suc-
When replacing bolts, use only those having the tion) lines.
same specifications of the original, or one which is
equivalent. 2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
2. Unless specific torque requirements are given within even the smallest amount of dirt or foreign matter
the text, standard torque values should be used on entering a system can cause wear or damage to the
heat-treated bolts, studs, and steel nuts, in accor- components and generally results in faulty opera-
dance with recommended shop practices. See the tion. Every precaution must be taken to keep
Torque Chart in Section 1 - Specifications. hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
Hydraulic Lines and Electrical Wiring cleaned, and/or replaced as necessary, at the speci-
Clearly mark or tag hydraulic lines and electrical wiring, as fied intervals required in Section 1. Always examine
well as their receptacles, when disconnecting or removing filters for evidence of metal particles.
them from the unit. This will assure that they are correctly
3. Cloudy oils indicate a high moisture content which
reinstalled.
permits organic growth, resulting in oxidation or cor-
rosion. If this condition occurs, the system must be
Hydraulic System drained, flushed, and refilled with clean oil.
1. Keep the system clean. If evidence of metal or rub- 4. It is not advisable to mix oils of different brands or
ber particles are found in the hydraulic system, drain types, as they may not contain the same required
and flush the entire system. additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
2. Disassemble and reassemble parts on clean work
ambient temperatures in which the machine is oper-
surface. Clean all metal parts with non-flammable
ating, are recommended for use.
2-2 – JLG Lift – 3120636

NOTE: Metal particles may appear in the oil or filters of new Lubrication Specifications
machines due to the wear-in of meshing compo-
Specified lubricants, as recommended by the component
nents.
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
Hydraulic Oil meet a variety of single purpose grease requirements.
Should any question arise regarding the use of greases in
1. Refer to Table 1-1 for recommendations for viscosity
maintenance stock, consult your local supplier for evalua-
ranges.
tion. Refer to Table 1-2 for an explanation of the lubricant
2. JLG recommends Mobilfluid 424 hydraulic oil, which key designations appearing in the Lubrication Chart.
has an SAE viscosity of 10W-30 and a viscosity
index of 152.
2.4 CYLINDERS - THEORY OF OPERATION
NOTE: Start-up of hydraulic system with oil temperatures
below -15 degrees F (-26 degrees C) is not recom- 1. Cylinders are of the double acting type. Systems
mended. If it is necessary to start the system in a incorporating double acting cylinders are as follows:
sub-zero environment, it will be necessary to heat Lift, Telescope, Steer, Master Level, Slave Level, Axle
the oil with a low density, 100VAC heater to a mini- Extend, Frame Lift (if equipped) and Extend-A-
mum temperature of -15 degrees F (-26 degrees C). Reach (if equipped). A double acting cylinder is one
that requires oil flow to operate the cylinder rod in
3. The only exception to the above is to drain and fill both directions. Directing oil (by actuating the corre-
the system with Mobil DTE 11 oil or its equivalent. sponding control valve to the piston side of the cylin-
This will allow start up at temperatures down to -20 der) forces the piston to travel toward the rod end of
degrees F (-29 degrees C). However, use of this oil the barrel, extending the cylinder rod (piston
will give poor performance at temperatures above attached to rod). When the oil flow is stopped,
120 degrees F (49 degrees C). Systems using DTE movement of the rod will stop. By directing oil to the
11 oil should not be operated at temperatures above rod side of the cylinder, the piston will be forced in
200 degrees F (94 degrees C) under any condition. the opposite direction and the cylinder rod will
retract.
Changing Hydraulic Oil 2. Holding valves are used in the Lift, Slave Level, Tele-
scope, and Extend-A-Reach circuits to prevent
1. Use of any of the recommended crankcase or
retraction of the cylinder rod should a hydraulic line
hydraulic oils eliminates the need for changing the
rupture or a leak develop between the cylinder and
oil on a regular basis. However, filter elements must
its related control valve.
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this man- 2.5 VALVES - THEORY OF OPERATION
ual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assis- Solenoid Control Valves (Bang-Bang)
tance in selecting the proper equivalent. Avoid mix- Control valves used are four-way three-position solenoid
ing petroleum and synthetic base oils. JLG valves of the sliding spool design. When a circuit is acti-
Industries recommends changing the hydraulic oil vated and the control valve solenoid energizes, the spool
annually. is shifted and the corresponding work port opens to per-
mit oil flow to the component in the selected circuit, with
2. Use every precaution to keep the hydraulic oil clean.
the opposite work port opening to reservoir. Once the cir-
If the oil must be poured from the original container
cuit is deactivated (control returned to neutral), the valve
into another, be sure to clean all possible contami-
spool returns to neutral (center) and oil flow is then
nants from the service container. Always clean the
directed through the valve body and returns to reservoir.
mesh element of the filter and replace the cartridge
any time the system oil is changed.
3. While the unit is shut down, a good preventive main-
tenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.
3120636 – JLG Lift – 2-3

A typical control valve consists of the valve body, sliding the load requirement, with the valve diverting excess
spool, and two solenoid assemblies. The spool is pump delivery back to the reservoir when operating pres-
machine fitted in the bore of the valve body. Lands on the sure of the component is reached.
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the Crossover Relief Valves
valve body open to common flow. At the same time other
Crossover relief valves are used in circuits where the actu-
ports would be blocked to flow. The spool is spring-
ator requires an operating pressure lower than that sup-
loaded to center position, therefore when the control is
plied to the system. When the circuit is activated and the
released, the spool automatically returns to neutral, pro-
required pressure at the actuator is developed, the cross-
hibiting any flow through the circuit.
over relief diverts excess pump flow to the reservoir. Indi-
vidual, integral reliefs are provided for each side of the
Manual Hydraulic Control Valves circuit.
The manual hydraulic control valves consist of four-way,
multi-position valve sections, each section incorporating a
sliding spool, spring-loaded to neutral or off. Each spool is 2.6 BOOM CHAINS
attached to a control lever which provides for proportional
control of the selected system function. This proportional Adjusting Procedures
control enables metering of oil flow in accordance with
spool position, affording variable and smooth speed con-
trol capability. Spool movement causes work ports within
the valve to align in a predetermined way, permitting flow ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE.
to the selected function, with the opposing work ports
positioned to allow return flow to the hydraulic reservoir. 1. Position boom fully retracted at +5 degrees horizon-
tal, no load in platform.
Proportional Control Valves - Vickers 2. Torque outer mid section extend chain adjuster to 59
The Vickers proportional valves provide a power output ft. lb. (80 Nm).
matching that required by the load. A small line connected 3. Torque outer mid section retract chain adjuster to 59
to a load sensing port feeds load pressure back to a ft. lb. (80 Nm).
sequence valve. The sequence valve senses the differ-
ence between the load and pump outlet pressure, and 4. Torque fly section extend chain adjuster to 59 ft. lb.
varies the pump displacement to keep the difference con- (80 Nm).
stant. This differential pressure is applied across the 5. Torque fly section retract chain adjuster to 59 ft. lb.
valve’s meter-in spool, with the effect that pump flow is (80 Nm).
determined by the degree of spool opening, independent
of load pressure. Return lines are connected together, 6. Cycle boom (extend at least 6 feet [2 meters], then
simplifying routing of return flow and to help reduce cavi- retract fully).
tation.
7. Recheck outer mid section extend chain.
Load sensing lines connect through shuttle valves to feed
8. Recheck outer mid section retract chain.
the highest load signal back to the sequence valve. Inte-
gral actuator port relief valves, anti-cavitation check 9. Recheck fly section extend chain.
valves, and load check valves are standard.
10. Recheck fly section retract chain.
Relief Valves 11. Repeat steps (2) thru (10) if necessary.
Main relief valves are installed at various points with the 12. Check for proper operation of boom.
hydraulic system to protect associated systems and com-
ponents against excessive pressure. Excessive pressure JLG Industries, Inc. requires a complete boom disassem-
can be developed when a cylinder reaches its limit of bly, per instructions outlined in Boom Maintenance in this
travel and the flow of pressurized fluid continues from the section, every two years. All boom chains and related
system control. The relief valve provides an alternate path components (i.e., sheaves, pins, sprockets, wear pads,
for the continuing flow from the pump, thus preventing etc.) must also be inspected and replaced (as necessary)
rupture of the cylinder, hydraulic line or fitting. Complete during this disassembly.
failure of the system pump is also avoided by relieving cir-
cuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
2-4 – JLG Lift – 3120636

Adjustable Relief
Meter-Out Poppet
Actuator Port "A"
Return Port
Actuator Port "B"
Load Drop Check
"B" Solenoid
Electro-Hydraulic
Reducing Valve Spool Pilot Relief
Load Sensing Check Valves
Vent
Meter-In Spool
Meter-In Chambers
Valve Inlet Port
Gasket
Pilot Supply Passages

"A" Solenoid
Figure 2-1. Proportional Control Valve
3120636 – JLG Lift – 2-5

OUTER MID EXTEND
OUTER MID RETRACT

FLY EXTEND
FLY RETRACT
Figure 2-2. Boom Chain Adjustments
2-6 – JLG Lift – 3120636

Figure 2-3. Typical Boom Assembly
3120636 – JLG Lift – 2-7

An immediate disassembly of the boom assembly and Inspection Procedure

inspection of the boom chains and related components is
Inspect boom chains for the following conditions:
required if any of the following conditions occur:
1. Wear: Always inspect that segment of chain that
1. After the machine is exposed to hostile environ-
operates over a sheave. As the chain flexes over the
ments or conditions (i.e. extreme cold, dust, sand,
extend/retract sheaves, joints and plate edges very
blasting grit, salt, chemicals, etc.), which could
gradually wear. Chain “stretch” can be measured
adversely affect boom operation.
using a manufacturers wear scale or steel tape.
2. Erratic boom operation or unusual noise exists. See When chains have elongated 3% they must be
the Troubleshooting section in this Service Manual. removed and replaced. Refer to Table 2-1, Chain
Stretch Tolerance for proper chain specifications
3. Chain adjustment is required more often than speci-
and allowable stretch tolerances. Peening and wear
fied in the Preventive Maintenance and Inspection
of chain plate edges are caused by sliding over a
Schedule or links need to be removed (chain short-
chain worn contact face of a sheave, or unusually
ened) to make the proper adjustment.
heavy loads. All of the above require replacement of
4. The machine is idle for an extended period (6 the chain and correction of the cause. Chain side
months or longer.) wear, noticeable when pin heads and outside plates
show a definite wear pattern, is caused by misalign-
5. The boom is overloaded or sustained a shock load. ment of the sheave/chain anchors and must be cor-
rected promptly. Do not repair chains; if a section of
chain is damaged, replace the entire chain set.
FAILURE TO DISASSEMBLE THE BOOM ASSEMBLY AND PROP-
ERLY INSPECT AND/OR REPLACE THE BOOM CHAINS AND
RELATED COMPONENTS (I.E., SHEAVES, PINS, SPROCKETS,
WEAR PADS, ETC.) COULD RESULT IN THE DAMAGE AND/OR
BREAKAGE OF THE BOOM CHAINS AND/OR RELATED COMPO-
NENTS. DAMAGE AND/OR BREAKAGE OF THESE ITEMS COULD H for a 1" chain = 0.950"
RESULT IN UNCONTROLLED EXTENSION OR RETRACTION OF Maximum wear = 5% of 0.950" = 0.047"
THE BOOM ASSEMBLY AND COULD CAUSE SERIOUS INJURY OR Minimum plate depth = 0.950" - 0.047" = 0.903"
DEATH TO PERSONNEL OPERATING THE JLG BOOM LIFT.


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
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









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
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2-8 – JLG Lift – 3120636

Table 2-1.Chain Stretch Tolerance
Pin to Pin
Chain Size Allowable Stretch
Measurement
0.50 in. (1.27 cm) pitch 14 in. (36 cm) or 28 pitches 0.42 in. (1.07 cm)
1 in. (2.54 cm) pitch 14 in. (36 cm) or 14 pitches 0.42 in. (1.07 cm)
2. Lubrication: One of the most important but often 5. Tight Joints: All joints in the roller chain should flex
overlooked factors is adequate lubrication. In addi- freely. On roller chain, tight joints are usually caused
tion to reducing internal friction, maintaining a film of by rust/corrosion, or the inside plates “walking” off
oil on all chain surfaces will inhibit rusting and corro- the bushing. Limber up rusty/corroded chains (after
sion. This is important as corrosion of highly inspecting carefully) with a heavy application of oil
stressed, hardened steel chain components can (preferably a hot oil dip). Tap inside “walking” plates
cause a major reduction in the load capacity of leaf inward; if “walking” persists, replace the chain. This
chain and result in link plate cracking. type of problem is accelerated by poor lubrication
maintenance practice, and most tight joint chains
NOTE: The need for lubrication can be determined by the have been operated with little or no lubrication. Tight
presence of rust on the exposed portions of chain. joints on leaf chain are generally caused by:

3. Rust and Corrosion: Rust and corrosion will cause 1. Bent pins or plates.
a major reduction in the load carrying capacity of the 2. Rusty joints.
chain, because these are primary reasons for side 3. Peened plate edges.
plate cracking. The initial lubrication at the factory is 
applied in a hot dip tank to assure full penetration Oil rusty chains, and replace chains with bent or
into the joint. Do not steam clean or degrease peened chain components. Keep chains lubricated.
chains. At time of chain installation, factory lube
must be supplemented by a maintenance program TIGHT JOINTS
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 dip- 6. Protruding or Turned Pins: Chains operating with
ping in heated oil, and reinstall on the machine. inadequate lube generate tremendous friction
Keep chains lubricated. between the pin and plates (pin and bushing on
4. Fatigue Cracks: Fatigue is a phenomenon that roller chain). In extreme cases, this frictional torque
affects most metals, and is the most common cause can actually turn the pins in the outside press-fit
of chain plate failures. Fatigue cracks are found plates. Inspect for turned pins, which can be easily
through the link holes, perpendicular (90 degrees) spotted as the “V” flats on the pin heads are no
from the pin in-line position. Inspect chains carefully longer in line. Replace all chains showing evidence
after long time use and heavy loading for this type of of turned or protruding pins. Keep chains lubricated.
crack. If any cracks are discovered, replace all 7. Stress Corrosion Cracking: The outside link
chains, as seemingly sound plates are on the verge plates, which are heavily press-fitted to the pins, are
of cracking. Fatigue and ultimate strength failures on particularly susceptible to stress corrosion cracking.
JLG Lifts are incurred as a result of severe abuse as Like fatigue cracks, these initiate at the point of high-
design specs are well within the rated lifting capacity est stress (aperture) but tend to extend in an arc-like
of these chains. path, often parallel to the rolling grain of the material.
3120636 – JLG Lift – 2-9


2.7 WEAR PADS
ABNORMAL PROTRUSION OR
TURNED PINS 9. Shim up wear pads to within 1/16 in. (0.8 mm) toler-
ance between wear pad and adjacent surface.
10. Replace wear pads when worn within 1/8 in. (3.2
mm) of threaded insert.
Also, more than one crack can often appear on a

2.8 DRIFT TEST
link plate. In addition to rusting, this condition can NOTE: It is recommended that the machine be shut down in
be caused by exposure to an acidic or caustic the test mode for at least one hour prior to beginning
medium or atmosphere. Stress corrosion is an envi- the drift test. This will allow the oil temperature in the
ronmentally assisted failure. Two conditions must be cylinder to stabilize with the ambient temperature.
present - corrosive agent and static stress. Thermal expansion or retraction of the hydraulic oil
 can greatly affect cylinder movement.
ARC-LIKE CRACKED PLATES
(STRESS CORROSION)
Telescope Cylinder
NOTE: Switches referenced in this procedure are located on

the Ground Control Panel.
In the chain, static stress is present at the aperture 1. Activate hydraulic system, properly set extendable
due to the press fit pin. No cycle motion is required axles and position boom in stowed position; adhere
and the plates can crack during idle periods. The to all safety precautions.
reactions of many chemical agents (such as battery
acid fumes) with hardened metals liberate hydrogen
which attacks and weakens the metal grain struc-
ture.
8. 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.

Sheaves should be inspected for worn flanges,
which would indicate misalignment, and wear on the
outside diameter of the sheave. A worn sheave can
mean several problems, as follows:

1. Chains too tight.
2. Sheave bearings/pin bad.
3. Bent/misaligned chains.






2-10 – JLG Lift – 3120636

2. Attach tape measure or cord to bottom of platform.
BEFORE RAISING AND EXTENDING BOOM, ENSURE THAT

AREAS ABOVE AND BELOW BOOM AND PLATFORM AND AHEAD
BEFORE RAISING BOOM, ENSURE THAT AREAS ABOVE AND
OF PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PER-
BELOW BOOM AND PLATFORM ARE CLEAR OF ALL OBSTRUC-
SONNEL.
TIONS AND PERSONNEL.
2. Position LIFT control switch to UP and hold until
3. With boom fully retracted, place LIFT control switch
boom reaches horizontal.
to UP and hold until platform is approximately 6 feet
3. Position TELESCOPE control switch to OUT and (2 meters) above ground level. Shut down engine.
hold until boom extends approximately four (4) feet
4. Tag and carefully disconnect hydraulic lines to lift
(1.2 meter); measure from end of base section to
cylinder at control valve. Use a suitable container to
end of mid section.
retain any residual hydraulic fluid.
4. Position LIFT control switch to UP and hold until
5. Observe oil flow from cylinder lines. Oil leaking from
boom reaches maximum elevation. Shut down
extend port hose indicates a leaking counterbalance
engine.
valve. Oil leaking from retract port hose indicates
5. Tag and carefully disconnect the hydraulic lines to leakage by cylinder piston.
the telescope cylinder at control valve.
6. Leave boom elevated in test position for approxi-
6. Observe oil flow from cylinder lines. Oil leaking from mately one (1) hour.
extend port hose indicates a leaking counterbalance
7. With tape measure or cord used for reference,
valve. Oil leaking from retract port hose indicates
check to see whether boom has lowered (crept)
leakage by cylinder piston.
more than 3 inches (7.6 cm).
7. Leave boom elevated in test position for approxi-
8. If boom has lowered and oil is leaking around rod-
mately one hour.
end cap of cylinder, seals in cylinder are defective
and require replacement. If boom has lowered and
oil is leaking from the counterbalance valve, the
BEFORE LOWERING BOOM, ENSURE THAT AREAS BELOW valve is either improperly adjusted or defective and
BOOM AND PLATFORM ARE CLEAR OF ALL PERSONNEL AND requires replacement.
OBSTRUCTIONS.
8. Position LIFT control switch to DOWN and hold until

E N S U R E T H AT H Y D R A U L I C L I N E S A R E C O N N E C T E D A S
boom reaches horizontal; check boom length
MARKED PRIOR TO BEING DISCONNECTED.
against measurement. If boom has retracted more
than 1 inch (2.5 cm) and oil is leaking around rod-
9. Connect hydraulic lines to control valve.
end of telescope cylinder (check with light and
inspection mirror), seals are defective and require
replacement, or cylinder rod is scored and cylinder
requires overhaul or replacement. If boom has 2.9 CYLINDER CHECKING PROCEDURES
retracted and oil is leaking from counterbalance NOTE: Cylinder checks must be performed any time a cylin-
valve, the valve is either improperly adjusted, or der component is replaced or when improper system
defective and requires replacement. operation is suspected.
9. Connect hydraulic lines to control valve.
Cylinder w/o Counterbalance Valves
Lift Cylinder Steer Cylinder, Master Level Cylinder, Axle Extension Cylin-
ders
NOTE: Switches referenced in this procedure are located on
the Ground Control Panel.
1. Activate hydraulic system, properly set extendable OPERATE FUNCTIONS FROM GROUND CONTROL STATION
axles and position boom in stowed position; adhere ONLY.
to all safety precautions.
1. Using all applicable safety precautions, activate
NOTE: Tape measure or cord should be at least 7 feet (2.1 engine and fully extend cylinder to be checked. Shut
meters) long for use in this test. down engine.
3120636 – JLG Lift – 2-11

Figure 2-4. Boom Positioning and Support - Cylinder Repair
2. Carefully disconnect hydraulic hose from retract port

of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
After the initial discharge, there should be no further ONLY.
leakage from the retract port.
1. Using all applicable safety precautions, activate
3. Activate engine and activate cylinder extend func- hydraulic system.
tion. Check retract port for leakage.
4. If cylinder leakage is 6-8 drops per minute or more,
piston seals are defective and must be replaced. If WHEN WORKING ON THE LIFT CYLINDER, RAISE THE BOOM TO
cylinder retract port leakage is less than 6-8 drops HORIZONTAL AND SUPPORT THE BOOM USING A SUITABLE
per minute, carefully reconnect hose to retract port BOOM PROP OR OVERHEAD LIFTING DEVICE.
and retract cylinder.
5. With cylinder fully retracted, shut down engine and 2. If working on the lift cylinder, raise boom to horizon-
carefully disconnect hydraulic hose from cylinder tal and place a suitable boom prop approximately 1
extend port. inch (2.5 cm) below the boom. If working on the tele-
scope cylinder, raise the boom above horizontal and
6. Activate engine and activate cylinder retract func- extend the fly boom approximately 1 foot (30.5 cm).
tion. Check extend port for leakage.
3. Shut down hydraulic system and allow machine to
7. If cylinder leakage is 6-8 drops per minute or more, sit for 10-15 minutes. Turn ignition switch to ON,
piston seals are defective and must be replaced. If move control switch or lever for applicable cylinder
extend port leakage is less than 6-8 drops per in each direction, then turn ignition switch to OFF.
minute, carefully reconnect hose to extend port, This is done to relieve excess pressure in the
then activate cylinder through one complete cycle hydraulic lines. Carefully remove hydraulic hoses
and check for leaks. from appropriate cylinder port block.
Cylinders w/Single Counterbalance Valves 4. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
Lift Cylinder, Telescope Cylinder, Extend-A-Reach Cylinder discharge, there should not be any further leakage
(if equipped) from the ports. If leakage continues at a rate of 6-8
2-12 – JLG Lift – 3120636

drops per minute or more, cylinder repairs must be

made. If the retract port is leaking, the piston seals 2.10 CYLINDER REMOVAL AND
are defective and must be replaced. If the extend INSTALLATION
port is leaking, the counterbalance valve is defective
and must be replaced. Telescope Cylinder Removal
5. If no repairs are necessary or when repairs have 1. Place machine on a flat and level surface, with axles
been made, carefully reconnect hydraulic hoses to extended and the boom fully retracted and in the
the appropriate ports. horizontal position.
6. If used, remove boom prop or lifting device from 2. Shut down engine. Support boom platform end with
boom, activate hydraulic system and run cylinder a prop or suitable overhead lifting device.
through one complete cycle to check for leaks.
3. Remove boom end cover.
Cylinders w/Dual Counterbalance Valve 4. Remove boom length/angle indicator from boom
Platform Slave Level Cylinder, Extend-A-Reach Slave Level assembly.
Cylinder (if equipped), Axle Lift Cylinder (if equipped)
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-

ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
CONTAMINANTS INTO THE SYSTEM.
ONLY.
1. Using all applicable safety precautions, activate 5. Tag and disconnect hydraulic lines to telescope cyl-
hydraulic system. inder. Use suitable containers to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
2. If working on the telescope cylinder, raise the boom
above horizontal and extend the fly boom approxi- 6. Remove the two (2) cotter pins that retain the tele-
mately 1 foot (30.5 cm). If working on the platform scope rod attach pin to the base boom.
slave level cylinder, stroke platform level cylinder for- 7. Using a suitable brass drift, carefully drive the tele-
ward until platform sits at a 45° angle. scope cylinder rod attach pin from the base boom.
3. Shut down hydraulic system and allow machine to 8. Remove the telescope cylinder trunnion attach pin
sit for 10-15 minutes. Turn ignition switch to ON, cover from each side of the base boom.
move control switch or lever for applicable cylinder
in each direction, then turn ignition switch to OFF. 9. Remove the setscrews securing the telescope cylin-
This is done to relieve pressure in the hydraulic der attach pin from each side of the telescope cylin-
lines. Carefully remove hydraulic hoses from appro- der trunnion.
priate cylinder port block. 10. Using a suitable slide hammer, remove the half pins
4. There will be initial weeping of hydraulic fluid which attaching the telescope cylinder to the inner mid
can be caught in a suitable container. After the initial boom section.
discharge, there should not be any further leakage 11. Attach a suitable sling to the telescope cylinder rod.
from the ports. If leakage continues at a rate of 6-8 Support with an overhead crane or other suitable lift-
drops per minute or more, the counterbalance valve ing device.
is defective and must be replaced.
12. Remove the rod support bracket at the aft end of the
5. To check piston seals, carefully remove the counter- base boom.
balance valve from the retract port. After initial dis-
charge, there should not be any further leakage from 13. Remove the two (2) extension chain adjusting nuts
the ports. If leakage occurs at a rate of 6-8 drops per at the aft end of the base boom.
minute or more, the piston seals are defective and
14. Remove the three (3) bolts, washers and lockwash-
must be replaced.
ers attaching the chain adjust bracket to the aft end
6. If no repairs are necessary or when repairs have of the base boom and remove bracket.
been made, replace counterbalance valve and care-
fully reconnect hydraulic hoses to cylinder port
block.
7. Activate hydraulic system and run cylinder through
one complete cycle to check for leaks.
3120636 – JLG Lift – 2-13

