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Service 3120775 03-17-08 ANSI English

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1. NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2 3 15SP Mast Assembly Components 5 Section 2 24 JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES MAST SECTION 4 MAST ew HH SECTION 1 Se ind e H MAST SECTION 2 5 SECTION 3 LIFT CYLINDER gt Gu CNN Il gt ORIGINAL 1 DESIGN Mii ra LIFT Loy ES X 79 CYLINDER ol qe d 5 x d oe ey M D Cc NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2 4 12SP Mast Assembly Components 4 Section 3120775 JLG Lift 2 25 SECTION 2 SERVICE PROCEDURES MAST SECTION 5 MAST SECTION 4 MAST SECTION 3 MAST SECTION 2 MAST SECTION 1 C 0 6 ASSEMBLYS re exe e J 8 900007 a di CHAIN ANCHOR BRACKETS Figure 2 5 Mast Chain Routing Diagram 3120775 JLG Lift 2 26 SEC
2. JLG Lift 3120775 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 CAPACITIES Hydraulic Oil Reservoir DC Models 5 qts U S 4 7 ltr 1 2 COMPONENT DATA Hydraulic Pump Electric Motor Assembly DC MODELS 12 VOLT DC MOTOR PUMP Motor 12v DC Standard Duty Pump Displacement 098 cu in rev AFC 1 6 cc rev Pump Output 1 42 GPM 800 PSI 11 7v DC 135 AMPS 45 Centistrokes 200 SSU Pressure Relief Adjustable Range 1500 to 5000 PSI Set to 2800 PSI 193 bar at factory Batteries WET Standard 12 Volt 165 Amp min Deep Cycle Marine RV DRY Option 12 Volt 165 Amp min Deep Cycle Marine RV AGM Absorption Gas Mat Option 12Volt 100 O A H M2 Marine Combination Battery Charger 110 240 Volts AC 50 60 Hz input 12 Volt DC 10 Amp output Automatic SCR Charger Selectable Voltage NOTE A high output 12Volt DC 20 Amp output SCR charger is supplied with the AGM battery option 3120775 1 3 PERFORMANCE DATA Platform Capacity Max Rated Load 12SP amp 15SP 500 Ib 227kg ANSI U S A Latin America 12SP amp 15SP 400 Ib 181kg CSA Canada Evenly distributed on platform floor Extendible Platform Max 250 Ib on rear 250 Ib on front when extended Not Available for CSA Machine Speeds 12SP Lift up 25 seconds Lift down 13 to 20 seconds 1
3. MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that maintenance per sonnel pay strict attention to these warnings and precau tions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight and never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND M
4. AN Motor Brush Cover Removal Installation 1 Motor Brush Cover a 3 Washers 5 Power Lead Clip Attach Screws 2 Cover Screws b 4 Power Leads to Lead Clips Soldered NOTICE REMOVE THE MOTOR COVER CAREFULLY THE SHORT POWER LEADS INSIDE THE COVER FROM THE POSTS ARE SOL DERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS ITEM 5 RAISE THE COVER STRAIGHT UP REMOVE THE SCREWS THEN HINGE THE COVER UP SEE CENTER ILLUSTRATION AND PRY THE CLIPS OFF OF THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER NOTE a Once cover screws are removed you may need to tap lightly around the edge of the top cover to separate it from the motor housing Read the important note above before attempting to remove the cover b These steel screws are threaded into the aluminum valve body do not overtighten 2 14 JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES Brush Carrier Assembly Remove Install 4 2 e e ec man E SSE em eM P SS 29 7 5 Due ff LN Brush Carrier Assembly Remove Install 1 Stator Brush Carrier Screws Pump Rear 3 Mark Brush Carrier Position on Motor Housing 2 Stator Brush Carrier Screws Pump Front a 4 Brush Carrier Assembly NOTE a Removed p
5. 2 28 2 10 MAST TO BASE FRAME 2 28 2 11 MAST CHAINS CABLES AND SEQUENCING CABLES ADJUSTMENT 2 29 Mast Chain Cable 2 29 Sequencing Cable 2 31 2 12 SEQUENCE CABLE REPLACEMENT 2 31 Remove Old Cables de eee eee hed 2 31 Replacement Cable 1 5 2 31 Clamp Installation Drum Socket Type 2 32 ii JLG Lift 3120775 TABLE OF CONTENTS SECTION 3 TROUBLESHOOTING 3 1 General ses Tae me Rng ae bb PN wath A tude 3 1 3 2 Troubleshooting Information 3 1 3 3 Hydraulic Circuit 3 1 3 4 ELECTRICAL SYSTEM MULTIMETER BASICS 3 1 GROUN GING 3 done Dok tah dat a heb a wea bead OON E ange ave Gah 3 1 Backptobing ee eaten Sie eed tied SO ane 3 1 Min Max uus phn Sa eee 3 1 Qe o APPS Ua debs edd Archos be Debe Medos 3 2 ege R
6. b ePi 1 1 Hydraulic Oil 1 1 1 1 2 COMPONENT le be sia debs A D ob ee Oe ud tt 1 1 Hydraulic Pump Electric Motor 1 1 oe Oe ence Ne uer A OP ee d p Ries pid 1 1 Batt ry soe RE E EE PAR RA rd 1 1 1 8 PERFORMANCE 4 rni eim AI REN petere dee Dawe 1 1 Platform Capacity Max Rated 1 1 Machilie Speeds ues Rod E LE DRE e RAMS RE iis onl its 1 1 Machine Weight With Standard Platform 1 1 Machine Height Platform 1 1 Maximum Platform Height Mast Fully 1 1 Maximum Working Height Average Person 1 1 Machine Overall Width And Length 1 1 1 4 TORQUE 1 1 1 5 LUBRICATION quero ped un EH edet dw Y Ses 1 2 Hydtaulic Oil 1 2 ui doe es PP a eS 1 2 Lubrication Specifications 1 2 1 6 HYDRAULIC PRESSURE
7. eee ee eee ee 5 Sl ls a Im BASE FOOT BRAKE INTERLOCK E Sr BRAKES DEPRESSED RED 3 a S 136 i4 i39 NO B i gt l i g NC 2g Eee Te 7 BLUE 2 BLUE 1 GREEN 2 GREEN BEACON F BLACK DESENT ALARM Figure 3 7 Electrical Diagram With Floor Brake Gate Alarm Option 3 10 JLG Lift 3120775 SECTION 3 TROUBLESHOOTING OUTLET E Ses GREEN I WHITE O I BLACK 3 9 2 3 CABLE SPIRAL BLACK LINE GOLD CABLE JUNCTION WHITE NEUTRAL SILVER BOX GREEN GROUND GREEN BLK WHT BLACK MAST SWITCH ORTINAL GREEN D T 1 AUXILLARY LOWER I NG i 13 14 NOT AVAILABLE i N C HORN WITH GATE ALARM i 6 i 818 WB i eH 21 22 RED RED RED 1 BI B GROUND CONTROL WHITE IE LU od t DENT O R GREEN ORANGE Z ORANGE Q INTERLOCK lt YELLOW ORANGE LIFT DE FLOOR BRAKE DOWN UP ALARM RELAY VALVE DUMP a VALVE 987 m gt
8. 4 Unlay the cable strands by gently forcing a screw driver between the outer strands to unlay the cable When done properly the outer strands will form a symmetrical basket Do not straighten out the spiral lay of the strands unlay any wires that make up the strand or allow the strands to cross each other inside the sleeve STRANDS UNLAYED Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug Use a metal tube plug driver and hammer to drive the plug into the sleeve while assuring that the strands are spaced somewhat equally around the plug Drive the plug until it is firmly seated and no more than 1 3 of the plug is visible from above the sleeve eene PLUG DRIVER n INSERT PLUG it IN THIS 4 PLUG POSITION 2 33 SECTION 2 SERVICE PROCEDURES 6 Reclamp the assembly in the vise on the flats of the sleeve Using the plug driver a metal tube or pliers bend the outer strands toward the center strands enough that the socket can be slipped over all the strands SHAPE PLUG DRIVER STRANDS METAL TUBE AROUND OR PLIERS PLUG NOTE When assembling stainless steel parts all threads 2 34 must be coated with a dry lubricant or an anti sieze lubricant to prevent seizing NOTE JLG Lift Coat the threads of the socket and sleeve with lubri cant and install the socket by twisting it over the strands of th
9. 3120775 SECTION 3 TROUBLESHOOTING CYLINDER PRES COMPENSATED FLOW VALVE SOLENOID TWO POSITION TWO WAY DUMP VALVE FILTER SCREEN P nd HOSE LIFT CYLINDER MANIFOLD EXTEND HOSE ENDHEAD POSITION TWO WAY DUMP VALVE ADJ RELIEF VALVE CHECK VALVE MOTOR FILTER SCREEN TANK 2792491 A Figure 3 5 Hydraulic Schematic SP Series 3120775 JLG Lift 3 7 SECTION 3 TROUBLESHOOTING 4933188 C SPIRAL CABLE REQ D ON 12 FT MODEL BLACK WHITE BECOMES ORANGE 15 ORANGE LACK WHITE om PLATFORM CONTROL BOX 16 5 CABLE PLATFORM uM 5 RED m OPTIONAL oo EE FOOT PEDAL CONTROL LIFT e lt late WHITE d ai i BLK WHT i WHITE RED RED ENABLE AUXILLARY 94 0 LOWERING eo RED m RED RED 2 WHITE LIFT DOWN GREEN o GREEN GREEN x aa
10. 1 1 2 1 7 CYLINDER SPECIFICATIONS d cR nate deed dare xoc Sack Rx 1 2 1 8 SERIAL NUMBER 8 2 2 1 2 SECTION 2 SERVICE PROCEDURES 2 1 MACHINE PREPARATION INSPECTION AND 2 1 Generali ine Ae i rm ewe e dee eg eg t 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection Dm 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 2 1 Preventative 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 2 3 SERVICING AND MAINTENANCE GUIDELINES 1 2 4 General 44 Foes orbes p o teste eoi RO E Red 2 4 Safety and Workmanship 2 4 ets PP 2 4 Components Removal and 1 2 4 Component Disassembly and Reassembly 2 4 Pressure Fit Parts oe detecte dan Rt adde ATP A anita 2 4 amp M uL 2 4 CC IET 2 4 Bolt Usage and Torque Application 2 5 Hydraulic Lines and Electrical Wirin
11. GREEN 86 85 BLUE 9 GREEN B ej ST lt 2 GREEN m a E S S 2 5 GATE ALARM STARTER FUSE RELAY RELAY 81A 087 GREEN GREEN C 869 985 ORANGE 30 ORANGE PUMP MOTOR RED RED RED RED a a S a a 22 H GREEN 8 E rr 5 BLACK CHARGER RED B B 12VDC BATTERY NOTE THIS SHEET 15 BE USED FOR THE FLOOR BRAKE GATE ALARM OPTION Figure 3 7 Electrical Diagram With Floor Brake Gate Alarm Option Lift 3 11 SECTION 3 TROUBLESHOOTING 27 NOTES 3 12 JLG Lift 3120775 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemical known to the State of Califormia to cause cancer and reproductive harm WASH HANDS AFTER HANDLING An Oshkosh Corporation Company JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 461265811111 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 717 485 6417 JLG Industries UK L
12. JLG Lift c Check mast section for side play If play exists add 015 shims dividing the thickness equally between both sides of mast Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side d When mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be snug in channels but still be able to slide in channel by hand Insert slide pads into the slide pad channels top of mast between section 1 and 2 one on each side of the mast with beveled surface facing in towards section 2 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 1 outside rail top of mast and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly If hydraulic cylinder needs to be extended the pro tective caps on the extend and return ports will need to be temporarily removed Be careful not to nick or scour rod surface when extending also catch any oil draining out of cylinder to avoid spillage onto work area Locate the hydraulic lift cylinder slide the lift cylinder into the closed rail side of
13. 2 1 3 3 3 3 Continuity 3 4 3 4 Current Measurement 3 4 3 5 Hydraulic Schematic SP 3 7 3 6 Electrical Diagram 2 3 8 3 7 Electrical Diagram With Floor Brake Gate Alarm 3 10 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Hydraulic Oil Operating 1 2 1 2 Lubrication 1 2 1 3 Cylinder Specifications 2 1 2 1 4 Lubrication Intervals for Various 1 3 2 1 Inspection and 2 2 2 2 Preventive Maintenance amp Inspection Schedule 2 3 2 3 Chain Stretch Tolerances 3 ies oOo deen ve Ga a ee he Age a d dues 2 5 2 4 AM Series Mast Component Features 2 20 3 1 DC Unit Troubleshooting e men 3 6 3120775 JLG Lift iii TABLE OF CONTENTS 27 NOTES
14. SERVICE PROCEDURES SECTION 2 SERVICE PROCEDURES 21 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspec tions and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for further requirements for aerial work platforms The fre quency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Freque
15. b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 5 If the switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise Ifthe switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Induc tive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing fac
