Service 3121813 02-11-08 CE English

Service and Maintenance Manual
Model
E600
E600J
E600JP
M600
M600J
M600JP
P/N - 3121813
February 11, 2008
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A
GENERAL
MAINTENANCE
This section contains the general safety precautions

which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN

THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A

RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS
SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
REMOVE ALL RINGS, WATCHES AND JEWELRY

WHEN PERFORMING ANY MAINTENANCE.
The specific precautions to be observed during 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 weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
DO NOT WEAR LONG HAIR UNRESTRAINED, OR

LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.
KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
Relieve system pressure by cycling the applicable control

several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be disconnected with minimal fluid loss.
3121813
JLG Lift
A-1
INTRODUCTION
REVISON LOG
Original Issue
Revised
Revised
Revised
A-2
- August 10, 2000

- November 22, 2000
- April 15, 2003
- February 11, 2008
JLG Lift
3121813
TABLE OF CONTENTS
SECTION NO.
TITLE
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A
B
C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Drive/Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
SECTION 2 - GENERAL
2.1
2.2
3121813
Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
JLG Lift
TABLE OF CONTENTS
SECTION NO.
2.3
2.4
2.5
2.6
2.7
2.8
TITLE
PAGE NO.
Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6
Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .2-6
Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
SECTION 3 - CHASSIS & TURNTABLE

3.1
3.2
3.3
ii
Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive Hub -REAR (Prior to S/N 0300112585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Disengaging for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engaging after Towing is Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Disassembly of Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Disassembly of the first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Disassembly of second stage planet gears (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Assembly of first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Assembly of end cover unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Initial Start-Up and After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Drive Hub (S/N 115723 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Output Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hub-Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Cover Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
JLG Lift
3121813
TABLE OF CONTENTS
SECTION NO.
3.4
3.5
3.6
3.7
3.8
3.9
3121813
TITLE
PAGE NO.
Drive Hub (front 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Mechanical Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Park Brake Disassembly Instructions (B-M only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Drum Brake Shoe Inspection and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Motor Disassembly Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Disassembling Front Casing Motor Type F with Drum Brake (C-M Motor Only) . . . . . . . . . 3-23
Disassembling Front Casing, All Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Disassembling the Rear Casing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Disassembling Rotating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Reassembling Front Casing, All Types (Except C-M Motors). . . . . . . . . . . . . . . . . . . . . . . . 3-30
Reassembling Dynamic Brake (C-M Motors Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Reassembling Casing, F Type with Drum Brake (C-M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Setting Drum Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Reassembling Rotating Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Reassembling Rear Casing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Reassembly of Park Brake (B-M Motor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Park Brake Test (B-M Motor Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Appendix A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Appendix B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Speed Sensor Installation Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Verification w/ Analyzer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Oscillating Axle Lockout Test (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
Oscillation Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Checking Oscillation Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
Roll, Leak and Brake Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Hub-shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Motor-Brake Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Motor-Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Tube Fitting Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Procedure for Setting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
JLG Lift
iii
TABLE OF CONTENTS
SECTION NO.
3.10
3.11
3.12
3.13
3.14
iv
TITLE
PAGE NO.
Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Setting Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69
Battery Maintenance, Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Optional On Board Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Battery Charging (On Board Charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Removing the Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Generator (Prior to S/N 88375) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74
Timing Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
To Connect the JLG Control System Analyzer to the Generator . . . . . . . . . . . . . . . . . . . . . 3-77
Alarms and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Output Current and Voltage Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Priming the Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Generator (S/N 88375 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Dynamo and Dynamo Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Dynamo Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Control Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Start Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Engine Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Start Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Fuel Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Glow Plug Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Alternator Output Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
RBS Engine/Generator Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
System Status and Performance Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
RBS Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
RBS shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
RBS Alarms and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Resetting the RBS Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
APU Engine Start Battery Boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Supplementary fuse for Engine Generator Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
Tools And Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
JLG Lift
3121813
TABLE OF CONTENTS
SECTION NO.
TITLE
PAGE NO.
SECTION 4 - BOOM & PLATFORM

4.1
4.2
4.3
4.4
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Load Cell Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Platform Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Jib Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
SECTION 5 - HYDRAULICS
5.1
5.2
5.3
5.4
5.5
3121813
Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Cup and Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Lift, Telescope, Slave, Master, Oscillation (if equipped), Jib (if equipped), and Steer. . . . . 5-3
Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Cylinder Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cylinders With Dual Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Pressure settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Proportional Main Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Lift Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Flow Control / Bang Bang Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Platform Level Up Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Jib Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
JLG Lift
TABLE OF CONTENTS
SECTION NO.
TITLE
PAGE NO.
SECTION 6 - JLG CONTROL SYSTEM

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Help Descriptions and Fault Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
System Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5
7.6
7.7
7.8
7.9
7.10
vi
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-4
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
JLG Lift
3121813
LIST OF FIGURES
FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
2-1.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
3-26.
3-27.
3-28.
3-29.
3-30.
3-31.
3-32.
3-33.
3-34.
3-35.
3-36.
3-37.
3-38.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3121171
TITLE
PAGE NO.
Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Torque Chart - (N, m) - (For Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Engine Operating Temperature Specifications - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Output Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Input Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Hub Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
B-M Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Dynamic Brake C-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Front Case, F Type with C-M Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
MCR 10, 15, 20, & 40 Front Case C & F Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
MCR 3 & 5 Front Case C, F, & G Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
MCR 3 & 5 Front Case A, D, & E Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
MCR 10 Front Case D Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Two Speed Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Two Speed Spool Valve - Code 2W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Two Speed Spool Valve - Code 2W Alternative Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
MCR 3 & 5 Low Displacement, AOM, Single Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
MCR 3 & 5 Low Displacement, AOM, Two Speed MCR 10 & 15 Low Displacement,
AOM, Single & Two Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
MCR 20 & 40 Low Displacement, AOM, Single & Two Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Low Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
High Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
MCR 3 & 5 Front Case - C, F, & G Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
MCR 3 & 5 Front Case - A, D, & E Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
MCR 10 Front Case - D Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
MCR 10, 15, 20, & 40 Front Case - C & F Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Dynamic Brake C-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
Front Case, F Type with C-M Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
Low Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
High Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Low Displacement, AOM MCR 3, 5 Two Speed & MCR 10, 15 Single & Two Speed . . . . . . . . . .3-35
MCR 3 Low Displacement, AOM, Single Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
MCR 20 & 40 Low Displacement, AOM, Single & Two Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
Code 2L/2R Two Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
Code W Two Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
Code W Two Speed Only - Alternative Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
MCR 20 Single Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
MCR 10 & 15 Single Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
MCR 40 Single Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
JLG Lift
vii
LIST OF FIGURES
FIGURE NO.
3-45.
3-46.
3-47.
3-48.
3-49.
3-50.
3-51.
3-52.
3-53.
3-54.
3-55.
3-56.
3-57.
3-58.
3-59.
3-60.
3-61.
3-62.
3-63.
3-64.
3-65.
3-66.
3-67.
3-68.
3-69.
3-70.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-10.
4-11.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
5-14.
viii
TITLE
PAGE NO.
Low Displacement, Single Speed, B-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Special Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Speed Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
Motor Control Valve Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
Hub Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
Swing Drive and Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
Battery Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
Battery Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82
Boom Assembly - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Boom Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Transport Limit Switch (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Load Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Platform Rotator Assembly - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Operating Principle - Jib Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Jib Rotator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Tool for Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
JLG Lift
3121171
LIST OF FIGURES
FIGURE NO.
5-15.
5-16.
5-17.
5-18.
5-19.
5-20.
5-21.
5-22.
5-23.
5-24.
6-1.
6-2.
6-3.
6-4.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
7-18.
7-19.
7-20.
7-21.
7-22.
7-23.
7-24.
7-25.
3121171
TITLE
PAGE NO.
Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Hydraulic Tank and Pump (Prior to S/N 51941) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Hydraulic Tank and Pump (S/N 51941 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Hydraulic Control Valve - Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
Hydraulic Control Valve - Platform Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Connector Assembly Figure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Electrical Schematic - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
JLG Lift
ix
LIST OF TABLES
TABLE NO.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
4-1
5-1
5-2
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
TITLE
PAGE NO.
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Motor Torque Table 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Piston Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Park Brake Assembly Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Drive Brake Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
RBS Prestart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
RBS Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
Controller Interface Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86
RBS Alarms and Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Machine Setup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
Calibration Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Calibration Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
JLG Lift
3121813
SECTION 1. SPECIFICATIONS
1.1 CAPACITIES
Table 1-2. Operating Specifications

Maximum Manual Force
Table 1-1. Capacities

Generator Fuel Tank (M Models Only)
Hydraulic Tank
Prior to S/N 51941
S/N 51941 to Present
Drive Hub
13 gallons (49.2 liters)

15 gallons (57 liters)
15.9 gal.(60.2 L)
12.4 gal. (46.9 L) to full mark
500 lb (230 kg)

30%
5
4
3
60 ft. (18.29 m)
43 ft. (13.11 m)
42 ft. 9 in. (13.11 m)
Machine Length
E/M600
E/M600J
E/M600JP
30 ft. 11 5/16 in. (9.43 m)

30 ft. 8 15/16 in. (9.37 m)
33 ft. 3 3/4 in. (10.15 m)
20 amps DC
15 amps DC
Table 1-4. Battery Charger

AC Input
120V - 240V Auto Seeking
AC Draw
17 amps at start of charging
DC Output
48 volts, 23 amps
1.5 DRIVE/STEER SYSTEM

Drive Motor
48 VDC, 12.5 H.P. @ 3200 rpm. continuous, rotation - reversible
Drive Brake
spring-applied, hydraulically released
1.6 TIRES
15 ft. 3 in. (4.65 m)

Table 1-6. Tires
4 ft. (1.23 m)
Maximum Tire Load:
7700 lbs. (3500 kg)
Maximum Ground Bearing Pressure

E600J/M600J
E600JP/M600JP
52 psi (3.7 kg/cm2)

51 psi (3.6 kg/cm2)
Size
Type
Pressure
36/14 LL-22.5
pneumatic
55 psi (4.0 Bar)
36/14 LL-22.5
foam filled
N/A
3.0 mph (1.3 m/s)

48 volts
Maximum Hydraulic System Pressure
3200 psi (221 Bar)
Maximum Wind Speed
28 mph (12.5 m/s)
3121813
12 volt, 15 amp DC
Dynamo Output Fuse
Table 1-5. Drive System

7 ft. 11 7/16 in. (2.42 m)
7 ft. 11 3/8 in. (2.42 m)
Electrical System Voltage
Dynamo
1.4 BATTERY CHARGER
Machine Width
2WD
4WD
Maximum Drive Speed:
10W30 (Refer to Engine Manual)
Control Fuse
Tilt Alarm Setting (See Section 3)

ANSI, CSA
CE E/M600 & E/M600J
CE E/M 600JP
Turning Radius (inside)
12 volts
Engine Oil
Turning Radius (outside)
3100
Start Battery
Maximum Travel Grade (Side Slope) with

Boom retracted and approximately horizontal. Tower Boom fully lowered.
Maximum Horizontal Platform Reach

E600
E600J
58 volts @ 45 Amps
RPMs under max. load
Table 1-2. Operating Specifications
Maximum Vertical Platform Height:
Table 1-3. Generator

Alternator Output
1.2 OPERATING SPECIFICATIONS
Maximum Travel Grade (Gradeability)

with Boom retracted and approximately
horizontal. Tower Boom fully lowered.
16,300 lb. (7,393 kg)

16,800 lb. (7,620 kg)
1.3 GENERATOR
0.4 gal. (1.5 liters)
Maximum Work Load (Capacity)

Unrestricted:
400N
Gross Machine Weight (Platform Empty)

E600J/M600J
E600JP/M600JP
JLG Lift
1-1
1.7 FUNCTION SPEEDS
Test Notes
1. Stop watch should be started with the function, not
with the controller or switch.
Table 1-7. Function Speeds

Lift Up
55-61
Lift Down
55-61
Swing Right & Left
72-84
Telescope Out
46-50
Telescope In
46-50
Platform Rotate Left & Right
24-26
Jib Up
25-27
Jib Down
21-23
Jib Swing
2. Drive test results reflect 36/14LL-22.5 tires.