SETSCREW
PISTON SEALS
ROD
HEAD SEALS
ROD SUPPORT
PISTON
HEAD RETAINER
SPACER
BARREL
TELESCOPE HEAD
CYLINDER
ROD
SUPPORT
BLOCK
HEAD SEALS
HOLDING
VALVE
PISTON
RETAINER
SPACER
SETSCREW
HEAD
BARREL
ROD
AXLE LIFT
CYLINDER PISTON
SEALS
Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.
Figure 2-5. Typical Hydraulic Cylinders - Sheet 1 of 5
2-14 – JLG Lift – 3120636

HEAD SEALS
RETAINER
PISTON
SPACER
HEAD
SETSCREW
BARREL
HOLDING
ROD VALVE
LIFT
CYLINDER
PISTON
SEALS
PISTON
SETSCREW HOLDING
VALVE
HOLDING
VALVE
NUT
PISTON HEAD SEALS

SEALS
SPACER
ROD
SLAVE
BARREL
CYLINDER HEAD
3120636 – JLG Lift – 2-15

SETSCREW
PISTON
SETSCREW
SPACER
NUT
HEAD SEALS
PISTON
SEALS
ROD
BARREL
STEER HEAD
CYLINDER
SETSCREW
PISTON SEALS
ROD
HEAD SEALS
NUT
PISTON
SPACER
BARREL
MASTER
CYLINDER HEAD
HEAD RETAINER
2-16 – JLG Lift – 3120636

HEAD SEALS
RETAINER
PISTON
HEAD SETSCREW
NUT
BARREL
ROD
AXLE
CYLINDER SPACER
PISTON
SEALS
HEAD SEALS
HOLDING
VALVE
PISTON
SETSCREW
HEAD
BARREL
ROD
SPACER
SLAVE PISTON
CYLINDER SEALS
(Extend-A-Reach) HOLDING
VALVE
3120636 – JLG Lift – 2-17

HEAD SEALS
PISTON
RETAINER
SETSCREW
HEAD
HOLDING
VALVE
BARREL
ROD
SPACER
EXTEND-A-REACH PISTON
SEALS
LIFT CYLINDER
NUT
Typical Hydraulic Cylinders - Sheet 5 of 5
1. Pull boom sections apart several feet. 8. Using another lifting device, support the sheave
wheel end of the cylinder and remove the cylinder
2. Using the lifting equipment, raise the cylinder to
from the boom assembly.
obtain sufficient clearance for removal of the cylin-
der. 9. Carefully lift the cylinder clear of the boom assembly
and lower to the ground or suitably supported work
3. Connect a suitable lifting device to the extension
area.
chain adjust rod on top of the telescope cylinder.
4. Using both lifting devices, carefully pull the cylinder Telescope Cylinder Installation
from the boom assembly.
1. Using suitable lifting equipment, carefully lower the
NOTE: The extension rod will come out of the boom twice as cylinder to the boom assembly.
far as the telescope cylinder proportionally.
2. Using another lifting device, support the sheave
5. Continue sliding the cylinder and extension rod out wheel end of the cylinder and install the cylinder into
of the boom until the rod can be separated from the the boom assembly.
extension chain by removing the chain clevis attach 3. Slide the extension cylinder into the boom, sliding
pin. the extension chain in place as the cylinder is mov-
6. Using the lifting equipment, remove the extension ing in.
chain bar. 4. Using the lifting equipment, install the extension
7. Continue sliding the cylinder from the boom, laying chain bar.
the extension chain on top of the base boom as the 5. Continue sliding the cylinder and extension rod into
cylinder is coming out. the boom until the rod can be attached to the exten-
sion chain by installing the chain clevis attach pin.
2-18 – JLG Lift – 3120636

6. Install the chain adjust bracket and install the three 2. Using auxiliary power, retract the lift cylinder rod
(3) bolts, washers and lockwashers which attach the completely.
bracket to the aft end of the base boom.
3. Remove the barrel end attach pin retaining plate and
7. Install the two (2) extension chain adjusting nuts at hardware. Using a suitable brass drift drive out the
the aft end of the base boom. barrel end attach pin from the upright.
8. Install the rod support bracket at the aft end of the 4. Remove the cylinder from the boom and place in a
base boom. suitable work area.
9. Remove the sling attached to the telescope cylinder
Lift Cylinder Installation
rod.
10. Pull boom sections back into the fully retracted posi- 1. Install lift cylinder in place using suitable slings or
tion. supports, aligning attach pin mounting holes on the
upright.
11. Using a suitable brass drift, if necessary, install the
half pins attaching the telescope cylinder to the 2. Using a suitable drift, drive the barrel end attach pin
inner mid boom section. through the mounting holes in the lift cylinder and
the upright. Secure in place with the pin retaining
12. Install setscrews that attach the telescope cylinder plate and hardware.
attach pins to each side of the telescope cylinder
trunnions. 3. Remove cylinder port plugs and hydraulic line caps
and correctly attach lines to cylinder ports.
13. Install the telescope cylinder trunnion attach pin
cover to each side of the base boom. 4. Using auxiliary power, extend the cylinder rod until
the attach pin hole aligns with those in the boom.
14. Carefully install the telescope cylinder rod attach pin Using a suitable drift, drive the cylinder rod attach
into the base boom. pin through the aligned holes, taking care to align
15. Install the two (2) cotter pins that retain the tele- the grooved pin holes. Secure the pin in place with
scope rod attach pin to the base boom. the bolt, lockwasher and nut.
16. Remove applicable hydraulic line and port caps and 5. Place boom in the stowed position and shut down
correctly connect the hydraulic lines to the tele- engine. Check hydraulic fluid level and adjust
scope cylinder. Ensure that all hoses are correctly accordingly.
routed.
Master Level Cylinder Removal
17. Cycle telescope function several times to dissipate
any air from cylinder and lines. Properly torque 1. With the main boom positioned to horizontal and
boom chains to 59 ft. lb. (80 Nm). properly supported, prepare to remove the upright
18. Install boom length/angle indicator on boom assem- level cylinder.
bly. 2. Remove the bolt, lockwasher and nut securing the
NOTE: Boom length/angle indicator will need to be adjusted level cylinder rod attach pin to the tower boom.
as per the procedure listed in Section 2.30, Boom Using an appropriate brass drift, drive out the level
Length/angle Sensor Adjustment Procedures. cylinder rod attach pin.
3. Tag, disconnect and cap hydraulic lines to level cyl-
19. Using all applicable safety precautions, operate the inder.
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary. NOTE: When disconnecting hydraulic lines, any residual
hydraulic fluid should be drained into a suitable con-
20. Install boom end cover. tainer.
21. Retract boom fully and place in stowed position.
4. Make up two temporary hose assemblies (3/8 In. x
Lift Cylinder Removal 10 ft.) to carry power from the turntable swing motor
supply hoses to the lift cylinder. Couple temporary
1. Place the machine on a flat and level surface. Start hoses to swing motor supply hoses, using reducer
the engine and place the boom in a horizontal posi- fittings if necessary. Plug ports in swing motor.
tion. Shut down the engine and attach a suitable 5. After installing temporary hoses, activate swing func-
support device to the boom. Using a suitable brass tion, using auxiliary power, to fully retract level cylin-
drift drive out the cylinder rod attach pin. der rod.
3120636 – JLG Lift – 2-19

6. Remove temporary hoses from level cylinder and 1. Connect a suitable auxiliary hydraulic power source
cap them. Plug cylinder ports. to the cylinder port block fitting.
7. Using slings, restrain level cylinder.
8. Remove retaining plate and bolts from upright cylin- DO NOT FULLY EXTEND CYLINDER TO END OF STROKE.
der attach pin. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
9. Using an appropriate brass drift, drive out the SURE.
upright attach pin. Carefully remove restraining
slings and remove level cylinder from boom 2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
Master Level Cylinder Installation source. Adequately support the cylinder rod, if appli-
cable.
1. With the boom positioned at horizontal and properly 3. If applicable, remove the cartridge-type holding
supported, place the master level cylinder in posi- valve and fittings from the cylinder port block. Dis-
tion on the boom and secure in place using slings. card o-rings.
2. Align barrel end bushing with pin attach blocks in
turntable upright and install upright attach pin using
appropriate brass drift. Secure pin with retaining
plate and retaining plate bolts.
3. Remove caps from temporary hydraulic lines and BARREL CLAMP
ROD SUPPORT
attach to level cylinder ports. Using auxiliary power,
activate swing function and extend cylinder rod until
rod bushing aligns with boom lift cylinder rod end PROTECTED
attach bushing. ROD CLAMP
4. Using an appropriate brass drift drive the rod attach

pin through the aligned bushings of the cylinder rod SUPPORT
and boom lift cylinder rod end attach plate, taking TABLE
care to align holes for bolt attachment. Secure rod
end attach pin with bolt, lockwasher and nut.
5. Remove restraining slings from level cylinder.
Figure 2-6. Cylinder Barrel Support
6. Remove temporary hydraulic lines from cylinder
ports and turntable swing motor hydraulic supply.
Reattach hydraulic supply to swing motor. 4. Place the cylinder barrel into a suitable holding fix-
ture.
7. Remove caps from cylinder hydraulic lines and cor-
rectly install lines to cylinder. 5. Tap around outside of cylinder head retainer, if appli-
cable, and/or cylinder head gland with a suitable
8. Remove boom support. Place boom in stowed posi- hammer to shatter loctite.
tion. Check hydraulic fluid level and adjust accord-
ingly. 6. Using a suitable spanner wrench or chain wrench,
loosen the cylinder head retainer, if applicable, and/
or cylinder head gland, and remove from cylinder
2.11 CYLINDER REPAIR barrel. If using a chain wrench, keep wrench toward
outside (rod side) of gland nut to avoid distorting
NOTE: The following are general procedures that apply to threads.
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted. 7. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
Disassembly
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-

INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. CYLINDER BARREL SURFACES.
2-20 – JLG Lift – 3120636

8. With the barrel clamped securely, apply pressure to 3. Inspect threaded portion of rod for excessive dam-
the rod pulling device and carefully withdraw the age. Dress threads as necessary.
complete rod assembly from the cylinder barrel.
4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
ONCE THE HEAD GLAND HAS CLEARED THE CYLINDER CASE
5. Inspect threaded portion of barrel for damage. Dress
MOUTH, THE ROD MUST BE SUPPORTED CLOSE TO THE CYLIN-
threads as necessary.
DER CASE PRIOR TO THE PISTON BEING PULLED PAST THE
CYLINDER CASE THREADS. THIS IS DONE TO AVOID DAMAGE 6. Inspect piston surface for damage and scoring and
TO THE CYLINDER CASE THREADS, AND/OR THE PISTON AND for distortion. Dress piston surface or replace piston
PISTON SEALS. as necessary.
7. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
essary.
8. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
ROD SUPPORT
as necessary.
9. Inspect seal and o-ring grooves in head for burrs
PROTECTED
ROD CLAMP and sharp edges. Dress applicable surfaces as nec-
essary.
SUPPORT 10. If applicable, inspect cylinder head retainer or end

TABLE cap for surface or thread damage. Repair or replace
as necessary.
11. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
Figure 2-7. Cylinder Rod Support as necessary.
12. If applicable, inspect thread ring for scoring or other
9. Using suitable protection, clamp the cylinder rod in damage. Dress threads or applicable surfaces as
a vise or similar holding fixture as close to the piston necessary.
as possible.
13. If applicable, inspect rod and barrel bushings for
10. Remove the set screw(s), if applicable, and nut signs of correct lubrication and excessive wear.
which attach the piston to the rod, and remove the Replace as necessary.
piston. Discard nylon point set screws.
14. Inspect travel limiting collar or spacer for burrs and
11. Remove the piston rings. sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
12. Remove and discard the piston o-rings, seal rings,
and backup rings. 15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
13. Remove the set screw, if applicable, piston spacer,
and wear ring, if applicable, from the rod. 16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
14. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer, if applicable. 17. If applicable, inspect piston rings for cracks or other
Discard the o-rings, back-up rings, rod seals, and damage. Replace as necessary.
wiper seals.
Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
3120636 – JLG Lift – 2-21

Assembly Table 2-2.Cylinder Piston Nut Torque Specifications.
Nut Setscrew
NOTE: Prior to cylinder assembly, ensure that the proper
Description Torque Value Torque Value
cylinder seal kit is used. See your JLG Parts Manual.
(Wet) (Dry)

Apply a light film of hydraulic oil to all components Lift Cylinder 600 ft. lbs. 200 in. lbs.
prior to assembly. (814 Nm) (22.5 Nm)
Slave Cylinder 80 ft. lbs. 100 in. lbs.
(109 Nm) (12 Nm)
Master Cylinder 80 ft. lbs. 100 in. lbs.
WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS,
(109 Nm) (12 Nm)
ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO FIGURE
2-8., POLY-PAK SEAL INSTALLATION FOR CORRECT SEAL ORI- Steer Cylinder 80 ft. lbs. 100 in. lbs.
ENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN (109 Nm) (12 Nm)
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION. Telescope Cylinder 600 ft. lbs. 100 in. lbs.
(814 Nm) (12 Nm)
Axle Extension Cylinder 80 ft. lbs. 100 in. lbs.
(109 Nm) (12 Nm)
Axle Lift Cylinder 400 ft. lbs. 100 in. lbs.
(553 Nm) (12 Nm)
Extend - A - Reach
Lift Cylinder 400 ft. lbs. 100 in. lbs.
(553 Nm) (12 Nm)
Slave Cylinder 200 ft. lbs. 100 in. lbs.
Figure 2-8. Poly-Pak Seal Installation (271 Nm) (12 Nm)
NOTE: Self-locking setscrews used on piston nuts should be

1. Place a new wiper seal and rod seal into the applica-
discarded and replaced whenever they are removed.
ble cylinder head gland grooves.
2. Carefully install the head gland on the rod, ensuring 8. If applicable, torque the piston nut to the proper
that the wiper and rod seals are not damaged or dis- torque as outlined in Table 2-2. Spot drill the piston
lodged. Push the head along the rod to the rod end, rod at the point where the setscrew is inserted into
as applicable. the piston nut. Install the setscrew(s) which secure
the piston attaching nut to the diameter groove.
3. Carefully slide the piston spacer on the rod. If appli-
cable, align the oil holes in the rod and the spacer. 9. Remove the cylinder rod from the holding fixture.
Secure the spacer, if applicable.
10. Place new o-rings and seals in the applicable out-
4. If applicable, correctly place a new o-ring and back- side diameter grooves of both the piston and the cyl-
up rings in the inner piston diameter groove. inder head.
5. Carefully place the piston on the cylinder rod, ensur- 11. Position the cylinder barrel in a suitable holding fix-
ing that the o-ring and back-up rings are not dam- ture.
aged or dislodged.
6. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
as possible. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
7. Push the piston onto the rod until it abuts the spacer AND CYLINDER BARREL SURFACES.
end and install the attaching nut.
12. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
IF CYLINDER IS EQUIPPED WITH A PISTON NUT, APPLY “LOC- barrel cylinder. Ensure that the piston loading o-ring
QUIC PRIMER T” AND LOCTITE #242 TO PISTON NUT THREADS, and seal ring are not damaged or dislodged.
THEN TIGHTEN NUT TO TORQUE SHOWN IN TABLE 2-2, CYLIN-
DER PISTON NUT TORQUE SPECIFICATIONS.
2-22 – JLG Lift – 3120636

13. Continue pushing the rod into the barrel until the cyl- retract ports, while supporting the cylinder rod, cycle
inder head gland can be inserted into the barrel cyl- the cylinder a minimum of 5 times with the bleeder
inder or, if applicable, until the cylinder head threads port unplugged, venting all trapped air to atmo-
engage the threads of the barrel. sphere. A suitable hose may be attached to the
bleeder port with the end in a container suitable to
14. If applicable, secure the cylinder head retainer using
contain the hydraulic fluid. After all air is vented
a suitable spanner type wrench in the holes pro-
remove all attached hoses, and install the bleeder
vided.
port plug. Also plug the extend and retract ports until
15. After the cylinder has been reassembled, the rod cylinder is installed in boom.
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
2.12 BOOM MAINTENANCE
16. If applicable, install the cartridge-type holding valve
and fittings in the rod port block using new o-rings
as applicable. Torque holding valves in accordance
Removal
with Table 2-3, Holding Valve Torque Specifications.
1. Shut down machine systems.
NOTE: Boom Assembly weighs approximately 10,000 (4536

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON kg).
THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE 2. Using suitable lifting equipment, adequately support
EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER boom weight along entire length of retracted boom.
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD.
Table 2-3.Holding Valve Torque Specifications ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF
CONTAMINANTS INTO SYSTEM.
Description Torque Value
Sun - 7/8 Hex M20 x 1.5 Thds. 30-35 ft. lbs. 3. Tag and disconnect hydraulic lines that run along
(41-48 Nm) the side of the boom.
Sun - 1 1/8 Hex 1/14 UND Thds. 45-50 ft. lbs.
4. Remove hardware attaching upper lift cylinder
(61-68 Nm)
attach pin to boom.
Sun - 1 1/4 Hex M36 x 2 Thds. 150-160 ft. lbs.
(204-217 Nm) 5. Using a slide hammer or similar tool, and taking care
not to damage pin, remove pin from boom.
Racine - 1 1/8 Hex 1 1/16 - 12 Thds. 50-55 ft. lbs.
(68-75 Nm) 6. Using all applicable safety precautions, and only if
Racine - 1 3/8 Hex 1 3/16 - 12 Thds. 75-80 ft. lbs. necessary, operate crane and fully retract lift cylin-
(102-109 Nm) der.
Racine - 1 7/8 Hex 1 5/8 - 12 Thds. 100-110 ft. lbs. 7. Shut down machine systems.
(136-149 Nm)
8. Tag and disconnect all wiring to ground control box.
NOTE: Steps (17) thru (20) apply to the telescope cylinder. 9. Remove boom length/angle indicator box.
10. Loosen and remove hardware securing boom pivot
17. Elevate the barrel end of the cylinder to a work pin.
bench or other suitable device.
11. Ensuring that boom is adequately supported and
18. Plug the retract port and supply hydraulic power to using a suitable slide hammer, carefully remove
the extend port. pivot pin from boom and turntable structure. Ensure
19. Open the bleeder port plug (TP), venting all trapped that boom and turntable structure are not damaged.
air to atmosphere. Retighten the bleeder port plug. 12. Carefully lift boom assembly clear of turntable and
Disconnect the hydraulic power source and remove lower to ground or suitably supported work surface.
plug from retract port.
20. An alternative to steps (18) thru (20) is to position
the barrel horizontally in a suitable holding device,
attach a hydraulic power source to both extend and
3120636 – JLG Lift – 2-23

Disassembly 15. Remove bolts and lockwashers attaching top front

wear pad to base section. Remove pad and shims.
NOTE: Left or right is determined facing the machine from 16. Using suitable lifting equipment, partially slide
the platform. assembled inner mid, outer mid and fly sections out
of base section.
1. Loosen the right side powertrack bracket and pow-
ertrack and lay on top of boom assembly. 17. Using suitable straps, tie off outer mid section retract
chains to underside of inner mid section as inner
mid, outer mid and fly sections are exiting base sec-
tion.
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF 18. Carefully lift inner mid, outer mid and fly sections
CONTAMINANTS INTO SYSTEM. clear of base section and lower to a suitably sup-
ported work area.
2. Tag and disconnect hydraulic lines to slave level cyl-
19. Using suitable lifting equipment, support telescope
inder and rotator motor.
cylinder rod.
3. Tag and disconnect wiring to platform control box.
20. Remove setscrews securing trunnion pins that
4. Remove the left side powertrack. secure inner mid section to telescope cylinder.
5. Remove platform from boom assembly. 21. Using a suitable tool, scribe a line on the outer end
of each trunnion pin and boom structure as an aid to
6. Remove cotter pins retaining telescope cylinder rod pin alignment during boom assembly.
attach pin to base section.
22. Using a suitable slide hammer, remove trunnion pins
7. Using a suitable brass drift, carefully drive telescope attaching telescope cylinder to inner mid section.
cylinder pin from base section.
23. Remove cotter pins and chain attach pins attaching
8. Remove outer mid section extend chain adjust nut outer mid section retract chains to lower aft end of
and locknut at upper aft end of base section. outer mid section and remove chains.
9. Remove bolts, washers and lockwashers attaching 24. Remove setscrews which attach chain sheave pins
outer mid section extend chain attach block to upper at lower aft end of inner mid section.
aft end of base section. Remove block.
25. Using a suitable brass drift, carefully drive sheave
10. Remove fly section extend chain adjust nut and pins from inner mid section and remove sheaves
locknut at lower front end of inner mid section. and thrust washers. If necessary, remove bushings
11. Remove outer mid section retract chain adjust nut from sheaves and replace. Ensure that pins, grease
and locknut at lower front end of base section. fittings and corresponding boom and sheave sur-
faces are not damaged.
12. Remove fly section retract chain adjust nut and lock-
nut at lower front end of inner mid section. 26. Remove cotter pins and chain attach pins attaching
fly section retract chains to lower aft end of fly sec-
NOTE: Note and record the number and thickness of any tion and remove chains.
wear pad shims during wear pad removal.
27. Remove setscrews which attach chain sheave pins
13. Remove bolts and lockwashers attaching side wear at lower aft end of outer mid section.
pads to front of base section. Remove pads and any 28. Using a suitable brass drift, carefully drive sheave
shims. pins from outer mid section and remove sheaves,
14. Remove bolts, washers and lockwashers attaching seals, and thrustwashers. If necessary, remove
lower front wear pads and mounting blocks to base bushings from sheaves and replace. Ensure that
section. While supporting assembled fly, outer mid pins, grease fittings and corresponding boom and
and inner mid sections, remove wear pads, mount- sheave surfaces are not damaged.
ing blocks and shims. 
 
 
 
 
2-24 – JLG Lift – 3120636

29. Pull boom sections out several feet to allow ample 38. Remove bolts and lockwashers which attach top
clearance for telescope cylinder removal. wear pad at front of inner mid section and remove
pad and any shims.
30. Remove outer mid section extension chain adjust
nut and locknut from clevis at lower aft end of outer 39. Using suitable lifting equipment, carefully slide outer
mid section. mid and fly sections clear of inner mid section and
lower to ground or other suitably supported work
31. Using suitable lifting equipment, carefully slide tele-
area.
scope cylinder out of fly, outer mid, and inner mid
sections, along with extension chain and bar. 40. Remove bolts and lockwashers which attach upper
aft outer mid section wear pads and remove pads
32. When approximately one-half of the telescope cylin-
and any shims.
der is removed from the boom assembly, the exten-
sion bar attach to chain will become accessible. 41. Remove bolts and lockwashers which attach bottom
Remove cotter pins and clevis pin attaching exten- wear pads at front of outer mid section and remove
sion bar to chain and remove bar. pads and any shims.
33. Carefully lift telescope cylinder clear of boom 42. Remove bolts and lockwashers which attach side
assembly and lower to ground or suitably supported wear pads at front of outer mid section and remove
work area. pads and any shims.
34. Remove bolts attaching outer mid section retract 43. Remove bolts and lockwashers which attach top
chain adjust block at lower front end of inner mid wear pads to front of outer mid section and remove
section and remove block. pads and any shims.
NOTE: Note and record number and thickness of any wear 44. Remove bolt, washer and lockwasher attaching fly
pad shims during wear pad removal. section right hand extend chain sheave attach pin to
front of outer mid section.
35. Remove bolts and lockwashers which attach upper
45. Using a suitable brass drift, carefully drive each
aft inner mid section wear pads and remove pads
sheave pin from the boom section and remove the
and any shims.
sheave assemblies. Inspect pins, lubrication fittings
36. Remove bolts, washers and lockwashers which and sheave bearings for damage and dirt or foreign
attach bottom wear pads at front of inner mid sec- material. Replace components as necessary.
tion and remove pads and any shims.
46. Repeat steps (42) and (43) for left hand sheave.
37. Remove bolts and lockwashers which attach side
47. Using suitable lifting equipment, carefully slide fly
wear pads at front of inner mid section and remove
section clear of outer mid section and lower to
pads and any shims.
ground or suitably supported work area.



