16. os 0089 lt 90 0 PI 05 0828 99 Sb 05 0062 OF Ze SZ 0099 8 800 Pe gre 0644 05 Or Sp 0002 9 8 ez oe 94100 9i 2 0085 0 02 ez 0225 12 LL 0022 08900 HO Gz Ovzs 0 8 SZ Oct 6 9L l 1 2900 114781 14781 13 81 13 81 14 91 14 81 13 81 13 81 Or 58 00 89i 9 00 040 7900 2220 86 y L O9 800 vv 092 S0 c 96 0202 87200 02 is 89 000 986 000000 20 ZE 09 ol 029 094100 24 0 g le 006 29100 molo 8 g ly zZz 0 006 00 00 Ze Sz 06 8l 09 81000 _97 Em 08 9L 085 606000 o BL o9 4 6 0 199000 ozo 6 2 05 9 8 086 09000 Or 13 81 1 NI 871 NI 81 NI 81 NI 7871 NI 97 NI 83 NI 97 5 sey 41 102 252 2 21 81 292 230 CID 6 0 01 40 19 311901 97 080 wowma QVOl anoHor ssayis 325 nog E TE 51108 avs 51108 HL 5 438925 dV daaividNf KINO 61108 134114 INIZ SINIYA 1 4 SECTION 2
17. 21 21 21 ANSI and EMI Manuals Handbooks Installed 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 22 General Structural Condition and Welds 2 4 2 4 All Fasteners Pins Shields and Covers 1 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 22 Paint and Appearance 7 7 Stamp Inspection Date on Frame 22 Notify JLG of Machine Ownership 22 Drain and Refill with fresh hydraulic fluid every two years Footnotes 11 Check for proper fluid level Prior to use each day or at each Operator change 2 Prior to each sale lease or delivery 3 In service for 3 months or Out of service for 3 months or more or Purchased used 4 Annually no later than 13 months from the date of the prior inspection 16 17 Inspection and Maintenance Codes age 1 Check for proper and secure installation 19 2 Visual inspection for damage cracks distortion or 20 excessive wear 3 Check for proper adjustment 21 4 Check for cracked or broken welds 22 5 Operates properly 23 6 Returns to neutral or off position when released 24 7 Clean and free of debris e 8 Interlocks function properly 9 Check signs of leakage 10 Decals installed and legible 2 4 J
18. 3 into the opening between mast section 3 4 and mast section 4 5 Slide the threaded ends through the holes in bottom chain anchor plate located on bottom of mast section 4 5 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Slide mast section 4 5 back into mast section 3 4 until bottom ends of masts are even Check to make sure chain set attached to top of section 2 3 is seat ing properly in cable sheave wheels attached to top of mast section 3 4 Mast section 2 3 may need to be restrained to keep it s slide pads from pushing out the bottom of mast sections 1 2 Adjust top and bottom ends of mast sections so they are all even with each other At bottom of mast assembly thread all chain adjusting nuts on threaded ends until they are snug against the bot tom anchor plates and all slack is removed from chains Check that chains are seated in their sheave wheels at top of mast assembly Assemble the mini covers to the top of each mast section and the sequencing cables and hardware to the side of the mast assembly Mast assembly should now be complete 2 10 MAST TO BASE FRAME INSTALLATION 1 JLG Lift Using an overhead crane or suitable lifting device capable of supporting the weight of base frame attach a sling strap or chain to the front crossmem ber of the base frame raise base frame Extend hydraulic cylinder out from bottom of mast assembly ap
19. CHARGER IF MACHINE IS STILL UNDER WARRANTY OPENING THE BAT TERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER FROM THE FACTORY ALSO BEFORE REPLACING ANY COMPONENT USE THE CHARGER MANUFACTURERS SCR BATTERY CHARGER MAN UAL INCLUDED WITH THE MACHINE FOR CHECKING THE INTER NAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT HAS FAILED COMPLETE WIRING DIAGRAMS PERTAINING TO YOUR MODEL CHARGER ARE ALSO INCLUDED IN THE MANU FACTURERS SCR BATTERY CHARGER MANUAL The AM Series dual AC input battery charger allows for replacement of the following internal components Con sult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department Transformer Printed Circuit Board Shunt Assembly Interlock Relay SCR Rectifier AC Circuit Breaker DC Circuit Breaker Replacement and troubleshooting of these components requires removal of the battery charger from it s mounting on the charger battery box assembly 3120775 Battery Charger Removal 1 If plugged in unplug the AC voltage cord from AC receptacle and remove the charger battery box unit from the machine 2 Disconnect the RED and BLACK charging wires from the charger to the battery terminals in the lower battery compartment 3 Remove the four 4 mounting bolts and washers located on the back of the up
20. If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends changing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contaminants from the service container While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well asa functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to table in Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 3120775 SECTION 2 SERVICE PROCEDURES 2 5 BATTERY CHARGER ASSEMBLY AND DISASSEMBLY General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY
21. determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recom mended for the measurements in these procedures This section shows diagrams of a common digital VOM con figured for several different circuit measurements Instruc tions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connec tor is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this tech nique especially on sealed connectors Whenever possi ble insert probes int
22. i BLUE 5 lt GREEN 8 12 3 CABLE YEL 5 5 5 d E lu BASE FOOT BRAKE INTERLOCK Mo Ep BRAKES DEPRESSED Fl B F 5 E 13 No Qu No Qi m 5 Q NC ge 9 NC ge Dc xn RED BLUE 2 BLUE 1 GREEN 2 GREEN 1 BEACON BLACK DESENT ALARM Figure 3 6 Electrical Diagram Standard 3 8 JLG Lift 3120775 SECTION 3 TROUBLESHOOTING AIC OUTLET BON 5 5 ry le ale 12 3 CABLE en SPIRAL SPIRAL BLACK L I NE GOLD JINCTION WHITE NEUTRAL SILVER GREEN GROUND GREEN BLK MHT i OPTINAL i AUXILLARY a LOWERING gt 1 Jie EMERGENCY i i STOP MC DTE 1 6 07 RED om 01 i WHITE o TUNES GROUND CONTROL ______ i amp E TERLOCK ORANGE LA RELAY 87A 86 85 GREEN 30 LIFT DOWN LIFT VALVE uP m DUMP 5 VALVE BLUE GREEK E GREEN 5 YEL E e 5 AMP _ h GREEN ORANGE ORANGE 1 PUMP MOTOR RED n SEE SH
23. lt 0912 0 6 OOSSIL 4090 706 08 4 0860 000v0L 408 lt 06 OOLL 097 00 79 055 g 088 00220 000404 019 005 00004 00996 006 still 006 Ovcl 00969 0220 0052 e 0921 00696 0002 096 081 00228 928 600 0 8 00 0 00866 06960 4 082 00958 929 990 080 00047 896 208 099 088 00927 0998 0 05211 3120775 Figure 1 2 Torque Chart JLG Lift 0 1 00292 00 020 096 08007 00 89 078 009 008 006009 069 0 1 8VvV 516 0099 964 OP 000 006 SEL 9 OES 00 004 0990 9 00 598 00909 066 489 089 006 00015 579 6 5 08 00 00986 09090 8 Seg 00608 5227 vtS 009 099 0089 OZS OSE 0 7 00 6 06050 2 40 0000 099 0927 009 009 60 gt 986 006 00760 02980 6 00 004 GO oee oze ozr 00986 oee 898 ozz oos 0088 06220 2 0 9b pe 00 106 082 086 00106 Sez Ore 002 092 00610 0 60 OL 022 00952 592 vOZ 08 0 0002 06 Sk 02 00891 095020 pego 80 ge 0 2 00922 OvZ 08 01 002 05604 SOL SEL 00 OSL 00 09220 W 0002 061 064 00 0628 60 06 002 09601 00000 2920 BL 0028 590 00 00 00 OcL 86 08 OLL 009I 08 0 2 0666 901 06 02 OOL 08 S9 06 00 0 66910 ogogo 04 2 06 020 96 08 0522 98 99 SG G4 0506 6LvLO Sn 028 06 04 09 08 00 0 09 05 Or SS 0662 2840 0 a 04 Oc900 08 9 SG OL 0556 99 Sp
24. mast section chain cable set Also to step each front mast sec tion up approximately 1 4 in 7mm from the section behind it to allow clearance for the individual mast section covers Adjust using the following procedure 1 NOTE With mast retracted step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel Be certain all chain cable sets are seated in their sheaves prop erly at the top of each mast section Then with no load in the platform check the side pro file of the top of the mast for the amount of adjust ment necessary to obtain the 1 4 in 7mm step for mast sections 3 and up See Figure 2 6 Mast section 1 is fixed to the base and mast section 2 is attached to the lift cylinder these sections require no adjustment Adjust one mast section at a time starting from the back section 8 section 4 etc of the mast and work forward i e if three is OK then jump to four etc To adjust elevate the platform until the chain cable anchor adjust nuts are accessible at the front and bottom of each mast section A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING 5 NOTE JLG Lift Start with the mast section which needs adjustment and loosen the bottom jam nut on each chain cable Tighten to raise mast section or loosen to lower m
25. performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply The design and manufacturing tolerances of the compo nent working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and gener ally results in faulty operation Every precaution must be 2 8 JLG Lift taken to keep hydraulic oil clean including reserve oil in storage Cloudy oils indicate a high moisture content which per mits organic growth resulting in oxidation or corrosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wear in of meshing compo nents Hydraulic Oil For best performance JLG recommends the use of ISO Vg grade 32 46 oil with a viscosity range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 7 for recommended hydraulic oils Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis
26. same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommenda tions Table 1 1 Hydraulic Oil Operating Range HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 0 F to 180 F 10W 18 C to 483 C 40 F to 210 F 10W 20 10W 30 18 C to 99 C 450 F to 4210 F 20W 20 410 C to 99 C Lubrication Specifications Table 1 2 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil ISO Vg grade 32 46 CL ChainLube Use a good quality chain lubricant 1 6 HYDRAULIC PRESSURE ADJUSTMENT See Table 1 1 Adjust system pressure so that platform will raise with rated capacity in platform Turning adjustment screw clockwise increases system pressure turning screw counterclockwise decreases system pressure Do not adjust system pressure higher than required to raise maximum rated load capacity Make pressure adjust ment with oil at normal operating temperature If pressure is set when oil is cold platform may not raise rated load after oil has war
27. 0 659 500 El 446 0 850 659 534
28. 5SP Lift up 30 seconds Lift down 18 to 25 seconds Timed with maximum rated load 500 Ib Machine Weight With Standard Platform 12SP 1 180 Ibs 535 kg 15SP 1 240 Ibs 563 kg Machine Height Platform Stowed 12SP amp 15SP 78 in 1 9 m Maximum Platform Height Mast Fully Extended 12SP 11 ft 7 in 3 53 m 15SP 15 ft 2 in 4 62 m Maximum Working Height Average Person 12SP 18 ft 5 4 m 15SP 21 ft 6 4 m Machine Overall Width And Length Stowed 12SP 34 in W x 73 in L 86 cm x 185 155 34 in W x 75 5 in L 86 cm x 192 cm Length includes platform and battery pack end to end 1 4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the Torque Chart Table 1 2 to deter mine proper torque value JLG Lift 1 1 SECTION 1 SPECIFICATIONS 1 5 LUBRICATION Hydraulic Oil Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 For cold weather applications i e when temperatures remain consistently below 20 F 7 C JLG recom mends using Mobil DTE 13 hydraulic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not con tain the
29. AINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR 3120775 HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir Pressure feed lines to system compo nents can then be disconnected with minimal fluid loss MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON NEL INJURY OR DEATH AND IS A SAFETY VIOLATION REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL DANGER WARNING CAU TION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATT
30. EE An Oshkosh Corporation Company Service and Maintenance Manual Model 12SP 15SP 3120775 March 17 2008 JL LBS NOTES FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose It is important to over stress proper machine usage All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL Keep it with the machine REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER ATING PERSONNEL ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTERATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES PER OSHA REGULATIONS THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED Safety of personnel and proper use of the machine are of prima
31. EET 2 FOR RELAY FLOOR BRAKE GATE ALARM OPTION WIRING BATTERY BLACK 01715 Tu CHARGER RED BAT CBL ES UJ 2 BAT CBL aa ee 12700 BATTERY 4933188_C Figure 3 6 Electrical Diagram Standard 3120775 JLG Lift SECTION 3 TROUBLESHOOTING 4933188 C 2 SPIRAL CABLE ON 12 FT MODEL GATE SWITCHES BLACK WHITE BECOMES ORANGE e e e e PLATFORM CONTROL BOX REF 125 THIS WIRE 15 ORANGE 155 THIS WIRE 15 BLACK WHITE Lig ORANGE i i 16 5 CABLE RED 212 PLATFORM 10 pem 5 Pod RED i e eo 5222 ecen FOOT PEDAL CONTROL 9 5 LIFT LIFT i BIET AM i ere WHITE PN BLK WHT WHITE RED ENABLE Calip p du REDE E E i RED WHITE LIFT DOWN i i i e o 9 GREEN GREEN a SS aS I irre BLUE _ 12 3 CABLE a GREEN B _ ____ __ o zi a a a ee ee ee ere E
32. ERHEAD SLING Cleanliness The most important single item in preserving the long ser vice life of a machine is to keep dirt and foreign materials out of the vital components Precautions have been taken to safeguard against this Shields covers seals and fil ters are provided to keep the wheel bearings mast sec tions and oil supply clean however these items must be maintained on a scheduled basis in order to function properly At any time when oil lines are disconnected clear adja cent areas as well as the openings and fittings them selves As soon as a line or component is disconnected cap or cover all openings to prevent entry of foreign mat ter Clean and inspect all parts during servicing or mainte nance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their containers until they are ready to be used 3120775 Components Removal and Installation Use adjustable lifting devices whenever possible if mechanical assistance is required slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an eyebolt or sim ilar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degree
33. ERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a EFFECTIVITY PAGE EFFECTIVITY CHANGES June 2 1999 Original Issue of Manual March 7 2000 Manual Revised added CSA Latin America Specifications April 13 2000 Manual Revised added 12SP Model April 25 2000 Manual Revised corrected Mast Disassembly Assembly Section 2 November 22 2000 Manual Revised Pages Affected Section 2 Pages 2 4 through 2 19 January 25 2001 Manual Revised Pages Affected Section 2 Page 2 14 and 2 15 January 16 2002 Manual Revised January 20 2006 Manual Revised July 10 2006 Manual Revised March 17 2008 Manual Revised b JLG Lift 3120775 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO MAINTENANCE SAFETY 6 a General D does e AR oe idol Hydraulic System 2 0 Maintenance a rei EE CE CAR EFFEGCTIVITY CHANGES etie ded terea rack e ae basse Ne Tear eed b SECTION 1 SPECIFICATIONS 1 1 GAPAGITIES ub ee iue dine uet
34. LG Lift 12 13 14 15 Check for chafing and proper routing Check for proper tolerances Properly lubricated Torqued to proper specification No gouges excessive wear or cords showing Properly inflated and seated around rim Proper and authorized components Fully charged No loose connections corrosion or abrasions Verify Perform Sealed properly Overrides Platform controls Inspected per Service and Maintenance Manual 3120775 SECTION 2 SERVICE PROCEDURES 2 3 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that ade quate support is provided A WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OV
35. LG equipment mechanic as a person who has successfully completed the JLG Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropri ate JLG inspection form for performance of this inspec tion Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference Table 2 2 Preventive Maintenance amp Inspection Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as envir
36. PECTION AND REBUILD 2 17 Cylinder 1 424 1 2 17 Cylinder Disassembly 2 17 Lift Cylinder Component 2 17 Cylinder 2 2 19 eei e ESL ahh Erat Ape tu docere 2 19 2 8 MAST ASSEMBLY AND DISASSEMBLY 5 2 20 Mast Disassembly 2 20 Platform Section 1 2 20 Mast Section 4 2 21 Mast Section 3 2 21 Mast Section 2 2 21 Mast Section 1 Disassembly 2 21 2 9 MAST ASSEMBLY uro MEER RES eU ek ur eR 2 22 Mast Section 1 Assembly 2 22 Mast Section 2 Assembly 2 22 Mast Section 3 Assembly 2 26 Mast Section 4 Assembly 2 27 Platform Mounting Section
37. SECTION 2 SERVICE PROCEDURES Clamp Installation Drum Socket Type THE MANUFACTURER OF THE DRUM SOCKET CLAMP MENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT JLG P N 7023275 TO ASSEMBLE THE CLAMP TO THE WIRE ROPE THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING ASSEMBLY NOTE The tools in the clamp assembly kit may be frabri cated if necessary The vise clamp consists of vise jaws with a hole 1 32 in smaller than the diameter of the wire rope you are working with i e 1 8 in rope 3 32 in hole The plug driver is a metal tube with a hole in the bot tom to allow the strands of the wire rope to be shaped after the plug has been tapped into the cen ter of the wire rope 1 Using the recommended vise jaws clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws CABLE RECOMMENDED VISE JAWS MARK ON CABLE 2 Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made made on the wire rope SLEEVE INSTALLED 3120775 JLG Lift 3 Usea suitable tool and cut the cable as shown in the illustration following For 1 8 in cable the recom mended length is 5 8 in past the end of the sleeve
38. SHOOTING Continuity Measurement Current Measurement L wy Figure 3 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity 3 4 JLG Lift Figure 3 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected e f meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads 3120775 SECTION 3 TROUBLESHOOTING 3120775 3 5 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 De energize the circuit 2 Isolate the switch from the rest of the circuit if possi ble If not possible keep in mind it may affect read ings 3 Access the terminals to the switch 4 If the switch has two terminals a Measure resistance across the terminals
39. TION 2 SERVICE PROCEDURES 15 16 17 18 19 20 ft Ibs Align the hole in the mounting journal with the hole in the cylinder and Install the 1 5 16 bolt New Design Cylinder Install the mounting pin through the side mounting brackets and the cylinder valve body and through the mounting brackets on the other side of the mast Install the snap rings to each end of the mounting pin Slide the chain anchor block onto the cylinder rod end at the top of the lift cylinder Locate the narrow chain assembly set single anchor plate with two narrow chains Lay out chain assembly with anchor plate end towards mast be certain floor surface is clean and free of any metal chip or debris which may Stick to lubricated chains or lay chains in a clean bucket Align the holes in the cylinder rod the chain anchor block and chain anchor plate and slide the attach pin through all secure pin with snap ring Slide mast section 2 out of mast section 1 approxi mately one foot Assemble chain sheaves on chain assembly anchor block attached to cylinder rod end and attach to mast section 2 using following steps a Insert sheave pin through anchor block on cylin der rod end b Place sheave wheels for wide chain on sheave pin one each side of anchor block c On outside of each sheave wheel place a sheave pin attach bar rectangular plate with threaded holes on each side of pin bore hole d Slide the whole a
40. ach bars with holes in mast rails e Attach to top of mast section 4 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 into section 3 until ends are even Check to make sure chain assembly narrow chains are seating properly in chain anchor block chain sheave wheels attached to mast sec tion 3 Insert slide pads into the top end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing inward towards section 4 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 3 and 4 one on each side of the mast with beveled surface facing out towards sec tion 3 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt
41. ains if a section of chain is damaged replace the entire chain set L 5 of H H for a 1 chain 0 950 Maximum wear 5 of 0 950 0 047 Minimum plate depth 0 950 0 047 0 903 Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate crack ing The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease chains At time of chain installa tion factory lube must be supplemented by a mainte nance program to provide a film of oil on the chains at all times If chains are corroded they must be inspected especially the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Table 2 3 Chain Stretch Tolerance Pin to Pin Chain Size Allowable Stretch 50 pitch 12 or 24 pitches 24 in 12 in span 625 pitch 15 or 24 pitches 301 15 in span Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the pin in line position Inspect chains carefully after long time use and heavy
42. ast section the adjusting nut against the anchor plate on each chain cable Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 2 6 when the mast is retracted It is more important that the threaded ends studs protruding on the adjustments are equal side to side on a mast section than it is that the tension in the chains is equal The chain equalizers will always assure equal tension but if the adjustment isn t equal as described the chains may tend 1o pull to 3120775 SECTION 2 SERVICE PROCEDURES MAST SIDE PROFILE MAST CHAIN CABLE ADJUSTERS I STEP APPROXIMATELY 1 4in 7
43. at the pump is serviceable then a sys tematic check of the circuit components would follow NOTE For aid in troubleshooting refer to Figure 3 5 for HYDRAULIC DIAGRAM circuit 3 4 ELECTRICAL SYSTEM MULTIMETER 3 2 TROUBLESHOOTING INFORMATION 3120775 The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 3 1 DC Unit Troubleshooting Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the remedial action should where possi ble be checked in the order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to