3. All speed tests are run from the platform. These
speeds do not reflect the ground control operation.
4. The platform speed knob control must be at full
speed (turned clockwise completely).
5. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature
above 100 F (38 C).
30-40
High Drive (200 ft.)
42-46 (3.0 mph)
Drive above Horizontal (50 ft.)
65-71 (0.5 mph)
6. Some flow control functions may not work with the

speed knob clicked into the creep position.
4150273-N
1.8 PRESSURE SETTINGS

Machine Orientation When Doing Speed
Tests
Table 1-8. Pressure Settings

PSI
BAR
Proportional Main Relief
3200
220
Bang Bang Main Relief
3000
207
Lift Up
2500
172
Lift Down
1100
76
Telescope: Boom at Full Elevation; Telescope Retracted;

Telescope Out, Record Time. Telescope In, Record Time.
Swing
2500
172
Swing Brake
320
22
Drive: Test to be done on a smooth level surface. Start

approximately 25 ft. (7.62 m) from starting point so that
the unit is at maximum speed when starting the test.
Results should be recorded for a 200 ft. (60.96 m) course.
Drive Forward, record time. Drive Reverse, Record Time.
Steer
1800
124
Platform Level Up
2500
172
Platform Level Down
1500
103
Jib Up
2300
158.5
Jib Down
2300
158.5
Lift: Boom Retracted. Telescope Retracted. Lift Up,

Record Time, Lift Down, Record Time.
Swing: Boom at Full Elevation. Telescope Retracted.
Swing the Turntable to the end stop. Swing the Opposite
Direction, Record Time.
Drive (Above Horizontal): Test should be done on a

smooth level surface. The Platform Speed Knob should be
selected out of the creep speed. This verifies that the
switches are working when the boom is above horizontal.
Results should be recorded for a 50 ft. course. Drive Forward, Record Time. Drive Reverse, Record Time.
SETTING
Platform Rotate: Platform level and completely rotated

one direction. Rotate the opposite direction, Record Time.
Rotate the other direction, Record Time.
Articulating Jib: Platform level and centered with the
boom. Start with the Jib down. Jib Up, Record Time. Jib
Down, Record Time.
1-2
JLG Lift
3121813
1.9 TORQUE REQUIREMENTS
1.11 SERIAL NUMBER LOCATION
Table 1-9. Torque Requirements

Description
Torque Value (Dry)
Interval Hours
Wheel Lugs
170 ft. lbs.(238 Nm)
150
T/T Counterweight
Bolts
400 ft.lbs.(560 Nm)
A/R
Swing Bearing Bolts
240 ft.lbs.(336 Nm)
50/600*
A serial number plate is affixed to the right side of the

frame. If the serial number plate is damaged or missing,
the machine serial number is stamped on the left side of
the frame at the top.
*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter. (See Swing Bearing in Section 3.)
NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart to
determine proper torque value.
SERIAL NUMBER
PLATE
1.10 MAJOR COMPONENT WEIGHTS

Table 1-10. Component Weights
Component
Pounds
Kilograms
Frame (bare)
1381
626
T/T (bare)
2093
950
Boom Assembly (E/M 600)
4464
2025
Boom Assembly (E/M 600J)
4464
2025
Tire & Wheel
226
102.5
Swing Drive
70
32
Swing Bearing
100
45.4
Platform Console
25
11
Side Entry Platform - 30x72 (bare)
175
80
Side Entry Platform - 30x48 (bare)
144
66
Counterweight
2560
1161
Foam Fill (Filled Tires)
441
200
3121813
SERIAL NUMBER
STAMPED ON FRAME
Figure 1-1. Serial Number Location
JLG Lift
1-3
1.12 HYDRAULIC OIL
Table 1-13. Mobil DTE 13M Specs
Table 1-11. Hydraulic Oil
ISO Viscosity Grade

Hydraulic System
Operating
Temperature Range
S.A.E. Viscosity
Grade
Specific Gravity
0.877
Pour Point, Max
-40F (-40C)
+0 to + 180 F
(-18 to +83 C)
10W
Flash Point, Min.
+0 to + 210 F
(-18 to +99 C)
10W-20, 10W30
+50 to + 210 F
(+10 to +99 C
20W-20
330F (166C)
Viscosity
NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system service.
Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they
may not contain the same required additives or be
of comparable viscosities. If use of hydraulic oil
other than Mobil DTE 11M is desired, contact JLG
Industries for proper recommendations.
Table 1-12. Mobil DTE 11M Specs
at 40 C
33cSt
at 100 C
6.6 cSt
at 100 F
169 SUS
at 210 F
48 SUS
cp at -20 F
6,200
Viscosity Index
140
Table 1-14. Mobil EAL H 46 Specs

Synthetic Biodegradable
Type
ISO Viscosity Grade
46
Specific Gravity
.910
Pour Point
-44F (-42C)
Flash Point
500F (260C)
Operating Temp.
0 to 180F (-17 to 162C)
Weight
7.64 lb. per gal.

(0.9 kg per liter)
ISO Viscosity Grade
#15
Gravity API
31.9
Pour Point, Max
-40F (-40C)
at 40 C
45 cSt
330F (166C)
at 100 C
8.0 cSt
Viscosity Index
153
Flash Point, Min.
Viscosity
Viscosity
at 40 C
1-4
#32
15 cSt
at 100 C
4.1 cSt
at 100 F
80 SUS
at 210 F
43 SUS
cp at -30 F
3.200
Viscosity Index
140
JLG Lift
3121813
Figure 1-2. Operator Maintenance and Lubrication Diagram
1.13 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication
Diagram.
Table 1-15. Lubrication Specifications.
KEY
SPECIFICATIONS
MPG
Multipurpose Grease having a minimum dripping point of

350 degrees F. Excellent water resistance and adhesive
qualities; and being of extreme pressure type (Timken OK
40 pounds minimum).
EPGL
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION

UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTISHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
NOTE: It is recommended as a good practice to replace all
filters at the same time.
Extreme Pressure Gear Lube (oil) meeting API Service

Classification GL-5 or Mil-Spec Mil-L-2105.
HO
Hydraulic Oil. Mobil DTE-11M
OG*
Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG Part No. 3020027)
BG*
Bearing Grease (JLG Part No. 3020029) Mobilith SHA

460.
LL
Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG

Part No. 3020022)
EO
Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L2104C.
*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.
3121813
1. Swing Bearing - Internal Ball Bearing
JLG Lift
Lube Point(s) - 1 Grease Fittings

Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
1-5
2. Generator Engine (If Equipped)
4. Hydraulic Filter
Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter or as indicated by
Condition Indicator.
Comments - Under certain conditions, it may be
necessary to replace the filter on a more frequent
basis.
5. Wheel Drive Hub
Lube Point(s) - Fill Cap

Capacity - Refer to Engine Manual
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with engine manual.
3. Hydraulic Tank
Lube Point(s) - Level/Fill Plug
Capacity - 0.4 gal. (1.5 L)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation
Lube Point(s) - Fill Cap

Capacity Prior to S/N 51941 - 15 gal. tank (56.7 L)
S/N 51941 to present - 15.9 gal. system (56.7L)
12.4 gal. (46.9 L) to Full Mark
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
1-6
JLG Lift
3121813
3121813
JLG Lift
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.1120
IN
BOLT
DIA.
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
SQ. IN.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
FT-LB
8
9
16
18
30
31
43
49
96
120
IN-LB
263
TENSILE
CLAMP DRY OR
STRESS
LOAD LOCTITE
AREA
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
FT-LB
6
7
12
13
22
23
32
36
75
86
IN-LB
LUB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
FT-LB
IN-LB
LOCTITE
262
TORQUE
Note: These torque values do not apply to cadmium plated fasteners.
1-1/2
1-3/8
1-1/4
1-1/8
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
SIZE
THDS.
PER
INCH
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
FT-LB
105
135
IN-LB
LOCTITE
242 OR
271
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
1280
1440
1820
2000
2380
2720
3160
3560
FT-LB
12
13
23
25
41
43
60
68
144
168
IN-LB.
263
CLAMP DRY OR
LOAD LOCTITE
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
960
1080
1360
1500
1780
2040
2360
2660
FT-LB
9
10
17
19
31
32
45
51
108
120
IN-LB
LUB
22
25
40
45
63
70
96
108
139
154
180
204
301
336
485
534
687
796
1030
1155
1453
1610
1907
2165
2530
2844
FT-LB
IN-LB
LOCTITE
262
TORQUE
30
30
50
55
80
90
120
130
165
190
240
265
420
465
660
725
990
1100
1400
1575
2000
2200
2625
3000
3475
3925
FT-LB
160
185
IN-LB
LOCTITE
242 OR
271
SAE GRADE 8 BOLTS & GRADE 8 NUTS

& SOCKET HEAD CAP SCREWS
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
SAE GRADE 5 BOLTS &

GRADE 2 NUTS
UNPLATED CAP SCREWS
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
3180
3640
LB.
25
27
45
50
70
75
110
115
155
165
210
220
365
400
585
635
865
915
1240
1380
1750
1880
2320
2440
3040
3270
FT-LB
160
168
IN-LB
PATCH
28
30
50
55
77
82
120
127
170
182
231
242
400
440
645
700
950
1000
1365
1520
1925
2070
2550
2685
3345
3600
FT-LB
168
178
IN-LB
PATCH
TORQUE
CLAMP WITHOUT
WITH
LOAD LOC-WEL LOC-WEL
UNBRAKO 1960 SERIES