3120636 – JLG Lift – 2-25

16
12
17
16
5
16
14
Figure 2-9. Boom Assembly - Sheet 1 of 2
2-26 – JLG Lift – 3120636

1. Boom Base 10. Tele Cylinder Sheave

2. Inner Mid Boom 11. Sheave
3. Outer Mid Boom 12. Chain Extend Rod
4. Fly Boom 13. Chain Attach Pin
5. Telescope Cylinder 14. Chain Adjustment Assembly
6. Outer Mid Extend Chain 15. Chain Adjustment Assembly
7. Fly Extend Chain 16. Upper Rear Wear Pad
8. Fly Retract Chain 17. Adjustment & Jam Nuts
9. Outer Mid Retract Chain 18. Safety Chain
13
10
18
4
8 7
9 18
15
15
11
Figure 2-10. Boom Assembly - Sheet 2 of 2
3120636 – JLG Lift – 2-27

Inspection Assembly
1. Inspect all sheaves (extend chains, retract chains NOTE: When installing fly section wear pads, install same
and telescope cylinder) for excessive groove wear, number and thickness of shims as were removed
burrs or other damage. Replace sheaves as neces- during disassembly.
sary.
1. Install upper aft fly section wear pads and shims, as
2. Inspect extend chain and retract chain sheave bear-
required, using bolts and lockwashers.
ings for wear, scoring, or other damage, and for
ovality. Replace bearings as necessary, ensuring 2. Using suitable lifting equipment, carefully slide fly
they are installed flush with sheave surface. section into outer mid section.
3. Inspect extend chain and retract chain sheave pins 3. Install fly section extend chain sheaves on front of
for scoring, tapering, ovality and evidence of correct outer mid section and install sheave pins. If neces-
lubrication. Replace pins as necessary. sary, tap pins into place using a soft headed mallet.
Secure pins using bolts, washers and lockwashers.
4. Inspect telescope cylinder sheave pin for tapering,
scoring, ovality and evidence of correct lubrication. 4. Install lubrication fittings in ends of pins and lubri-
Replace pin as necessary. cate sheaves with MPG.
5. Inspect boom pivot pin for wear, scoring or other NOTE: When installing outer mid section wear pads, install
damage, and for tapering or ovality. Replace pin as same number and thickness of shims as were
necessary. removed during disassembly.
6. Inspect upper lift cylinder attach pin for tapering,
ovality, scoring, wear, or other damage. Ensure pin 5. Install outer mid section top front wear pads and
surfaces are protected prior to installation. Replace shims, as required, using bolts and lockwashers.
pin as necessary. 6. Install outer mid section side front wear pads and
7. Inspect telescope cylinder trunnion attach pin for shims, as required, using bolts and lockwashers.
tapering, ovality, scoring, wear, or other damage. 7. Install outer mid section bottom front wear pads and
Replace pin as necessary. shims, as required, using bolts and lockwashers.
8. Inspect extend chain attach clevis pins for wear, 8. Install outer mid section upper aft wear pads and
scoring, or other damage. Replace pins as neces- shims, as required, using bolts and lockwashers.
sary.
9. Using suitable lifting equipment, carefully slide
9. Inspect telescope cylinder rod attach pin for scoring, assembled outer mid and fly sections into inner mid
wear, or other damage. Replace pin as necessary. section.
10. Inspect inner diameter of boom pivot bushing for NOTE: When installing inner mid section wear pads, install
scoring, distortion, wear, or other damage. Replace same number and thickness of shims as were
bushing as necessary. removed during disassembly.
11. Inspect all wear pads for excessive wear or damage.
Replace pads when worn to within 1/8 in. (3.2 mm) 10. Install inner mid section top front wear pads and
of insert. shims, as required, using bolts and lockwashers.
12. Inspect extend and retract chains and chain attach 11. Install inner mid section side front wear pads and
components for cracks, stretching, distortion, or shims, as required, using bolts and lockwashers.
other damage. Replace components as necessary. 12. Install inner mid section bottom front wear pads and
13. Inspect all threaded components for damage such shims, as required, using bolts, washers and lock-
as stretching, thread deformation, or twisting. washers.
Replace as necessary. 

14. Inspect structural units of boom assembly for bend- 
ing, cracking, separation of welds, or other damage. 
Replace boom sections as necessary. 


2-28 – JLG Lift – 3120636

13. Install inner mid section upper aft wear pads and 25. Install fly section retract chain clevis into attach
shims, as required, using bolts and lockwashers. block at lower front end of inner mid section. Install
adjust nut and locknut on clevis.
14. Install fly section retract chain adjust block on lower
front end of inner mid section and secure with bolts. 26. Install outer mid section retract chain sheaves and
thrust washers at aft end of inner mid section.
15. Place outer mid section extend chain assembly
along telescope cylinder chain rest with chain adjust 27. Install sheave pins and, if necessary, tap pins into
assembly hanging just below cylinder sheave. place using a soft headed mallet. Secure pins with
setscrews.
16. Using lightweight motor oil (SAE 20W), adequately
lubricate portion of chain occupying cylinder chain 28. Install lubrication fittings on ends of pins and lubri-
rest. cate sheaves with MPG.
17. Using suitable lifting equipment, maneuver tele- 29. Install outer mid section retract chains at lower aft
scope cylinder and outer mid section extend chain end of outer mid section. Install chain attach pins
assembly into position at aft end of assembled and flatwashers and secure with cotter pins.
boom sections.
30. Carefully place outer mid section retract chains
18. With a slight downward angle on the cylinder, insert around chain sheaves at aft end of inner mid sec-
sheave and chain adjust into boom sections until it tion. Tie chains to underside of inner mid section
is possible to insert chain adjust into attach block at using suitable straps.
rear of outer mid section. Temporarily install chain
31. Using suitable lifting equipment, carefully align holes
adjust and locknuts.
in telescope cylinder trunnion and holes in aft end of
19. Carefully feed telescope cylinder approximately half- inner mid section.
way into boom sections, lubricating chain with light-
32. Install trunnion pins, ensuring that holes in pins align
weight motor oil as it passes along chain rest. Attach
with holes in trunnion. If necessary, tap pins into
extension bar to chain and continue inserting into
place with a soft headed mallet. Secure pins with
boom sections.
setscrews.
20. Install fly section retract chain sheaves, seals and
33. Using suitable lifting equipment, carefully slide
thrustwashers at aft end of outer mid section.
assembled inner mid, outer mid, and fly sections
21. Install sheave pins and if necessary, tap pins into into base section.
place using a soft headed mallet. Secure pins with
34. As sections are being installed, remove straps from
setscrews.
outer mid section retract chains and feed attach cle-
22. Install lubrication fittings on ends of pins and lubri- vis through holes in bottom of forward end of base
cate sheaves with MPG. section.
23. Install fly section retract chains at lower aft end of fly 35. Install outer mid section retract chain clevis into
section. Install chain attach pins and flatwashers and attach block at lower front end of base boom sec-
secure with cotter pins. tion. Install adjust nut and locknut on clevis.

24. Carefully place fly section retract chains around

chain sheaves at aft end of inner mid section and

through bottom of inner mid section.























3120636 – JLG Lift – 2-29

NOTE: When installing base section wear pads, install same 6. If necessary, gently tap pin into position with a soft
number and thickness of shims as were removed headed mallet, ensuring that pin plate holes are
during disassembly. aligned with attach holes in boom structure. Install
pin attaching bolts, washers and lockwashers.
36. Install base section top front wear pads and shims,
as required, using bolts and lockwashers.
8. Connect hydraulic lines running along side of boom.
37. Install base section lower front wear pads, mounting
blocks, and shims, as required, using bolts, wash- 9. Install boom length/angle sensor box. Adjust boom
ers, and lockwashers. length/angle sensor box in accordance with para-
graph 2-30.
38. Install base section side front wear pads and shims,
as required, using bolts and lockwashers. 10. Using all applicable safety precautions, operate
machine systems and raise and extend boom fully,
39. Carefully align telescope cylinder rod end with holes
noting the performance of the extension cycle. If
in aft end of base boom section and install attach
chattering is apparent, extend chain system requires
pin. If necessary, tap pin into place using a soft
adjustment.
headed mallet. Secure pin with cotter pins.
11. Retract and lower boom, noting performance of
40. Install outer mid section extend chain attach block at
retraction cycle. If chattering is apparent, retract
aft end of base section and secure with bolts and
chain system requires adjustment.
lockwashers.
41. Install outer mid section extend chain clevis through
hole in attach block and secure with adjust nut and 13. Adjust extend and retract chain systems as required
locknut. and secure adjustment locknuts.
42. Attach platform to boom assembly. 14. As necessary, lubricate all points requiring lubrica-
tion.
43. Attach the left side powertrack to boom assembly.
44. Connect wiring to platform control box.
45. Connect hydraulic lines to slave level cylinder and
2.13 TILT ALARM SWITCH LEVELING
rotator motor. NOTE: Each machine is equipped with a tilt alarm switch,
46. Attach the right side powertrack bracket and power- factory set to activate at 5 degrees, which will illumi-
track to boom assembly. nate a warning light, sound a warning horn and cut
out 2 Speed Drive. Consult factory for tilt sensor
Installation adjustment. The only field adjustment necessary is
leveling the switch on the spring loaded studs. There
1. Using suitable lifting equipment, position assembled are two methods of adjustment, a manual adjust-
boom on turntable so that boom pivot holes in both ment and an adjustment using a voltmeter.
boom and turntable are aligned.
2. Insert boom pivot pin, ensuring that locating slots in
pin are aligned with setscrew locating holes in pin PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI-
bushings. MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION
3. If necessary, gently tap pin into position with a soft AND ADJUSTMENT OF SWITCH.
headed mallet. Secure pin with setscrews.
Manual Adjustment
4. Connect all wiring to ground control box.
5. Using all applicable safety precautions, operate lift- 1. Park the machine on a flat, level surface. Ensure
ing equipment in order to position boom lift cylinder machine is level and tires are filled to rated pressure.
so that holes in cylinder rod end and boom structure NOTE: Ensure switch mounting bracket is level and securely
are aligned. Insert lift cylinder pin. attached.

 2. Level the base of the indicator by tightening the
 three flange nuts. Tighten each nut through approxi-
 mately one half of it’s spring’s travel. DO NOT
ADJUST THE “X” NUT DURING THE REMAINDER
OF THE PROCEDURE.
2-30 – JLG Lift – 3120636

RED
WHITE
BLACK
YELLOW
Figure 2-11. Tilt Switch Adjustment - Voltmeter
3. With the electrical connections complete, slowly 6. Repeat steps 3 through 5 for the remaining “Y” nut.
tighten one of the “Y” nuts until the circuit is closed The switch is now level.
and the light on the Platform Control Console illumi-
7. Individually push down on one corner at a time;
nates.
there should be enough travel to cause the switch to
trip. If the switch does not trip in all three tests, the
flange nuts have been tightened too far. Loosen the
“X” nut and repeat steps 3 through 7.
Y
X Y Voltmeter Adjustment
1. Park machine on a flat, level surface. Ensure
machine is level and tires are filled to rated pressure.
2. If engine is not running, turn ignition switch to ON.
3. Connect black lead of voltmeter to ground and red
lead to yellow wire protruding from pot on bottom of
sensor.
4. Adjust leveling nuts to obtain the highest possible
Figure 2-12. Tilt Switch Adjustment - Manual
voltage reading.
4. Slowly back off the nut, counting the number of 5. Check voltage at trip point in all four directions. If
turns, until the circuit is again closed and the light voltage reading is not symmetrical, repeat step 4
again illuminates. above.

5. Divide the number of turns determined in step 4 in 
half. Tighten the nut this many turns. The line deter-
mined by this nut and the “X” nut is now parallel to

the ground. 





3120636 – JLG Lift – 2-31

2.14 LIMIT SWITCH ADJUSTMENTS 2.16 THROTTLE CHECKS AND PRECISION

GOVERNOR ADJUSTMENTS - FORD
Boom Limit Switch ENGINE
The boom limit switch is located on the left side of the
base section of the boom. The switch will activate when Checks
the boom is extended past a set point with the axles
retracted. When activated, the switch cuts out Telescope 1. Check that anti-dieseling solenoid is operating. If
Out and Lift Up. Adjust the limit switch to trip at 10 feet (3 solenoid is operating, an audible click at the carbu-
meters) of boom extension. retor should be heard when the ignition is switched
on.
Horizontal Cut-Out Switch 2. Check throttle linkage for smooth operation by rotat-
The horizontal cut-out switch is located on the right side of ing throttle lever by hand to full throttle position, then
the boom at the boom pivot pin. When activated, the slowly back to idle position, felling closely for stick-
switch cuts out the High Engine, High Drive and 2 Speed ing or binding. To accomplish this, the throttle must
functions. Adjust the switch to activate when the boom first be disconnected.
reaches horizontal.
Automatic Choke Adjustments
2.15 THROTTLE CHECKS AND 1. At 70°F the choke plate should be open 1/32" (not
ADJUSTMENTS - DEUTZ F4L-912 touching the choke bore).
ENGINE 2. If the ambient temperature is not 70°F, an additional
adjustment is required.
NOTE: Never run fuel tank dry. Diesel engines cannot be
restarted after running out of fuel until fuel system a. Loosen the three cover plate screws.
has been air-vented or “bled” of air. See Deutz b. Adjust the cover to open the choke plate 1/32".
instruction manual for procedure.
1. Disconnect actuator cable from throttle lever. With 1/32"

the aid of an assistant, start the engine and allow it
to come up to operating temperature. Adjust throttle
lever stop until engine runs at 1800 RPM. Shut down
engine. Reattach actuator cable to throttle lever,
making sure that low (mid) engine setting remains
the same. If necessary, adjust slide pin to contact
low (mid) engine limit switch at 1800 RPM. Shut
down engine.
2. Start the engine from ground controls and allow to
come up to operating temperature. Inside the
ground control terminal box, attach a “hot” wire from
the 12 Volt power (red) wire at the PLATFORM/
GROUND SELECT switch to terminal 1 (brown/black 
wire) on the relay circuit card at the top of the 
ground control terminal box. This will cause the 
engine to run as if HIGH ENGINE and HIGH DRIVE 
are activated. Adjust slide pin to contact high engine 
limit switch at 2500 RPM. Remove “hot” wire from 
terminal 1 and from PLATFORM/GROUND SELECT 
switch. Shut down engine. 
NOTE: Actuator cable travel must stop slightly before lever 
makes contact with throttle lever stop. Failure to do 
so will burn out actuator. 


2-32 – JLG Lift – 3120636

THROTTLE LEVER ACTUATOR CABLE
INJECTION PUMP
THROTTLE LEVER STOP
ADECO ACTUATOR
ADECO ACTUATOR
ACTUATOR CABLE SLIDE PIN (1)
LIMIT SWITCH
HIGH ENGINE LIMIT SWITCH

LOW ENGINE
SLIDE PIN (2)
Figure 2-13. Throttle Checks and Adjustments - Deutz Engine
3120636 – JLG Lift – 2-33

LOW (MID)
ENGINE
ADJUSTMENT
PC BOARD
NOTE
All pots should be sealed with finger nail
polish or its equivalent after all adjustments
are completed.
GAIN P2
HIGH ENGINE P1
DROOP P3
Figure 2-15. Precision Governor Adjustment - Ford Engine - Sheet 2 of 2
2-34 – JLG Lift – 3120636

CHOKE
FUEL
SHUTOFF
VALVE
VACUUM
PULLOFF CHOKE
IDLE SPEED
SCREW
OR
THROTTLE
LEVER
FUEL SHUT OFF VALVE IDLE

AIR
THROTTLE MIXTURE
ROD
LINKAGE HIGH ENGINE NO LOAD,
BUFFER SCREW
PRECISION
GOVERNOR
ACTUATOR
Figure 2-14. Precision Governor Adjustment - Ford Engine - Sheet 1 of 2
3120636 – JLG Lift – 2-35

c. Readjust for ambient temperature by rotating the ‘high engine’ (P1) adjusting screw until engine runs
cover one (1) mark per 5°F from 70°F. Rotate at 3000 RPM. Turning the screw CW increases RPM.
CCW (lean) if warmer than 70°, CW (rich) if Turning the screw CCW decreases RPM.
colder than 70°. (If actual temperature is 80°, set
8. While your assistant continues to depress the foot-
at 1/32" and rotate two (2) marks CCW [lean]
switch, have them place engine speed switch to
direction.)
LOW ENGINE. Turn ‘low (mid) engine’ adjusting
screw until engine runs at 1625 RPM. Turning the
MARK
screw CW increases RPM. Turning the screw CCW
decreases RPM. Shut down engine.
NOTE: If engine surges under no load and you cannot get

enough response from adjusting ‘gain’ (P2), try
adjusting surge screw on actuator. Loosen surge
screw locknut. Disconnect throttle linkage. Turn
surge screw CW until linkage arm moves. Manually
stroke the linkage fully and allow to return slowly
until it stops. Try to move linkage toward return posi-
tion. If linkage moves, turn surge screw CCW 1/2
turn. Again stroke linkage and allow to return slowly
until it stops. Try to move linkage toward return posi-
tion. If linkage moves, turn surge screw CCW 1/2
turn. Again stroke linkage and allow to return slowly
d. Tighten the three cover plate screws and check until it stops. Try to move linkage toward return posi-
for free rotation (no sticking or binding) of the tion. If linkage moves, turn surge screw CCW 1/2
choke shaft. turn. Repeat this procedure until linkage does not
move after stroking. This will set buffer spring ten-
Carburetor and Governor Adjustments sion properly. Reconnect throttle linkage.
1. With the aid of an assistant, start the engine at the 9. With engine speed switch set to LOW ENGINE,
platform console and allow it to come up to operat- when footswitch is depressed, engine should imme-
ing temperature with the air cleaner installed. Adjust diately respond. If response times lags, turn ‘gain’
carburetor idle screw until engine idles at 1000 RPM. (P2) adjusting screw CW to improve response time.
Shut down engine. Turn adjusting screw in small increments only until
response time is correct. Turning adjusting screw
NOTE: Steps 2, 3, and 4 are preliminary settings.
too far CW can cause surging. (See step (7) above.)
2. With engine shut down, turn ‘low (mid) engine’
adjusting screw CCW to the stop. Do not turn past
stop, as this breaks the pot, disabling the governor. 2.17 PRESSURE SETTING PROCEDURES
3. On controller, turn ‘high engine’ (P1) adjusting screw Sequence Pressure (Prior to 1990)
25-30 turns CCW, then 10 turns CW.
4. On controller, turn ‘gain’ (P2) adjusting screw CCW 1. Plug pressure gauge into quick-connect on high
to the stop, then CW until screw slot is vertical drive dump valve. Monitor gauge.
(approximately 1/4 turn). 2. On sequence valve, loosen nut at main relief. On
5. On controller, turn ‘droop’ (P3) adjusting screw CCW sequence valve 4640535 depress plunger; on
to the stop, then CW until screw slot is vertical sequence valve 4640580 use an allen wrench to turn
(approximately 1/4 turn). No further adjustment the plunger in. Use plunger to set main relief to 300
should be necessary to ‘droop’ (P3). psi (21 bar).
6. With the aid of an assistant at platform control con- 3. Loosen nut on sequence cartridge and adjust
sole, start engine and allow to come up to operating sequence pressure to 450 psi (31 bar). Tighten nut.
temperature. Then have assistant depress foot- 4. Use plunger to set main relief to 3500 psi (241 bar)
switch and place engine speed switch to HIGH and tighten nut on main relief cartridge.
ENGINE.
5. Remove pressure gauge.
7. If engine surging occurs at this point, turn ‘gain’ (P2)
adjusting screw CCW until surging ceases. Turn
2-36 – JLG Lift – 3120636

Lift Down Adjustment - A Side

Lift Up Adjustment - B Side
Drive Adjustment Telescope In Adjustment - A Side

Telescope In Adjustment - B Side
Swing Adjustment
Install pressure gauge at

quick disconnect
PROPORTIONAL VALVE
Main Relief
Pressure Reducing
Cartridge
Sequence
Cartridge
ACCESSORY VALVE
Figure 2-16. Pressure Setting Adjustments (Sheet 1 of 3)
3120636 – JLG Lift – 2-37

STEER LEFT & STEER RIGHT

ADJUSTMENT
CHECK POINT FOR LEVEL,

STEER, ROTATE, AND
MAIN RELIEF
MAIN RELIEF ADJUSTMENT
ROTATE LEFT & ROTATE RIGHT

ADJUSTMENT
SOLENOID (Bang-Bang) VALVE

Machines Built to 1995
2-38 – JLG Lift – 3120636

STEER LEFT & STEER RIGHT

ADJUSTMENT
CHECK POINT FOR LEVEL,

STEER, ROTATE, AND
MAIN RELIEF
MAIN RELIEF
ADJUSTMENT
ROTATE LEFT & ROTATE RIGHT

ADJUSTMENT
SOLENOID (Bang-Bang) VALVE

Machines Built 1995 to Present
3120636 – JLG Lift – 2-39

Sequence Pressure (1990 to Present) b. Remove torque plug at lift down relief and adjust
pressure to 1200 psi (83 bar). Add shims to
1. Plug pressure gauge into quick-connect on high increase pressure, remove shims to decrease
drive dump valve. Monitor gauge. pressure. Install torque plug.
2. Run an electrical current to activate the dump valve. c. Release lift down function.
3. Loosen the lock nut on sequence cartridge and 3. Lift Up Relief.

adjust sequence pressure to 450 psi (31 bar). Turn a. Activate lift up function, bottom out function and
the adjusting screw clockwise to increase pressure monitor pressure gauge.
or counterclockwise to decrease pressure.
b. Remove torque plug at lift up relief and adjust
4. Tighten the lock nut and remove the electrical cur- pressure to 3000 psi (207 bar). Add shims to
rent from the dump valve. increase pressure, remove shims to decrease
pressure. Install torque plug.
5. Remove pressure gauge.
c. Release lift up function.
Pilot Pressure 4. Telescope In Relief.
1. Plug pressure gauge into quick-connect on acces- a. Activate telescope in function, bottom out func-
sory valve at PO port. Monitor gauge. tion and monitor pressure gauge.
b. Remove torque plug at telescope in relief and
2. Activate lift down function and bottom out function.
adjust pressure to 2500 psi (172 bar). Add shims
3. Loosen nut on pressure reducing cartridge and to increase pressure, remove shims to decrease
adjust cartridge to 550 psi (38 bar). Tighten nut. pressure. Install torque plug.
4. Release lift down function. c. Release telescope in function.
5. Remove pressure gauge. 5. Telescope Out Relief.

a. Activate telescope out function, bottom out func-
Proportional Valve tion and monitor pressure gauge.
b. Remove torque plug at telescope out relief and
NOTE: Make all proportional valve adjustments with engine adjust pressure to 1500 psi (103 bar). Add shims
at low rpm and pressure gauge attached to quick- to increase pressure, remove shims to decrease
connect on high drive dump valve. pressure. Install torque plug.
1. Swing Relief. c. Release telescope out function.
a. Plug pressure gauge into quick-connect on high 6. Drive Relief.

drive dump valve. a. Disconnect and cap hose to drive motor and
b. Lock turntable, activate swing right function, bot- plug port on drive section of proportional valve.
tom out function and monitor pressure gauge. Monitor pressure gauge.
c. Remove torque plug at swing right relief and b. Have an assistant activate drive forward.
adjust pressure to 1200 psi (83 bar). Add shims c. Remove torque plug at drive forward relief and
to increase pressure, remove shims to decrease adjust pressure to 3500 psi (241 bar). Add shims
pressure. Install torque plug. to increase pressure, remove shims to decrease
d. Release swing right function, activate swing left pressure. Install torque plug.
function, bottom out function and monitor pres- d. Have assistant deactivate drive forward and acti-
sure gauge. vate drive reverse.
e. Remove torque plug at swing left relief and e. Remove torque plug at drive reverse relief and
adjust pressure to 1200 psi (83 bar). Add shims adjust pressure to 3500 psi (241 bar). Add shims
to increase pressure, remove shims to decrease to increase pressure, remove shims to decrease
pressure. Install torque plug. pressure. Install torque plug.
f. Release swing left function and unlock turntable. f. Have assistant deactivate drive reverse.
2. Lift Down Relief. g. Remove plugs from drive ports on proportional
valve and reconnect drive motor hoses to valve.
a. Activate lift down function, bottom out function
and monitor pressure gauge.
2-40 – JLG Lift – 3120636

7. Main Relief. 3. Platform Rotate Relief.

a. Disconnect and cap hoses to drive motor; plug a. Activate platform rotate right function, bottom
ports on drive section of proportional valve. out function and monitor pressure gauge.
Monitor pressure gauge. b. Loosen locknut on platform rotate right cartridge
b. On accessory valve, loosen nut on main relief and turn adjusting screw to adjust platform
cartridge and back out adjustment two (2) turns rotate right relief pressure to 2500 psi (172 bar).
(CCW). Tighten locknut.
c. Have an assistant activate drive function. c. Release platform rotate right function, activate
d. Slowly turn adjustment in (CW) and watch pres- platform rotate left function, bottom out function
sure gauge. Continue turning until gauge stops and monitor pressure gauge.
moving (approximately 3500 psi [241 bar]). d. Loosen locknut on platform rotate left cartridge
e. Turn adjustment in an additional 1/2 turn. This and turn adjusting screw to adjust platform
will result in a relief setting approximately 200 psi rotate left relief pressure to 2500 psi (172 bar).
(14 bar) higher than the drive relief setting. Tighten locknut.
e. Release platform rotate left function.
Solenoid Valve
Extend-A-Reach Valve (If Equipped)
NOTE: Make all solenoid valve adjustments with engine at
low rpm and pressure gauge attached to quick-con- NOTE: Make extend-a-reach valve adjustment with engine
nect on solenoid valve. at low rpm and pressure gauge attached to quick-
connect on solenoid valve.
1. Main Relief.
a. Activate extend-a-reach up function, bottom out
a. Activate platform level up function, bottom out
function and monitor pressure gauge.
function and monitor pressure gauge.
b. Loosen locknut on extend-a-reach up cartridge
b. Remove plug from main relief section and turn
and turn adjusting screw to adjust extend-a-
adjusting screw to adjust main relief pressure to
reach up relief pressure to 2500 psi (172 bar).
2500 psi (172 bar). Turn adjusting screw CW to
Tighten locknut.
increase pressure, CCW to decrease pressure.
Replace plug. c. Release extend-a-reach up function, activate
extend-a-reach down function, bottom out func-
c. Release platform level up function.
tion and monitor pressure gauge.
2. Steer Relief. d. Loosen locknut on extend-a-reach down car-
a. Activate steer right function, bottom out function tridge and turn adjusting screw to adjust extend-
and monitor pressure gauge. a-reach down relief pressure to 700 psi (48 bar).
Tighten locknut.
b. Loosen locknut on steer right cartridge and turn
adjusting screw to adjust steer right relief pres- e. Release extend-a-reach down function and
sure to 2000 psi (138 bar). Turn adjusting screw remove pressure gauge from solenoid valve.
CW to increase pressure, CCW to decrease
pressure. Tighten locknut.
c. Release steer right function, activate steer left
function, bottom out function and monitor pres-
sure gauge.
d. Loosen locknut on steer left cartridge and turn
adjusting screw to adjust steer left relief pres-
sure to 2000 psi (138 bar). Turn adjusting screw
CW to increase pressure, CCW to decrease
pressure. Tighten locknut.
e. Release steer left function.