44. d also be adjusted to eliminate twisting the chain for an even load distribution Inspect the sheaves sheave bearings sheave grooves and pins for extreme wear replace as necessary A worn sheave can mean several problems as follows a Chains too tight b Sheave bearings pin bad c Bent misaligned chains Mast Cable Inspection Procedure NOTICE MAST CABLES ARE TO BE INSPECTED EVERY THREE MONTHS OR MORE FREQUENTLY AS DESCRIBED FOLLOWING A CAUTION WEAR PROTECTIVE GLOVES TO PROTECT HANDS WHEN HAN DLING CABLE The periodic inspection shall cover the entire length of the cable The inspection frequency shall be based on such factors as expected cable life as determined by experi ence on the particular application or similar installations severity of environment percentage of capacity lifts fre quency rates of operation and exposure to shock loads Inspection should be more frequent as cables approach the end of their useful lives Only the surface wires of the cable require inspection do not attempt to open the cable Any deterioration resulting in any loss of original strength such as described below JLG Lift 2 7 SECTION 2 SERVICE PROCEDURES shall be noted and then a determination made if further use would constitute a hazard Mast cables must be replaced after machine has been in service for five 5 years regardless of cable condition or sooner if conditions dictate Conditions such as the fol
45. d aluminum protected with an anodized surface finish The mast sections rails are interlocked into each other when assembled and are guided by slide pads mounted at the top and bottom of the rails on both sides of the mast section The current SP model mast assemblies have been designed with four 4 and five 5 mast sections Table 2 4 AM Series Mast Component Features Model of Mast Extend Device Sections 125 4 Chain 15SP 5 Chain When assembing mast sections carefully slide the mast sections together from bottom until mast ends are even when sliding mast sections together be careful not to scratch the anodized surface in the slide pad channels Assemble the hardware to the bottom of mast section first then slide this section out the top of previous section and assemble hardware to the top of mast See Figure 2 2 Always install slide pad shims with slide pads inserted into the slide pad channels ends of mast sections even NOTE The following procedures are used for both the four 4 and five 5 section masts When referring to the mast sections in these procedures a split mast sec tion number like 4 5 will refer to either section 4 or section 5 depending on which applies to your mast assembly See Figure 2 3 amp Figure 2 4 Mast Disassembly Procedure See Figure 2 2 1 After the platform and other hardware have been removed from the mast and mast has been removed from machine
46. e cable and engage the threads of the sleeve with the socket Tighten until four threads or fewer are visible If more than four threads are visi ble proof load the cable and retighten the socket fit ting There is no specific requirement for torque INSPECTION INSTALL HOLE SOCKET AND TIGHTEN FOUR THREADS OR LESS SHOWING Inspect for proper assembly prior to loading the cable Strands visible through the inspection hole are your assurance of a proper assembly The end of the rope may not be visible in the inspec tion hole after loading Install cable on machine and adjust per instructions shown previously in Section 2 11 MAST CHAINS CABLES AND SEQUENCING CABLES ADJUST MENT 3120775 SECTION 3 TROUBLESHOOTING SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 3 3 HYDRAULIC CIRCUIT CHECKS The first reference for improper function of a hydraulic sys tem where the cause is not immediately apparent should be the Hydraulic Diagram Circuit The best place to begin the problem analysis is at the power source pump Once it is determined th
47. e where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows Remove prox switch from its mount 2 Reconnect harness if it was disconnected for step 1 and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehicle or control system documenta tion on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to fol low mounting instructions and properly set the gap between the switch and object sensed Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pres sure for example to the switch These switches may need to be energized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Ana lyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or temp
48. ection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine 3120775 SECTION 2 SERVICE PROCEDURES Table 2 2 Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START 1 3 MONTH 6 MONTH PRE DELIVERY 2 ANNUAL 4 INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT 3 YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION MAST ASSEMBLY 7 Mast Sections 2 5 2 5 Chain Systems 14 3 14 14 25 Sequence Cable Systems 3 1 2 3 Cove
49. era ture for example The state indicated in the control system should change Switch Wiring Low Side High Side When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can measure the voltage at both power ter minals with respect to battery ground The difference between those two measurements is the voltage applied to the load JLG Lift 3 5 SECTION 3 TROUBLESHOOTING Table 3 1 DC Unit Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform does notrise Power source is OFF or unplugged Check power source or Ground Station Ke
50. f a harness or wire longer than the reach of standard instrument leads is possible to perform the check without excessively long leads Using the other wires in the harness one can deter mine the condition of a particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity 3 2 JLG Lift Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accu rate measurement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not completely isolated disconnect battery terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 On one side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuit
51. g 2 5 Hydraulic System ER ER DICE ORC LAORE dn 2 5 Lubrication and Servicing 2 5 Batteries eec Ree BPE pee Sea ee eS 2 5 Mast Chain Inspection 2 5 Mast Cable Inspection 2 6 3120775 JLG Lift TABLE OF CONTENTS 2 4 LUBRICATION 2 7 Hydraulic System 5 pe Bie dads Ha fone LICHE TERRENAE URS Rn 2 7 Hydraulic Oil v dal bah ewes oe be RS ur pb PME SV EP qu 2 7 Changing Hydraulic 1 2 7 Lubrication Specifications 2 2 7 2 5 BATTERY CHARGER ASSEMBLY AND 5 2 8 General e 2 8 Battery Charger Removal 2 8 Gover REMOVAL a on ettari ete S n Rr vB E LR edt e FUE APR RUN re 2 8 Transformer 2 9 Printed Circuit Board 2 9 DC Circuit Breaker Replacement 2 9 AC Circuit Breaker and Voltage Selection S
52. ge Hyd Oil after every 1200 Reservoir Hyd Oil hrs of operation 2 SwivelRaceways 2 FrontCasters MPG Pressure Gun v 3 MastChains 2 PerSection CL Brush or Spray v Inspect lubricate if dry or rusting Applies Only to MastSections with Chains Keyto Lubricants MPG Multipurpose Grease HO Hydraulic Oil ISO Vg grade 32 46 CL Chain Lube Use a good quality chain lubricant Notes 1 Becertainto lubricate like items on each side of the machine 2 Recommended lubricating intervals are based on normal use If machine is subjected to severe operating conditions such as a high number of cycles location corrosive dirty environment etc user must adjust lubricating requirements accordingly 3 Lubricating intervals are calculated on 50 hours of machine operation a week 4 Prior to checking hydraulic oil level operate machine through one complete cycle of lift function full up and down Failure to do so will result in incorrect oil level reading on the hydraulic reservoir 3120775 JLG Lift 1 3 SECTION 1 SPECIFICATIONS 8 9 AVS AVS s1euajse oj Ajdde op 3 0N 0465 00086 9262 0992 0956 00007 0066 v246L Ov9L 00046 00228 0089 00 oroe 00S0vL 6 76 0292 0922 09 5 00992 9202 992 09 076 00087 090 9 Ortz OOSLEL 000 59 6 070 0226 00 8 06 1 906 092 0891 000
53. h can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated Stress Corrosion Cracking The outside link plates which are heavily press fitted to the pins are particularly susceptible to stress corrosion cracking Like fatigue cracks these initiate at the point of highest stress aper ture but tend to extend in an arc like path often parallel to the rolling grain of the material ABNORMAL PROTRUSION OR TURNED PINS e Also more then one crack can often appear on a link plate In addition to rusting this condition can be caused by exposure to an acidic or caustic medium or atmo sphere Stress corrosion is an environmentally assisted failure Two conditions must be present corrosive agent and static stress ARC LIKE CRACKED PLATES STRESS CORROSION In the chain static stress is present at the aperture due to the press fit pin No cycle motion is required and the plates can crack during idle periods The reactions of many chemical agents such as battery acid fumes with hardened metals liberate hydrogen which attacks and weakens the metal grain structure Chain Anchors and Sheaves An inspection of the chain must include a close examination of chain anchors and sheaves Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They shoul
54. he piston should be replaced Lift Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unacceptable condition occurs the tube assembly should be repaired or replaced 2 19 SECTION 2 SERVICE PROCEDURES Cylinder Assembly See Figure 2 1 1 NOTE 2 20 Rinse the inside of the tube with hydraulic fluid and allow to drain A high pressure rinse followed by a wipe with a lint free rag is preferable Clean all inter nal components of any foreign material Lubricate the head and all seals with hydraulic fluid prior to installation Install the seal wiper o ring back up ring and retraining ring to the cylinder head Lubricate the piston and all components with hydraulic fluid Install the seal and wear ring to the piston Re check that seals are not twisted or pinched and are properly seated Place the rod on a clean table Install the static o ring seal into the groove on the piston end of the rod Install the head followed by the piston onto the rod noting the pro
55. ightened New Design Cylinder Mount Install the cylinder mounting plates at the bottom of the mast section 1 Mount plates two each side using the the 2 two long pass through bolts and nuts apply Loctite 242 to the bolt threads before tightening nuts Original Design Cylinder Clamp the cylinder in the mounting journal of the cylinder mount Apply Loc tite 242 to the journal bolt threads and torque to 85 ft Ibs Align the hole in the mounting journal with the hole in the cylinder and Install the 1 5 16 bolt New Design Cylinder Install the mounting pin through the side mounting brackets and the cylinder valve body and through the mounting brackets on the other side of the mast Install the snap rings to each end of the mounting pin Connect the hydraulic fittings and lines new fittings should be used Slide the mast together stowed position from the top of the mast Stand machine upright on it s base wheels Connect the hydraulic line fittings at the pump Check oil level in the hydraulic oil reservoir add oil to fill line if necessary Install the ground station pump cover Set up machine for operation and cycle mast up and down approximately 3 ft to 4 ft a few times Check the hydraulic oil reservoir again add oil to the fill line 3120775 SECTION 2 SERVICE PROCEDURES 2 8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The SP Series personnel lift mast sections are contructed of extrude