SOCKET HEAD
Figure 1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners)
1-7
1-8
JLG Lift
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
SQ. IN.
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
IN
0.1120
TENSILE
STRESS
AREA
BOLT
DIA.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
CLAMP
LOAD
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
N, m
.8
1.0
1.8
2.0
3.4
3.4
5
6
11
14
DRY OR
LOCTITE
263
N, m
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
N, m
.8
.8
1.4
1.6
2.4
2.6
3.6
4
8
10
N, m
LUB
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
N, m
N, m
LOCTITE
262
TORQUE
1-1/2
1-3/8
1-1/4
1-1/8
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
SIZE
THDS.
PER
INCH
26
28
47
54
75
81
115
136
163
183
224
258
386
447
644
705
915
997
1139
1254
1593
1763
2068
2373
2745
3118
N, m
12
15
LOCTITE
242 OR
271
N, m
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
CLAMP
LOAD
34
34
61
68
95
108
149
163
203
230
298
325
515
569
813
895
1220
1356
1735
1952
2468
2712
3227
3688
4284
4827
N, m
1.4
1.5
2.6
2.8
4.6
5
7
8
16
19
DRY OR
LOCTITE
263
N, m
24
27
47
47
75
81
108
122
149
176
230
244
380
434
624
678
922
1003
1302
1464
1844
2034
2413
2766
3200
3606
N, m
1.0
1.0
2.0
2.2
3.4
3.6
5
6
12
14
N, m
LUB
30
34
54
61
85
95
130
146
188
209
244
277
408
456
658
724
931
1079
1396
1566
1970
2183
2586
2935
3430
3856
N, m
N, m
LOCTITE
262
TORQUE
41
41
68
75
108
122
163
183
224
258
325
359
569
630
895
983
1342
1491
1898
2135
2712
2983
3559
4067
4711
5322
N, m
18
21
LOCTITE
242 OR
271
N, m
SAE GRADE 8 BOLTS & GRADE 8 NUTS

& SOCKET HEAD CAP SCREWS
SAE GRADE 5 BOLTS &

GRADE 2 NUTS
UNPLATED CAP SCREWS
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
3180
3640
LB.
CLAMP
LOAD
34
37
61
68
95
102
149
156
210
224
285
298
495
542
793
861
1173
1241
1681
1871
2373
2549
3145
3308
4122
4433
N, m
18
19
38
41
68
75
104
111
163
172
230
247
313
328
542
597
874
949
1288
1356
1851
2061
2610
2807
3457
3640
4535
4881
N, m
19
20
TORQUE
WITHOUT
WITH
LOC-WEL LOC-WEL
PATCH
PATCH
N, m
N, m
UNBRAKO 1960 SERIES

SOCKET HEAD
Figure 1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners)
3121813
CLASS 8.8 METRIC BOLTS &

CLASS 8 METRIC NUTS
SIZE
PITCH
CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS
TORQUE
TENSILE
STRESS
AREA
CLAMP
LOAD
sq. mm
TORQUE
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
CLAMP
LOAD
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
.5
5.03
2.19
1.3
1.0
1.2
1.4
3.13
1.9
1.4
1.5
2.1
3.5
.6
6.78
2.95
2.1
1.6
1.9
2.3
4.22
3.0
2.2
2.4
3.3
.7
8.78
3.82
3.1
2.3
2.8
3.4
5.47
4.4
3.3
3.5
4.8
.8
14.2
6.18
6.2
4.6
5.6
6.8
8.85
8.9
6.6
7.1
9.7
20.1
8.74
11
7.9
9.4
12
12.5
15
11
12
17
28.9
12.6
18
13
16
19
18
25
19
20
28
1.25
36.6
15.9
25
19
23
28
22.8
37
27
29
40
10
1.5
58.0
25.2
50
38
45
55
36.1
72
54
58
79
12
1.75
84.3
36.7
88
66
79
97
52.5
126
95
101
139
14
115
50.0
140
105
126
154
71.6
200
150
160
220
16
157
68.3
219
164
197
241
97.8
313
235
250
344
18
2.5
192
83.5
301
226
271
331
119.5
430
323
344
473
20
2.5
245
106.5
426
320
383
469
152.5
610
458
488
671
22
2.5
303
132.0
581
436
523
639
189.0
832
624
665
915
24
353
153.5
737
553
663
811
220.0
1060
792
845
1170
27
459
199.5
1080
810
970
1130
286.0
1540
1160
1240
1690
30
3.5
561
244.0
1460
1100
1320
1530
349.5
2100
1570
1680
2310
33
3.5
694
302.0
1990
1490
1790
2090
432.5
2600
2140
2280
2860
36
817
355.0
2560
1920
2300
2690
509.0
3660
2750
2930
4020
42
4.5
1120
487.0
4090
3070
3680
4290
698.0
5860
4400
4690
6440
METRIC CLASS 8.8
METRIC CLASS 10.9
Figure 1-5. Torque Chart - (N, m) - (For Metric Class Fasteners).
3121813
JLG Lift
1-9
NOTES:
1-10
JLG Lift
3121813
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 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 comprehensive inspection and preventive maintenance program. The
following table outlines the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
environment, severity and frequency of usage requires.
Pre-Start Inspection
It is the Users or Operators primary responsibility to perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operators 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 performing the Pre-Start Inspection.
Reference the JLG Pre-Delivery and Frequent Inspection

Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection

The Annual Machine Inspection must be performed by a
Factory-Certified Service Technician on an annual basis,
no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Certified Service Technician 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
appropriate JLG inspection form for performance of this
inspection.
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 manual 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
Pre-Delivery Inspection and Frequent
Inspection
The Pre-Delivery Inspection and Frequent 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 recognized 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 procedures are performed in the same manner, but at different 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 service 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.
3121813
In conjunction with the specified inspections, maintenance 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, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.
JLG Lift
2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance

Primary
Responsibility
Service
Qualification
Reference
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
Mechanic
Service and Maintenance

Manual and applicable JLG
inspection 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
Purchased used.
Qualified JLG
Mechanic

inspection form.
Annual Machine
Inspection
Annually, no later than 13 months from the

date of the prior inspection.
Factory-Certified
Service Technician

inspection form.
Preventative
Maintenance
At intervals as specified in the Service and

Maintenance Manual.
Qualified JLG
Mechanic

Manual
Type
Frequency
Pre-Start Inspection
2.2 SERVICE AND GUIDELINES
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this book.
3. Clean and inspect all parts during servicing or maintenance, 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.
Safety and Workmanship

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
Components Removal and Installation
Cleanliness
1. The most important single item in preserving the
long service 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 filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.
1. Use adjustable lifting devices, whenever possible, if

mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90 degrees.
3. 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.
2-2
JLG Lift
3121813
SECTION 2 - GENERAL
Component Disassembly and Reassembly

When disassembling or reassembling a component, complete 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.
2. 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
Torque Chart Section 1.)
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
Bearings
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain
and flush the entire system.
1. When a bearing is removed, cover it to keep out dirt

and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.
2. Disassemble and reassemble parts on clean work

surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
2. Discard bearings if the races and balls (or rollers)

are pitted, scored, or burned.
3. 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.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the
inner race.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Lubrication
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.
Battery
Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.
Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
3121813
JLG Lift
2-3
SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION
Changing Hydraulic Oil

1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this 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 synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.
Hydraulic System
1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suction) lines.
2. The design and manufacturing tolerances of the
component 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 generally results in faulty operation. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.
4. 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.
2. 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. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.
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 evaluation. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.
NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends Mobil DTE-11M hydraulic oil for
this machine.
NOTE: Start-up of hydraulic system with oil temperatures
below -15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).
2-4
JLG Lift
3121813
SECTION 2 - GENERAL
2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured
using the following methods.
2.5 PINS AND COMPOSITE BEARING REPAIR

GUIDELINES
Filament wound bearings.
1. Pinned joints should be disassembled
inspected if the following occurs:
Platform Drift
Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, upper boom fully
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
If the machine does not pass this test, proceed with the
following.
and
a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any
of the following is observed:
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
Cylinder Drift
c. Bearings that have moved or spun in their housing.
Table 2-2. Cylinder Drift

Cylinder Bore Diameter
inches
mm
d. Debris embedded in liner surface.
Max. Acceptable Drift

in 10 Minutes
inches
mm
3. Pins should be replaced if any of the following is

observed (pin should be properly cleaned prior to
inspection):
76.2
0.026
0.66
3.5
89
0.019
0.48
101.6
0.015
0.38
b. Flaking, pealing, scoring, or scratches on the pin

surface.
127
0.009
0.22
c. Rusting of the pin in the bearing area.
152.4
0.006
0.15
177.8
0.005
0.13
203.2
0.0038
0.10
228.6
0.0030
0.08
a. Detectable wear in the bearing area.
4. Re-assembly of pinned joints using filament wound

bearings.
a. Housing should be blown out to remove all dirt
and debris...bearings and bearing housings
must be free of all contamination.
Drift is to be measured at the cylinder rod with a calibrated

dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.
The cylinder must have the normal load, which is the normal platform load applied.
If the cylinder passes this test, it is acceptable.
b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubricated.
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would damage the bearing during installation and operation.
NOTE: This information is based on 6 drops per minute cylinder leakage.
3121813
JLG Lift
2-5
SECTION 2 - GENERAL
2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to
the machine and to welding performed from the
machine on an external structure, or component,
Do the Following When Welding on JLG

Equipment
2.7 APPLYING SILICONE DIELECTRIC

COMPOUND TO ELECTRICAL
CONNECTIONS
Silicone Dielectric Compound must be used on all electrical connections for the following reasons:
To prevent oxidation at the mechanical joint between
male and female pins.
Disconnect the battery.

Disconnect the moment pin connection (where fitted)
Ground only to structure being welded.
Do NOT Do the Following When Welding on

JLG Equipment
Ground on frame and weld on any other area than the
chassis.
To prevent electrical malfunction caused by low level

conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with
external seals.
1. To prevent oxidation, silicone grease must be
packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.
Ground on turntable and weld on any other area than

the turntable.
Ground on the platform/support and weld on any other
area than the platform/support.
Ground on a specific boom section and weld on any
other area than that specific boom section.
NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing circuit failure.
Allow pins, wear pads, wire ropes, bearings, gearing,

seals, valves, electrical wiring, or hoses to be between
the grounding position and the welded area.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY

RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the connector should also be sealed.
NOTE: This condition is especially common when machines
are pressure washed since the washing solution is
much more conductive than water.
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to
the contacts only.
NOTE: Curing-type sealants might also be used to prevent
shorting and would be less messy, but would make
future pin removal more difficult.
2-6
JLG Lift
3121813
SECTION 2 - GENERAL
2.8 PREVENTIVE MAINTENANCE AND

INSPECTION SCHEDULE
The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.
The preventive maintenance and inspection 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" of the table, the various systems
along with components that make up that system are
listed. The "INTERVAL" portion of the table is divided into
five columns representing the various inspection time
periods. The numbers listed within the interval column
represent the applicable inspection code for which that
component is to be checked.
2. Check for visible damage and legibility.

3. Check for proper fluid level.
4. Check for any structural damage; cracked or broken
welds; bent or warped surfaces.
5. Check for leakage.
6. Check for presence of excessive dirt or foreign
material.
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 depending on the location and use of the machine.
JLG Industries requires that a complete annual inspection
be performed in accordance with the "Annual Machine
Inspection Report" form. Forms are supplied with each
new machine and are also available from JLG Customer
Service. Forms must be completed and returned to JLG
Industries.
7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.
9. Check for proper tightness and adjustment.
10. Drain, clean and refill.
11. Check for proper operation while engine is running.
12. Check for proper lubrication.
13. Check for evidence of scratches, nicks or rust and
for straightness of rod.
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL

INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
"ANNUAL MACHINE INSPECTION REPORT" FORM.
14. Check for condition of element; replace as necessary.