3120636 – JLG Lift – 2-41

0.0015" feeler gauge between the bolt head and

2.18 SWING BEARING hardened washer at the arrow indicated position.
Turntable Bearing Mounting Bolt Condition

Check
NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and .0015" Feeler Gauge
retorquing bolt or bolts recheck all existing bolts for
looseness.
Figure 2-17. Swing Bearing Bolt Feeler Gauge Check
Check the frame to bearing. Attach bolts as follows:
1. Elevate the fully retracted boom to 70 degrees (full Bearing Wear Tolerance
elevation).
2. At the positions indicated on Figure 2-17., Swing 1. From the underside of the machine, at rear center,
Bearing Bolt Feeler Gauge Check, try and insert the with the boom fully elevated and fully retracted (Fig-
0.0015" feeler gauge between the bolt head and ure 2-18., Swing Bearing Tolerance Boom Place-
hardened washer at the arrow indicated position. ment), measure and record the distance between
the swing bearing and the frame using a magnetic
3. Assure that the 0.0015" feeler gauge will not pene- base dial indicator. (Figure 2-18., Swing Bearing Tol-
trate under the bolt head to the bolt shank. erance Boom Placement)
4. Swing the turntable 90 degrees, and check some 2. At the same point, with the boom at horizontal and
selected bolts at the new position. extended until red marking band on mid section is
5. Continue rotating the turntable at 90 degrees inter- exposed, measure and record the distance between
vals until a sampling of bolts have been checked in the swing bearing and frame using a magnetic base
all quadrants. dial indicator. (Figure 2-18., Swing Bearing Toler-
ance Boom Placement)
Check the turntable to bearing. Attach bolts as follows:
3. If a difference greater than 0.64 in. (1.625 mm) is
1. Elevate the fully retracted boom to 70 degrees (full determined, the swing bearing should be replaced.
elevation).
4. If a difference less than 0.64 in. (1.625 mm) is deter-
2. At the positions indicated on Figure 2-17., Swing mined, and any of the following conditions exist, the
Bearing Bolt Feeler Gauge Check, try and insert the bearing should be removed, disassembled, and
.0015" feeler gauge between the bolt head and hard- inspected for the following:
ened washer at the arrow indicated position.
a. Metal particles in the grease.
3. Lower the boom to horizontal and fully extend the
b. Increased drive power required.
boom.
c. Noise.
4. At the position indicated on Figure 2-17., Swing
d. Rough rotation.
Bearing Bolt Feeler Gauge Check, try and insert the
2-42 – JLG Lift – 3120636

FORWARD
MEASURING POINT
MEASURING POINT
a. BOOM FULLY ELEVATED b. BOOM AT HORIZONTAL

AND FULLY RETRACTED AND FULLY EXTENDED
Figure 2-18. Swing Bearing Tolerance Boom Placement
TURNTABLE REF.
SWING BEARING
FRAME REF.
MEASURING POINT
Figure 2-19. Swing Bearing Tolerance Measuring Point
3120636 – JLG Lift – 2-43

5. If bearing inspection shows no defects, reassemble g. Use the lifting equipment to carefully lift the com-
bearing and return to service. plete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame mounted components.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS h. Carefully place the turntable on a suitably sup-
ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFT- ported trestle.
ING ARE CONCENTRATED, AT THE CENTER OF ROTATION. i. Use a suitable tool to scribe a line on the outer
BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING race of the swing bearing and the frame. This
BEARING BOLTS IS A MUST FOR SAFE OPERATION. line will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which
Bearing Replacement attach the outer race of the bearing to the frame.
Discard the bolts. Use suitable lifting equipment
1. Removal. to remove the bearing from the frame; move the
bearing to a clean suitably supported work area.
a. From ground control station, operate the boom
lift control and raise boom adequately to provide 2. Installation.
access to frame opening or, if equipped, to the
rotary coupling. NOTE: The following note and steps a thru m pertain to the
use of Devcon and apply only to those machines
built prior to mid-1991.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST PROVIDING NOTE: Manufacturing tolerances of frames and turntables
ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING. are inspected prior to the factory installation of swing
bearings to determine the need for use of Devcon
b. Attach an adequate support sling to the boom filler. When servicing machine swing bearing, apply
and draw all slack from sling. Block the boom if Devcon filler only to those machines having Devcon
feasible. previously applied at the factory. If new turntable or
NOTE: Steps c and d apply to those machines equipped frame is being installed contact manufacturer for pro-
with a rotary coupling. cedures to determine the need for Devcon applica-
tion.
c. From under side of machine frame, remove bolts
and lockwashers which attach rotary coupling a. Use suitable standard tools and equipment to
retaining yoke to coupling housing. carefully remove any hardened epoxy residue
from the bearing mounting area of frame and
turntable.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI- b. Apply a layer of Devcon (or equivalent) filler
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF approximately 3 mm thick on the bearing mount-
CONTAMINANTS INTO THE SYSTEM. ing plate on the frame.
c. Use suitable lifting equipment to carefully lower
d. Tag and disconnect the hydraulic lines from the the swing bearing into position on the frame.
fittings on the top and sides of the rotary cou- Ensure that the scribed line of the outer race of
pling. Use a suitable container to retain any the bearing aligns with the scribed mark on the
residual hydraulic fluid. Immediately cap lines frame (if a new swing bearing is used, ensure
and ports. that the filler plug fitting is at 90 degrees from the
e. Attach suitable overhead lifting equipment to the fore and aft centerline of the frame).
base of the turntable weldment. d. Ensure that all frame and bearing attachment
f. Use a suitable tool to scribe a line on the inner holes are aligned, and install four diametrically
race of the swing bearing and on the underside opposed bolts or clamps to secure the bearing
of the turntable. This line will aid in aligning the to the frame. Tighten the bolts or clamps evenly
bearing upon installation. Remove the bolts, in a diametrical pattern to a torque of 20 ft. lb.
nuts and washers which attach the turntable to (27 Nm).
the bearing inner race. Discard the nuts and e. Allow Devcon filler to cure at room temperature
bolts. (approximately 70 degrees F [21 degrees C]) for
 10 to 16 hours.

2-44 – JLG Lift – 3120636

f. After the appropriate interval, release the clamps

or remove the bolts. Use a suitable lifting device
to carefully remove the bearing from the frame. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING
g. Carefully remove any excess filler from the frame NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW
mounting area, from the bearing attachment NUTS AND BOLTS. SINCE THE SWING BEARING IS THE ONLY
holes, and from between the gear teeth. STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT
IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS
JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS
HIGHLY RECOMMENDED.
ENSURE THAT TURNTABLE IS ADEQUATELY SUPPORTED WHILE
APPLYING DEVCON AND WHILE INSTALLING THE BEARING.
p. Apply a light coating of Loctite #277 to the new
EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING
bearing bolts, and loosely install the bolts and
STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL.
washers through the frame and outer race of
bearing.
h. Apply a layer of Devcon (or equivalent) filler
approximately 1/8 in. (3 mm) thick to the under-
side of the bearing mounting area of the turnta-
ble base plate. IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT
i. Use suitable hydraulic jacks to carefully raise the WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH-
swing bearing to the underside of the turntable MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL
mounting plate. Ensure that the scribed line of SHOULD BE CHECKED PRIOR TO USE.
the inner race of the bearing aligns with the
scribed mark on the turntable (If a new swing q. Following the Torque Sequence diagram shown
bearing is used, ensure that the filler plug fitting in Figure 2-20., tighten the bolts to an initial
is at 90 degrees from the fore and aft centerline torque of 180 ft. lbs. (244 Nm). Then following
of the turntable. See Figure 2-20., Swing Bearing the same sequence tighten the bolts to a final
Bolt Torquing Sequence). torque of 240 ft. lbs. (325 Nm).
j. Ensure that all turntable and bearing attachment r. Remove the lifting equipment from the bearing.
holes are aligned, and install four (4) diametri- s. Use suitable lifting equipment to carefully posi-
cally opposed clamps or bolts and nuts to tion the turntable assembly above the machine
secure the bearing to the turntable. Tighten the frame.
nuts and bolts or clamp evenly in a diametrical t. Carefully lower the turntable onto the swing
pattern to a torque of 20 ft. lb. (27 Nm). bearing, ensuring that the turntable and bearing
k. Allow the Devcon filler to cure at room tempera- align as noted in step i above.
ture (approximately 70 degrees F [21 degrees
C]) for 10 to 16 hours.
l. After the appropriate interval, place a suitable IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT
hydraulic jack under the bearing and release the WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH-
clamps or remove the nuts and bolts; use the MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL
hydraulic jack to carefully remove the bearing SHOULD BE CHECKED PRIOR TO USE.
from the turntable.
m. Carefully remove excess filler from the turntable u. Apply a light coating of Loctite #277 to the new
mounting area, from the bearing attachment bearing bolts, and install the bolts, washers and
holes and from between the gear teeth. nuts through the turntable and inner race of the
n. Position the bearing on the machine frame in the bearing.
same position as noted in step c above. v. Following the Torque Sequence diagram shown
o. Use suitable lifting equipment to carefully lower in Figure 2-20., Swing Bearing Bolt Torquing
the swing bearing into position on the frame. Sequence, tighten the bolts to an initial torque of
Ensure that the scribed line of the outer race of 180 ft. lbs. (244 Nm). Then following the same
the bearing aligns with the scribed mark on the sequence tighten the bolts to a final torque of
frame (if a new swing bearing is used, ensure 240 ft. lbs. (325 Nm).
that the filler plug fitting is at 90 degrees from the w. Remove the lifting equipment.
fore and aft centerline of the frame). 

3120636 – JLG Lift – 2-45

NOTE: INSTALL BEARING WITH FILL PLUG ON SIDE.

(AS CLOSE TO CENTERLINE OF ROTATION
AS POSSIBLE.)
Figure 2-20. Swing Bearing Bolt Torquing Sequence
x. Install the rotary coupling retaining yoke; apply a 3. Swing Bearing Torquing Sequence, (See Figure 2-
light coating of Loctite Sealant Number TL277- 20.)
41 to the attaching bolts and secure the yoke to
the rotary coupling with the bolts and lockwash-
ers.
RETORQUE INNER AND OUTER SWING BEARING BOLTS TO 22O
y. Connect the hydraulic lines to the rotary cou- FT.LBS. (298 NM) AFTER FIRST 200 HOURS OF OPERATION AND
pling as tagged prior to removal. EVERY 500 HOURS THEREAFTER.
z. At ground control station, use boom lift control 
to lower boom to stowed position. 
aa.Using all applicable safety precautions, activate 
hydraulic system and functionally check swing 
system for proper and safe operation.
Swing Bearing Torque Values

1. Outer Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs.
(230 Nm) wet, 220 ft.lbs. (298 Nm) dry.
2. Inner Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs.
(230 Nm) wet, 220 ft.lbs. (298 Nm) dry.
2-46 – JLG Lift – 3120636

stick in carrier counterbore. Inspect thrust washers

2.19 DRIVE TORQUE HUB and thrust bearing for wear and replace if necessary.
Disassembly 10. Lift internal gear (21) out of hub.
1. Position hub over suitable container and remove

drain plug (37) from unit. Allow oil to completely EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
drain. REMOVAL.
2. Remove sixteen bolts (1), four shoulder bolts (2),
and twenty lockwashers (3) from cover (4) and lift 11. Remove keeper ring (40), retaining ring (35), and
cover from unit. Remove o-ring (14) from counter- bearing shim (34) from end of spindle. Remove hub
bore of cover. from spindle.
3. Disassemble cover (4) as follows: 12. Remove bearing cone (32) and seal (31) from spin-
dle (30). Seal will possibly hold bearing cone into
a. Remove two bolts (12) securing disconnect cap hub. If so, remove both from hub. If bearing cups
(11) to cover and remove disconnect cover. (33) require replacing they can be driven out of hub
b. Remove two bolts (12) securing cover cap (7) to counterbores. Discard seal and replace with new
cover and remove cap. seal.
c. Remove disconnect rod (9) from cover cap and
remove o-rings (8 and 10) from cover cap. Dis-
card o-rings. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
d. If necessary, remove pipe plugs (5 and 6) from REMOVAL.
cover.
13. To remove cluster gear (27) from carrier, remove
4. Remove two thrust washers (15) and thrust bearing
retaining ring (25) from planet shaft (23) and drive
(16) from carrier counterbore. One thrust washer
planet shaft out of carrier.
may stick to cover. Inspect thrust washers and bear-
ing for wear and replace if necessary. 14. Cluster gear and bearings (27, 29) can now be slid
out of carrier and spacer (18) removed from carrier
5. Lift carrier assembly (22) from hub and spindle
bore. If bearing cups (28) require replacing they can
assembly (30).
be driven out of cluster gear counterbores.
6. Disassemble carrier as follows:
15. Repeat steps (12) and (13) for remaining cluster
gears.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING

REMOVAL.
WHEN REBUILDING THE UNIT, O-RINGS AND RETAINING RINGS
SHOULD ALWAYS BE REPLACED.
a. Remove retaining ring (25) from planet shaft
(23).
b. Remove spacer (26) from planet shaft, then,
using a suitable drift, drive planet shaft from car- 1. Thoroughly clean all parts in an approved cleaning
rier, shearing off roll pin. Tap remaining roll pin solvent.
from carrier using a suitable punch.
2. Inspect geared or splined components in primary
c. Remove cluster gear (27) from carrier and
and secondary planet carriers, input and output sun
remove bearing cones (29) from cluster gear.
gears, ring gear, coupling and input shaft for
d. If necessary, press bearing cups (28) from clus- chipped or broken teeth, and excessive or uneven
ter gear. wear patterns. Replace components as necessary.
7. Lift ring gear (13) from housing (36). Remove o-ring 3. Inspect all thrust washers for scoring, pitting, ero-
(14) from counterbore of ring gear and discard. sion, discoloration or excessive wear. Replace thrust
8. Remove input (sun) gear (17), input spacer (18), and washers as necessary.
input shaft (20) from spindle (30). 4. Inspect all bearing cones and cups for scoring, pit-
9. Remove two thrust washers (15) and thrust bearing ting or excessive wear. If necessary, using a suitable
(16) from end of spindle. One thrust washer may press, remove bearing cups from hub and replace
bearings as a set.
3120636 – JLG Lift – 2-47

1. Bolt
2. Bolt
3. Lockwasher
4. Cover
5. Pipe Plug
6. Pipe Plug
7. Cover Cap
8. O-ring
9. Disconnect Rod
10. O-ring
11. Disconnect Cap
12. Bolt
13. Ring Gear
14. O-ring
15. Thrustwasher
16. Thrust Bearing
17. Input Gear
18. Thrust Spacer
19. Retaining Ring
20. Input Shaft
21. Internal Gear
22. Carrier
23. Planet Shaft
24. Roll Pin
25. Retaining Ring
26. Spacer
27. Cluster Gear
28. Bearing Cup
29. Bearing Cone
30. Spindle
31. Seal
32. Bearing Cup
33. Bearing Cone
34. Bearing Shim
35. Retaining Ring
36. Hub
37. Pipe Plug
38. Magnetic Plug
39. Stud
40. Keeper Ring
41. Retaining Ring
42. Washer
43. Spring
44. Not Used
45. Input Coupling
Figure 2-21. Drive Torque Hub
2-48 – JLG Lift – 3120636

5. Inspect all needle rollers for scoring, pitting or d. Install bearing cone (32) into bearing cup.
excessive wear. Replace all rollers as necessary.
6. Inspect planet gear pins for grooves, scoring or
excessive wear. Replace pins as necessary.
7. Inspect all threaded components for damage includ-
ing stretching, thread deformation, or twisting.
Replace as necessary.
8. Inspect oil seal surfaces in hub and spindle for burrs
or sharp edges. Dress applicable surfaces or
replace components as necessary.
9. Inspect mating surfaces of hub, ring gear and cover
for burrs and sharp edges. Dress applicable sur-
faces or replace components as necessary. e. Press seal (31) into hub counterbore with flat
metal side facing out. Use a flat object to ensure
Assembly that seal is pressed evenly and is flush with hub
face.
1. If necessary, assemble the hub/spindle assembly
(36 and 30) as follows:
a. With large open end of hub (36) up, press bear-
ing cup (33) into hub. If no press is available,
bearing cup may be frozen and tapped into
place with a non-metallic faced hammer.
f. Lower hub onto spindle (30) with large open end

up.
b. Turn hub over, small diameter up. Install two

pipe plugs (37) into hub.
c. Press bearing cup (33) into small diameter end
of hub. If no press is available, bearing cup may
be frozen and tapped into place with a non-
metallic faced hammer.
3120636 – JLG Lift – 2-49

g. Place bearing cone (32) over end of spindle and j. Install retaining ring keeper ring (40) in location
into bearing cup. around retaining ring and on bearing shim.
h. Place bearing shim (34) over end of spindle and k. With large open end of hub/spindle assembly
against bearing cone. facing up, place one spacer washer (42) into
spindle counterbore.
l. Place spring (43) into spindle counterbore.

INSTALLATION.
i. Secure retaining ring (35) completely into spin-

dle groove and against bearing shim. Ensure
retaining ring is entirely in groove.
2-50 – JLG Lift – 3120636

m. Set second spacer washer (42) on top of spring. 3. Lower internal gear (21) onto spindle.
4. Place one thrust bearing (16) between two thrust

washers (15) and place them onto spindle pilot.
INSTALLATION.
n. Compress spacer washer and spring into spin-

dle counterbore and install retaining ring (41)
into spindle groove.

INSTALLATION.
5. Install retaining ring (19) in groove of input shaft

2. Position hub/spindle assembly (36 and 30) with (20).
large open end up.
3120636 – JLG Lift – 2-51

6. Place input shaft into spindle counterbore of hub/ a. Press bearing cups (28) into both ends of cluster
spindle assembly. The action of the disengaged gear (27) with large inside diameter facing out.
spring should be checked at this time. Use an arbor type press with an adapter tool.
7. Slide thrust spacer (18) onto input shaft. b. Place planet shaft (23) on a flat surface with
large diameter down. Place one bearing cone
(29) over shaft and against shoulder. This should
be a slip fit.
BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING

c. Place cluster gear over planet shaft and onto
THIS O-RING.
bearing cone, with large gear on top.
8. Place o-ring (14) into counterbore of hub/spindle
assembly. Use grease or petroleum jelly to hold o-
ring in place.
9. Assemble carrier assembly (22) as follows:
2-52 – JLG Lift – 3120636

d. Place another bearing cone (29) over planet g. See if retaining ring (25) will fit onto planet shaft
shaft and into cluster gear. This is a slip fit. groove. If not, try smaller spacer (26) until retain-
ing ring fits. This will set bearings at 0.000-0.152
mm.
e. Slide largest spacer (26) onto planet shaft.
h. Place carrier on edge of a table with one set of

holes hanging over the edge. Side with roll pin
hole should be down.
f. Bearings in cluster gear must be seated by

applying 25-50 lbs. (11-23 kg) against them and
rotating cluster gear at the same time. This can
be done by sliding a second spacer (26) over
planet shaft and pushing downward while rotat- i. Place bearing cones (29) into cluster gear.
ing the gear.







3120636 – JLG Lift – 2-53

j. Place cluster gear into carrier with large gear up. m. Place carrier on table with something under
planet shaft to hold it in correct position and
install retaining ring (25).
k. Slide planet shaft through carrier and cluster

gear from bottom side. Slot in planet shaft must
line up with roll pin hole in edge of carrier.
EYE PROTECTION SHOULD BE WORN DURING THIS OPERATION.
n. Drive roll pin (24) into carrier. Use a punch to

drive roll pin completely into planet shaft.
l. While holding planet shaft in position, slide cor-

rect spacer onto planet shaft.
o. Repeat steps (a) through (n) for remaining two

cluster gears.
10. Time carrier gears as follows:
a. Place carrier assembly on a flat surface, posi-
tioning two top gears at ten o’clock and two
o’clock, and one bottom gear at six o’clock as
shown in Figure 2-22., Torque Hub Carrier Tim-
ing.

INSTALLATION.
2-54 – JLG Lift – 3120636

b. Find marked (punch mark) teeth on large gears. 13. Locate the one hole on underside of ring gear that
Rotate gears until punch mark is located in a has an “X” stamped beside it. This hole should be
straight up, 12 o’clock, position. Punch marks at positioned in line with one of four counterbored
ten o’clock and two o’clock will be located just holes in face of hub. These holes have been coun-
under edge of carrier and not readily visible. terbored to accept four shoulder bolts upon installa-
tion of cover.
11. Taking care to ensure that timing is maintained,
install ring gear (13) in mesh with large diameter
cluster gear. Side of ring gear with long shoulder is
installed down.
14. Thrust spacer (18) and input gear (17) are installed
onto input shaft (20). Counterbore in input gear
should be facing thrust spacer.
12. While holding ring gear in mesh with carrier assem-
bly, lower into internal gear (21). Small diameter
cluster gear will mesh with internal gear. Slight rota-
tion of ring gear may be necessary.
15. Place one thrust bearing (16) between two thrust

washers (15) and place into carrier counterbore.











 
 
 
 

3120636 – JLG Lift – 2-55

16. Assemble cover assembly as follows: d. Push disconnect rod into bore of cover cap.
a. Screw pipe plugs (5 and 6) into cover 4.
e. Locate large clearance hole in cover cap over

pipe plug in cover and install cover cap in cover.
b. Install o-ring (8) over cover cap (7).
Use two bolts (12) torqued to 70 to 80 in.lbs. (81-
92 kgcm).
c. Install o-ring (10) into bore of cover cap 7. Dis-

connect rod (9) may be used to push o-ring
f. Install disconnect cap (11) to cover cap with two
down to groove in cover cap bore.
remaining bolts (12) torqued to 70 to 80 in.lbs.
(81-92 kgcm).