56. ing two 2 3 8 16UNC x 2 1 2 long hex head bolts flatwashers and nuts for each attach block Place a flatwasher under bolt head and nut Mast Section 2 Assembly NOTE NOTE 3120775 When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Locate mast section 2 carefully slide mast section 2 closed rail into section 1 open rail Slide sections together until ends are even Insert slide pads into the slide pad channels at bot tom end of mast between section 1 and 2 one on each side of the mast with beveled surface facing out towards section 1 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in mast section 2 inside rail into the slide pad inserts Thread in enough to hold pad in place Shim slide pads using the following steps Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the mast section a Start with a 036 thick shim and a 075 thick shim per side at each slide pad b Slide shims into place between slide pad and mast rail Tighten the slide pad mounting bolts be sure there are no air gaps between shims shim and mast or shim and slide pad when tight ened NOTE 10 NOTE 11 12 13 14
57. iper rod seals looking particulary for metallic particles embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and backup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the 3120775 SECTION 2 SERVICE PROCEDURES RETAINING RING GROOVE WEAR RING CYLINDER TUBE ASSEMBLY LOCKNUT Torque 175 200 Ft Lb PISTON WHEN ASSEMBLING CYLINDER APPLY ANTI SEIZE COMPOUND AROUND THE HEAD HEAD IN THIS AREA ONLY PISTON SEAL CYLINDER HEAD O RING RETAINING RING BACKUP O RING RING 3120775 Figure 2 1 Lift Cylinder Internal Component Assembly Cross Section event that an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs t
58. lay mast assembly down with the shortest mast section 4 5 on TOP and fac ing up 2 Remove the sequencing retract cables from sides of mast assembly the chain guard and the mini covers from the top of each mast section Platform Section Removal 3 Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 4 5 short platform mount ing section Push threaded ends of chain through anchor plate 4 At TOP of mast section 4 5 pull chains out and allow to hang loose gt CLOSED RAIL REFERS TO CLOSED RAIL BACK OF MAST SECTION OPEN RAIL REFERS TO OPEN RAIL p FRONT OF MAST SECTION ZZ mid REFERS TO TOP END OF MAST SECTION END WITH COVER AND SHEAVE WHEELS ATTACHED BOTTOM BOTTOM END OF MAST SECTION END WHICH SETS AT MACHINES BASE FRAME Figure 2 2 Mast Section Assembly Disassembly Reference 3120775 JLG Lift 2 21 SECTION 2 SERVICE PROCEDURES NOTE When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide short mast section 4 5 out BOTTOM of mast section 3 4 rails Disassemble slide pads shims and cable anchor plate from mast section 4 5 if necessary Mast Section 4 Removal NOTE NOTE 10 Mast 11 12 13 14 2 22 Steps 6 through 10 will be used only for five 5 sec ti
59. lly slide the head rod piston assembly out of the cylinder tube A gentle tap on the head assembly may be required to remove the head from the cylin der tube 5 Place the head rod piston assembly on a surface that will not damage the chrome 6 Remove the piston locknut and separate the piston from the rod 7 Slide the head off the rod from the piston end NOTE When removing the old seals use only blunt tools be sure there are no sharp edges that may damage the seal grooves during removal Scratching the groove may cause by pass 8 Remove and discard all old seals Lift Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals w
60. loading for this type of crack If any cracks are dis covered replace all chains as seemingly sound plates 2 6 JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES 3120775 are on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lift ing capacity of these chains Tight Joints All joints in the leaf chain should flex freely On leaf chain tight joints are usually caused by rust corro sion or the inside plates walking off the bushing Limber up rusty corroded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrica tion Tight joints on leaf chain are generally caused by a Bent pins or plates b Rusty joints c Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubricated TIGHT JOINTS QoS S Protruding or Turned Pins Chains operating with inade quate lube generate tremendous friction between the pin and plates pin and bushing on leaf chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins whic
61. lowing shall be sufficient reason for questioning continual use of the cable or increasing the frequency of inspection 1 In running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay 2 One outer wire broken at the point of contact with the core of the rope which has worked its way out of the rope structure and protrudes or loops out from the rope structure Additional inspection of this sec tion is required 3 Wear of one third the original diameter of outside individual wires 4 Kinking crushing birdcaging or any other damage resulting in distortion of the rope structure 5 Evidence of any heat damage from any cause 6 Reductions from nominal diameter of more than a 1 64 in 0 4mm for diameters up to and including 5 16th in 8mm NOTE A good indicator of a stretched extend retract cable is if the adjusting nuts are bottomed out If no adjust ment remains the cables have stretched and need replacement Also check for cracked bent worn severely corroded or improperly installed cable ends Inspect sheaves sheave grooves and sheave pins for excessive wear replace as necessary 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when
62. mast section 2 with rod end to top and port end to bottom of mast Cylinder should extend out of mast on both ends Return tube should be on right side when facing bottom of mast assembly Original Design Cylinder Mount Install the cylin der mount and cylinder mounting plates into the bot tom of the mast section 1 Shim to eliminate any side clearance to prevent any strain on the sides of the mast when the bolts are tightened New Design Cylinder Mount Install the cylinder mounting plates at the bottom of the mast section 1 Mount plates two each side using the the 2 two long pass through bolts and nuts apply Loctite 242 to the bolt threads before tightening nuts Original Design Cylinder Clamp the cylinder in the mounting journal of the cylinder mount Apply Loc tite 242 to the journal bolt threads and torque to 85 2 23 SECTION 2 SERVICE PROCEDURES in MS MAST SECTION 1 MAST 1 SECTION 2 i de MAST an SECTION 3 MAST SECTION 5 L DanS LIFT _ CYLINDER 2 fes ORIGINAL 4 DESIGN Ox CYLINDER SS MOUNT
63. med PRESSURE ADJUSTMENT ADJUSTMENT SCREW SCREW CAP m SHOWN REMOVED CD HYDRAULIC A OIL TANK GROUND CONTROL STATION COVER i Figure 1 1 Hydraulic Pressure Setting Adjustment Screw Located at Base of Pump Motor Remove Hex Head Cap as Shown 1 7 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent centimeters cm given in parenthe 565 Table 1 3 Cylinder Specifications DESCRIPTION BORE STROKE ROD DIA in cm in cm i 1 63 32 5 1 38 Lift Cylinder 12SP 4 1 825 ne ift 1 63 415 138 Lift Cylinder 155 4 1 1054 Es 1 8 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located on the back of the mast just above the mast support bracket In addition should the serial number plate be damaged or missing the machine serial is stamped on the mast and on the base frame JLG Lift 3120775 SECTION 1 SPECIFICATIONS Table 1 4 Lubrication Intervals for Various Components INTERVAL HOURS ITEM COMPONENT LUBE METHOD 3MOS 6MOS 1YR 2 YRS COMMENTS LUBE POINTS or or or or 150 Hrs 300 Hrs 600 Hrs 1200 Hrs 1 Hydraulic Oil Fill To Line HO Check Check Hyd Oil after every on Reservoir Hyd Oil Level v 10 hrs of operation 5 Qt 4 31 HO Change Chan
64. mm m 6 SEQUENCE CABLE al ADJUST NUT gt O amp O UM R em i e CHECK IF OVERALL HEIGHT gH OF MACHINE FROM SECTION 1 a He FLOOR TO TOP OF MAST FIXED J IS WITHIN SPECIFICATION TO BASE SECTION 2 EXTENDED BY CYLINDER SECTION 3 o oo M Hy SECTION 4 EXTENDED BY CHAIN CABLE SECTION 5 PLATFORM HEADER SECTION 5 M o E ADJUST NUT o i ote When chain adjustment is complete before JAM BUT ej 5 tightening the jam nut THREADED h SIT m qc against the adjust nut CARIE 1 apply Loctite 242 to the he EBEN Q threads under the jam nut BINE Figure 2 6 Mast Chain Cable Sequence Cable Adjustment Components Typical one side or the other were loosened Then re tighten the loosened jam The threaded end of the chain cable may need to be nuts until tight against the top adjust nut Chain restrained while tightening the adjust nut to keep the cable should have slight tension but should not be chain cable from twisting taut 10 After all mast adjustments are complete if neces sary adjust the bumpers on the underside of the stock picker platform so the platform rests slightly 8 Repeat steps 1 through 7 for remaining mast sec abo
65. moving When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 2 out BOTTOM of sec tion 1 Remove slide pads and shims if necessary Section 1 Disassembly Ail Masts Slide the TOP of the remaining mast section 1 out over edge of work surface and remove the bolts attaching the anchor blocks of the two 2 chain assemblies to mast section 1 Remove chain assem blies from mast and lay aside Remove slide pads and shims from mast section 1 is necessary Mast disassembly should now be complete JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES 2 9 MAST ASSEMBLY See Figure 2 3 Figure 2 4 amp Figure 2 5 Mast Section 1 Assembly 1 Place mast section 1 rail open side up See Figure 2 1 on a clean flat surface preferably a table or work bench capable of supporting the weight of the entire mast assembly Slide mast out over end of work surface far enough to allow access to the chain anchor attach holes at top of mast Locate the two 2 single wide chain assemblies Lay out each chain assembly with anchor block end towards mast and notched end of block down be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket Insert the block anchor end with notched end on bottom into the top of mast section 1 and secure us
66. nchor block assembly with sheave pin wheels and pin attach bars into top of mast section 2 Position anchor block with narrow chains facing up e Attach to top of mast section 2 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten Slide mast section 2 back into section 1 until end are even Mast Section 3 Assembly NOTE When sliding mast sections together be careful not 21 22 3120775 to scratch or score the anodized finish in the slide pad channels Locate mast section 3 carefully slide section 3 closed rail into section 2 open rail Slide sections together until ends are even Locate one 1 of the chain bottom anchor plates one with threaded holes horizontally aligned to out 23 24 25 26 27 NOTE 28 29 JLG Lift side of bracket Attach using outer set of holes in bottom of mast section 3 with two 2 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Slide mast section 3 approximately two feet out of the top of mast section 2 Install the triangular shaped chain upper anchor plate to the top of mast section 3 using the remain ing large pin and pin keeper Locate the remaining narrow chain set and attach them to the anchor plate just attached to the top of mast section 3 in the previous step Allow to hang out the top of mast section 3 till later Inse
67. nt Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection The Annual Machine Inspection must be performed by a qualified JLG equipment mechanic on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc recog nizes a qualified J