15. Check for proper inflation.
This machine requires periodic safety and maintenance

inspections by a JLG Dealer. A decal located on the turntable affords a place to record (stamp) inspection dates.
Notify dealer if inspection is overdue.
16. Clean or replace suction screen.

17. Drain and clean.
* To be performed quarterly.
** Inspection and Maintenance Code 10, 12, 16 to performed every two years.
3121813
JLG Lift
2-7
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL
AREA
Boom Assembly
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Preventive or Frequent3
Maintenance Maintenance Inspection
Annual4
(Yearly)
Inspection
9
1,2,4
1,2,4
1,2,9,12
1,2,9,12
Pivot Pins and Pin Retainers
1,2
1,2
Sheaves, Sheave Pins
1,2
1,2
Bearings
1,2
1,2
Wear Pads
1,2
1,2
Covers or Shields
1,2
1,2
1,2,3
1,2,3
Boom Weldments
Hose/Cable Carrier Installations
Extend/Retract Chain or Cable Systems
Platform Assembly
Platform
1,2
Railing
1,2
1,2
Gate
Floor
1,2
9,5
Rotator
Lanyard Anchorage Point
Turntable Assembly
1,2
1,5
1,2
15
1,2,10
1,2,10
1,2,14
1,2,3,13,14
11
11
1,2,5
1,2,5
1,2,5
Swing Bearing
Swing Drive System
Turntable Lock
Hood, Hood Props, Hood Latches
Chassis Assembly
Every 2
Years
Tires
16,17
16,17,18
16,17,18
Wheel Nuts/Bolts
15
15
15
14,24
Wheel Bearings
5,8
Oscillating Axle/Lockout Cylinder Systems

Steer Components
Drive Motors
Drive Hubs
11
11
Functions/Controls
Platform Controls
Ground Controls
Function Control Locks, Guards, or Detents
1,5
1,5
Footswitch
1,5
2-8
JLG Lift
3121813
SECTION 2 - GENERAL

INTERVAL
AREA
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Annual4
(Yearly)
Inspection
Emergency Stop Switches (Ground & Platform)
Function Limit or Cutout Switch Systems
5
5
Capacity Indicator
Drive Brakes
Swing Brakes
5
5
Boom Synchronization/Sequencing Systems

5
9,11
11
11
1,7
Manual Descent or Auxiliary Power
Power System
Engine Idle, Throttle, and RPM

Engine Fluids (Oil, Coolant, Fuel)
11
Air/Fuel Filter
1,9
Exhaust System
Batteries
1,9
Battery Fluid
11
Battery Charger
Fuel Reservoir, Cap, and Breather
Hydraulic/Electric System
11,9
19
11
11
5
1,5
1,5
9
1,9
Hydraulic Pumps
1,9,7
Hydraulic Cylinders
1,2,9
2
1,2,9
1,2,9
1,2
1,2
Cylinder Attachment Pins and Pin Retainers
1,9
Hydraulic Hoses, Lines, and Fittings
1,9
12
1,2,9,12
1,2,9,12
1,9
1,5
1,5
7,11
7,11
20
20
Hydraulic Reservoir, Cap, and Breather
11
1,9
Hydraulic Filter
Hydraulic Fluid
Every 2
Years
11
Electrical Connections
Instruments, Gauges, Switches, Lights, Horn
24
5,23
General
Operators and Safety Manuals in Storage Box
21
21
21
21
ANSI and EMI Manuals/Handbooks Installed

Capacity Decals Installed, Secure, Legible
21
21
21
All Decals/Placards Installed, Secure, Legible
21
21
21
Walk-Around Inspection Performed
21
Annual Machine Inspection Due
21
No Unauthorized Modifications or Additions
21
3121813
JLG Lift
21
2-9
SECTION 2 - GENERAL

INTERVAL
AREA
Pre-Start1
Inspection
Weekly
Monthly
Pre-Delivery2
Preventive
Annual4
(Yearly)
Inspection
All Relevant Safety Publications Incorporated
21
21
General Structural Condition and Welds
2,4
2,4
All Fasteners, Pins, Shields, and Covers
1,2
1,2
Grease and Lubricate to Specifications
22
22
21
21, 22
Function Test of All Systems
21
Paint and Appearance

Stamp Inspection Date on Frame
22
Notify JLG of Machine Ownership
22
Every 2
Years
Footnotes:
1 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 150 Hours; 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
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
2-10
JLG Lift
3121813
SECTION 2 - GENERAL
4150548 D
Figure 2-1. Engine Operating Temperature Specifications - Kubota
3121813
JLG Lift
2-11
SECTION 2 - GENERAL
NOTES:
2-12
JLG Lift
3121813
SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS
Tire Inflation
The air pressure for pneumatic tires must be equal to the
air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.
Tire Damage
For pneumatic tires, JLG Industries, Inc. recommends that
when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be
taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the
tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered,
measures must be taken to remove the JLG product from
service immediately and arrangements must be made for
replacement of the tire or tire assembly.
a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length
any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
any punctures which exceed 1 inch in diameter
any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria,
the tire must be inspected on a daily basis to insure the
damage has not propagated beyond the allowable criteria.
Tire Replacement
pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure
recommended by JLG. Due to size variations between
tire brands, both tires on the same axle should be the
same.
Wheel Replacement
The rims installed on each product model have been
designed for stability requirements which consist of track
width, tire pressure, and load capacity. Size changes such
as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may
result in an unsafe condition regarding stability.
Wheel Installation
It is extremely important to apply and maintain proper
wheel mounting torque.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE

PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS,
AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE
AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent
wheels from coming loose. Use a torque wrench to tighten
the fasteners. If you do not have a torque wrench, tighten
the fasteners with a lug wrench, then immediately have a
service garage or dealer tighten the lug nuts to the proper
torque. Over-tightening will result in breaking the studs or
permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is as
follows:
JLG recommends a replacement tire be the same size, ply

and brand as originally installed on the machine. Please
refer to the JLG Parts Manual for the part number of the
approved tires for a particular machine model. If not using
a JLG approved replacement tire, we recommend that
replacement tires have the following characteristics:
1. Start all nuts by hand to prevent cross threading. DO

NOT use a lubricant on threads or nuts.
Equal or greater ply/load rating and size of original

Tire tread contact width equal or greater than original
Wheel diameter, width, and offset dimensions equal to
the original
Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a
3121813
JLG Lift
3-1
2. Tighten nuts in the following sequence:

ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED
WITH THE MACHINE AT A STANDSTILL.
THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR

TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR
DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT
AND CAUSE INJURY.
ENSURE TH E AREA SURROUNDING TH E DISCONNECT IS

CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER
CONTAMINANTS DO NOT ENTER THE GEAR DRIVE.
3. The tightening of the nuts should be done in stages.
Following the recommended sequence, tighten nuts
per wheel torque chart.
1. Remove the two hex head bolts from the cover.
Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage
2nd Stage
3rd Stage
40 ft. lbs.
(55 Nm)
100 ft. lbs.

(130 Nm)
170 ft. lbs.

(255 Nm)
4. Wheel nuts should be torqued after first 50 hours of

operation and after each wheel removal. Check
torque every 3 months or 150 hours of operation.
3.2 DRIVE HUB -REAR (PRIOR TO S/N

0300112585)
The final drive consists of two planetary stages with an
integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an
equal load distribution. All torque transmitting components are made of forged quenched and tempered highalloy steels. External gears are carburized. Precision roller
bearings support the sprocket or wheel loads. A shaft seal
protects the unit against contamination.
2. Remove the cover.
Disengaging for Towing

PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO
BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY
MOVEMENT, I.E. VIA TOW BAR TO PULLING VEHICLE. THE
MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO
THE TOWING VEHICLE TO PREVENT RUNAWAY.
3-2
JLG Lift
3121813
3. Rotate the cover to show the inside diameter

THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR
TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR
DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT
AND CAUSE INJURY.
ENSURE TH E AREA SURROUNDING TH E DISCONNECT IS

CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER
CONTAMINANTS DO NOT ENTER THE GEAR DRIVE.
THE COVER IS UNDER SPRING FORCE

1. Remove the 2 hex head bolts securing the cover
evenly and remove the cover.
2. Rotate the cover 180 degrees and secure with the
two hex head bolts.
4. Press the cover sufficiently against the shift rod to

insert the bolts at least 2 to 3 threads into the cover.
This will subject the shift rod to spring force.
3. Torque the hex head bolts 6.3 ft.lbs. (8.8 Nm).
5. Install the bolts and torque 6.3 ft. lbs. (8.8 Nm) until
they are flush with the cover.
6. The sun gear shaft and input shaft are now disconnected and the machine is ready to be towed.
PULL VERY SLOWLY WITH THE TOWING VEHICLE CONNECTED

TO THE MACHINE TO ALLOW THE SPLINE OF THE SUN GEAR
SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT.
BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE, EITHER THE GEAR DRIVE HAS TO BE REENGAGED OR SUITABLE MEASURES MUST BE TAKEN TO SECURE THE MACHINE
FROM MOVEMENT.
DO NOT OPERATE THE MOTOR TO MAKE THE SUN GEAR SHAFT

TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT.
4. Check to ensure all bolts are tight and all components are returned to their original positions.
Engaging after Towing is Complete

PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO
BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY
MOVEMENT, I.E. VIA TOW BAR TO PULLING VEHICLE. THE
MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO
THE TOWING VEHICLE TO PREVENT RUNAWAY.
5. The gear drive should now be reengaged and the

machine can be disconnected from the towing vehicle.
ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED

WITH THE MACHINE AT A STANDSTILL.
3121813
JLG Lift
3-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Planet Gear
Planet Gear
Sun Gear
Shaft Nut
Planet Bolt
Support Ring
Planet Carrier
Cover
Not Used
Roller Bearing
Roller Bearing
Roller Bearing
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Not Used
Retaining Ring
Retaining Ring
Retaining Ring
Support Disk
Not Used
O-ring
Ring Seal
Plug
Ring Seal
Bolt
24. Ball
25. Expander
26. to 28. Not Used
29. Housing Washer
29. Ring Gear
31. & 32. Not Used
33. O-ring
34. Retaining Ring
35 to 42. Not Used
43. Sun Gear Shaft
44. Input Shaft
45 to 48. Not Used

49. Thrust Washer
50. Not Used
51. Cover
52. Disk
53. Bolt
54. O-ring
55. Pressure Spring
56. Shaft Rod
57 & 58. Not Used
59. Disk Rotor
60. Spindle
61. Not Used
62. Coupler
63 to 65. Not Used
66. Snap Ring
67 to 80. Not Used
81. Ball Bearing
82. Snap Ring
83. Snap Ring
84 to 87. Not Used
88. Wheel Stud
Figure 3-1. Torque Hub
3-4
JLG Lift
3121813
Disassembly
Disassembly of Cover
1. Position drive so that one of the fill holes is at the

bottom of the end cover and drain the oil.
1. Loosen and remove hex head bolts (53) to remove

cover (51).
2. Remove all bolts holding the motor and Remove

motor from drive.
2. Remove shaft rod (56) and o ring (54).
3. Compress the disc (59) using a simple fixture or

other suitable device.
4. Remove snap ring (66) and release pressure on disc
until loose. Remove tool and disc.
3. Remove sleeve (52).
Disassembly of the first stage planetary

assembly (7)
1. Push sun gear shaft (43) out of the first stage.
5. Remove the spring (55) from the input shaft (44).
2. Remove snap rings (14).
6. Turn unit so that cover (8) is in the up position.
3. Press planet pins (5) out of the planet gears (2).
7. Remove the screw plugs (22) and seal rings (21).
4. Pull cylindrical roller bearing (10) out of the planet

gears (2).
8. Remove snap rings (34), and remove the cover unit

(8) from drive.
5. Remove snap ring (16) from sun gear (3) and

Remove planet carrier (7) from sun gear (3).
9. Remove o ring (33).