2-56 – JLG Lift – 3120636

19. Install sixteen Grade 8 bolts (1) and lockwashers (3)

in remaining holes.
BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING
THIS O-RING.
g. Place o-ring (5) into cover counterbore. Use

petroleum jelly to hold o-ring into place.
20. Tighten bolts and shoulder bolts evenly and torque

to 100-110 ft.lbs. (14-15 kgm).
17. Place cover assembly (4) onto ring gear (13). Rotate
cover assembly until pipe plug (6) is located 90
degrees and 180 degrees from pipe plugs (38) in
opposite end of hub.
21. Install coupling (45) into spindle onto input shaft.
2.20 SWING TORQUE HUB
Disassembly
18. Secure cover assembly and ring gear to hub with 1. Remove oil plugs (25 and 26) and drain oil from unit
four shoulder bolts (2) and lockwashers 3. Shoulder into a suitable container. Replace drain plugs.
bolts fit into four counterbored holes in hub. It may
be necessary to start bolts into hub by tapping NOTE: The screws, hub pinion gear, and retaining plate ref-
lightly on bolts with a hammer. erenced in steps (2) and (3) are not shown in Figure
2-20, but are attached to the hub output shaft (item
30).
2. Remove the two screws which attach the hub pinion

gear retaining plate and remove plate.
3. Carefully remove pinion gear from splined hub out-
put shaft.
4. Using suitable protection, clamp drive hub assembly
in a vise or suitable holding fixture.
5. Remove four shoulder bolts (3) and lockwashers (4)
from counterbored holes in cover of drive hub
assembly.
3120636 – JLG Lift – 2-57

Figure 2-22. Torque Hub Carrier Timing
6. Remove remaining eight bolts (2) which attach cover dle rollers (13) on each shaft are not damaged
(1) to ring gear 7. or lost.
7. Carefully remove cover assembly (1) from input gear c. Lift cluster gears (11) from carrier (10) and
(18) together with outer thrust washers (8) and thrust remove thrust washers (12), needle rollers (13)
bearing 9. Remove and discard outer o-ring (6). and roller spacer (14).
d. Drive roll pins (16) from shafts (15) and discard
8. Remove thrust washer (17) from small diameter of
pins.
input gear (18).
17. If necessary, disassemble hub and shaft assembly
9. Carefully withdraw input gear (18) from cluster gear
(24) as follows:
(11) and output shaft (30).
a. Using suitable snap ring pliers, remove retaining
10. Rotate ring gear (7) and check that each of the three
ring (20) from groove in output shaft (30).
cluster gears (11) incorporates a punched timing
mark. b. Remove spacer shim (21) from output shaft.
c. Place hub in a suitable hand-operated hydraulic
11. Carefully withdraw ring gear (7) from assembly.
press with external portion of shaft (30) down
12. Carefully withdraw carrier assembly (10) from inter- and with suitable block supporting hub (24).
nal gear (19). d. Using suitable protection between inner end of
13. Remove and discard inner o-ring (6). shaft (30) and press cylinder drift, operate press
and carefully press shaft from inner bearing
14. Remove inner thrust washers (8) and thrust bearing assembly (22 and 23).
(9) from counterbore in carrier assembly 10. e. Remove seal (29) from shaft and discard seal.
15. Carefully withdraw internal gear (19) from output f. Remove bearing cone (22) from cup (23).
shaft (30). g. Using press, remove bearing cups (23 and 27)
16. If necessary, disassemble planet carrier assembly from hub (24) and cone (28) from shaft (30).
(10) as follows:
a. Remove three pins (16) by gently tapping a suit-
able punch against the roll pin until the pin is 1. Clean all parts thoroughly in an approved cleaning
driven into planet shaft (15). solvent.
b. Using a suitable drift, carefully and gently tap
2. Inspect bearing components (22, 23, 27, 28) for
shafts (15) from carrier (10), ensuring that nee-
damage, pitting, corrosion or excessive wear.
Replace bearings as a complete set if necessary.
2-58 – JLG Lift – 3120636

Figure 2-23. Swing Torque Hub
3120636 – JLG Lift – 2-59

3. Inspect all thrust washers for scoring or excessive c. Apply a liberal coating of petroleum or multi-pur-
wear. pose grease to inner diameter of cluster gear
(11).
4. Inspect all geared or splined components for
chipped or broken teeth and for excessive or d. Position spacer (14) at the approximate midpoint
uneven wear patterns. of the gear diameter.
e. On each side of spacer (14), position needle roll-
5. Inspect o-ring grooves in hub (24) and cover (1) for
ers (13) in inner diameter of gear.
burrs or sharp edges. Dress applicable surfaces as
necessary. f. Position assembled cluster gear (11) into carrier
(10) between the two thrust washers (12).
6. Inspect all thrust washer and bearing surfaces for Ensure that larger gear is on the roll pin side of
damage. Repair or replace as necessary. carrier.
7. Inspect all threaded components for damage includ- g. Position planet shaft (15) into carrier hole, with
ing stretching, thread deformation or twisting. shaft roll pin hole on same side as carrier roll pin
Replace as necessary. hole.
8. Inspect planet shafts (15) for scoring or other dam- h. Continue inserting shaft through thrust washers
age. Replace as necessary. (12) and cluster gear 11. Ensure that needle roll-
ers (13) are not displaced.
Assembly i. Align roll pin holes in both shaft (15) and carrier
(10) with chamfered portion of shaft hole upper-
1. If necessary, assemble hub and shaft assembly. most.
a. Using a suitable hydraulic press, install bearing j. Position new roll pin (16) in hole in carrier (10)
cups (23 and 27) into hub (24). and drive pin into hole until end of pin is flush
with carrier surface.
b. Using the hydraulic press, install bearing cone
(28) onto output shaft (30). k. Repeat steps (a) through (j) for remaining two
cluster gears.
c. Correctly position shaft (30) into hub (24) with
cone (28) in cup (27). 3. Position internal gear (19) on inner end of output
d. Using a suitable shaft support in the hydraulic shaft (30).
press, install bearing cone (22) on shaft (30) 4. Time carrier cluster gears as follows:
until cone abuts bearing cup (23).
a. Place carrier assembly on a flat surface, posi-
e. Position spacer shim (21) on shaft (30) between
tioning two top gears at ten o’clock and two
retainer ring groove and bearing cone (22).
o’clock, and one bottom gear at six o’clock as
f. Using suitable snap ring pliers, install retaining shown in Figure 2-22., Torque Hub Carrier Tim-
ring (20) on shaft (30). ing.
g. Using the hydraulic press, install a new seal (29) b. Find marked (punch mark) teeth on large gears.
over shaft and into hub (24). Ensure that seal is Rotate gears until punch mark is located in a
installed squarely. straight up, 12 o’clock, position. Punch marks at
h. Check that output shaft (30) rotates freely in the ten o’clock and two o’clock will be located just
hub. The oil seal will create a small amount of under edge of carrier and not readily visible.
drag. By tapping the outside of the shaft with a
5. Place ring gear (7) over cluster gears (11), with
soft headed mallet, any excessive tightness will
raised shoulder of ring gear facing down.
be reduced.
6. While holding ring gear (7) in position, invert carrier
2. If necessary, assemble planet carrier assembly (10)
assembly (10) so that ring gear and larger diameter
as follows:
of cluster gears (11) are facing down.
a. Apply a light coating of petroleum jelly or multi-
7. Apply a light coating of petroleum jelly or multi-pur-
purpose grease to flanged surface of thrust
pose grease to inner thrust washer (8) and thrust
washers (12).
bearing (9).
b. Position thrust washers (12) in carrier (10) with
tang in appropriate carrier cutaway portion. 8. Position thrust washer (8), thrust bearing (9), and
Ensure that washers are flat against surface on thrust washer (8) into applicable groove of carrier
both sides of carrier. assembly (10).
pose grease to new inner o-ring (6).
2-60 – JLG Lift – 3120636

10. Position o-ring (6) in groove in hub (24). 3. Bearing (18) is pressed onto shaft (7) and must be
removed before removal of rotating discs (11) and
11. While holding ring gear (7) and carrier assembly
stationary discs (12).
(10), insert smaller diameter of cluster gears (11)
into internal gear (19). 4. Further disassembly is not recommended unless
necessary for the replacement of specific parts.
12. Rotate ring gear (7) until hole marked “X” is located
over hub shaft assembly (24). 5. If further disassembly is required, remove shaft (7)
and stack sub-assembly from housing (1) by lightly
13. Insert input gear (18) into carrier assembly (10) so
tapping or pressing on the small external spline end
that input gear and larger diameter of cluster gears
of the shaft and removing the shaft, bearings and
(11) are in mesh. Check that carrier assembly (10)
stack from housing.
rotates freely.
6. Remove bearing (18), stationary disc (12), rotating
14. Position thrust washer (17) on shaft of input gear
disc (11), springs (10) and primary disc 9.
(18).
7. Remove bearing (3) from shaft, taking care not to
damage seal 4. Remove seal.
pose grease to new outer o-ring (6).
8. Remove springs (6) and spring retainer (5) from
16. Position o-ring (6) into groove of cover (1).
housing.
9. Remove piston (13) from power plate by introducing
pose grease to outer thrust washers (8) and thrust
low pressure air (15 psi [10 bar]) into the hydraulic
bearing (9).
inlet. Direct piston away from operator.
18. Position outer thrust washer (8), thrust bearing (9)
10. Remove o-rings (15 and 17) and back-up rings (14
and thrust washer (8) in cover (1).
and 16) from piston OD and ID grooves. Back-up
19. Position cover (1) on ring gear (7) with oil check rings will be damaged and should not be removed if
plug (5) in cover located at 90° from oil fill plugs (25 replacement is not planned.
and 26) in hub (24).
11. Pressure relief valve (23) can be removed and
20. Install four shoulder bolts (3) and lockwashers (4) inspected to assure spring loaded ball moves freely
into appropriate counterbored holes in hub (24). and is contamination free.
21. Install eight bolts (2) which attach cover (1) to ring
gear (7) and hub (24) and tighten to a torque of 23- Cleaning and Inspection
27 ft.lbs. (3.2-3.7 kgm).
22. Carefully install hub pinion gear on splined output 1. Clean all parts thoroughly.
shaft. If necessary, gently tap into position with a soft 2. Closely inspect all parts for damage, excessive wear,
headed mallet. cracks and chips. Replace parts as necessary.
23. Apply No. 2 Lift Grade Loctite to pinion gear retain- 3. Discard seals and o-rings.
ing plate screws.
4. Closely inspect bearings and bearing contact sur-
24. Position gear retaining plate and install attaching faces.
screws.
NOTE: Bearings may be re-used if, after thorough inspec-
25. Remove oil fill plug (25 or 26) and fill hub assembly
tion, they are found to be in good condition.
with approximately one quart of approved extreme
pressure gear lubricant. Install fill plug.
Assembly
NOTE: Lubricate all seals, o-rings, cylinder of the power

2.21 SWING BRAKE - AUSCO - MACHINES
plate and piston with clean hydraulic oil prior to
BUILT TO 1992 assembly.
Disassembly 1. Assemble piston (13) into power plate (21) using a

shop press, being careful not to damage the o-rings
1. With shaft protruding downward, remove bolts (22) or back-up rings. Visually align the center of the cut-
alternately and evenly to reduce spring tension. outs in piston with torque pin (8) holes in power
2. Remove power plate (21) and gasket (2). plate. Avoid pushing the piston all the way to the
bottom of the cylinder in the power plate. Try to keep
3120636 – JLG Lift – 2-61

Figure 2-24. Swing Brake - Ausco - Machines Built to 1992
2-62 – JLG Lift – 3120636

the top surface of the piston flush to 1/8 in. (3.2 mm) 4. Remove piston (40) from end cover by inserting two
below the machined surface of the power plate. 1/4-20 UNC bolts into threaded holes in piston. By
turning and pulling, piston can be removed from
2. When pressing the bearing onto the shaft, press on
bore.
the inner race of the bearing and support the shaft
properly. 5. Remove o-ring (38), back-up ring (39), o-ring (41)
and back-up ring (42) from piston.
3. Rotating discs must be clean and dry. Worn or
heavily scored discs must be replaced. 6. Remove separators (49) from housing (56).
4. Press bearing (3) into housing 1. Bearing must be 7. Remove shaft assembly, consisting of shaft (45),
seated against shoulder in housing. discs (46, 50), friction plates (48), springs (47), snap
ring (44) and bearings (3, 54) from housing by
5. Before installing seal (4), lubricate lip of seal with
pressing or using a soft mallet on male end of shaft.
system hydraulic fluid or other suitable lubricant.
Face lip of seal toward outside of brake in order to 8. Remove springs (47) from between tabs of discs
keep gear box oil or other external contaminants out (46, 50).
of brake. Using a shop press, install seal (4) by
9. Remove bearings (37, 54) from shaft (45) with
pressing evenly around OD of seal. Use care to
appropriate bearing puller. The discs and friction
avoid cocking seal.
discs will then slide off male end of shaft. Remove
6. Install shaft (7) into housing. Support inner race of snap ring and shaft.
bearing (3) when pressing bearing onto shaft.
10. Remove dowel pins (53), springs (51, 52) and o-ring
7. Install gasket 2. Align properly. After installing all (55) from housing.
remaining brake components, install bearing (18).
Properly support shaft when pressing bearing onto Cleaning and Inspection
shaft.
1. Clean all parts thoroughly.
8. Install power plate sub-assembly. Use a shop press
to evenly lower plate into position. There should be 2. Closely inspect all parts for excessive wear, cracks,
no gap at the OD when power plate is properly and chips. Replace parts as necessary.
seated against housing. If a shop press is not avail-
3. Discard seals and o-rings.
able, use assembly bolts (22). Tighten sequentially,
one at a time, until power plate is properly seated. 4. Closely inspect bearings and bearing contact sur-
Torque bolts to 50 to 60 ft. lb. (68 to 81 Nm). faces. Replace as necessary.
9. If replacement of pressure relief valve is necessary, NOTE: Bearings may be reused if, after thorough inspection,
install 1/2 to 3/4 turns beyond finger tight. they are found to be in good condition.
10. Bleed air from brake via bleeder screw.
Assembly
2.22 SWING BRAKE - MICO - MACHINES NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
BUILT TO 1992
1. Separate end cover (34) from housing (56) by 1. Insert new o-ring (55), dowel pins (53) and springs
removing capscrews (31) and lockwashers (32). (51, 52) in housing (56).
2. Install new bearing (54) in housing and press until
bearing bottoms on shoulder in housing.
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
3. Position new large diameter disc (50) in housing
1,500 LB. (680 KG). THE FOUR BOLTS SHOULD BE LOOSENED
with tabs guided by dowel pins (53) until disc rests
EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS
on springs (51, 52).
AVAILABLE (3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE
HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND
LOCKWASHERS.
DISCS (46,50) AND FRICTION DISCS (48) SHOULD REMAIN DRY
2. Tap cover with a soft mallet in order to dislodge DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED
bearing from cover. TO CONTAMINATE DISC SURFACES.
3. Remove o-ring (36), square-ring (35), pipe plug (33)
and bleeder (43) from end cover.
3120636 – JLG Lift – 2-63

Figure 2-25. Swing Brake - Mico - Machines Built to 1992
2-64 – JLG Lift – 3120636

4. Place a new friction disc (48) on bottom disc (50),

centering it as closely as possible. Insert one spring 2.23 SWING BRAKE - MACHINES BUILT 1992
(47) on each dowel pin. TO PRESENT
5. Add additional new discs (46), new friction discs 1. Separate end cover (2) from housing (21) by remov-
(48) and springs (47) as required for specific model. ing capscrews (1).
6. Install snap ring (44) on shaft (45). Insert shaft (45)

thru friction discs (48) until shaft contacts bearing
(54). Press shaft (45) until it shoulders on inner race END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
of bearing. A small preload will exist on snap ring 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO
(44) at this point. RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE
(3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN
7. Insert separators (49) over spiral pins in housing POSITION WHILE REMOVING THE CAPSCREWS AND LOCK-
(56). Separators will contact top of bottom disc (50) WASHERS.
when properly installed.
8. Install new o-ring (38), new back-up ring (39), new o- 2. Remove case seal (4) from the housing (21), then
ring (41) and new back-up ring (42) on piston (40). remove bleeder screw (3) from the end cover (2).
Insert piston (40) into end cover (34), being careful 3. Remove piston (7) from end cover (2).
not to shear o-rings or back-up rings. Inserting 1/4-
20 UNC bolts in piston may simplify installation. 4. Remove o-ring (5), back-up ring (6), o-ring (8) and
back-up ring (9) from piston (7).
9. Install new o-ring (36), new bearing (37), new square
ring (35), pipe plug (33) and bleeder screw (43) in 5. Remove separators (13) from housing (21).
end cover.
6. Remove stack assembly, consisting of discs (11),
10. Position end cover (34) on housing, aligning dowel return plate (14) and friction discs (12) from housing
pin (53) with holes in end cover. (21).
11. Install capscrews (31) and lockwashers (32). Tighten NOTE: Not all models use the same number of springs or
evenly to draw end cover (34) to housing and bear- spring pattern. Record this information for assembly
ing (37) onto shaft (45). Torque capscrews to 68 Nm. purposes. Spring retainer (17) was not used in ear-
lier models.
NOTE: If available, a hydraulic press will simplify installation
of end cover on housing. Clamp cover in position 7. Remove dowel pins (20), springs (15 & 16) and
while tightening capscrews. spring retainer (17) from housing (21).
12. Press on inner ring of bearing (37) until it shoulders 8. Remove retaining ring (18) from housing (21).
on shaft (45) to eliminate binding on bearings. Be
9. Remove shaft by pressing or using a soft mallet on
certain to restrain opposite end of shaft to avoid
male end of shaft (10).
excessive thrust loading on bearing (54).
NOTE: Earlier models did not use retaining ring (22).
10. Remove retaining ring (22) and bearing (19) from

PRESS FORCE SHOULD BE LIMITED TO 2,000 LB. (907 KG) MAXI-
shaft (10).
MUM TO AVOID POSSIBLE DAMAGE TO SNAP RING (44).
11. Press Rotary oil seal (23) from housing (21).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 1. Clean all parts thoroughly.
138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUP-
PLEMENTAL CLAMPING. 2. Closely inspect all parts for excessive wear, cracks,
 and chips. Replace parts as necessary.

faces. Replace as necessary.
NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.
3120636 – JLG Lift – 2-65

25
24
23 22
21
17
19
18
16
20
15
14
26 13
12
11
12
9 3
11
8
10
7
6
5
4
2
24
25
1. Capscrew 10. Shaft 19. Bearing

2. End Cover 11. Disc 20. Dowel Pin
3. Bleeder Screw 12. Friction Disc 21. Housing
4. Case Seal 13. Separators 22. Retaining Ring
5. O-ring 14. Return Plate 23. Rotary Oil Seal
6. Back-Up Ring 15. Spring 24. O-ring
7. Piston 16. Spring 25. Gasket
8. O-ring 17. Spring Retainer 26. Pin
9. Backup Ring 18. Retaining Ring
Figure 2-26. Swing Brake - Machines Built 1992 to Present
2-66 – JLG Lift – 3120636

Assembly
NOTE: Lubricate all seals and o-rings with clean hydraulic IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
oil prior to assembly. BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUP-
1. Clean all parts thoroughly before assembly. PLEMENTAL CLAMPING.
2. Press new rotary oil seal (23) into housing (21). Note
direction of the seal. 2.24 DRIVE BRAKE - AUSCO - MACHINES
NOTE: Earlier models did not use retaining ring (22). BUILT PRIOR TO MARCH 1992
3. Install new bearing (19) and retaining ring (22) on Disassembly

shaft (10).
1. With shaft protrusion downward, remove bolts (21)
4. Insert shaft assembly and retaining ring (18) in hous- alternately, power plate (20) and gasket 2.
ing (21).
2. Bearing (18) is pressed onto shaft (7) and must be
NOTE: Be sure to use the same number of springs and removed before removal of rotating discs (11) and
spring pattern as recorded during disassembly. stationary discs (12).
Spring retainer (17) was not used in earlier models.
3. Remove shaft and stack subassembly from housing
5. Insert dowel pins (20), spring retainer (17) and by lightly tapping or pressing on the small external
springs (15 & 16) in housing (21). spline end of the shaft and removing the shaft, bear-
ings and stack from the housing (1).
6. Position new large diameter return plate (14) in
housing with tabs guided by dowel pins (20) until 4. Remove bearing (18), stationary discs (12), rotating
disc rests on springs (15 & 16). discs (11), springs (10) and primary disc 9.
5. Remove bearing (3) from shaft, using care not to
damage seal 4. Remove seal and inspect sealing lip
DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY and OD for damage. If damaged, replace per reas-
DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED sembly instructions.
TO CONTAMINATE DISC SURFACES.
6. Remove springs (6) and spring retainer (5) from
7. Place a new friction disc (12) on shaft (10) until it housing (1).
contacts return plate (14). 7. Remove piston (13) from power plate by introducing
8. Add additional new discs (11) and new friction discs low pressure air (15 psi [1 Bar]) into the hydraulic
(12) as required to complete assembly. inlet. Make sure piston is directed away from the
operator. Remove o-rings (15 and 17) and back-up
9. Insert separators (13) in holes of return plate. rings (14 and 16) from piston OD and ID grooves.
10. Install new o-ring (5), new backup ring (6), new o- 8. Pressure relief valve (22) can be removed and
ring (8) and new back-up ring (9) on piston (7). Note inspected to assure spring-loaded ball moves freely
order of o-rings and back-up rings. Insert piston (7) and is free of contaminants.
into end cover (2) being careful not to shear o-rings
or back-up rings. Inspection
11. Install new case seal (4) in housing (21) then install
1. Clean all parts thoroughly.
bleeder screw (3) in end cover (2).
2. Closely inspect all parts for excessive wear, cracks
12. Position end cover (2) on housing (21) aligning
and chips. Replace parts as necessary.
dowel pins (20) with holes in end cover.
NOTE: If available, a hydraulic press will simplify installation
of end cover on housing. Clamp cover in position 4. Closely inspect bearings and bearing contact sur-
while tightening capscrews. faces. Replace as necessary.
13. Press on inner ring of bearing (37) until it shoulders NOTE: Bearings may be reused if, after thorough inspection,
on shaft (45) to eliminate binding on bearings. Be they are found to be in good condition.
excessive thrust loading on bearing (54).
3120636 – JLG Lift – 2-67

1. Housing 10. Separator Disc

2. Gasket 11. Rotating Disc
3. Bearing 12. Stationary Disc
4. Oil Seal 13. Piston
5. Spring Retainer 14. Back-Up Ring
6. Compression Spring 15. O-ring
7. Splined Shaft 16. Back-Up Ring
8. Torque Pin 17. O-ring
9. Primary Disc 18. Bearing
Figure 2-27. Drive Brake - Ausco (Prior to March 1992)
2-68 – JLG Lift – 3120636

Assembly 12. Install in place between motor and torque hub. After
connecting hydraulic line to brake, bleed air from
NOTE: Lubricate all seals and o-rings with clean hydraulic brake via bleeder screw.
1. Cylinder of the power plate, piston and o-rings must 2.25 DRIVE BRAKE - MICO - MACHINES
be clean prior to assembly, and pre-lubed with sys- BUILT MARCH 1992 TO S/N 33476
tem hydraulic fluid.
2. Assemble piston (13) into power plate (20) using a Disassembly
shop press, being careful not to damage o-rings or
teflon back-up rings. Visually align center of cutouts 1. Separate end cover (2) from housing (21) by remov-
in piston (13) with torque pin (8) holes in power plate ing capscrews (1).
(20).
NOTE: Avoid pushing the piston all the way to the bottom of
the cylinder in the power plate. Generally, try to keep
907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO
the top surface of the piston flush to 3.2 mm below
RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE
the machined surface of the power plate.
(3,000 LBS. (1,360 KG) MINIMUM), THE COVER CAN BE HELD IN
POSITION WHILE REMOVING THE CAPSCREWS AND LOCK-
3. When pressing bearing onto shaft, press on inner
WASHERS.
race of bearing and support shaft properly.
4. Rotating discs must be clean and dry. There should 2. Remove case seal (4) from the housing (21), then
be no presence of oil on any lining material or mat- remove bleeder screw (3) from the end cover (2).
ing surfaces of the stationary discs. Worn or heavily
3. Remove piston (7) from end cover (2).
scored rotating discs must be replaced.
4. Remove o-ring (5), back-up ring (6), o-ring (8) and
5. Press bearing (3) into housing 1. Bearing must be
back-up ring (9) from piston (7).
seated against shoulder in housing.
5. Remove separators (13) from housing (21).
6. Before installing seal (4), lubricate lip of seal with
system hydraulic fluid. Use a shop press to install 6. Remove stack assembly, consisting of discs (11),
seal. Face lip of seal toward outside of brake in return plate (14) and friction discs (12) from housing
order to keep gear box oil or other external contami- (21).
nants out of brake.
NOTE: Not all models use the same number of springs or
7. Install seal (4) into housing by pressing evenly spring pattern. Record this information for assembly
around OD of seal. Use care to avoid cocking. Back purposes. Spring retainer (17) was not used in ear-
of seal must be installed flush to surface of housing. lier models.
8. Install shaft (7) into housing. Support inner race of
bearing (3) when pressing shaft into bearing. 7. Remove dowel pins (20), springs (15 & 16) and
spring retainer (17) from housing (21).
9. Install gasket 2. Be sure to properly align. After
installing all remaining internal components of 8. Remove retaining ring (18) from housing (21).
brake, install bearing (18). Properly support shaft 9. Remove shaft by pressing or using a soft mallet on
when pressing bearing onto shaft. male end of shaft (10).
10. Install power plate sub-assembly. Use a shop press NOTE: Earlier models did not use retaining ring (22).
to evenly lower plate into position. There should be
no gap at OD when power plate is properly seated 10. Remove retaining ring (22) and bearing (19) from
against housing. If a shop press is not available, use shaft (10).Press Rotary oil seal (23) from housing
assembly bolts (21). Tighten sequentially, one turn (21).
at a time, until power plate is properly seated.
Torque to 50-60 ft.lbs. (68-81 Nm). Cleaning and Inspection
11. If replacement of pressure relief valve (22) is neces-
sary, install 1/2 to 3/4 turns beyond finger tight. 1. Clean all parts thoroughly.
2. Closely inspect all parts for excessive wear, cracks,
3120636 – JLG Lift – 2-69

Figure 2-28. Drive Brake - Mico (March 1992 to S/N 33746)
2-70 – JLG Lift – 3120636