68. o the side of the connector such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed connec tor by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the con tact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent condi tions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down JLG Lift 3 1 SECTION 3 TROUBLESHOOTING Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the loca tion of the signal and that the leads are connected to the device under test correctly Also check that the lead on the port goes to the ground or negative side of the sig nal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 kQ 1200 Q Example 50 mA 0 05A Continuity Measurement Over Long Distances When trying to determine continuity o
69. oe a ea ii UP ee e eee onc ph a Eis 3 2 Continuity Measurement Over Long Distances 3 2 Requirements 2 lh n c RR 3 2 Procedure rodea PP EIDEM Iwate ALS potete plo UP eR dA eee 3 2 3 5 ELECTRICAL SWITCH TESTING 4 3 5 Basie Checken suain eR E Le os 3 5 Lirnit SWitclies uir Cen rw eia ote Pe Pa Pec Us peer teris 3 5 Automatic SWitCIies inciden e dos doce 3 5 Switch Wiring Low Side High 3 5 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Hydraulic Pressure Setting Adjustment Screw Located at Base of Pump Motor 1 2 1 2 Torque Chart Re iets eet oo rats 1 4 2 1 Lift Cylinder Internal Component Assembly Cross Section 2 18 2 2 Mast Section Assembly Disassembly Reference 2 20 2 3 15SP Mast Assembly Components 5 2 23 2 4 12SP Mast Assembly Components 4 2 24 2 5 Mast Chain Routing ne 2 25 2 6 Mast Chain Cable Sequence Cable Adjustment Components Typical 2 30 3 1 Voltage Measurement 1 3 3 3 2 Resistance
70. oltage Selection Switch terminals To remove the breaker or switch from the front face of the charger on the inside of the charger front face push in on the tabs located on the sides of the breaker switch assembly and remove the assembly out the front of the charger Shunt Assembly Varistor and SCR Rectifier Replacement See Illustration Shunt Assembly Item 71 1 Carefully remove the screw from the end of the shunt assembly The white insulator may need to be restrained to keep it from turning while removing the shunt assembly fasteners Also make note of the position of each washer nut and wire connector when removing for later assembly SCR Rectifier Replacement Item 2 1 2 3 Remove the wiring from the SCR Rectifier Remove the nut securing the rectifier to the insulated aluminum chassis bracket Remove the SCR Rectifier Varistor Replacement Item 3 1 Remove the fasteners securing the varistor to the aluminum angle bracket see illustration below One through the rear panel of the base with a short white spacer and one at the long white insulator attaching the shunt assembly to the bracket Remove the varistor from it s mount 3120775 JLG Lift 2 11 SECTION 2 SERVICE PROCEDURES 2 6 HYDRAULIC LIFT PUMP SERVICING Remove hydraulic pump from machine Motor Brush Installa
71. on ment severity and frequency of usage requires 3120775 JLG Lift 2 1 SECTION 2 SERVICE PROCEDURES Table 2 1 Inspection and Maintenance TYPE FREQUENCY PRIMARY RESPONSIBILITY SERVICE QUALIFICATION REFERENCE Pre Start Inspection Prior to use each day or At each Operator change User or Operator User or Operator Operator and Safety Manual Pre Delivery Inspection Prior to each sale lease or rental delivery Owner Dealer or User Qualified JLG Service and Maintenance Man Mechanic ual and applicable JLG inspec tion form Frequent Inspection In service for 3 months or 150 hours whichever comes first or Out of service for a period of more than 3 months or Pur chased used Owner Dealer or User Qualified JLG Mechanic Service and Maintenance Man ual and applicable JLG inspec tion form Annual Machine Inspection Annually no later than 13 months from the date of the prior inspection Owner Dealer or User Qualified JLG Mechanic Service and Maintenance Man ual and applicable JLG inspec tion form Preventative Maintenance Atintervals as specified in the Service and Maintenance Manual Owner Dealer or User Qualified JLG Service and Maintenance Man Mechanic ual 2 2 JLG Lift 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE See Table 2 2 The preventive maintenance and insp
72. on mast assemblies If disassembling a four 4 section mast go to step 11 Mast Section 3 Removal Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 4 Push threaded ends of cable through anchor plate At TOP of mast section 4 pull chains out and allow to hang loose be certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket Slide mast section 4 out TOP of mast section 3 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section 4 and remove sheave wheel assembly When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 4 out BOTTOM of sec tion 2 Remove slide pads shims and chain anchor plate if necessary Section 3 Removal Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOT TOM end of mast section 3 Push threaded ends of chain through anchor plate At top of mast section 3 pull chains out and allow to hang loose Slide mast section 3 out TOP of mast section 2 far enough to allow access to the chain sheave wheel assembly Remove countersunk flathead screws securing chain sheave wheel assembly attach ba
73. onents and assemblies requiring lubrication and servicing are shown on the Lubrication Chart in Section 1 Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Mast Chain Inspection Procedure Inspect mast chains for the following conditions Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the sheaves joints and plate edges very gradually wear Chain stretch can be measured using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 2 3 for proper chain specifications and allowable stretch tolerances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replacement of the chain and correction of the cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalignment of the sheave chain anchors and must be corrected promptly Do not repair ch
74. p end out of the upper anchor bracket then at the bottom end pull the cable out though the sheave pulley anchor bracket until it is completely clear of the machine Replacement Cable Installation 3 Be certain the mast is completely retacted and at the bottom of travel Check the mast Side Profile at the top of the mast as shown in Figure 2 6 adjust mast sections to proper height if necessary To determine where the clamp will be installed at the bottom of the replacement cable temporarily assemble the new replacement cable to the top cable anchor bracket on the mast using the wash ers spring spring cap and lock nut previously dis assembled Thread the lock nut on until approximately 1 8 in 3mm of threads are exposed At the bottom of the mast thread the loose end of the replacement cable through the proper sheave pulley and through the hole in the sheave pully anchor bracket on the mast section ahead of the sheave pulley Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed Use a black marker to mark the cable on the top side of the sheave pully anchor bracket This will determine where the clamp drum socket sleeve will be positioned on the cable NOTICE DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED JLG Lift 3120775
75. per battery box sec tion securing the charger into the upper section 4 Remove the charger through the front opening while pulling the charging wires RED BLACK through the hole on the bottom of the upper battery box section Cover Removal 5 Remove the ten 10 screws on the sides and top of the charger cover and remove cover JLG Lift 2 9 SECTION 2 SERVICE PROCEDURES Transformer Replacement 1 Disconnect the wiring connecting the transformer to other components within the charger assembly Remove the four nuts from the cap screws securing the transformer brackets to the base of the charger chassis Remove transformer OAN S lt Printed Circuit Board Replacement 1 Disconnect the wide wiring connector from the end of the circuit board Remove the four 4 screw attaching the card to the front face of the charger chassis Remove the circuit board 2 10 gt cc gt DC Circuit Breaker Replacement 1 Remove the wiring from the breaker terminals 2 Remove the bolt nut and washer from each side of the breaker remove the breaker from the housing JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES AC Circuit Breaker and Voltage Selection Switch Replacement 1 Remove the wiring from the AC breaker or V
76. per orientation of each component Torque the piston nut to 175 200 ft Ibs When the rod assembly is ready to be installed into the tube liberally apply an anti seize lubricant to the head outer surface especially the static seal Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube Watch the seals as they pass over the rod port if visible to be sure they are not nicked or cut Install the head until the retaining ring seats in it s groove Installation lg 2 NOTE 10 11 12 13 14 15 16 JLG Lift Remove the plastic plugs from the cylinder Pull rod out of cylinder approximately 3 ft The following step is easier done with two people one to slide the cylinder into the mast the other to guide the rod into the cylinder block at the top of the mast Slide the cylinder into the mast and install the rod into the cylinder attach block Apply Loctite 222 purple to the setscrew securing the lift cylinder rod to the sheave wheel anchor block at the top of mast section 2 Install the setscrew in the cylinder attach block at the top of the mast coat the threads of the setscrew with Loctite RC 640 blue before tightening Original Design Cylinder Mount Install the cylin der mount and cylinder mounting plates into the bot tom of the mast section 1 Shim to eliminate any side clearance to prevent any strain on the sides of the mast when the bolts are t
77. proximately one 1 foot Caps on extend and return ports will need to be removed to extend cylinder Catch any hydraulic fluid expelled from return port in a container to prevent spillage onto work area Bring base frame into position in front of mast assembly base frame and mast assembly must be held at 90 angle to each other 2 29 SECTION 2 SERVICE PROCEDURES 10 11 12 13 14 Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel Return port tube side of cylinder must be on right side facing bottom of base and mast Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting channel Secure hydraulic cylinder to cyl inder mounting channel tab using a 5 16 18UNC x 5 8 long hex head bolt and flat washer Carefully push mast assembly and base assembly together until the four 4 holes on bottom rear of mast align with holes in the base frame mast support crossmember Attach mast to base using four 4 3 8 16UNC x 1 long hex head bolts locknuts and flatwashers place a flatwasher under bolt head and nut and mount with nuts on inside of frame Locate the two 2 mast support braces attach to sides of base frame using a 3 8 16UNC x 1 long hex head bolt nut and flatwashers each brace place a flatwasher under bolt head and nut and mount with nuts on inside of frame Use access hole in bottom of frame to a