10. Remove the first stage planetary assembly (7).
6. Remove thrust washer (49).
11. Remove hex bolts (23).
Disassembly of second stage planet gears

(1)
12. Remove ring gear (30) and o ring (19).

13. Remove snap rings (15).
Press cylindrical roller bearings out of planet gears (1).
14. Pull off planet gears (1) together with cylindrical

roller bearings (11) from spindle (60).
NOTE: Further disassembly of the hub is discouraged. reinstallation of the shaft nut (4) requires a special tool
and a torque of 626 ft./ lbs. (876 Nm) for proper reassembly. These components Will Fail if not properly
reassembled.
Assembly of first stage planetary assembly

(7)
15. Inspect the planetary stage assemblies as complete

units. Thoroughly clean and check both the gearing
and the bearings for damage and apply new oil. If
the gears or bearings need replacing, they must be
replaced as complete sets.
16. The first stage planetary gears (2) must be changed
in sets of three pieces.
17. The first stage planetary gears (2) must be changed
as a complete set of three and JLG recommends
changing the sun gear shaft (43) along with this set
of planets.
1. Pre-freeze planet pins (5) and install into planet carrier (7).
2. Install planet carrier (7) together with planet pins (5)
on sun gear (3), and install snap ring (16).
3. Pre-heat thrust washer (49) and Install onto sun gear
shaft (43).
4. Put sun gear shaft (43) into sun gear (3).
5. Pre-heat stay rings (17) and install onto planet pins
(5).
6. Pre-heat cylindrical roller bearings (10) and install
onto planet pins (5) and fix bearings with snap rings
(14).
18. The second stage planetary bearings (11) must be

replaced in sets of four pieces.
19. The second stage planetary gears (1) must be
changed as a complete set of four and JLG recommends changing the sun gear (3) along with this set
of planets.
3121813
JLG Lift
3-5
Assembly of end cover unit (8)
Initial Start-Up and After Repairs

Before operating the machine, make sure that the drive is
filled with clean oil, approximately 0.2 us gallons (0.8 L).
An accurate oil level is determined by the oil level plug,
which should be removed before oil fill.
1. Press sleeve (52) into cover (8).

2. Install "o" ring (54) into groove of cover (8).
3. Install shift rod (56) into cover (8).
4. Install the cover (51) into cover (8) and fix cover (51)
with hex bolts (53). Tighten bolts with torque wrench
to 6.3 ft. lbs. (8.5 Nm).
Final Assembly
With the gear case filled to their proper levels, start the
machine and allow sufficient time for run-in at moderate
pressure and speed before running at full speed. After 4
hours of operation, recheck oil level.Maintenance
Daily: - Check for oil leakage
1. Install thrust washer (29) in spindle (60).
Weekly: - Check oil level
2. Install "o" ring (19) into groove of support ring (6).
Monthly: - Check mounting bolt torque
3. Install planet gears (1) onto planet pins which are

part of spindle (60).
Oil Change Interval-Gear Drive
4. Install snap rings (15) on planet pins of spindle (60)

in order to fix the planet gears (1).
1. Perform the first oil change after approximately 150

hours.
5. Put ring gear (30) onto support ring (6) and fix ring
gear (30) with hex head bolts (23). Tighten bolts with
torque wrench to 15.5 ft. lbs.(21.1 Nm).
2. Subsequent changes, every 1500 hours or annually,

whichever occurs first.
6. Insert the first stage planetary assembly (7) into

drive.
7. Install o ring (33) in groove of ring gear (30).
8. Install end the cover unit (8) on shoulder ring gear
(30) and fix with snap ring (34).
NOTE: Flush the drive before filling with new oil.
3.3 DRIVE HUB (S/N 115723 TO PRESENT)

Roll and Leak Testing
9. Install seal rings (21) and screw plugs (22).

10. Before installation of motor, CHECK THAT THERE IS
1-2mm OF CLEARANCE BETWEEN THE MOTOR
SPLINE SHAFT SHOULDER AND THE COUPLER
(62).
11. Install the motor and reconnect hydraulic lines.
12. Roll motor so that one fill plug is at 12 oclock position, and the other is at 3 oclock. Fill to bottom of 3
o clock plug with gear oil. reinstall plugs
Torque-Hub units should always be roll and leak tested

before disassembly and after assembly to make sure
that the units gears, bearings and seals are working
properly. The following information briefly outlines what
to look for when performing these tests.
THE ROLL TEST
The purpose of the roll test is to determine if the units
gears are rotating freely and properly. You should be
able to rotate the gears in your unit by applying constant force to the roll checker. If you feel more drag in
the gears only at certain points, then the gears are not
rolling freely and should be examined for improper
installation or defects. Some gear packages roll with
more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
THE LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to
fall after the unit has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs,
the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be
detected by brushing a soap and water solution
around the main seal and where the o-rings or gaskets
3-6
JLG Lift
3121813
meet on the exterior of the unit, then checking for air

bubbles. If a leak is detected in a seal, o-ring or gasket,
the part must be replaced, and the unit rechecked.
Leak test at 10 psi for 20 minutes.
Main Disassembly
1. Perform Roll Check and Leak Check if applicable
prior to disassembling the unit.
2. Drain oil from unit. Note the condition and volume of
the oil.
Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure that the bolts are not
tightened beyond their specified torque.
3. Remove Coupling (7) from Spindle End first.

4. Remove Retaining Ring (6G) by prying the open end
of Retaining Ring out of the groove in the Ring Gear
(1F) with a screwdriver, then grasp the loose end
with pliers and pull the Retaining Ring completely
out of the groove.
The following steps describe how to tighten and torque

bolts or socket head cap screws in a bolt circle.
1. Tighten (but do not torque) bolt "A" until snug.
2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
5. Remove the Cover Subassembly (6) from the unit.

The unit can be carefully pressurized with air to pop
the cover out of the unit. Washer (2) may have to be
removed separately because of the loose attachment.
3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply the specified
torque to bolt "A".
5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the remaining bolts.
6. Remove the First Stage Sun Gear (10) if applicable.

NOTE: On units with ratios greater than 36:1 numerically,
there will not be a separate First Stage Sun Gear
(10), as the gear teeth will be integral to the Input
Shaft (9).
7. Remove the Input Carrier Sub-assembly (3). Continued on next page.
8. Remove the Second Stage Sun Gear (11).
9. Remove the Input Shaft (9).
NOTE: On units with a ratio 48:1, the Sun Gear (11) and the
Input Shaft (9) will need to be removed together.
10. Remove the Output Stage Carrier Sub-assembly (4)
11. Loosen and remove the three Flat Head Bolts (19)
that retain the Ring Gear (1F) to the Housing (1G).
12. Lift the Ring Gear (1F) off of the Housing (1G).
13. Remove the O-ring (18) from between the Housing
(1G) and the Ring Gear (1F).
3121813
JLG Lift
3-7
1F.
1G.
2.
3.
4.
6.
6G.
Ring Gear
Housing
Washer
Input Carrier Subassembly
Output Carrier Subassembly
Cover Assembly
Retaining Ring
7.
9.
10.
11.
15.
18.
19.
Coupling
Input Shaft
First Stage Sun Gear
Second Stage Sun Gear
I.D. Plate
O-ring
Flat Head Bolts
Figure 3-2. Main Disassembly Drawing 1
3-8
JLG Lift
3121813
1F.
1G.
4.
5.
6.
6G.
Ring Gear
Housing
Output Carrier Subassembly
Retaining Ring
Cover Assembly
Retaining Ring
9.
10.
11.
18.
19.
20.
Input Shaft
First Stage Sun Gear
Second Stage Sun Gear
O-ring
Flat Head Bolts
Retaining Ring
Figure 3-3. Main Disassembly Drawing 2
3121813
JLG Lift
3-9
Output Carrier Disassembly
3. Using a 1/8" diameter punch, drive the Roll Pin (4G)

out of the Planet Shaft (4E). NOTE: The Roll Pins
(4G) should not be reused when reassembling the
unit.

into the Planet Shaft (4E) until it bottoms against the
Carrier (3A).
4. Slide the Planet Gear Sub-assembly (4) out of the

Output Carrier (4A) being careful to not drop the
Needle Bearings (4C) in the process.
2. Using a soft face hammer, tap the Planet Shaft (4E)

out of the Carrier (4A).
4A
4B
4C
4D
Output Carrier
Thrust Washer
Needle Bearing
Thrust Spacer
4E
4F
4G
4H
Planet Shaft
Planet Gear
Roll Pin
Thrust Washer
Figure 3-4. Output Carrier
3-10
JLG Lift
3121813
5. Remove 4 Thrust Washers (4B), 28 Needle Rollers

(4C) and the Thrust Spacer (4D) from the Second
Stage Planet Gear (4F).
1F
4B
4C
4D
4F
6. Repeat Steps 1 though 5 for the remaining two

Planet Gears (4F).
7. Remove the Thrust Washer (4H) from the counterbore in the Output Carrier (4A).
Output Carrier
Thrust Washer
Needle Bearing
Thrust Spacer
Planet Gear
Figure 3-5. Planet Gear
3121813
JLG Lift
3-11
Input Carrier Disassembly
(4G) should not be reused when reassembling the

unit.

into the Planet Shaft (3E) until it bottoms against the
Carrier (3A).
2. Using a soft face hammer, tap the Planet Shaft (3E)
out of the Carrier (3A).
out of the Planet Shaft (3E). NOTE: The Roll Pins
4. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A).
5. Remove the 14 needle Bearings (3C) from the bore
of the Planet Gear (3F).
6. Repeat steps 1 through 5 for each of the two remaining planet gears.
3A
3B
3C
3E
3F
4G
Carrier
Thrust Washer
Needle Bearing
Planet Shaft
Planet Gear
Roll Pin
Figure 3-6. Input Carrier
3-12
JLG Lift
3121813
Hub-Spindle Disassembly
6. If necessary, press 9 Studs (1H) out of Hub (1G).