3. Discard seals and o-rings. NOTE: If available, a hydraulic press will simplify installation
of end cover on housing. Clamp cover in position
while tightening capscrews.
NOTE: Bearings may be reused if, after thorough inspection, 13. Press on inner ring of bearing (37) until it shoulders
they are found to be in good condition. on shaft (45) to eliminate binding on bearings. Be
Assembly excessive thrust loading on bearing (54).
NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly. IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
1. Clean all parts thoroughly before assembly. 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUP-
PLEMENTAL CLAMPING.
2. Press new rotary oil seal (23) into housing (21). Note
direction of the seal.
NOTE: Earlier models did not use retaining ring (22). 2.26 DRIVE BRAKE - MICO - MACHINES
BUILT S/N 33476 TO PRESENT
3. Install new bearing (19) and retaining ring (22) on
shaft (10). Disassembly
4. Insert shaft assembly and retaining ring (18) in hous-
ing (21). 1. With the shaft protrusion downward, remove end
cover (13) by removing capscrews (12).
NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
Spring retainer (17) was not used in earlier models.
5. Insert dowel pins (20), spring retainer (17) and 681 KG. THE FOUR CAPSCREWS SHOULD BE LOOSENED
springs (15 & 16) in housing (21). EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS
AVAILABLE (1362 KG MAXIMUM), THE COVER CAN BE HELD IN
6. Position new large diameter return plate (14) in POSITION WHILE REMOVING THE CAPSCREWS AND LOCK-
housing with tabs guided by dowel pins (20) until WASHERS.
disc rests on springs (15 & 16).
2. Remove case seal (11) from housing (7) then
remove bleeder screw (14) from end cover (13).
DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY 3. Remove piston (24) from end cover (13).
DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED
4. Remove o-ring (19), back-up ring (18), o-ring (21)
TO CONTAMINATE DISC SURFACES.
and back-up ring (20) from piston (24).
7. Place a new friction disc (12) on shaft (10) until it 5. Remove separators (10) from housing (7).
contacts return plate (14).
6. Remove stack assembly, consisting of discs (23),
8. Add additional new discs (11) and new friction discs return plate (8) and friction discs (22) from housing
(12) as required to complete assembly. (7).
9. Insert separators (13) in holes of return plate. 7. Remove dowel pins (17), springs (5 & 6) from hous-
10. Install new o-ring (5), new backup ring (6), new o- ing (7).
ring (8) and new back-up ring (9) on piston (7). Note 8. Remove retaining ring (3) from housing (7).
order of o-rings and back-up rings. Insert piston (7)
into end cover (2) being careful not to shear o-rings 9. Remove shaft by pressing or using a soft mallet on
or back-up rings. male end of shaft (4).
11. Install new case seal (4) in housing (21) then install 10. Remove retaining ring (15) bearing (2) from shaft
bleeder screw (3) in end cover (2). (4).
12. Position end cover (2) on housing (21) aligning 11. Press rotary seal (1) from housing (7).
3120636 – JLG Lift – 2-71

29
28
1
15
54
2
3
56
52
53
17
58
22
23
22
23
51
20
21
57
18
19
11
14
13
25
55
28
29
1. Capscrew 10. Shaft 19. Bearing

2. End Cover 11. Disc 20. Dowel Pin
3. Bleeder Screw 12. Friction Disc 21. Housing
4. Case Seal 13. Separators 22. Retaining Ring
5. O-ring 14. Return Plate 23. Rotary Oil Seal
6. Back-Up Ring 15. Spring 24. O-ring
7. Piston 16. Spring 25. Gasket
8. O-ring 17. Spring Guide 26. Pin
9. Backup Ring 18. Retaining Ring
Figure 2-29. Drive Brake - Mico (S/N 33476 to Present)
2-72 – JLG Lift – 3120636

Inspection NOTE: Discs (8 & 23) and friction discs (22) should remain
dry during installation. No oil contaminate disc sur-
1. Clean all parts thoroughly. faces.
2. Closely inspect all parts for excessive wear, cracks

NOTE: Bearings may be reused if, after thorough inspection,

they are inspection, they are found to be in good
condition.
Assembly
NOTE: Lubricate all seals and o-rings with clean hydraulic

1. Press new rotary seal (1) into housing (7). Note the
direction of seal.
2. Install new bearing (2) on shaft (4).
3. Install shaft assembly and retaining ring (3) into
housing (7).
4. Install dowel pins (17), spring retainer (16), and
springs (5 & 6) into housing (7). Figure 2-30. Spring Loading
NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly. 6. Place new disc (22) on shaft (4) until it contacts
return plate (8).
5. Position new large diameter return plate (8) in hous-
7. Add additional discs (23) as required to complete
ing with tabs guided by dowel pins (17) until disc
assembly.
rests on springs (5 & 6).
8. Insert separators (10) in holes of return plate (8).
9. Install new o-ring (19), new back-up ring (18), new o-
ring (20) and new back-up ring (21) on piston (24).
Insert piston (24) into end cover (13) being careful
not to shear o-rings or back-up rings.
10. Install new case seal (11) in housing (7) then install
bleeder screw (14) in end cover.
11. Position end cover (13) on housing (7) aligning
12. Insert capscrews (12) and tighten evenly to draw
end cover (13) to housing (7). Torque capscrews to
55 ft. lbs. (75 Nm).
3120636 – JLG Lift – 2-73

HI RANGE Adjustment
2.27 FREE WHEELING OPTION
1. Move handle all the way forward.
To Disengage Drive Motors and Brakes (Free
Wheel) for Towing, etc. 2. Back off controller approximately 10°.
3. If function slows down, controller is at or below max-
1. Chock wheels securely if not on flat level surface. imum output. If this is satisfactory, do not adjust fur-
2. Disconnect both drive hubs by inverting disconnect ther.
caps in center of hubs. 4. If function speed is too slow, turn HI RANGE trimpot
3. If equipped, move steer/tow selector valve to float CW to increase speed. If function speed is too fast,
(tow) position by pulling valve knob out. turn trimpot CCW to decrease speed.
5. If necessary, repeat steps (1) through 4.
To Engage Drive Motors and Brakes (Normal
Operation) IRS - RAMP RATE Adjustment
1. If equipped, move steer/tow selector valve to steer 1. Turning RAMP RATE trimpot CW increases the time
position by pushing valve knob in. to turn ON or OFF; CCW decreases the time it takes
to turn ON or OFF when handle is moved.
2. Connect both drive hubs by inverting disconnect
cap in center of hub. 2. Trimpot has a wide adjustment range, therefore it
will be necessary to make 2 or 3 turns to notice a dif-
3. Remove chocks from wheels as required.
ference in function response.d.
2.28 OEM CONTROLLERS LO RANGE Adjustment (CREEP)

LED’s on the circuit board show if the controller works. 1. Turn CREEP switch on and completely stroke han-
The A Terminal LED lights when the handle is moved in dle.
the A direction, B Terminal LED in the B direction.
2. Adjust LO RANGE trimpot for desired output or func-
tion speed. CW increases speed/output, CCW
decreases speed/output.
ADJUSTMENTS MUST BE MADE IN THE ORDER LISTED.
Before making adjustments, position CREEP switch to

OFF, IGNITION switch to ON and depress footswitch.
THRESHOLD Adjustment
1. Move controller handle approximately one (1) inch
(2.5 cm), until LED light comes on.
2. Adjust THRESHOLD trimpot CW to increase function
speed, CCW to decrease speed.
3. Adjust trimpot so that function just starts to move
after LED light comes on.



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
2-74 – JLG Lift – 3120636

2.29 BOOM MARKING TAPE INSTALLATION
NOTE: SEE TABLE 2-4 FOR

PROPER DIMENSIONS.
Figure 2-31. Boom Marking Tape Installation - 100HX+10
NOTE: SEE TABLE 2-4 FOR

PROPER DIMENSIONS.
Figure 2-32. Boom Marking Tape Installation - 100HX and 110HX
Boom marking tape installation for Models 100HX, 110HX

and 100HX+10 is shown in Figure 2-31. and Figure 2-32.
and Table 2-4.
3120636 – JLG Lift – 2-75

Table 2-4.Boom Marking Tape Installation
w/4620038 Turntable
Model Dim. A Dim. B Dim.C
110HX Single Capacity N/R 119-1/2 in. (303.5 cm) 154-1/2 in. (392.4 cm)
110HX Dual Capacity 82-1/2 in. 209.6 cm) 119-1/2 in. (303.5 cm) 154-1/2 in. (392.4 cm
100HX+10 50in. (127.0 cm) 84 in. (213.4 cm) 135 in. (342.9 cm)
w/4620044 or 4620078 Turntable
w/o Boom Wipers
Model Dim. A Dim. B Dim.C
110HX Dual Capacity 51-1/4 in. (130.2 cm) 90 in. (228.6 cm) 123 in. (312.4 cm)
110HX Single Capacity N/A 112-1/2 in. (285.8 cm) 160-1/2 in. (407.7 cm)
110HX Dual Capacity 85-1/2 in. (217.2 cm) 122-1/2 in. (311.2 cm) 160-1/2 in. (407.7 cm)
100HX+10 41-1/4 in. (104.8 cm) 80 in. (203.2 cm) 131 in. (332.7 cm)
w/Boom Wipers Installation 0239257
Model Dim. A Dim. B Dim. C
100HX Dual Capacity 50-1/4 in. (127.6 cm) 89 in. (226.1 cm) 122in. (309.9 cm)
110HX Single Capacity N/A 121-1/2 in. (308.6 cm) 159-1/2 in. (405.1 cm)
110HX Dual Capacity 83-3/8 in. (211.8 cm) 121-1/2 in. (308.6 cm) 159-1/2 in. (405.1 cm)
100HX+10 40-1/4 in. (102.2 cm) 79 in. (200.7 cm) 130 in. (330.2 cm)
w/Boom Wipers Installation 0253303
Model Dim. A Dim. B Dim. C
100HX Dual Capacity 49-1/8 in (124.8 cm) 87-7/8 in. (223.2 cm) 120-7/8 in. (307.8 cm)
110HX Single Capacity N/A 120-3/8 in. (305.8 cm) 158-3/8 in. (402.3)
110HX Dual Capacity 83-3/8 in. (211.8 cm) 120-3/8 in. (305.8 cm) 158-3/8 in. (402.3)
2-76 – JLG Lift – 3120636

2. Boom Angle Sensor Adjustment.

2.30 BOOM LENGTH/ANGLE SENSOR
ADJUSTMENT PROCEDURES a. With the boom completely retracted and in the 0
degrees horizontal position, measure the volt-
age at TP3 on the load radius circuit card and at
the yellow wire on the boom angle sensor.
LOAD RADIUS CIRCUIT CARD P/N-0610106 WAS SUPERSEDED
WITH LOAD RADIUS CIRCUIT CARD P/N-0610130. ALTHOUGH b. Adjust the spring-loaded screw on the boom
DIFFERENT IN COMPONENT LAYOUT AND POSITION OF TEST angle sensor mounting plate (1st generation) or
POINTS, THE TEST POINTS ARE LABELED AND FUNCTION the trimpot on the boom angle sensor (second
EXACTLY THE SAME. generation) until the voltage at TP3 on the load
radius circuit card and the yellow wire on the
NOTE: The boom length/angle sensor is factory set and nor- boom angle sensor reaches the proper voltage.
mally does not require adjusting unless it is removed For third generation sensor boxes, loosen the
from the base boom for maintenance purposes, etc. three screws securing the sensor to the box and
The boom length/angle sensor has been built to rotate the sensor until the proper voltage read-
three different configurations, hereafter referred to as ing is obtained, then retighten the screws. (See
1st generation, 2nd generation and 3rd generation. Table 2-5 for proper voltage.)
3. Radius Adjustment.
1st and 2nd Generation Radius Cards
a. With the boom completely retracted and level
100HX, 110HX horizontal, telescope the boom until the yellow
1. Length Indicator Adjustment. marking tape on the mid boom is exposed.
b. At this point, measure the voltage at TP6 on the
a. With the engine running, check test point 10
load radius circuit card. This voltage represents
(TP10).
the critical radius from the center line of rotation.
b. Fully retract the boom and place in the 0 (+3/-0)
c. Put the voltmeter probe on TP8 and adjust P2 on
degrees horizontal position.
the load radius circuit card until the voltage mea-
c. Set TP1 on the load radius circuit card to 1.8 sured at TP6 is obtained at TP8. The yellow light
Volts by adjusting trimpot TP1, then proceed on the “Reach Display” should just turn on.
with the following adjustments.
d. Continue extending the boom until the red mark-

ing tape on the mid boom is exposed
Loosen Allen screws which anchor the timing
belt pulley (1st generation) or timing gear (2nd e. Measure the voltage at TP6 on the load radius
generation) to the shaft of the 5K pot. On 3rd circuit card. This voltage represents the critical
generation sensor boxes, loosen the three radius from the center line of rotation.
screws holding the pot in place. This enables f. Adjust P3 on the load radius circuit card until the
pot/pot shaft to move freely. voltage measured at TP6 is obtained at TP9. The
 red light on the “Reach Display” should just turn
Turn the ignition switch on. Adjust the 5K pot/pot on.
shaft until the proper voltage appears at TP2 on
the load radius circuit card and also at the green NOTE: If replacing the boom radius circuit card, P4 must be
wire on the 5K pot. (See Table 2-5 for proper set at the same voltage as P3. The test point for P4
voltage.) voltage is TP7.

Tighten the Allen screws on the timing belt pul-
ley/timing gear or tighten the three screws, as
applicable.




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



3120636 – JLG Lift – 2-77

Table 2-5.Card Adjustment - 1st and 2nd Generation
Boom Radius Use Procedure
Model Length Indicator Boom Angle Sensor
100HX 2.5 Volts 0.18 Volts
110HX 2.0 Volts 0.20 Volts
100HX+10 2.5 Volts 0.18 Volts
Table 2-6.Card Adjustment - 3rd Generation
Boom Radius Use Procedure
Adjustment 100HX 110HX 110HX 100HX+10

Location Dual Capacity Single Capacity Dual Capacity Single Capacity
P1 1.114 Volts 1.151 Volts 1.151 Volts 1.018 Volts
P5 1610 Ohms 1340Ohms 1340 Ohms 1000 Ohms
4. \Operational Check. 100HX+10

a. With no load in the platform, raise the boom 1. Length Indicator Adjustment.
completely and fully extend the boom.
a. Fully retract the boom and place it in the 0 (+3/-
b. Engage auxiliary power. 0) degrees horizontal position.
c. Engage LIFT DOWN until the blue light turns off b. With the engine running, check test point 10
and the yellow light turns on. When the yellow (TP10). Adjust trimpot 5 (P5) until 10 Volts is
light turns on, shut down the machine and check obtained on TP10.
the boom angle. The boom angle should be 63-
67 degrees. If the boom angle is within this
c. Set TP1 on the load radius circuit card to 1.8
range, proceed to step 4. If the boom angle is
Volts by adjusting P1.
not within this range, contact the JLG Service
Department for further assistance. d. Loosen the Allen screws which anchor the tim-
 ing belt pulley (1st generation) or timing gear
Engage LIFT DOWN until the blue light turns off (2nd generation) to the shaft of the 5K pot. On
and the red light turns on. When the red light 3rd generation sensor boxes, loosen the three
turns on, shut down the machine and check the screws holding the pot in place. This enables
boom angle. The boom angle should be 55-58 the pot/pot shaft to move freely.
degrees. If the boom angle is within this range, e. Turn the ignition switch on. Adjust the 5K pot/pot
the boom length/angle indicating system is shaft until the proper voltage appears at TP2 on
working properly and requires no further adjust- the load radius circuit card and also at the green
ment. If the boom angle is not within this range, wire on the 5K pot. (See Table 2-5 for proper
contact the JLG Service Department for further voltage.)
assistance. f. Tighten the Allen screws on the timing belt pul-
d. Engage LIFT DOWN. The boom function should ley/timing gear or tighten the three screws, as
stop at 41 degrees or a higher angle. If the boom applicable.
does not stop at 41 degrees, contact the JLG
Service Department.
2-78 – JLG Lift – 3120636

Load Radius Circuit Card - First Generation
Load Radius Circuit Card - Second Generation
Load Radius Circuit Card - Third Generation
Figure 2-33. Load Radius Card Configurations
3120636 – JLG Lift – 2-79

Figure 2-34. Boom Length/Angle Sensor Configurations
2-80 – JLG Lift – 3120636

Figure 2-35. Load Radius Card
3120636 – JLG Lift – 2-81

2. Boom Angle Sensor Adjustment. e. Do the following subtraction:


a. With the boom completely retracted and in the 0
Subtract the voltage when the yellow tape is
(+3/-0) degrees horizontal position, measure
exposed from the voltage reading when the red
the voltage at TP3 on the load radius circuit card
tape is exposed. This is the voltage difference.
and at the yellow wire on the boom angle sen-

sor.
(Voltage when red tape is exposed — voltage
b. Adjust the spring-loaded screw on the boom when yellow tape is exposed = voltage differ-
angle sensor mounting plate (1st generation) or ence)
the trim pot on the boom angle sensor (2nd gen-
f. Put the voltmeter probe on TP11 and adjust trim-
eration) until the voltage at TP3 on the load
pot six (P6) until the “Voltage Difference” is
radius circuit card and the yellow wire on the
seen.
boom angle sensor reaches the proper voltage.
For the 3rd generation sensor boxes, loosen the g. With the boom still in the horizontal position and
three screws securing the sensor to the box and extended to the red tape, put the voltmeter
rotate the sensor until the proper voltage read- probe on TP8 and adjust P2 to the same voltage
ing is obtained, then retighten the screws. (See as TP6. The red light on the “Reach Display”
Table 2-5 for proper voltage.) should just turn on.
h. With the voltmeter probe on TP7, adjust P4 until
3. Radius Adjustment.
the voltage that was measured at the red tape
a. With the boom completely retracted and in the 0 position on TP2 is seen. This determines the
(+3/-0) degrees horizontal position, telescope length of boom (critical length) where the “Lift
the boom until the yellow marking tape on the Down Speed Limiter” is turned on.
mid boom is exposed. i. Finally, put the voltmeter on TP9 and adjust P3
b. At this point, measure the voltage at TP2 on the to 3 volts greater than the setting of TP8.
load radius circuit card. Record the voltage. This
4. Operational Check.
voltage represents the critical radius from the
center line of rotation. a. Raise the boom completely and fully extend the
c. With the boom still in the horizontal position, boom.
telescope outward until the red marking tape is b. Engage auxiliary power.
exposed from the mid boom. c. Engage LIFT DOWN until the blue light turns off
d. Measure the voltage at TP2 on the load radius and the red light turns on. When the red light
circuit card. Record the voltage. This voltage turns on, shut down the machine and check the
represents the critical radius from the center line boom angle. The boom angle should be 62-65
of rotation. degrees. If the boom angle is within this range,
 the boom angle/length indicator system is oper-
 ating properly and requires no further adjust-
 ment. If the boom angle is not within this range,
 contact the JLG Service Department for further
 assistance.





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

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
2-82 – JLG Lift – 3120636

3rd Generation Radius Cards 3. Radius Adjustment and Display Lights Setting Pro-
cedure
100HX Dual Capacity
a. On the Load Radius Circuit Card, measure TP11
1. Length Indicator Adjustment and adjust potentiometer P6 for a reading of 0.0
Volts DC.
a. Level the frame before beginning any adjust-
ments. b. On the Load Radius Circuit Card, measure TP8
and adjust potentiometer P2 for a reading of
b. Make all adjustments with the engine running
1.585 Volts DC.
unless otherwise noted.
c. On the Load Radius Circuit Card, measure TP9
c. Fully retract the boom.
d. On the Load Radius Circuit Card, measure TP10 1.959 Volts DC.
and insure that 10 Volts DC (+0.1/-0 Volts DC) is
d. Telescope the boom until the leading edge of
present.
the yellow marking tape is exposed from the mid
e. On the Load Radius Circuit Card, adjust P1 to boom. Adjust potentiometer P2 until the yellow
1.114 Volts DC while measuring TP1. light just turns on and the blue light turns off.
f. Make the following adjustment with the power e. Telescope the boom until the leading edge of
off. the red marking tape is exposed from the mid
 boom. Adjust potentiometer P3 until the red light
On the Load Radius Circuit Card, disconnect just turns on and the yellow light turns off.
connector J2 (the 6 pin connector on the printed
f. Measure TP2 and adjust potentiometer P4 until
circuit board). Measure between Pin (6) of the
TP7 measures 0.05 Volts DC more than TP2.
socket connector and ground (TB1-1), adjust
This determines the length of the boom (critical
potentiometer P5 to a value of 1610 Ohms (+/- 5
length) where the lift down speed limiter is
Ohms).
turned on.

Adjust the 5K Ohm potentiometer in the boom 100HX+10 (110HXER)
cable reel by loosening the three screws holding 1. Length Indicator Adjustment
it in place.
NOTE: When checking the resistance on the 6 pin connec- ments.
tor as outlined in step (c), be sure to use connector
pins (6) and (3) corresponding to pins (6) and (3) on
plug 2 on the circuit card.
c. Fully retract the boom.
Rotate the 5K Ohm potentiometer until you mea- d. On the Load Radius Circuit Card, measure TP10
sure 100 Ohms between Pin (3) and Pin (6) on and insure that 10 (+0.1/-0) Volts DC is present.
the 6 pin plug connector which mates with J2. e. On the Load Radius Circuit Card, adjust P1 to
 1.018 Volts DC while measuring TP1.
Tighten the three (3) screws on the 5K Ohm
f. Make the following adjustment with the power
potentiometer in the boom cable reel.
off.
g. Turn the power on and measure TP2. It should 
be 1.183 Volts DC. Re-adjust the 5K Ohm poten- On the Load Radius Circuit Card, disconnect
tiometer if necessary. connector J2 (the 6 pin connector on the printed
2. Boom Angle Sensor Adjustment
a. With the platform level, the boom fully retracted potentiometer P5 to a value of 1000 (+/- 5)
and at 45 (+/- 1) degrees elevation, measure the Ohms.
DC voltage at TP5 on the Load Radius Circuit 
Card. Adjust the 5K Ohm potentiometer in the boom
b. Loosen the three screws securing the sensor to cable reel by loosening the three screws holding
the box and rotate the sensor until 7.1 (+/- 0.1) it in place.
Volts DC is measured at TP5. Tighten the screws NOTE: When checking the resistance on the 6 pin connec-
on the sensor. tor as outlined in step (c), be sure to use connector
c. Return the boom to horizontal. pins (6) and (3) corresponding to pins (6) and (3) on
3120636 – JLG Lift – 2-83

Rotate the 5K Ohm potentiometer until you mea- 110HX Single Capacity
sure 100 Ohms between Pin (3) and Pin (6) on
1. Length Indicator Adjustment
the 6 pin plug connector which mates with J2.
 a. Level the frame before beginning any adjust-
Tighten the three (3) screws on the 5K Ohm ments.
potentiometer in the boom cable reel. b. Make all adjustments with the engine running
g. Turn the power on and measure TP2. It should unless otherwise noted.
be 1.120 Volts DC. Re-adjust the 5K Ohm poten- c. Fully retract the boom.
tiometer if necessary. d. On the Load Radius Circuit Card, measure TP10
2. Boom Angle Sensor Adjustment and insure that 10 (+0.1/-0) Volts DC is present.
e. On the Load Radius Circuit Card, adjust P1 to
a. With the platform level, the boom fully retracted
1.151 Volts DC while measuring TP1.
and at 45 (+/- 1) degrees elevation, measure the
DC voltage at TP5 on the Load Radius Circuit f. Make the following adjustment with the power
Card. off.

b. Loosen the three screws securing the sensor to
On the Load Radius Circuit Card, disconnect
the box and rotate the sensor until 7.1 (+/- 0.1)
Volts DC is measured at TP5. Tighten the screws
on the sensor.
c. Return the boom to horizontal. potentiometer P5 to a value of 1340 (+/- 5)
3. Radius Adjustment and Display Lights Setting Pro- Ohms.
cedure 
Adjust the 5K Ohm potentiometer in the boom
a. On the Load Radius Circuit Card, measure TP11 cable reel by loosening the three screws holding
and adjust potentiometer P6 for a reading of it in place.
0.525 Volts DC.
NOTE: When checking the resistance on the 6 pin connec-
b. On the Load Radius Circuit Card, measure TP8
pins (6) and (3) corresponding to pins (6) and (3) on
2.577 Volts DC.
and adjust potentiometer P3 for a reading of 5.0 Rotate the 5K Ohm potentiometer until you mea-
Volts DC. sure 100 Ohms between Pin (3) and Pin (6) on
d. Telescope the boom until the leading edge of the 6 pin plug connector which mates with J2.
the red marking tape is exposed from the mid 
boom. Adjust potentiometer P2 until the red light Tighten the three (3) screws on the 5K Ohm
just turns on and the blue light turns off. potentiometer in the boom cable reel.
e. Measure TP2 and adjust potentiometer P4 until g. Turn the power on and measure TP2. It should
TP7 measures 0.05 Volts DC more than TP2. be 1.237 Volts DC. Re-adjust the 5K Ohm poten-
This determines the length of the boom (critical tiometer if necessary.
length) where the lift down speed limiter is 
turned on. 
 