78. reviously with motor cover disassembly shown for reference only Brush Assembly Remove Install Brush Assembly Remove Install 1 Brush Assembly a 4 Brush Terminal Screw 2 Brush Carrier Socket 5 Brush Attach Terminal 3 Brush Tab Slot NOTE a Slide brush assembly into socket until tab is in slot at rear of socket 3120775 Lift 2 15 SECTION 2 SERVICE PROCEDURES TANK AND PUMP REMOVAL All Pumps Tank Installation Pump Installation Pump Installation 1 Pump Assembly 3 Pump Shaft Seal 2 Pump Assembly Screws 4 Pump End Head Tank Installation 1 Tank Assembly 3 O Ring Seal 2 Tank Screws 4 4 Use Screwdriver to pry tank away from pump head Filter Screen Installation 1 KY 2 SSS Filter Screen Installation iL 1 Filter Screen 2 Pump Pick Up Tube Pump O Ring Installation 1 Pump Assembly 2 O Ring Seal 3 O Ring Seal 2 16 JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation 1 Adjust Valve Cap 4 Valve Ball N gt Pre
79. rs on both side rails at top of mast section 6 and remove sheave wheel assembly 15 NOTE 16 While mast section 3 is still extended from section 2 remove the bolts attaching the two 2 chain assem bly anchor eyelets to the TOP of mast section 3 Remove chains When sliding mast sections apart be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 out BOTTOM of sec tion 2 Remove slide pads shims and chain anchor plate if necessary Mast Section 2 Removal 17 18 19 20 21 NOTE 22 Mast 23 24 Slide mast section 2 out TOP of mast section 1 far enough to allow access to the chain anchor block sheave wheel assembly Remove countersunk flathead screws securing chain anchor block sheave wheel assembly attach bars on both side rails at TOP of mast section 2 Slide the chain anchor block sheave wheel assemby and hydraulic cylinder out the TOP of mast section 2 far enough to allow removal of the sheave wheel attach bars sheave wheels and sheave pin from the chain assembly anchor block Remove the snap ring from the pin attaching the chain anchor block and chain anchor plate assem bly to the hydraulic cylinder rod end then remove the pin Lay the chain anchor block and chain assembly to side Remove the hydraulic cylinder through the BOTTOM of mast section 2 be careful not to nick or score inder rod surface while re
80. rs or Shields 1 Sheave Systems 1 2 1 2 Bearings 1 2 Slide Pads 1 2 PLATFORM ASSEMBLY 7 Platform and Material Tray 1 1 Guard Rails 1 2 4 1 2 4 Gate 1 5 1 5 Floor 1 2 1 2 Lanyard Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY 7 Front Caster Wheels 1 2 14 1 2 1 2 Rear Wheel Assembly 2 2 Bubble Level 1 7 1 7 Floor Stop Assembly s 1 3 7 FUNCTIONS CONTROLS Platform Controls 5 6 7 5 6 7 Ground Controls 5 6 5 6 14 Function Control Locks Guards or Detents 5 5 Function Enable System Emergency Stop Switches Ground amp Platform 5 Function Limit or Cutout Switch Systems 5 Manual Descent or Auxiliary Power 5 5 POWER SYSTEM Battery 19 9 18 Battery Charger 5 HYDRAULIC ELECTRIC SYSTEM 9 Hydraulic Pump 1 2 9 1 2 5 9 Hydraulic Cylinder 2 7 9 2 9 Cylinder Attachment Pins and Pin Retainers 1 2 1 2 Hydraulic Hoses Lines and Fittings 1 9 1 9 Hydraulic Reservoir Cap and Breather 5 7 5 7 Hydraulic Filter Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 3120775 JLG Lift 2 3 SECTION 2 SERVICE PROCEDURES Table 2 2 Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START 1 3 MONTH 6 MONTH PRE DELIVERY 2 ANNUAL 4 INSPECTION PREVENTATIVE PREVENTATIVE ORFREQUENT 3 YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION GENERAL Operator and Safety Manuals in Storage Box
81. rt the threaded the ends of chain assembly attached to top of mast section 1 into the opening between mast section 2 and mast section 3 Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section 3 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assembly Assemble chain sheaves for narrow chain assem bly to top of mast section 3 as follows a Locate the two 2 narrow chain sheave wheels and slide onto sheave pin b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin attach bars one each end of sheave pin to outside of space tubes d Holding complete sheave wheel assembly slide assembly into top of mast section 3 and align threaded holes in sheave pin attach bars with holes in mast rails e Attach to top of mast section 3 using two 2 3 8 16UNC x 1 2 long socket head countersunk flathead cap screws each side Coat threads with Loctite 171 and tighten When sliding mast sections together be careful not to scratch or score the anodized finish in the slide pad channels Carefully slide mast section 3 into section 2 until ends are even Check to make sure chain assembly wide chains are seating properly in chain anchor block chain sheave wheels attached to mast sec tion 2 Insert slide pads into the top end mast rails between sec
82. rts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage JLG Lift 2 5 SECTION 2 SERVICE PROCEDURES Bolt Usage and Torque Application Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the origi nal or one which is equivalent Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accordance with recommended shop practices See Section 1 Torque Charts Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System Keep the system clean If evidence of metal or rubber par ticles is found in the hydraulic system drain and flush the entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly Lubrication and Servicing Comp
83. ry concern DANGER WARNING CAUTION NOTICE INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH A CAUTION CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA TION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES Also in this Manual Notes are used to provide infor mation of special interest A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITU ATION WHICH IF NOT AVOIDED COULD RESULT IN SERI OUS INJURY OR DEATH NOTICE IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE NOTICE JLG INDUSTRIES INC MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT CONTACT JLG INDUS TRIES INC OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT Due to the continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information 27 NOTES
84. s If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning sol vent and allow to drip dry Compressed air can be used but do not spin the bearing Discard bearings if the races and balls or rollers are pit ted scored or burned If bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install Lubricate new or used serviceable bearings before instal lation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bearing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating pa
85. s to both sides of mast section 5 6 7 using five 5 1 4 20UNC x 1 1 4 long hex head cap screws per side with flatwasher under each bolt head Assemble shim stock and slide pad to mast section rail with shim stock against rail and slide pad with bev eled side out d Carefully thread the slide pad mounting bolts with flatwashers through slide pads and shim stock into threads in mast section 5 Be certain there are no air gaps between shims shim and mast or shim and slide pad when tightened Mast section 4 5 into section 3 4 fit should be very snug but still be able to be pushed together by hand If too tight remove section 4 5 disassemble slide pad and reduce thickness of shim stock e Begin sliding top of mast section 4 5 with closed rail down engaging the slide pads into slide pad channels at bottom of mast section 3 4 s open rail Continue to push section 4 5 into section 3 4 until BOTTOM ends of mast sections are even 50 51 52 53 54 f Check mast section for side play If play exists use thicker shims dividing thickness equally between both sides of mast g When mast slide pads are shimmed properly there should be no side to side movement of slide pad in rail channel Mast sections should be very snug in channels but still be able to slide in channel by hand Slide mast section 4 5 out even with top of section 3 4 Insert threaded ends of chain assembly attached to top of mast section 2
86. ssure Check Valve Installation 1 Check Valve Assembly 5 Check Valve Port 2 Adjustment Screw 5 Adjust Valve Port 2 O Ring Seal 6 Extend Pressure Port 3 Valve Spring 6 Extend Pressure Port 3 O Ring Seal 7 Return Port Shown Plugged 4 Backing Ring Note Adjust pressure per specification shown in Section 1 of this Note Extend Pressure and Return Ports Shown Plugged Service Manual 3120775 JLG Lift 2 17 SECTION 2 SERVICE PROCEDURES 2 7 HYDRAULIC LIFT CYLINDER REMOVAL INSPECTION AND REBUILD A WARNING HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE BE SURE ALL APPROPRIATE MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN THE CYLINDER BEFORE DISCONNECTING LINES Cylinder Removal 1 10 11 2 18 Disconnect power source Remove the DC power pack charger assembly from back of mast if so equipped Remove ground control pump cover Disconnect the hydraulic lines at the pump Using suitable lifting equipment lay machine down horizontal onto the back of mast to allow access to the bottom of the machine Preferably on an ele vated work surface capable of supporting the full weight of the machine Slide extend the mast out the top about 2 ft to 3 ft to allow access to the cylinder attach setscrew on the attach block at the top of mast section 2 Remove the cylinder attach setscrew from the attach block on top of mas
87. t section 2 Lowest set of sheaves Remove the protective mast cylinder hydraulic line cover plate from the base frame under the mast Use a container to catch the hydraulic oil from cylin der and hydraulic lines in next step discard oil Remove the hydraulic lines from the mast cylinder Original Design Cylinder Remove the one 1 5 16 bolt securing the cylinder to the cylinder mount and the four 4 1 2 bolts securing the cylinder mount to the mast section 1 side rails New Design Cylinder Remove the snap ring from either end of the cylinder mount pin running through the cylinder valve block While supporting the cylin der remove the mounting pin In the following step the mast cylinder mount will be shimmed tight in the mast Remove the cylinder mast mount from the mast In the following step the mast cylinder may be tight in the cylinder attach block at the top of the mast Pull the mast cylinder out of the mast JLG Lift Cylinder Disassembly 1 Before disassembling the cylinder clean away all dirt and foreign substances from openings particu larly the head area NOTE Always protect the chrome surface of the cylinder rod during assembly and disassembly Any damage to this surface will require replacement of the rod 2 Extend the rod until the piston bottoms out against the cylinder head 3 Compress the head retraining ring enough to allow the the cylinder head to be removed 4 Carefu
88. td Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 El 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 El 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 El 39 029 359 5845 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands 31 0 23 565 5665 El 31 0 23 557 2493 JLG Polska UI Krolewska 00 060 Warsawa Poland FF 48 0 914 320 245 125 48 0 914 358 200 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland d 44 0 141 781 6700 EL 444 0 141 773 1907 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 S www jlg com JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 85