Locate Hub (1G) on Seal (1B) end.
1. Place unit on bench with Spindle (1 A) end down.

2. Remove Retaining Ring (1J) with appropriate tool.
3. Remove Spacer (1N).
7. Remove Seal (1B) from Hub (1G).

NOTE: The Seal (1B) should NOT be reused when reassembling the unit.
4. Remove "A" position Bearing Cone (1C) from Bearing Cup (1D) in Hub (1G).
8. Remove "B" position Bearing Cone (1E) from Hub

(1G).
5. Lift Hub (1G) off of Spindle (1 A). Remove Boot Seal

(1Q) from Hub (1G) if applicable.
9. Using a soft steel rod, knock both Bearing Cups

(1D) out of Hub (1G).
1A
1D
1E
1G
3121813
Spindle
Tapered Bearing Cup
Tapered Bearing Cone
Hub (Housing)
1H Stud
1J Retaining Ring Ext.
1N Spacer
1Q Seal Boot
Figure 3-7. Hub Spindle
JLG Lift
3-13
Cover Disassembly
4. Pull Disengage Rod (6D) out from Cover (6A).

5. Use appropriate tool to remove O-ring (6E) from
internal groove in Cover (6A).
1. Remove O-Ring (17) from groove in Cover (6A).

2. Remove Thrust Washer (2) from Cover (6A) pockets.
3. Unscrew two Hex Head Bolts (6C) and remove Disengage Cap (6B) from Cover (6A).
2
3A
6A
6B
6C
6D
6E
6F
17
6. Remove two O-Ring Pipe Plugs (6F) from Cover

(6A).
Thrust Spacer
Input Carrier
Cover
Disengage Cap
Bolt, Hex
Dowel Pin
O-ring
Pipe Plug
O-ring
Figure 3-8. Cover Assembly
3-14
JLG Lift
3121813
Input Carrier Assembly
Output Planet Gear Assembly
(Refer to Figure 3-6., Input Carrier)
(Refer to Figure 3-5., Planet Gear)
1. Apply a liberal coat of grease to the bore of one

Input Planet Gear (3F).
1. Apply a liberal coat of grease to the bore of one Output Planet Gear (4F).
2. Line the inside of the Planet Gear (3F) with 14 Needle Rollers (3C).
2. Line the inside of the Planet Gear (4F) with 14 Needle Rollers (4C).
NOTE: The last roller installed must be installed end wise.

That is, the end of the last roller must be placed in
between the ends of the two rollers which form the
space, and then slid, parallel to the other rollers, into
place.
NOTE: The last roller installed must be installed end wise.

That is, the end of the last roller must be placed in
between the ends of the two rollers which form the
space, and then slid, parallel to the other rollers, into
place.
3. Set Carrier (3A) in an upright position.

4. Insert a Planet Shaft (3E) into the planet shaft hole in
the end of the Carrier (3A) opposite the splined end.
The end of the planet shaft that does NOT have the
roll pin hole should be inserted into the carrier
FIRST.
5. Place one Thrust Washer (3B) onto the end of Planet
Shaft (3E). Make sure the flat faces towards the
inside of the carrier and make sure the button fits in
the pocket on the inside of the Carrier (3A) towards
the OD.
3. Place Spacer (4D) into the bore of the Output Planet

(4F).
4. Repeat Step 2 to put in second roll of Needle Rollers
(4C).
5. Apply grease to hold two Thrust Washers (4B)
together and onto Output Planet Gear (4F) counterbore. Do the same to the other side.
6. Repeat Steps 1 -5 to finish the assembly of the two
remaining Output Planet Gears (4F).
6. Following the thrust washer, place Planet Gear (3F)

with needle rollers, onto Planet Shaft (3E).
7. Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align the Thrust
Washer (3B) in the same manner described in Step
5.
8. Now insert Planet Shaft (3E) through the opposite
planet shaft hole on Carrier (3A). Use an alignment
punch or similar tool to align the roll pin holes on
Carrier (3A) and Planet Shaft (3E).
NOTE: Be sure not to hit the Planet Gears (3F) when driving
in the Roll Pins (4G).
9. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with the flat of carrier.
10. Repeat Steps 1-9 for the installation of the two
remaining Planet Gears (3F).
NOTE: Some grease may need to be applied to the Thrust
Washers (3B) to hold them in place while installing
the planet gears.
3121813
JLG Lift
3-15
Output Carrier Assembly
Hub-Spindle Assembly
(Refer to Figure 3-4., Output Carrier)
(Refer to Figure 3-7., Hub Spindle)
1. Place Thrust Washer (4H) into counterbore of Carrier

(4A). BE SURE the small diameter side of Washer
(4H) facing planet gear side.
2. Place Planet Gear Sub-assembly (4) into Carrier
(4A). Visually align the planet gear bore with one of
the planet shaft holes on the Carrier (4A).
3. Insert a Planet Shaft (4E) into the planet shaft hole
described in Step 2 on Carrier (4A). The end of the
planet shaft that does NOT have the roll pin hole
should be inserted into the Carrier (4A) FIRST.
NOTE: Spray a light film of oil on all component parts during

assembly.
1. Place Hub (1G) into pressing base. Press nine Studs
(1H) into Hub.
NOTE: Use enough pressure to press in studs. Dont use
excessively high pressure to press in studs or hub
may crack.
NOTE: Spray a generous amount of oil on bearings during
installation.
2. Press Bearing Cup (1D), position "A", into Hub (1G)
using appropriate pressing tool.
4. Now insert Planet Shaft (4E) through the first set of

Thrust Washers (4B), Planet gear, then the second
set of Thrust Washers (4B). Use an alignment punch
or similar tool to align roll pin holes on Carrier (4A)
and Planet Shaft (4E).
3. Turn hub over and press Bearing Cup (1D), position

"B", into hub using appropriate pressing tool.
4. Place Bearing Cone (1E), into Bearing Cup (1D),
position "B".
NOTE: Be sure not to hit the Planet Gears (4F) when driving
in Roll Pins (4G).
5. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with OD of Carrier (4A).
5. Grease Seal (1B) lip and press seal into Hub (1G)
using appropriate tool until seal is flush with end of
hub.
6. Repeat Steps 1-5 for the installation of the two

remaining Planet Gears (4F).
6. Press Seal Boot (1Q) onto Hub (1G) if required. Turn

Hub (1G) over and lower onto Spindle (1A).
7. Install Bearing Cone (1C) into Bearing Cup (1D),
position "A".
8. Place Bearing Spacer (1N) on top of Bearing Cone
(1C).
9. Using appropriate tool, install Retaining Ring (1J)
into Spindle (1A) groove. Make sure ring is completely seated in groove.
NOTE: Extra bearing pre-load caused by using tool in Step
#9 must be removed. This should be done by placing a tool (NOT THE SAME TOOL USED IN STEP #9)
on the end of the spindle, and then striking the tool
with a piece of barstock. This should be adequate to
remove any additional bearing pre-load.
3-16
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Cover Subassembly
Main Assembly
(Refer to Figure 3-8., Cover Assembly)
(Refer to Figure 3-2., Main Disassembly Drawing 1 and

Figure 3-3., Main Disassembly Drawing 2)
1. Grease O-Ring (6E) and insert into internal groove in

Cover (6A).
2. Assemble Disengage Cap (6B) onto Cover (6A)
using two Hex Head Bolts (6C). Torque bolts to 7080 in-lbs.
NOTE: All components should receive a generous amount

of lubricant oil as they are being assembled.
1. Place Hub-Spindle Sub-Assembly on the bench.
2. Grease O-Ring (18) and place it into groove of Hub
(1G).
3. Insert Disengage Rod (6D) into hole in Cover (6A)

until it touches the inside of the Disengage Cap (6B).
3. Place Ring Gear (1F) onto Hub (1G). Align the three
shipping Cap Screw Holes on Hub (1G) and Ring
Gear (1F).
NOTE: The Disengage Rod can be inserted either end first.

4. Grease Face of Thrust Washer (2) and place in
Cover (6A) making sure that tangs on washer seat
into pockets in cover.
4. Install three shipping Cap Screws (19) into ring gear

and hub. Torque them to 15-20 ft-lbs.
5. Place Output Carrier Sub-Assembly (4) into mesh
with Spindle (1A) splines.
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The

plugs should be hand tight according to SAE standard.
6. Place External Retaining Ring (5) over 13T spline to

the retaining groove on Input Shaft (9).
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over
Input Shaft (9) first, then install External Retaining
Ring (5).
7. Using appropriate tool to install Retaining Ring (20)
into groove on Output Sun (11)
8. Place Input Shaft (9) spline end into mesh with Internal Coupling (7) splines.
9. With the modified spline end facing up, place the
Output Sun Gear (11) into mesh with the output
planet gears.
10. Place Input Carrier Sub-Assembly (3) onto Output
Sun Gear (11) splines. Drop Input Sun (10) into
mesh with planet gears for specific ratios, if
required. (No timing required)
11. Grease O-Ring (17) and insert into groove in Cover
Sub-Assembly (6).
12. Install Cover Sub-Assembly (6) into Ring Gear (1F)
counterbore and install Retaining Ring (6G) into
groove in Ring Gear (1F).
13. Attach ID Tag (15) onto unit using Drive Screws (16).
14. Check disconnect, roll and air check unit, leak check
brake, and record release pressure. 14. Insert Plastic Plug (12) into place if applicable.
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Figure 3-9. Hub Assembly - Sheet 1 of 2
3-18
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1A
1B
1C
1D
1E
1F
1G
1H
1J
1K
1L
1M
1Q
2
3A
Spindle
Lip Seal
Tapered Bearing Cup
Ring Gear
Hub (Housing)
Stud
Retaining Ring Ext.
Retaining Ring Int.
Spring (1.460,1.500)
Thrust Washer
Seal Boot
Thrust Spacer
Input Carrier
3B
3C
3E
3F
4A
4B
4C
4D
4E
4F
4G
4H
5
6A
6B
Thrust Washer
Needle Bearing
Planet Shaft
Planet Gear
Output Carrier
Thrust Washer
Needle Bearing
Thrust Spacer
Planet Shaft
Planet Gear
Roll Pin
Thrust Washer
Retaining Ring - Ext
Cover
Disengage Cap
6C
6D
6E
6F
6G
7
9
10
11
15
16
17
18
19
20
Bolt, Hex (.250-20 Unc, .500 Gr5)

Dowel Pin
O-ring
Pipe Plug
Retaining Ring - Int 7.086
Coupling
Input Shaft
Input Sun Gear
Output Sun Gear
ID Plate
Drive Screw
O-ring
O-ring
Bolt, Flat Head - Hex Skt (.375-16)
Retaining Ring - Ext.
Figure 3-10. Hub Assembly - Sheet 1 of 2
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3-19
Figure 3-11. Cup Pressing Tool
Figure 3-12. Cup Pressing Tool
3-20
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3.4 DRIVE HUB (FRONT 4WD)
Table 3-2. Motor Torque Table 1
NOTE: The following instructions cover various models of

the drive hub and some instructions may not be
applicable to the drive hub on this machine.
Motor Type
Screw Size
Screw Length
Torque
MCR3
M12
30mm
60Nm Approx.
MCR5
M16
30mm
120Nm Approx.
MCR10
M16
40mm
60Nm Approx.
MCR15
M20
45mm
230Nm Approx.
MCR20
M20
50mm
340Nm Approx.
Safety Instructions
DAMAGE OR INJURY MAY RESULT IF ANY OF THE INSTRUCTIONS IN THIS MANUAL ARE NOT FOLLOWED. IF IN DOUBT CONTACT AN AUTHORIZED JLG REPRESENTATIVE.
1. Prior to attempting any maintenance work on motor
ensure all pressure sources have been disconnected.
DISASSEMBLY
1. When disassembling the unit from the machine,
immediately close openings with plugs to prevent
ingress of contamination.
2. Motors contain stored energy in the form of compressed springs and this must be released using the
method specified in the disassembly instructions.
2. Make note of the details on code plate such as serial

number, type number and running time of unit (for
ordering spare parts).
3. Motors shall be fully supported as specified in installation instructions prior to application of pressure.
3. Remove external dirt.
4. When lifting motors use slings/shackles rated for

motor weight.
4. Have ready a clean work place, lay out tools ready.