 
 
 
 
 
 
 
 
 
 
 
 
2-84 – JLG Lift – 3120636

2. Boom Angle Sensor Adjustment 110HX Dual Capacity

a. With the platform level, the boom fully retracted 1. Length Indicator Adjustment
DC voltage at TP5 on the Load Radius Circuit
ments.
Card.
the box and rotate the sensor until 7.1 (+/- 0.1)
Volts DC is measured at TP5. Tighten the screws c. Fully retract the boom.
on the sensor. d. On the Load Radius Circuit Card, measure TP10
c. Return the boom to horizontal. and insure that 10 (+0.1/-0) Volts DC is present.
e. On the Load Radius Circuit Card, adjust P1 to
3. Radius Adjustment and Display Lights Setting Pro-
1.151 Volts DC while measuring TP1.
cedure
f. Make the following adjustment with the power
a. On the Load Radius Circuit Card, measure TP11 off.
and adjust potentiometer P6 for a reading of 0.0
Volts DC. On the Load Radius Circuit Card, disconnect
b. On the Load Radius Circuit Card, measure TP8
2.548 Volts DC.
potentiometer P5 to a value of 1340 (+/- 5)
c. On the Load Radius Circuit Card, measure TP9 Ohms.
and adjust potentiometer P3 for a reading of 5.0 
Volts DC. Adjust the 5K Ohm potentiometer in the boom
d. Telescope the boom until the leading edge of cable reel by loosening the three screws holding
the red marking tape is exposed from the mid it in place.
boom. Adjust potentiometer P2 until the red light
just turns on and the blue light turns off. NOTE: When checking the resistance on the 6 pin connec-
e. Measure TP2 and adjust potentiometer P4 until pins (6) and (3) corresponding to pins (6) and (3) on
TP7 measures 0.05 Volts DC more than TP2. plug 2 on the circuit card.
length) where the lift down speed limiter is Rotate the 5K Ohm potentiometer until you mea-
turned on. sure 100 Ohms between Pin (3) and Pin (6) on
 the 6 pin plug connector which mates with J2.
 
 Tighten the three (3) screws on the 5K Ohm
 potentiometer in the boom cable reel.

 g. Turn the power on and measure TP2. It should
 be 1.237 Volts DC. Re-adjust the 5K Ohm poten-
 tiometer if necessary.
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3120636 – JLG Lift – 2-85

2. Boom Angle Sensor Adjustment

2.31 LOAD MANAGEMENT SYSTEM
a. With the platform level, the boom fully retracted
The LMS (Load Management System) consists of three
independent systems.
DC voltage at TP5 on the Load Radius Circuit
Card.
Platform Position Indication System
the box and rotate the sensor until 7.1 (+/- 0.1) This system illuminates one of the two lamps in the plat-
Volts DC is measured at TP5. Tighten the screws form position display located on both the platform console
on the sensor. and ground control box. A blue light is used to indicate
that the platform is within the permitted operating enve-
c. Return the boom to horizontal.
lope and a red light is used to indicate when the platform
3. Radius Adjustment and Display Lights Setting Pro- is outside the permitted operating envelope. Either the
cedure blue or red light should be illuminated at all times.
a. On the Load Radius Circuit Card, measure TP11 The elevation angle is sensed by means of a pendulum
and adjust potentiometer P6 for a reading of 0.0 potentiometer and the extension of the boom sensed by a
Volts DC. multi-turn potentiometer driven by means of a cable
b. On the Load Radius Circuit Card, measure TP8 attached to the telescoping part of the boom. Both of
and adjust potentiometer P2 for a reading of these sensors are situated at the rear of the base boom
2.128 Volts DC. section and housed in a sealed steel box.

2.548 Volts DC.
d. Telescope the boom until the leading edge of
the yellow marking tape is exposed from the mid
boom. Adjust potentiometer P2 until the yellow
light just turns on and the blue light turns off.
e. Telescope the boom until the leading edge of
the red marking tape is exposed from the mid
boom. Adjust potentiometer P3 until the red light
just turns on and the yellow light turns off.
f. Measure TP2 and adjust potentiometer P4 until
TP7 measures 0.05 Volts DC more than TP2.
length) where the lift down speed limiter is
turned on.



 The signals from these sensors (elevation angle and
 extension distance) are fed into a load radius card which
 calculates the boom radius.

 Boom Radius = Boom Length x Cos Boom Angle







2-86 – JLG Lift – 3120636

MONITORING
TIMER
RELAYS
TEST SWITCH
RESET SWITCH
MONITOR LATCHING RELAYS LOAD MOMENT CIRCUIT CARD

MONITOR RELAY MODULE LOAD RADIUS CIRCUIT CARD
LOAD MOMENT CIRCUIT CARD
Figure 2-36. Control Box Components
This circuit card operates as follows: Also, when an overmoment condition is sensed by the
overmoment control circuit, a signal is sent to the logic cir-
A calibrated dc voltage representing the boom angle is
cuit network. This causes either the red or blue lamp to
sent from the boom angle sensor to the angle cosine cir-
flash indicating that an overmoment condition exists in
cuit. This voltage is converted to the cosine of the angle
that region. This condition also causes the audible warn-
and presented to the radius generator circuit.
ing to sound at the control consoles.
A calibrated dc voltage representing the boom length is
sent from the boom length sensor to the boom length cir- Overmoment Control System
cuit and presented to the radius generator circuit. The turntable is pivoted at the lower front area and com-
The length and cosine dc voltages are multiplied together pression springs, mounted towards the rear, provide a
in the radius generator circuit. The output dc voltage from reaction force to the moment produced by boom exten-
this circuit is passed to a radius limiting circuit. This circuit sion. The force produced by the springs is adjusted to bal-
is set to detect a specific boom radius dimension. The ance the moment produced when the boom is extended
resultant output signal is sent to a logic network circuit to the maximum permitted radius.
which determines which of the indicator lamps (blue or
red) should be energized.
There should be a signal from the sensors at all times,
however, if the signal line from the angle, or the boom
length sensor is cut a failure circuit detects this and acti-
vates an audible warning horn mounted in the console
panels.
The boom length circuit also produces output dc voltage
when the boom is within a predetermined critical boom
length. This signal energizes a 12 volt dc solenoid flow
control valve (via a relay in the overmoment control circuit
card) to enable the descend function to operate at full
speed. When this signal is removed, the descent function
defaults to a creep speed.
3120636 – JLG Lift – 2-87

Immediately beyond this point of balance the turntable is The monitoring system operates as follows:
permitted to pivot a maximum vertical distance of 3 mm.
There is an output of 12 volts dc at terminal 7 on the over-
This movement is sensed by two independent switches
moment circuit card only after the input at pin No 2 has
which power two independent control circuit channels.
received a 12 volt dc signal (from a sensing switch) for a
1. A positive break mechanical limit switch. time duration greater than 3 seconds and this output sig-
nal will continue 0.5 seconds after the input signal is
2. An inductive proximity switch.
removed.
These input signals also energize two independent 12 volt
timer relays (1 second delay off relay B) which control the
output signals from both circuit cards. If the input is
removed the timer relay B will de-energize after 1 second.
If an output signal from either card remains it will energize
two lockout latching relays (relay C). These relays control
the function signals to lift, lower, and extend the boom.
Therefore, when the latching coils receive a signal the
operator is permitted to retract the platform, to within 3
meters of the fully retracted position. This will enable oper-
ation of the boom lower function to bring the platform to
the ground level position. The machine will remain in this
condition (i.e. in the lowered position) until reset by a
competent person.
NOTE: The monitoring system only activates when there is

a malfunction of the overmoment control system.
Load Management System Daily Check

At the beginning of each days’ use, perform check with no
load (persons or material) in platform from ground control
station.
Each circuit channel is arranged as follows: 1. Extend all axles fully and insert lock pins (if applica-
The switch provides a 12 volt dc signal to a circuit card. ble).
The output from this card energizes a relay which permits 2. With boom fully retracted, raise boom to horizontal.
the functional signals for boom extend and descend.
When an input signal to a channel or an output signal 3. Position toggle switch located on the right side of
from a circuit card is not present, the lift down and tele- the ground control station in the “P” position and
scope out functions are interlocked. hold.
There is also a warning horn signal present, at both the 4. Extend boom until it stops. Boom must stop on
platform console and ground box, when either channel is white tape on mid boom. Release toggle switch.
not energized. 5. Retract boom until tele out wil function (system in
now reset).
Overmoment Control Monitoring System
6. Position toggle switch located on the right side of
The 12 volt dc input signals from the overmoment control the ground control station in the “M” position and
sensing switches are constantly monitored and compared hold.
with the output from the circuit cards by the monitoring
system circuit. 7. Extend boom until it stops. Boom must stop on
white tape on mid boom. If boom does not stop at
If any fault is detected (input to output on the same chan- white tape, system must be repaired by JLG autho-
nel or input to output on different channels) all movements rized service personnel before machine can be
of the platform that could increase instability (lift up, lift used.
down, telescope out) are shut down and the boom permit-
ted to retract and descend in a controlled sequence. The
machine will remain in this state until reset by a competent
person. 
2-88 – JLG Lift – 3120636

SWITCH
RESET
2
SWITCH
TEST
Figure 2-37. Load Moment Limiting System Monitoring Circuit
3120636 – JLG Lift – 2-89

2.32 LOAD MANAGEMENT SYSTEM 2.33 TURNTABLE SPRINGS

ADJUSTMENT
Turntable 4620038
Turntable 4620038
1. Removal.
1. With boom retracted, limit switch and proximity a. Fully retract boom.
switch are in neutral position.
b. Remove six (6) nuts and jam nuts from beneath
2. Extend boom in horizontal position until white tape turntable which attach to turntable spring bolts.
on inner mid boom is fully exposed, no load in plat- c. Remove cover from load management switches.
form. Remove bolts which attach load management
3. Adjust actuator to trip switch, then secure locking switches to underside of turntable. Allow
nut. switches to hang freely from underside of
machine.
4. Adjust proximity switch target until LED light goes
off, then secure locking nut.
5. To test cutoff switches, retract boom to reset posi- WRAP MASKING TAPE AROUND THE LOAD MANAGEMENT
tion, then extend boom to test cutoff. Do not extend SWITCHES TO INSURE THAT THE SWITCHES WILL STILL BE
boom past white tape. OPERABLE.
6. To test limit switch, retract boom to reset, then d. Position boom to horizontal.
extend boom to cutoff while holding test bypass
e. Telescope boom until white marking tape on mid
switch in “M” position. To test proximity switch,
boom is visible.
retract boom to reset, then extend boom to cutoff
while holding test bypass switch in “P” position. f. Remove two (2) bolts from turntable spring lock-
When testing switches, do not extend boom past ing bar located inside of turntable. Remove lock-
white tape on inner mid boom. ing bar.
g. Fully retract boom.
Turntables 4620044 and 4620078 h. Remove six (6) bolts, spacers and turntable
springs from turntable.
1. With boom retracted, limit switch and proximity
switch are in neutral position. 2. Installation.
2. Extend boom in horizontal position until white tape a. Install six (6) bolts, spacers and turntable
on inner mid boom is fully exposed, no load in plat- springs onto turntable.
form. b. Telescope boom until white marking tape on mid
3. Adjust proximity switch target until LED light comes boom is visible.
on (switch is tripped), then secure locking nut. c. Install turntable spring locking bar located inside
turntable.
4. Adjust actuator to trip switch, then secure locking
nut. d. Fully retract boom.
e. Fully elevate boom.
5. To test cutoff switches, retract boom to reset posi-
tion, then extend boom to test cutoff. Do not extend f. Install six (6) nuts and jam nuts on turntable
boom past white tape. spring bolts. Torque jam nuts to 75 ft. lb. (102
Nm), then torque nuts to 75 ft. lb. (102 Nm).
6. To test limit switch, retract boom to reset, then g. If removed, install load management switches
extend boom to cutoff while holding test bypass on mounting brackets.
switch in “M” position. To test proximity switch,
retract boom to reset, then extend boom to cutoff h. Position boom to horizontal. Refer to paragraph
while holding test bypass switch in “P” position. 2-28 and adjust load management switches as
When testing switches, do not extend boom past required.
white tape on inner mid boom. 




2-90 – JLG Lift – 3120636

Turntables 4620044 and 4620078

2.34 PUMP COUPLING CONVERSION
1. Removal. PROCEDURES
a. Fully retract boom. The following procedures are provided to assist in the
conversion from a solid pump coupling to a Lovejoy or
b. Remove rear turntable cover. Hayes pump coupling.
c. Remove five (5) nuts and jam nuts from beneath
turntable which attach to turntable spring bolts. Lovejoy Coupling
d. If necessary, remove bolts which secure load
management switches to mounting bracket and 1. Separate coupling disc and hub and align plastic
allow switches to hang freely. disc on flywheel with webbing facing flywheel. Install
attaching bolts and lockwashers and torque bolts to
30 ft. lb. (41 Nm).
WRAP MASKING TAPE AROUND THE LOAD MANAGEMENT 2. Attach pump mounting plate adapter to bell housing
SWITCHES TO INSURE THAT THE SWITCHES WILL STILL BE of engine and secure with bolts and lockwashers.
OPERABLE.
3. Slide coupling hub onto pump shaft bottoms out on
e. Position boom to horizontal. roll pin (located inside hub). Secure hub onto shaft
by torquing torque screws to 22 ft. lb. (30 Nm).
f. Remove five (5) bolts and turntable springs from
turntable. 4. Insert coupling hub (now affixed to pump shaft)
through pilot bore in pump mounting plate. Align
2. Installation.
coupling hub and disc, push pump into position and
a. Position boom to horizontal. secure with bolts and lockwashers.
b. Install five (5) bolts and turntable springs onto
turntable. Hayes Coupling
c. Install five (5) nuts and jam nuts on turntable 1. Install pump coupling on flywheel and secure with
spring bolts. bolts and lockwashers. Torque bolts to 30 ft. lb. (41
d. Extend boom to cutoff (white tape) position then Nm).
retract boom until turntable raises 1/4 in. (6.4
mm) from cutoff position, measured at spring
area.
BEFORE ASSEMBLING PUMP COUPLING AND PUMP, BE SURE
e. Snug jam nuts, then fully retract boom. TO COAT INTERNAL SPLINES OF COUPLING AND EXTERNAL
f. Torque jam nuts to 75 ft. lb. (10.4 kgm), then SPLINES OF PUMP SHAFT WITH TEXACO CODE 1912 GREASE.
tighten nuts.
g. If removed, install load management switches 2. Attach pump mounting plate adapter to bell housing
on mounting brackets. of engine and secure with bolts and lockwashers.
h. Position boom to horizontal. Refer to paragraph 3. Align pump shaft with coupling, push pump into
2-31 and adjust load management switches as position and secure with bolts and lockwashers.
required.








3120636 – JLG Lift – 2-91

NOTE: In most cases, the reservoir is above the pump inlet

2.35 HYDRAULIC COMPONENT START-UP so that the pressure head created by the higher oil
PROCEDURES AND level helps to keep the inlet pressures within an
RECOMMENDATIONS acceptable range and prevent high vacuum levels.
However, due to hose routing or low reservoir loca-
From a hydrostatic component standpoint, the goal at
tions, there may be air trapped within this line. It is
system start up is to put into functional operation, the
important to assure that the air is bled from this line.
hydrostatic system in such a way as to preserve the
This can be accomplished by loosening the hose at
designed life span of the system. The following start-up
the fitting closest the pump. When oil begins to flow,
procedure should be adhered to whenever a new pump
the line is full, the air has been purged, and the fitting
or motor is initially installed into a machine, or a system is
can be retightened to its specified torque. If the tank
restarted after either a pump or motor has been removed
needs to be pressurized in order to start the flow of
and/or replaced.
oil, a vacuum reading should be taken at the inlet of
the pump during operation in order to verify that the
pump is not being asked to draw an inlet vacuum
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO higher than it is capable of.
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK
FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING THE Be certain to fill the pump and/or motor housing with
PROCEDURE IN ORDER TO PREVENT INJURY. TAKE NECES- clean hydraulic fluid prior to start up. Fill the housing by
SARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/ pouring filtered oil into the upper case drain port.
MACHINE.
NOTE: It is highly recommended to use the highest possible
Prior to installing the pump and/or motor, inspect the case drain port, this ensures that the housing con-
unit(s) for damage that may have been incurred during tains as much oil as possible and offers the greatest
shipping and handling. Make certain that all system com- amount of lubrication to the internal components.
ponents (reservoir, hoses, valves, fittings, heat exchanger,
etc.) are clean prior to filling with fluid. NOTE: In initial start-up conditions, it may be convenient to
fill the housing, just prior to installing the case drain
Fill the reservoir with recommended hydraulic fluid. This line. Component, (especially motor), location may be
fluid should be passed through a 10 micron (nominal, no such that access to the case drain port after installa-
bypass) filter prior to entering the reservoir. The use of tion is not realistic.
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move- NOTE: Make certain that the oil being used to fill the compo-
ment. nent housing is as clean as possible, and store the
fill container in such a way as to prevent it from
NOTE: If a pump or motor is being replaced due to internal
becoming contaminated.
damage, the remaining units (pump or motors) need
to be inspected for damage and contamination, and
Install a 60 bar (or 1000 psi) pressure gauge in the charge
the entire hydraulic system will need to be flushed
pressure gauge port in order to monitor the charge pres-
and the fluid replaced. Failure to do so may cause
sure during start-up.
considerable damage to the entire system.
It is recommended that the external control input signal,
The inlet line leading from the reservoir to the pump must (electrical connections for EDC), be disconnected at the
be filled prior to start-up. Check the inlet line for property pump control until after initial start-up. This will ensure that
tightened fittings and make sure it is free of restrictions the pump remains in its neutral position.
and air leaks. 
 
 
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 


2-92 – JLG Lift – 3120636

Charge pressure may slightly decrease during forward or

reverse operation. Continue to cycle slowly between for-
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL ward and reverse for at least five minutes.
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
Shut down engine, remove gauges, and plug ports.
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
Check reservoir level and add filtered fluid if needed.
ACTUATED DURING INITIAL START-UP.
The machine is now ready for operation.
"Jog" or slowly rotate the engine until charge pressure
starts to rise. Start the engine and run at the lowest possi-
ble RPM until charge pressure has been established. 2.36 PLATFORM ROTATOR BRAKE
Excess air should be bled from the system lines as close
The platform rotator is equipped with a brake, which uses
to the motors as possible.
a stack of belleville washers to apply friction to the plat-
NOTE: With the engine on low idle, "crack", (loosen-don't form pivot point. To ensure proper friction, torque bolt
remove), the system lines at the motor(s). Continue securing belleville washers to 140 ft. lb. (190 Nm).
to run the engine at low idle and tighten the system
lines as soon as oil is observed to leak from them.
When oil is observed to "leak" at the motor the line is 2.37 PREVENTIVE MAINTENANCE AND
full, the air has been purged, and the system hoses INSPECTION SCHEDULE
should be retightened to their specified torque.
The preventive maintenance and inspection checks are
Once charge pressure has been established, increase listed and defined in the following table. This table is
speed to normal operating RPM. Charge pressure should divided into two basic parts, the "AREA" to be inspected,
be as indicated in the pump model code. If charge pres- and the "INTERVAL" at which the inspection is to take
sure is inadequate, shut down and determine the cause place. Under the "AREA" of the table, the various systems
for improper pressure. along with components that make up that system are
listed. The "INTERVAL" portion of the table is divided into
five columns representing the various inspection time
periods. The numbers listed within the interval column
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA- represent the applicable inspection code for which that
TOR' S ABILITY TO CONTROL THE MACHINE. component is to be checked.
The checks and services listed in this schedule are not
Shut down the engine and connect the external control
intended to replace any local or regional regulations that
input signal. Also reconnect the machine function(s), if
may pertain to this type of equipment nor should the lists
disconnected earlier. Start the engine, checking to be cer-
be considered as all inclusive. Variances in interval times
tain the pump remains in neutral. With the engine at nor-
may occur due to climate and/or conditions and depend-
mal operating RPM, slowly check for forward and reverse
ing on the location and use of the machine.
machine operation.

















3120636 – JLG Lift – 2-93

JLG Industries requires that a complete annual inspection 6. Check for presence of excessive dirt or foreign
be performed in accordance with the "Annual Machine material.
Inspection Report" form. Forms are supplied with each
7. Check for proper operation and freedom of move-
new machine and are also available from JLG Customer
ment.
Service. Forms must be completed and returned to JLG
Industries. 8. Check for excessive wear or damage.
9. Check for proper tightness and adjustment.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL 10. Drain, clean and refill.
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE 11. Check for proper operation while engine is running.
"ANNUAL MACHINE INSPECTION REPORT" FORM.
12. Check for proper lubrication.
This machine requires periodic safety and maintenance
13. Check for evidence of scratches, nicks or rust and
inspections by a JLG Dealer. A decal located on the turn-
for straightness of rod.
table affords a place to record (stamp) inspection dates.
Notify dealer if inspection is overdue. 14. Check for condition of element; replace as neces-
sary.
The inspection and maintenance code numbers are as fol-
lows: 15. Check for proper inflation.
1. Check for proper and secure installation. 16. Clean or replace suction screen.
2. Check for visible damage and legibility. 17. Drain and clean.
3. Check for proper fluid level. * Inspection and Maintenance Code 10, 12 and 16 to be
performed every two years.
4. Check for any structural damage; cracked or broken
welds; bent or warped surfaces. ** Inspection and Maintenance Code 8 to be performed
every two years.
5. Check for leakage.
*** Axle lockout test to be performed quarterly.
Table 2-7.Preventive Maintenance and Inspection Schedule
INTERVAL
AREA
DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY
BOOM
1. Platform 1,4 12
2. Platform Gate 1,4 12
3. Platform Rotator 5,11 8,12
4. Footswitch 1,11
5. Controllers 1,11
6. Switches 1,11
7. Placards and Decals 1,2
8. Control Tags 1,2
9. Valves 5,6
10. Carrier (Hoses and Cables) 1 4,8
11. Hydraulic Hoses and Tubing 1 5
12. Pins 8,12
2-94 – JLG Lift – 3120636

INTERVAL
AREA
13. Bushings 8,12
14. Wear Pads 8,12
15. Cylinders 1,5,6,13 12
16. Chains** 12
17. Chain Adjusters 9
18. Sheaves 8,12
19. Radius Limit Tape 1,2
TURNTABLE
1. Engine Oil (see mfg. manual) 3 5
2. Battery 3 5
3. Radiator 3 5
4. Air Cleaner 1 14
5. Exhaust System 1 1,5
6. Engine Mount 1
7. Ground Controls 1,2,11
8. Main Hydraulic Pump 1 5
9. Auxiliary Power Pump 1 5
10. Valves 1 5
11. Hydraulic Filters 5,14 14
12. Hydraulic Hoses 1 5
13. Hydraulic Oil Tank* 3 5 4 16
14. Breather Hydraulic Tank 6,14
15. Fuel Tank 3,5 4
16. Cylinders 1,5,6,13 4,12
17. Shields 1
18. Turntable Locking Pin 1,7 4
19. Horizontal Limit Switch 1,7
20. Oil Coupling 5
22. Tilt Alarm Switch 1,7
3120636 – JLG Lift – 2-95

INTERVAL
AREA
23. Swing Torque Hub 1,3,5,6 10
24. Swing Brake 1,5,6 8
25. Swing Bearing 1 12 9
CHASSIS
1. Wheel and Tire Assembly 1 8,9,15
2. Drive Motors 1,5,6
3. Drive Torque Hubs** 1,5,6 3 10
4. Drive Brakes 1,5,6 8
5. Steer Cylinders 1 1,5,6,13 12
6. Steer Components 1 4,6 8,12
7. Tie Rod Lock Pin 1 8
8. Hydraulic Hoses and Tubing 1 5
10. Shields 1
11. Wheel Bearings 8 12
12. Swing Bearing/Pinion Gear 12 9
2-96 – JLG Lift – 3120636

SECTION 3. TROUBLESHOOTING
It should be recognized that the majority of the problems

3.1 GENERAL arising in the machine will be centered in the hydraulic
This section contains troubleshooting information to be and electrical systems. For this reason, every effort has
used for locating and correcting most of the operating been made to ensure that all likely problems in these
problems which may develop. If a problem should areas are given the fullest possible treatment. In the
develop which is not presented in this section or which is remaining machine groups, only those problems which
not corrected by listed corrective actions, technically qual- are symptomatic of greater problems which have more
ified guidance should be obtained before proceeding with that one probable cause and remedy are included. This
any maintenance. means that problems for which the probable cause and
remedy may be immediately obvious are not listed in this
Troubleshooting and maintenance information pertaining section.
to the engine that are not contained in this manual are The first rule for troubleshooting any circuit that is hydrau-
contained in the applicable engine maintenance manual. lically operated and electrically controlled is to determine
if the circuit is lacking hydraulic oil and electrical control
power. This can be ascertained by overriding the bypass
3.2 TROUBLESHOOTING valve (mechanically or electrically) so that oil is available
to the function valve, then overriding the function valve
The troubleshooting procedures applicable to the aerial mechanically. If the function performs satisfactorily, the
platform are listed and defined in Tables 3-1 through 3-6. problem exists with the control circuit.
As an aid to table use, the aerial platform is divided into
four major groups, each covered separately within this
section. These groups are as follows: elevation system, 3.3 HYDRAULIC CIRCUIT CHECKS
chassis assembly, hydraulic system and electrical system.
The reference for improper function of a hydraulic system,
Each malfunction within an individual group or system is where the cause is not immediately apparent, should be
followed by a listing of probable causes which will enable the Troubleshooting Chart. The best place to begin the
determination of the applicable remedial action. The prob- problem analysis is at the power source (pump). Once it is
able causes and the remedial action should, where possi- determined that the pump is serviceable, then a system-
ble, be checked in the order listed in the tables. atic check of the circuit components, beginning with the
control, would follow. For aid in troubleshooting, refer to
It should be noted that there is no substitute for a thor- the Illustrated Parts Manual for hydraulic diagrams of the
ough knowledge of the equipment and related systems. various circuits
3120636 – JLG Lift – 3-1