89. the anodized finish in the slide pad channels Locate mast section 4 carefully slide section 3 closed rail into section 3 open rail Slide sections together until ends are even Locate one 1 of the chain bottom anchor plates one with threaded holes horizontally aligned to cen ter of bracket Attach using holes in bottom of mast section 4 with three 3 1 4 20UNC x 3 4 long bolts place a flatwasher under head of each bolt Slide mast section 4 approximately two feet out of the top of mast section 3 Insert threaded ends of chain assembly attached to top of mast section 2 into the opening between mast section 3 and mast section 4 Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section 4 Loosely thread two 2 3 8 16UNC nuts onto stud threads on each chain Chains will be adjusted later in assem bly 39 NOTE 40 41 NOTE 42 43 44 45 JLG Lift Assemble chain sheaves for narrow chain assem bly to top of mast section 4 as follows a Locate the two 2 narrow chain sheave wheels and slide onto sheave pin b Slide two 2 short spacer tubes onto sheave pin one each end of sheave pin to outside of sheave wheels c Place two 2 sheave pin attach bars one each end of sheave pin to outside of space tubes d Holding complete sheave wheel assembly slide assembly into top of mast section 4 and align threaded holes in sheave pin att
90. through holes on inside rail on bottom end of mast section 4 and into the slide pad inserts Thread in enough to hold pad in place 3120775 SECTION 2 SERVICE PROCEDURES 46 Shim per instructions in step 7 Mast Section 2 Assembly Platform Mounting Section Assembly 47 48 NOTE 49 NOTE NOTE 3120775 Locate the remaing mast section 4 5 platform mounting mast section Lay mast section on flat stable surface Attach the remaining chain bottom anchor plate one with threaded holes aligned at the outside of bracket Attach through set of holes in bottom of mast section 4 5 with four 4 1 4 200 x 3 4 long bolts place a flatwasher under head of each bolt The platform mounting section slide pads are assembled differently than the slide pads for the other mast sections Mast section 4 5 slide pads may need to be assembled disassembled several times in order to determine the correct shim stock required for proper fit Complete the following steps to determine shim stock thickness required for section 3 4 Always use the an even amount of shim material behind slide pads on both sides of the mast rails This will keep mast sections centered in rail chan nels and prevent any distortion of the section a Use two shim pieces per slide pad a thick one and a thin one b Start with a total thickness of approximately 035 and 075 thick shim stock c Attach shim stock and slide pad
91. tion FENNER BRAND PUMP Brush Replacement Motor Cap Motor Installation Brush Housing Installation Motor Cap Installation 1 Brush Housing 1 Cap Assembly Screws 2 Cap Assembly 2 Brush Housing Screws 3 Mark Front of Motor and Brush Housing for reference when reassembling Brush Assembly Connections 1 Negative Post 3 Brush Assemblies 1 Motor Assembly 3 Pump End Head 2 Positive Post 4 Spring Washer Note Length of wires to brush assemblies shown exaggerated for illustrative purposes 2 12 JLG Lift 3120775 SECTION 2 SERVICE PROCEDURES Once brush housing has been removed inspect the rotor commutator for excessive wear before installing a new brush set The rotor commutator surface when new is approximately 1 8 in 8mm in thickness New Brush Installation 1 Brush Terminal Screw 4 Brush Spring 2 Brush 5 See Installation Note Below 3 Brush Holder Installation the same for all four 4 brush assemblies Note Using a clean towel push each brush 2 up into it s holder 3 slide the spring 4 over the side of the brush This will hold each brush in place and allow them to clear the rotor commutator during reassembly Clean the rotor commutator with a non conductive electrical cleaner before assembling the brush housing to the motor hous ing 3120775 Brush Housing Final Assembl
92. tion 2 and 3 one on each side of the mast with beveled surface facing inward towards section 3 2 27 SECTION 2 SERVICE PROCEDURES NOTE 30 31 32 33 34 NOTE Mast NOTE 35 36 37 38 2 28 Before fastening and shimming the slide pad on the top left side of the mast install a sequence cable bracket against the mast under the flatwasher Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes in outside rail on top of mast section 2 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly Insert slide pads into the bottom end mast rails between section 2 and 3 one on each side of the mast with beveled surface facing out towards sec tion 2 Thread slide pad attaching bolts two 2 1 4 20UNC x 3 8 long hex head bolts place a flat washer under head of each bolt through holes on inside rail on bottom end of mast section 3 and into the slide pad inserts Thread in enough to hold pad in place Shim per instructions in step 7 Mast Section 2 Assembly If assembling the 12SP 4 Section mast skip the fol lowing Mast Section 4 Assembly steps and go directly to Platform Mounting Section Assembly Step 43 Section 4 Assembly When sliding mast sections together be careful not to scratch or score
93. ttach nut inside frame Before setting machine upright on base install a short 90 elbow fitting flow control valve and another short 90 elbow fitting on the end of the flow control valve in the extend left port on bottom of hydraulic cylinder Install a long 90 elbow fitting on return right port Use sealant tape on fitting threads Cap ports until hydraulic lines are installed Carefully set machine in an upright position on its base frame wheels Locate the mast support bracket Attach mast sup port bracket to mounting holes halfway up back of mast using four 4 3 8 16UNC x 2 3 4 long hex head bolts locknuts and flatwashers Place a flat washer under bolt head and nut and mount with nuts on inside of frame Using a 4 ft level ensure mast is set to vertical plumb on the base frame When mast is vertical plumb attach support braces bolted to base to the mast support bracket bolted to mast using 3 8 16UNC x 2 3 4 long hex head bolts nuts and flatwashers Place a flatwasher under bolt head and nut and mount with nuts on inside of bracket After securing mast to base frame using 4 ft level again check that mast is vertical plumb on base frame Mast installation should now be complete 2 30 2 11 MAST CHAINS CABLES AND SEQUENCING CABLES ADJUSTMENT Mast Chain Cable Adjustment The intention of this procedure is to assure equal load dis tribution between the individual chains cables of a
94. ve the base frame when it is lowered and empty tions 7 Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2 6 9 Once mast section adjustment is completed apply loctite 242 to the threads under the jam nuts that 3120775 JLG Lift 2 31 SECTION 2 SERVICE PROCEDURES Sequencing Cable Adjustment 1 2 32 Retract mast completely and check each sequenc ing cable on outside of masts for excessive slack Adjust only to remove slack from cable Tighten nylock nut just enough to remove excessive slack from sequencing cable The springs should not be compressed more than 25 after adjusting Run mast through several cycles to verify cable chain adjustments and ensure no interference exists between chain anchor brackets and mast 2 12 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables This kit consists of a replacement sequence cable with the threaded top end attached same as the top end of the factory cable Also included is a clamp drum socket type to secure the bottom end of the cable Use the following procedure to install the replacement cable and clamp kit Remove Old Cable T Remove the locking nut from the threaded end of the cable at the top of the mast and then remove the spring cap spring and spacer washers if installed Slide the threaded to
95. witch Replacement 2 10 Shunt Assembly Varistor and SCR Rectifier Replacement See Illustration 2 10 2 6 HYDRAULIC LIFT PUMP 2 11 FENNER BRAND PUMP Brush Replacement 2 11 Motor Cap Motor 2 11 Motor Brush Installation 2 ett III 2 11 Brush Housing Final Assembly 2 12 MONARCH BRAND PUMP Brush 2 13 Motor Assembly Remove Install Reference 2 13 Motor Brush Cover 2 13 Brush Carrier Assembly 2 14 Brush Assembly 2 14 TANK AND PUMP REMOVAL Pumps 2 15 Tank Installation RE Ge GUERRE EA ERG 2 15 Filter Screen Installation 2 15 Pump Installation siet Rel ese 2 15 Pressure Adjust Valve 1 2 16 Pressure Check Valve 1 2 16 2 7 HYDRAULIC LIFT CYLINDER REMOVAL INS
96. y Switch Red emergency stop button is engaged PUSHED IN on either ground control station or on platform Disengage TURN CLOCKWISE red emer gency button until it pops out Foot Stop is not engaged Engage Foot Stop at either side of machine Control relay not functioning Replace control relay Motor start relay not functioning Replace motor start relay Fuse s blown Replace blown fuse If fuse blows again check electrical circuit for short circuit Unit wiring not properly grounded Check all grounds in the wiring Check for loose wire s on Floor Brake Limit Switch causing an open circuit Properly reinstall wire to limit switch Platform lowers by itself Manual descent valve open Close manual descent valve Hydraulic hose and or fittings loose causing a hydraulic pressure leak Tighten hydraulic hose and or fittings Unit leaking hydraulic oil Lift DOWN solenoid valve not functioning Hydraulic hose and or fittings loose Replace Lift DOWN solenoid valve Tighten hydraulic hose and or fittings Valve and or plug loose Tighten valve and or plug Breather cap on tank is saturated or clogged with oil Replace breather cap on tank Unit lowers very slowly Hydraulic oil tank over filled Flow control valve not functioning Lower oil level to full mark on dipstick Replace flow control valve 3 6 JLG Lift
97. y both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measurement If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a prob lem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire pro cedure 3120775 SECTION 3 TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 3 1 Voltage Measurement DC Figure 3 2 Resistance Measurement If meter is not auto ranging set it to the correct range First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing If meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 3120775 JLG Lift 3 3 SECTION 3 TROUBLE
98. y Tips It is easier to install the brush housing assembly by sliding the rotor assembly completely out of the other end of the motor housing then attach the brush housing first After the brush housing is installed look into the motor housing from the opposite end to check that the positive post wires and static winding wires are positioned not to block the holes for the motor mounting bolts inside the motor housing After final assembly of the brush housing check that all brush terminal screws are tight and the brush springs are positioned properly before mounting the motor to the pump motor end head Brush Final Positioning ONCE THE ROTOR ASSEMBLY IS IN PLACE REMEMBER TO PUSH EACH BRUSH DOWN UNTIL THE BRUSH FACE IS IN CONTACT WITH THE COMMUTATOR ON THE ROTOR SHAFT AND THE BRUSH SPRING IS PUSHING DOWN ON TOP OF THE BRUSH Lift 2 13 SECTION 2 SERVICE PROCEDURES MONARCH BRAND PUMP Brush Replacement Motor Assembly Remove Install Reference Marks Pump Motor Removal Installation Reference Marks For reference when reassembling mark motor cover housing and valve body position before disassembling 1 Motor Top Cover 4 Housing Motor Valve Body 2 Cover Housing Reference Mark Reference Mark 5 Motor Valve Body 3 Motor Housing

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