5. Use only non-threading cleaning cloths.
General
6. Prior to applying Loctite to a part ensure it and its

mating part are clean, free from oil, grease and all
old Loctite.
The following repair instructions are intended to assist in

inspections and repairs to be carried out. It is prerequisite
that work is carried out only by qualified personnel. These
units are manufactured with great care and with adherence to defined tolerances to the highest manufacturing
accuracy.
Mechanical Brake Release

See Figure 3-13.
Remove screwed cap, item 73. Position a screw, as per
Table 3-2, Motor Torque Table 1 shown below, fitted with
special tool 12, washer, (on MCR10, 15, 20 & 40 motors a
bar, special tool 13, is to used instead of the tool 12)
through the centre of end plate, item 72, into item 67.
Hand tighten screw to brake piston, item 67. Turn screw
until brake is released (Approx 1 turn).
MECHANICAL BRAKE RELEASE SHOULD ONLY BE USED IN THE

E VE N T O F H Y DR A U L IC F AI L U R E. E N S U R E M E C H AN I CA L
RELEASE IS DISENGAGED AFTER USE TO MAINTAIN FAIL-SAFE
OPERATION OF BRAKE.
7. Carry out step by step disassembly.

8. The appearance of the parts removed often gives an
indication of the condition of the system.
For example:
Scored sliding surfaces,
heavy abrasion.
contaminated operating fluid.
Discoloration of components with heavy loading.
overheating of operating fluid,

incorrect choice of viscosity or
inadequate specification of
operating fluid.
insufficient oil.
Park Brake Disassembly Instructions (B-M

only)
See Figure 3-13.
1. Mark rotational position of brake housing, item 65,
relative to rear case, item 26.
ALWAYS REFER TO RELEVANT ASSEMBLY DRAWING.

2. Drain oil from the motor by removing drainage plug,
item 100.
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3-21
3. Remove all Socket Head Cap Screw, item 90.

Unscrew alternately, one turn at a time.
8. The brake housing, item 65, brake discs, items 77 &

78, shims, items 79, 80 and brake shaft, item 66 can
now be removed.
4. Remove cover plate, item 72, gasket, item 74, disc

spring, item 92.
5. Remove piston, item 67, using tapped hole.
6. Remove piston seal, item 82, from piston, item 67.
9. Remove seal, item 70, from brake housing, item 65.

10. Bush, item 94, should remain fixed to shaft, item 66,
unless damaged in which case it should be
replaced.
7. Remove all Socket Head Cap Screw, item 88 and all

washers, item 89.
Figure 3-13. B-M Park Brake
3-22
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Drum Brake Shoe Inspection and Removal
Motor Disassembly Instruction
See Figure 3-14., Dynamic Brake C-M and Figure 3-15.,

Front Case, F Type with C-M Brake.
See Figure 3-13., B-M Park Brake.

1. Mark the relative rotational positions of the front
case, rear case and rotational assemblies.
2. If not previously done, remove plug, item 100 and
drain oil from motor.
3. Remove all capscrews, item 53.
4. Remove rear case assembly, items 26 to 60 and
rotational assemblies items 18 to 25. For motors fitted with piston springs \(motor codes containing
XM\) take care to hold pistons, item 22, in cylinder
block, item 20, using cam, item 25.
Disassembling Front Casing Motor Type F

with Drum Brake (C-M Motor Only)
See Figure 3-14., Dynamic Brake C-M and Figure 3-15.,
Front Case, F Type with C-M Brake.
Figure 3-14. Dynamic Brake C-M

1. Fully release dynamic brake.
2. Plug brake port.
3. Remove brake drum, item 5. If it is tight, clean off the
rust at its joints and apply a small amount of penetrating fluid. Take care to avoid oil on brake shoes.
4. Check the thickness of the brake shoe friction lining.
If friction lining thickness is 1.5mm \(0.06in\) or less,
the shoe must be renewed.
5. Note the position of the shoes, the brake cable position relative to the motor and the holes fixing the
retaining springs.
6. Remove brake cable. Note how cable hooks onto
dynamic
7. Depress retaining springs, item A (2 off), and
unhook from back plate.
8. Remove bolts, item B (2 off). Allowing plate, item C,
to be removed.
9. Remove retaining springs, item D \(2off\).
Figure 3-15. Front Case, F Type with C-M Brake
10. Remove retaining spring, item E.

11. Remove brake shoes, item F (2 off).
1. Remove O-ring, item 41.
12. If brake shoes, item F, are glazed then roughen surface with emery paper.
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2. Remove split ring, item 4, using a soft steel drift to

separate. Then remove washer, item 3.
3-23
3. Support front casing on blocks and press shaft, item

1, out of bearings. Remove rear bearing cone, item
7, from assembly.
4. Remove wiper seal, item 10.
5. Remove all S.H.C.S, item
63, from front case, item
2.
6. Lift dynamic brake from
front case assembly.
7. Lever lip seal, item 11
\(and 14 if fitted\), from
front case.
8. Remove rear bearing
cup, of item 7, from front case using a mechanical
puller or a soft steel drift.
9. Remove front bearing cup, of item 6, from front case
using a mechanical puller or a soft steel drift.
10. Remove bearing cone, item 6, from the shaft, item 1,
using a mechanical puller.
11. If fitted, remove spacer, item 12, from shaft, item 1
Disassembling Front Casing, All Types

See Figure 3-16., Figure 3-17., Figure 3-18., and Figure 319.
Figure 3-16. MCR 10, 15, 20, & 40 Front Case C & F
Figure 3-17. MCR 3 & 5 Front Case C, F, & G Type
3-24
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6. Carefully remove seal, item 11, from front case, item

2.
7. Remove rear bearing cup, of item 6, from rear case
using a mechanical puller or soft steel drift.
8. Remove bearing cones, items 6 & 7, from the shaft,
item 1, using a mechanical puller or soft steel drift.
9. If fitted, remove shaft spacer, item 12, from shaft,
item 1.
Disassembling the Rear Casing Assembly

See Figure 3-23., Figure 3-24., and Figure 3-25.
1. A_M & C_M Motors only. Remove all hex head
screws, item 39, from rear case, item 26.
2. A_M & C_M Motors only. Remove end cover, item
38.
3. Remove O-rings, item 31, 41 \(and 36 if fitted\), from
rear case, item 26.
4. Drop the rear case assembly from approximately
80mm onto a wooden or plastic surface \(timing face
down\). This will release distributor, item 27, from
assembly. At all times take care not to damage timing face.
Figure 3-18. MCR 3 & 5 Front Case A, D, & E Type
5. Remove stop pin, item 28, from rear case, item 26.
6. Check timing face of distributor. If necessary lap timing face.
7. Remove and discard all the seal rings if fitted, items
47 to 51.
NOTE: Steps 8 thru 14 are applicable to Two Speed Motors
Only. See Figure 3-20., Figure 3-21., and Figure 322.
Figure 3-19. MCR 10 Front Case D Type

1. Remove O-ring, item 41.
2. Remove split ring, item 4, using a soft steel drift to
separate. Then remove washer, item 3.
3. Support front casing on blocks and press shaft, item
1, out of bearings. Remove rear bearing cone, item
7, from assembly.
4. Remove bearing cup, of item 7, using mechanical
puller.
5. Carefully remove seal, item 10, from shaft, item 1,
and/or front case, item 2.
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3-25
8. Remove spool valve assembly, items 55, 56, 58 and

Code 2W only items 71 & 76.
Figure 3-22. Two Speed Spool Valve - Code 2W

Alternative Design
Figure 3-20. Two Speed Spool Valve
10. Remove spring, item 57.

9. 2W Figure 3-21. only. Remove internal spool and
spring, item 71, from spool valve assembly.
11. Remove circlip, item 58, and washer, item 56, from
spool valve, item 55.
12. 2W Figure 3-21. only. Remove seal ring, item 54, and
seal, item 60, from cover or brake housing.
13. Remove seal, item 59, from cover or brake housing.
14. Inspect spool for damage, replace if required.
Figure 3-21. Two Speed Spool Valve - Code 2W
3-26
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Figure 3-23. MCR 3 & 5 Low Displacement, AOM, Single Speed
Figure 3-24. MCR 3 & 5 Low Displacement, AOM, Two Speed MCR 10 & 15 Low Displacement, AOM,
Single & Two Speed
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3-27
Figure 3-25. MCR 20 & 40 Low Displacement, AOM, Single & Two Speed
3-28
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Disassembling Rotating Assembly
4. Remove retaining rings, item 24 (2 off).
See Figure 3-26. and Figure 3-27.
5. All motors. Each piston assembly, item 21 & 22, can

be removed under gravity or by low air pressure
applied to the ports in the cylinder block, item 20.
1. Piston spring motors only (motor codes containing

XM). If optional springs fitted, care should be taken
when disassembling the piston assemblies. To prevent piston assemblies, items 21, 22 and the
springs, item 18, becoming damaged or lost, cloths
should be held firmly over the entire rotating group
when removing cam, item 25.
6. Remove rollers, item 21, from piston assembly and

check for wear on rollers piston seats.
7. Check timing face of cylinder block. If necessary lap
timing face.
REASSEMBLY
1. Use only genuine Rexroth Spare Parts. We recommend the use of pre-assembled, co-ordinated and
tested component groups. The required component
groups and seal kits should be selected from the
spares list and ordered by quoting the name plate
details. If in doubt contact the local authorized
Rexroth agent.
2. Assembly should be carried out observing the maximum cleanliness.
3. On completion of repair, close all openings with
plugs. Should difficulties arise, please contact your
nearest service centre.
4. Do not re-use old seals.
5. Oil all seal contact areas before assembly using system hydraulic oil unless otherwise stated in text.
6. Tighten screws with torque wrench according to
specification. We recommend that all fastening
screws, items 53, 88 and 90, are changed at reassembly.
Figure 3-26. Low

Displacement
Figure 3-27. High

Displacement
2. Remove cam, item 25, from rotational assembly.