Table 3-1. Platform Assembly - Troubleshooting
TROUBLE PROBABLE CAUSE REMEDY
Automatic leveling inoperative.
Hydraulic system oil low. Replenish oil as necessary.
Dual check valves dirty/inoperative. Clean or replace as necessary.
Restricted or broken hydraulic line or fitting on Clean, repair, or replace line or fitting.
slave cylinder or main lift cylinder.
Worn seal(s) in slave level or main lift cylinder. Replace seal(s).
Counterbalance valve in slave cylinder defec- Replace counterbalance valve.

tive.
Slave level or main lift cylinder not functioning Slave level or main lift cylinder not functioning
properly. properly.
Platform will not maintain level attitude.
Counterbalance valve on slave leveling cylinder Replace valve.

improperly adjusted or not functioning properly.
Worn seal(s) in slave level or main lift cylinder. Replace seal(s).
Damaged slave level or main lift cylinder. Repair or replace cylinder.
No response to platform leveling controls.
Level control switch inoperative. Repair or replace control switch lever.
System orifice plugged/dirty. Clean orifice.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Control valve not functioning properly. Repair or replace valve.
No electric to dump or control valve. See proper wiring diagram.
Slave cylinder not functioning properly. Repair or replace pump.
Platform will not adjust "up" or "down" to level.
Hydraulic pump not functioning properly. Repair or replace pump.
Slave cylinder not functioning properly. Repair or replace cylinder.
Electrical failure. See proper wiring diagram.
Orifice plugged. Clean orifice.
3-2 – JLG Lift – 3120636

Table 3-2. Boom Assembly - Troubleshooting
CONTROL VALVES
Valve spool sticking.
Dirt in oil causing excessive temperature build- Flush system and change oil using recom-
up. mended viscosity
Moisture in oil. Flush system and change oil using recom-

mended viscosity
Incorrect valve mounting causing warping of the Loosen valve and check mounting. Repair as
unit. necessary.
Valve spool scored. Remove valve and repair or replace as neces-

sary.
Tie-bolts in valve over torqued. Correctly torque bolts.
Return spring weak or broken. Remove valve and repair or replace as neces-
sary.
Relief valve malfunctioning causing excessive Check pressure delivery to and from valve and
pressure within valve. repair or replace as necessary.
Valve leaking.
Dirt or other foreign material under seal. Remove and repair valve as necessary.

sary.
Excessive back pressure caused by restricted Remove line and clear obstruction or replace line
return line to reservoir. as necessary.
Damaged valve seals. Remove valve and repair or replace as neces-

sary.
BOOM ELEVATION SYSTEM.
No response to lift control switch.
Lift control switch inoperative. Repair or replace control switch.
Lift cylinder holding valve inoperative. Repair or replace holding valve.
Dump valve (bypass) not operating. Determine cause and repair or replace valve.
Electrical malfunction. See wiring diagram.
Restricted or broken supply line on valve bank or Clean or replace line.

hydraulic pump.
Lift cylinder not functioning properly. Repair or replace cylinder
3120636 – JLG Lift – 3-3

Boom will not raise.
Load capacity exceeded (personnel or equip- Reduce load.(Refer to capacity placard.)

ment on platform).
Electrical failure to valves. See proper wiring diagram.
Pressure relief valve not functioning properly. Re-adjust or replace valve.
Bypass valve (dump) not functioning. Repair or replace valve.
Lift cylinder not functioning properly. Repair or replace cylinder.
Binding lift cylinder or boom pivot pin. Repair or replace cylinder or pin.
Boom will not lower.
See: Boom will not raise.
Pressure relief valve not functioning properly. Re-adjust or replace valve.
Holding valve not functioning properly. Re-adjust or replace valve.
Boom raises and lowers erratically.
Hydraulic system oil low. Replenish oil as required.
Counterbalance valve on lift cylinder improperly Replace valve.

adjusted or not functioning properly.
Worn seals in lift cylinder. Replace seals.
Cylinder not functioning properly. Repair or replace cylinder.
Boom drifts down.
Worn seals in lift cylinder. Replace seals.
Manual lowering valve not functioning properly Repair or replace valve.
Holding valve on cylinder not functioning prop- Repair or replace valve.

erly.
3-4 – JLG Lift – 3120636

Pump Volume, Wheel Motor Speed, and High Engine does not operate below horizontal.
Damaged wiring on level limit switch. Repair or replace wiring.
Solenoid failure. Replace solenoid.
Tripped circuit breaker. Reset circuit breaker.
Damaged level limit switch. Replace switch, repair or replace holder.
Defective relay, main terminal box. Replace relay.
Defective platform switch. Replace switch.
TELESCOPE SYSTEM.
No response to telescope control.
Telescope control switch inoperative. Repair or replace control switch.
Damaged wiring on control switch or solenoid Repair or replace wiring.

valve.

hydraulic pump.
Telescope cylinder not functioning properly. Repair or replace cylinder.
Boom will not extend.
Control valve not functioning properly. Repair or replace control valve.
Pressure setting incorrect. Check pressure/re-adjust as necessary.
Telescope cylinder not functioning properly. Repair or replace cylinder.
Boom extends and retracts erratically.
Wear pads worn. Replace pads as required.
Worn seals in telescope cylinder. Replace seals.
Cylinder not functioning properly. Repair or replace cylinder.
Distorted boom section(s) Replace distorted section(s)
Counterbalance valve not functioning properly. Replace counterbalance valve.
3120636 – JLG Lift – 3-5

BOOM SWING SYSTEM
No response to swing control.
Swing control switch not functioning. Repair or replace swing control switch.

hydraulic pump.
Swing motor not functioning properly. Repair or replace motor.
Restrictor valve(s) plugged. Clean or replace restrictor valve.
Foreign objects(s) wedged between swing Remove objects, check for damage, and repair
motor pinion and swing gear. or replace component(s) as required.
Sheared shaft on swing motor/brake. Repair or replace motor/brake.
Pressure reducing valve in swing circuit malfunc- Repair or replace pressure reducing valve.
tioning.
No electric power to valve. See proper wiring diagram.
Boom will swing in one direction only.
Foreign object(s) wedged between swing motor Remove object(s), check for damage and repair
pinion and swing gear. or replace component(s) as required.
Swing control switch not functioning properly. Repair or replace swing control switch.
Brake shuttle valve defective Replace shuttle valve.
Boom swings erratically in either direction.
Lack of lubricant on swing gear or speed reducer Lubricate as required. (See Lubrication Chart.)
pinion.
Swing motor not functioning properly. Repair or replace swing control switch.
Worn or broken teeth on swing gear or swing Replace gear(s) as required.

motor pinion.
Swing brake not functioning properly. Repair or replace swing brake.
Restrictor valves(s) plugged. Clean or replace restrictor valve.
3-6 – JLG Lift – 3120636

Table 3-3. Turntable Assembly - Troubleshooting
CONTROL VALVE.
Valve Spool Sticking.
Dirt in oil causing excessive temperature built- Change oil using recommended viscosity and
up. flush system.
Incorrect valve mounting causing warping of the Loosen valve and check mounting.Repair as
unit. necessary.

sary.
Return spring weak or broken. Remove valve and repair or replace as neces-
sary.
Relief valve malfunctioning causing excessive Check pressure delivery to and from valve and
pressure within valve. repair or replace as necessary.
Valve leaking.
Dirt or other foreign material under seal. Remove and replace valve as necessary.
Valve spool scored. Repair or replace valve.
Excessive back pressure caused by restricted Remove line and clear obstruction or replace line
return line to reservoir. as necessary.
Damaged valve seals. Repair or replace valve as necessary.
3120636 – JLG Lift – 3-7

Table 3-4. Chassis Assembly - Troubleshooting
POWER PLANT.
Engine will not start.
Station power selector switch not in required Actuate switch as required.

position.
Circuit breaker open. Determine and correct cause; reset circuit

breaker.
Defective starter motor. Replace starter motor.
Damaged wiring in ignition circuit (broken wire Repair, replace wiring.

on starter).
Ignition switch not functioning properly. Replace switch.
Ignition relay not functioning properly. Replace relay.
Ignition circuit shorted to ground. See proper wiring diagram.
Battery cable(s) not making contact. Clean and tighten cable(s).
Start lockout not working. See wiring diagram. Check relay.
Engine will not start (ignition OK).
No fuel. Replenish fuel as necessary.
Clogged fuel filter. Replace fuel filter.
Choke solenoid malfunction. Replace choke solenoid.
Restricted or broken fuel line. Clean or replace fuel line.
Fuel shut-off valve in carburetor stuck or frozen. Repair or replace fuel shut-off. Check for electri-
cal power.
Battery discharged. Charge battery, replace if defective.
Fuel pump not working. Replace fuel pump.
Cam timing belt jumped time or broken. Repair or replace timing belt.
Ignition timing slipped. Repair timing.
Engine will not accelerate above low.
Damaged wiring on speed control switch or high Repair or replace wiring.

engine solenoid.
Drive controller not functioning properly. Replace controller.
Actuator not functioning properly. Repair or replace solenoid.
High engine circuit breaker not functioning prop- Replace circuit breaker
erly.
3-8 – JLG Lift – 3120636

Switch not functioning properly or improperly Adjust, repair, or replace horizontal limit switch.
adjusted.
Excessive load on engine. Reduce load.
Engine worn badly. Rebuild engine.
Engine improperly timed. Time engine.
Engine overheating. Determine cause of overheating and remedy.
Dirty fuel filter. Replace filter.
Fuel line pinched. Replace fuel line.
Throttle governor not working properly. Repair or replace governor.
Engine surges.
Governor not adjusted properly. Correctly adjust governor.
Strong fuel odor.
Fuel tank overfilled. Check fuel tank and immediately wipe up spilled
fuel.
Fuel tank damaged. Drain all fuel from tank and remove tank for
replacement or repair.
Fuel line from tank damaged. Replace fuel line.
Carburetor flooding. Repair, replace or adjust carburetor.
FRONT FRAME AXLE AREA.
One or both wheels will not steer.
Steering link or tie rod broken or attaching hard- Replace steering link, tie rod or hardware as nec-
ware missing. essary.
One or both front wheels will not rotate or

rotate erratically.
Wheel hub or bearings damaged or not lubri- Replace hub or bearings as necessary and
cated. repack bearings with approved grease.
Hub attachment nut loose or missing. Secure or replace hub attachment nut and cotter
pin as necessary.
One or both front wheels will not rotate or

rotate erratically.
Air in oscillating axle hydraulic system. See bleeding procedure in Section 2.
Cam valve stuck or leaking. Repair or replace cam valve
Lockout cylinder leaking. Repair or replace cylinder.
3120636 – JLG Lift – 3-9

REAR FRAME AXLE AREA.
Difficulty encountered when moving

machine.
Load capacity exceeded. Reduce load. Apply loads only in accordance

with load capacity indicator.
Flow divider sticking. Repair or replace flow divider.
Machine being moved up too steep a grade. Remove machine from grade and check that
drive system operates correctly.
Grade too steep. See WARNING Placard on platform for specified

grades and sideslopes.
Towing valve not closed. Close towing valve.
Drive wheel tire treads worn smooth. Replace tires as necessary and inflate to speci-
fied pressure.
Drive brakes "dragging". Re-adjust pressure.
System pressure too low. Re-adjust pressure.
Drive hub(s) defective. Repair or replace hub.
Engine RPM’s not set. Correctly set engine RPM.
Drive motors worn. Repair or replace drive motors.
Counterbalance valve defective. Replace counterbalance valve.
Low amperage on controller. Correctly adjust controller.
DRIVE SYSTEM.
No response to control.
Restricted or broken pump supply line. Clean, repair or replace line.
Restricted or broken line on valve bank. Clean, repair or replace line.
Drive motor(s) not functioning properly. Repair or replace motor(s).
Air in wheel brake circuit. Bleed circuit, determine and correct cause.
Fuse is blow-out on control card. Replace fuse.
Damaged wiring on control switch. Repair or replace wiring.
Control switch not functioning properly. Replace switch.
Brake(s) not releasing. Determine cause and repair or replace.
3-10 – JLG Lift – 3120636

Machine will not travel in forward.
Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting.
Drive motor(s) not functioning properly. Repair or replace motor(s).

breaker.
No power to wheel motor speed switch. See proper wiring diagram.
Two speed valve sticking. Repair or replace valve.
Counterbalance valve sticking on return side. Adjust return counterbalance out 3 turns - cycle
drive - return to original position.
Motor turns slowly in the direction of the last com-

mand.
Valve not returning to neutral. Check neutral springs.
Function speed switch malfunction. Replace function switch.
Sticking spool due to contamination. Remove end cap and check spool freedom.
Repair as necessary.
Motor turns slowly at maximum command.
Valve spool is not traveling far enough due to: Repair or replace drive motor(s).
Worn, leaking drive motor(s). Repair or replace drive motor(s).
Engine RPM’s set too low. Properly adjust engine RPM’s.
Low control pressure supply. Replace pressure regulator if necessary.
Function speed switch malfunction. Replace switch.
Amperage too low on controller. Correctly adjust controller.
Defective pump, low oil volume. Repair or replace pump.
Poor response, function shuts off slowly

when command is removed.
Low spool spring preload. Check for correct spring and shims in end caps.
Sticking spool due to contamination. Remove end cap and check spool freedom.
Ramp set too high in controller. Adjust controller.
Sticking control handle. Repair or replace controller.
3120636 – JLG Lift – 3-11

STEERING SYSTEM.
No response to steer control.

breaker.
If equipped, steer/tow selector in "tow" position. Actuate control to "steer" position (Valve knob
in).
Hydraulic system pressure too low. Adjust pressure.
Damaged wiring on control switch or solenoid See proper wiring diagram.

valve.
Restricted or broken hydraulic line on valve Clean, repair or replace line.

bank, hydraulic pump or rotary coupling. (If
equipped.)
If equipped, swivel coupling leaking internally. Repair or replace coupling.

(Seals defective.)
Steer control valve not functioning properly. Repair or replace valve.
Steer cylinder not functioning properly. Repair or replace cylinder.
Machine hard to steer or steering is erratic.
Restricted hydraulic line or fitting. Clean, repair or replace line or fitting.
Restricted crossover relief valve. Clean or replace valve.
Steer system pressure low. Adjust pressure.
Bent linkage (tie rods). Repair or replace linkage as required.
Steering inoperative.

breaker.
Damaged wiring on control switch or solenoid See proper wiring diagram.

valve.
Solenoid valve not functioning properly. Repair or replace valve.
3-12 – JLG Lift – 3120636

Relief valve improperly set or not functioning Reset, repair or replace valves as required.
properly.
Machine will not steer left or to the right.
Wiring on control switch is damaged. See proper wiring diagram.
Wiring on solenoid valve damaged. Repair or replace wiring.
Coil in solenoid damaged. Replace coil.
No oil flow or pressure to steer circuit. Take pressure reading at steer valve and adjust
as necessary.
Bent cylinder rod. Repair or replace cylinder.
Damaged tie rod. Replace tie rod.
Crossover relief valve sticking. Repair crossover relief valve.
Cylinder packing defective. Repair or replace cylinder.
Machine wanders; steering not firm.
Crossover relief valve set too low or not function- Reset, repair or replace valve as required.
ing properly.
Steer linkages loose. Tighten linkage.
Steer wheel toe-in not set properly. Adjust toe-in for 1/4 inch overall.
Spindle bushings badly worn. Replace bushings.
Swivel seals leaking Repair swivel leak.
3120636 – JLG Lift – 3-13

Table 3-5. Hydraulic System - Troubleshooting
HYDRAULIC SYSTEMS - GENERAL.
Hydraulic pump noisy.
Air entering system through broken line or fitting. Repair or replace line or fitting.
(Suction Side.)
Suction screen dirty. Clean suction screen.
Air bubbles in oil. (Reservoir oil too low. Replenish oil as required.
Suction hose squeezed shut. Determine cause and repair.
Oil filter dirty. Replace hydraulic filter.
Wrong type of hydraulic oil. Replace hydraulic oil.
Pump cavitating. (Vacuum in pump due to oil

starvation.)
Restricted suction line. Clean, repair, or replace line.
Restricted reservoir air vent. Clean or replace vent.
Oil viscosity too high. Drain system and replace with recommended oil.
(Refer to Hydraulic Oils.)
Air leak in suction side of tank. Repair leak.
Restricted suction strainer. Clean strainer.
System overheating.
Oil viscosity too high. Drain system and replace with recommended oil.
Bypass valve not operating properly. Repair or replace valve.
Main relief valve set too high (Racine). Reset valve as required.
Main relief valve set too low (Vickers). Reset valve as required.
Port relief set too high. Reset valve as required.
Restricted or blocked return line. Repair or replace line.
3-14 – JLG Lift – 3120636

Pump not delivering oil.
Restricted suction line. Clean, repair, or replace line.
Air entering system through broken line or fitting. Repair or replace line or fitting.
Broken pump drive shaft/pump coupling. Repair or replace pump/pump coupling.

Note: Any time pump or pump drive coupling
is removed coat pump and drive coupling
splines with Lithium Soap Base Grease (TEX-
ACO CODE 1912 OR EQUIVALENT).
Function sluggish during operation. (System

pressure too low.)
Main relief valve set too low. Reset valve as required.
Pump section not delivering sufficient oil. Repair or replace pump section or pump.
Main relief valve stuck in open position. Clean, repair, or replace valve. (Check system oil
for contamination.)
Oil viscosity too low. Drain system and replace with recommended oil.
Leak in component, line or fitting. Repair or replace component, line or fitting.
Scored valve spool; scored cylinder. Replace valve; replace cylinder.
Amperage too low on controller. Correctly adjust controller.
Low sequence pressure. Reset valve as required.
Low pilot pressure. Reset valve as required.
Wrong/defective spool in drive section. Repair or replace drive section.
Low voltage in electrical system. Correct low voltage problem.
System(s) operate erratically.
Sticking or binding valve spools, pistons. Clean, repair, or replace components as

required.
AUXILIARY HYDRAULIC SYSTEM.
Auxiliary hydraulic pump inoperable.

breaker.
Engine is running. Shut down engine.
Check valve in system leaking. Repair or replace check valve.
Battery requires charging or will not hold a Charge or replace battery as required.
charge.
3120636 – JLG Lift – 3-15

Damaged wiring on control switch or auxiliary See proper wiring diagram.

pump.
Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting.
Pump motor solenoid not functioning properly. Replace solenoid.
Pump motor not functioning properly. Repair or replace motor.
3-16 – JLG Lift – 3120636

Table 3-6. Electrical System - Troubleshooting
PLATFORM CONTROLS.
No power to platform controls.
15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches
are making contact when pedal is depressed.
Repair or replace footswitch as necessary.
Contact block in footswitch malfunctioning. Repair, replace or adjust contact block as

required.
Faulty power circuit wiring. Check wiring continuity. Refer to proper wiring
diagram.
Select switch in wrong position. Place select switch to correct position.
ENGINE STARTER SYSTEM.
Starter will not crank.
Discharged battery or loose battery terminals. Check and charge battery or replace battery as
necessary. Clean and secure battery terminals.
Starter relay faulty or faulty relay connections. Using a test meter, check relay coil terminals for
presence of electrical power and for energization
of relay coil. Also check relay terminals for cor-
rect switching of contacts. Replace relay as nec-
essary.
Malfunctioning starter solenoid or motor. Replace solenoid or motor in accordance with

applicable manufacturer’s manual.
Malfunctioning ignition switch. Using a test meter, check ignition switch for cor-
rect switching of contacts. Replace switch as
necessary.
Faulty ignition and/or starter circuit wiring. Check wiring continuity. See proper wiring dia-
gram.
Faulty start lockout system. See correct wiring diagram.
Faulty start switch. Replace switch.
Engine continues to crank.
Faulty ignition and/or starter circuit wiring. Check wiring continuity. See proper wiring dia-
gram.
Malfunctioning starter solenoid or motor. Replace solenoid or motor in accordance with

applicable manufacturer’s manual.
Faulty start switch. Replace switch.
3120636 – JLG Lift – 3-17

INSTRUMENTS AND INDICATORS.
Travel warning horn inoperative.

breaker.
Damaged wiring in horn circuit. Repair or replace wiring.
Damaged horn. Replace horn.
Hourmeter inoperative.
Damaged wiring in hourmeter circuit. Repair or replace wiring.
Defective pressure switch. Replace pressure switch.
Inoperative hourmeter. Replace hourmeter.
Tilt alarm circuit.
Damaged wiring in tilt alarm circuit. Repair or replace wiring. See proper wiring dia-
gram.
Tilt alarm inoperative. Replace tilt alarm.
Tilt alarm not adjusted properly. Adjust tilt alarm.
Defective bulb in tilt light. Replace bulb.
Wheel Motor Speed Circuit
Switch damaged or inoperative. Replace switch.
Damaged or disconnected wiring in circuit. See proper wiring diagram.
Plugged orifice in shifter valve. Clean orifice.
Faulty shifter valve. Repair or replace bulb.
High engine speed will not function.
Boom above horizontal. Lower boom.
Horizontal limit switch malfunctioning. Repair or replace limit switch.
Drive controller defective. Replace controller.
High engine solenoid malfunctioning. Repair or replace solenoid valve.
Drive pressure switch malfunctioning. Replace pressure switch.
Electrical malfunction. See wiring diagram.
Defective engine governor. Repair or replace governor.
3-18 – JLG Lift – 3120636

Function speed control will not function.
Boom above horizontal. Lower boom.
Horizontal limit switch malfunctioning. Repair or replace limit switch.
Defective pump section. Repair or replace pump section.
Electrical malfunction. See correct wiring diagram.
3120636 – JLG Lift – 3-19

Figure 3-1. Wiring Diagram - Boom Indicator Pendulum
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Figure 3-2. Wiring Diagram - Dual Fuel (Ford Engine)
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Figure 3-3. Wiring Diagram - Generator (Deutz)
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Figure 3-4. Wiring Diagram - Generator (Ford)
3120636 – JLG Lift – 3-23

Figure 3-5. Wiring Diagram - Platform (100HX & 110HX)
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Figure 3-6. Wiring Diagram - Platform (100HX+10)
3120636 – JLG Lift – 3-25

Figure 3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3)
3-26 – JLG Lift – 3120636

3120636 – JLG Lift – 3-27

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Figure 3-10. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 1 of 3)
3120636 – JLG Lift – 3-29

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3120636 – JLG Lift – 3-31

Figure 3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4)
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3120636 – JLG Lift – 3-33

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Figure 3-17. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 1 of 4)
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3120636
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras  JLG Sverige AB
UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
+48 (0)914 320 245 Scotland 08755 Castellbisbal, Barcelona Sweden
+48 (0)914 358 200 Spain +46 (0)850 659 500
+44 (0)141 781 6700
+34 93 772 4700 +46 (0)850 659 534
+44 (0)141 773 1907
+34 93 771 1762
www.jlg.com

Manual de Servicio JLG 110 HX

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Service and Maintenance Manual

March 11, 2010

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

feed lines to system components can then be disconnected

• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-

Relieve system pressure by cycling the applicable control

3120636 – JLG Lift – A-1

March, 1989 - Original Issue

A-2 – JLG Lift – 3120636

SECTION NO. TITLE PAGE NO.

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SECTION NO. TITLE PAGE NO.

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SECTION NO. TITLE PAGE NO.

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FIGURE NO. TITLE PAGE NO.

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FIGURE NO. TITLE PAGE NO.

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TABLE NO. TITLE PAGE NO.

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TABLE NO. TITLE PAGE NO.

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Engine - Deutz F4L912

Engine - Ford LRG-425

3120636 – JLG Lift – 1-1

Drive System Hydraulic Filter - Tank

Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam 10 Microns Nominal

Drive Hub - 93.7:1 ratio.

Toe-In - Adjust for 1/4in. (6.4 mm) overall. Boom Speed

1st Section - 15.0 gpm (56.8 lpm) Boom Elevation

1-2 – JLG Lift – 3120636

110HX - 38 ft. 7 in. (11.8 m) Boom Chains 59 80 500

Wheelbase NOTE: When maintenance becomes necessary or a fas-

Multi-Viscosity Oils (CD-SE, CD-SF)

Use SAE Viscosity

* This viscosity can be used at colder temperatures only

3120636 – JLG Lift – 1-3

Deutz F4L912 Engine Table 1-3.Hydraulic Oil

Cummins 4B3.9C Engine

Use SAE Viscosity

Multi-Viscosity Oils (MS, SD, SE).

Use SAE Viscosity

NOTE: Crankcase oil should meet one of the following API

1-4 – JLG Lift – 3120636

Type Synthetic Biodegradable Type Petroleum Base

Table 1-5. Mobil EAL 224 H Specs

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Figure 1-1. Lubrication Diagram

1-6 – JLG Lift – 3120636

Table 1-8. Lubrication Chart

3 Boom Pivot Bushings 2 Grease Fittings MPG - Pressure Gun 150

10 Platform Door Hinges 2 Grease Fittings MPG - Pressure Gun 150

11 Platform Door Latch N/A SAE10 - Oil Can 150

15 Swing Bearing Gear N/A MPG - Brush 150

16 Swing Bearing 1 Grease Fitting MPG - Pressure Gun 150