3. High displacement motors only. Supporting cylinder
block, item 20, at the edges with blocks, remove circlip, item 23, (2 off).
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3-29
Reassembling Front Casing, All Types

(Except C-M Motors)
See Figure 3-28., Figure 3-29., Figure 3-30., and Figure 331.
Figure 3-29. MCR 3 & 5 Front Case - A, D, & E Type
Figure 3-28. MCR 3 & 5 Front Case - C, F, & G Type
Figure 3-30. MCR 10 Front Case - D Type
3-30
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5. MCR3 & 5 only. Fit seal, item 10, to shaft, item 1.

Smear lip of seal with G3 grease.
6. MCR10, 15, 20, 40 "C" & "F" Only. Fit both halves of
seal, item 10, to front case, item 2, and shaft, item 1,
using special assembly tool 1. Smear contact faces
with system oil.
7. MCR5 "F", MCR20 & 40 Only. Place spacer item 12,
onto shaft, item 1.
8. Place drive shaft, item 1, vertically on a press.
9. If required, place suitable sized cylinder underneath
shaft flange, item 1. (Cylinder should be large
enough to ensure shaft rests on cylinder not wheel
studs).
10. Warm front bearing cone, item 6, then press onto
shaft, item 1, using bench press and special assembly tool 2.
11. MCR3, 5 and MCR10 "D" Type only. Pack front bearing cone, item 6, with G3 grease.
12. Cover shaft spline diameter with tape, to protect lip
seal.
13. Fit front case assembly to shaft assembly.
14. MCR10, 15, 20 & 40 "C" and "F" Only. Insert seal,
item 11, into front case, item 2, using special tool 4.
Smear lip of seal, item 11, with G3 grease. Ensure
hole for plug, item 17, is ventilated during assembly
of seal, item 11.
15. Remove tape from spline.
16. Warm rear bearing cone, item 7, and fit to shaft, item
1, by pressing onto shaft using bench press and
special assembly tool 6 to a load of 4 tonnes. Rotate
the front case 5 times during this process.
17. Using bench press and special assembly tool 7,
apply a load of 4 tonne to rear bearing, item 7 and fit
split ring, item 4, onto shaft, item 1. Rotate case during this process.
Figure 3-31. MCR 10, 15, 20, & 40 Front Case C & F Type
1. Ensure all components are clean and free from
debris.
2. Insert bearing cup, item 6, into front case, item 2,
using special assembly tool 3.
3. MCR3, 5 & MCR10 "D" Only. Insert seal item 11, into
front case, item 2, using special assembly tool 4.
Smear lip of seal, item 11, with G3 grease.
4. Insert rear bearing cup, item 7, into front case, item
2, using special assembly tool 5.
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18. With pre-load still applied, measure gap between

bearing and split ring with slip gauges (This step
should be completed less than 10 minutes after
removing bearing from heater).
19. Remove load.
20. MCR3 & 5 only. Remove split ring, item 4, and fit a
washer, item 3, with thickness 0.1 to 0.2mm (0.004"
to 0.008") greater than measured gap, then refit split
ring.
21. MCR10, 15, 20 & 40 only. Remove split ring, item 4,
and fit a washer, item 3, with thickness 0.2 to 0.3mm
(0.008" to 0.012") greater than measured gap, then
refit split ring.
JLG Lift
3-31
22. Check shaft, item 1, rotates in front casing assembly.

23. MCR10, 15, 20 & 40 C and F Only. Half fill volume
with system oil, apply Loctite 542 to plug, item 17,
and insert in drive shaft, item 1.
24. MCR10 "D" Type Only. Fit Seal, item 10, into front
case, item 2. Smear lip of seal with G3 grease, prior
to assembly.
25. Place aside and cover to protect against ingress of
dirt.
9. Depress retaining springs, item A (2 off) and hook

springs onto back plate.
10. Fit brake cable.
11. If brake shoe has oil on it then remove all evidence
of oil from shoe. (Use brake and clutch cleaner).
Reassembling Casing, F Type with Drum

Brake (C-M)
See Figure 3-33.
Reassembling Dynamic Brake (C-M Motors

Only)
See Figure 3-32.
Figure 3-33. Front Case, F Type with C-M Brake

1. Ensure all components are clean and free from
debris.
Figure 3-32. Dynamic Brake C-M

1. Fit plate, item C, to back plate.
2. Insert bearing cup, item 6, into front case, item 2,

using special assembly tool 3.
2. Insert \(2 off\) screws, item B.
3. Combine back up ring, item 14, with lip seal, item 11

(MCR10 only).
3. Fit first brake shoe with attached lever.

4. Fit second brake shoe without lever and hook lever
with first brake shoe.
5. With a soft mallet tap shoes inward. This decreases
brake shoe O.D. so allowing brake drum to be fitted.
6. With pliers fit lower retaining spring, item E.
7. With pliers fit upper retaining springs, item D (2 off).
5. Smear lip of seal, item 11, with G3 grease.

6. Insert rear bearing cup, item 7, into front case, item
2, using special assembly tool 5.
7. Lift dynamic brake, item 62, onto front case assembly. Align bolt holes.
8. Insert retaining springs, item A (2 off).
3-32
4. Insert seal, item 11, or seal assembly \(MCR10

only\), items 11 & 14, into front case, item 2, using
special assembly tool 4.
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8. MCR3 and 10 only; Insert socket head capscrew,

item 63 (6 off), into front case, item 2.
MCR5 and 15 only; Fit washers, (6 off), to hex head
screw, item 63 (6 off), and insert into front case, item
2.
9. Torque screws, item 63 (6 off), in accordance with
Table 3-3, Motor Torque Table 2.
Motor Type
19. Warm rear bearing cone, item 7, and fit to shaft, item
1, by pressing onto shaft using bench press and
special assembly tool 6 to a load of 4 tonnes. Rotate
front case 5 times during this process.
20. Using bench press and special assembly tool 7,
apply a load of 4 tonne to rear bearing, item 7, and
fit split ring, item 4, onto shaft, item 1. Rotate case
during this process.
21. With pre-load still applied, measure gap between
bearing and split ring with slip gauges \(this step
should be completed less than 10 minutes after
removing bearing from heater\).
Item 63 Torque
MCR3
117-122 Nm (89-90 ft.lbs.)
MCR5
170-176 Nm (129-134 ft.lbs.)
MCR10
560-580 Nm (426-441 ft.lbs.)
22. Remove split ring, item 4, and fit washer, item 3,

thickness 0.05 to 0.1mm (0.002" to 0.004") greater
than measured gap, then refit split ring.
MCR15
560-580 Nm (426-441 ft.lbs.)
23. Remove load.
10. MCR5, 10 and 15 only; Insert spacer, item 12, onto

shaft, item 1.
11. Place suitable sized cylinder underneath shaft, item
1. Cylinder should be large enough to ensure shaft
rests on cylinder not wheel studs, if fitted.
12. Warm front bearing cone, item 6, then press onto
shaft, item 1, using bench press and special assembly tool 2.
13. Pack front bearing cone, item 6, with G3 grease.
14. Fit wiper seal, item 10, to shaft (MCR3 & 5 only),
item 1, or front casing (MCR10 & 15 only), item 2, as
shown in Figure 3-33., Front Case, F Type with C-M
Brake. Smear wiper seal with G3 grease.
24. MCR3 & 5 only. Remove split ring, item 4, and fit a
washer, item 3, with thickness 0.1 to 0.2mm (0.004"
to 0.008") greater than measured gap, then refit split
ring.
25. MCR10, 15, 20 & 40 only. Remove split ring, item 4,
and fit a washer, item 3, with thickness 0.2 to 0.3mm
(0.008" to 0.012") greater than measured gap, then
refit split ring.
26. Check shaft, item 1, runs free but slightly stiff in front
casing assembly.
27. Fit brake drum, item 5, to front case assembly.
Setting Drum Brake
15. Place front casing assembly, shaft assembly, rear

bearing, item 7, washer, item 3, and split ring, item 4,
on bench.
16. Cover shaft spline diameter with tape, to protect lip
seal, item 11.
1. Remove plastic plugs (4 off) from holes in drum

brake back
2. Using feeler gauges/shims measure gap between
brake drum, item 5, and brake shoe, item F, on each
side through measurement holes (2 off), see Figure
3-32. and Figure 3-33.
3. MCR5, 10 & 15 only: Set each gap in turn to 0.5mm
(0.020) by rotating relevant adjustor with a screwdriver through adjustment holes, see Figure 3-32.
17. Fit front case assembly to shaft assembly.

18. Remove tape from spline.
4. MCR3 only: Set gap on one side to 0.5mm (0.020)

and greater than 0.5mm (0.020) on the other by
rotating single adjustor with a screwdriver through
adjustment hole, see Figure 3-32.
5. Replace plastic plugs (4 off) in drum brake back
plate.
6. Place aside and cover to protect against ingress of
dirt.
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3-33
Table 3-4. Piston Assembly Information

Motor Type
Items 21 & 22 No. of
Low Displacement (cc/rev)
High Displacement (cc/rev)
MCR3
160, 225, 255, 280
325, 365, 400
MCR5
380, 470, 520, 565
680, 750, 820
MCR10
10
780, 940
1120, 1250, 1340
MCR15
10
1130, 1250, 1500
1780, 2150
MCR20
10
1750, 2100
2500, 3000
MCR40
10
2500, 3000, 3500, 4200
Reassembling Rotating Assembly

See Figure 3-34. and Figure 3-35.
Figure 3-35. High Displacement

1. Check all components are clean and free from
debris. Take care not to damage timing face.
Figure 3-34. Low Displacement
2. Fit roller, item 21, to piston assembly, item 22. Dip

piston assembly into oil.
3. Fit piston, item 22, and roller, item 21, to piston bore
in cylinder block, item 20.
3-34
JLG Lift
3121813
4. Repeat for each piston bore in cylinder block, item

20.
5. Piston Spring motors only (motor codes containing
XM) If optional springs are fitted, insert piston
assemblies, items 21 & 22, and springs, item 18, into
the cylinder block and hold in position using special
tool 10.
6. Place the cam, item 25, over the assembled rotary
group and carefully remove each special tool 10.
7. High displacement motors only: Fit retaining rings,
item 24 (2 off) to cylinder block, item 20 (Ensuring
orientation of ring area as shown in part view). Align
and secure using circlips, item 23 (2 off).
Reassembling Rear Casing Assembly

Figure 3-37. MCR 3 Low Displacement, AOM, Single
Speed
Figure 3-36. Low Displacement, AOM MCR 3, 5 Two

Speed & MCR 10, 15 Single & Two Speed
Figure 3-38. MCR 20 & 40 Low Displacement, AOM,

Single & Two Speed
debris.
2. Place springs, item 29 (see Table 3-5, Motor Torque
Table 3), into recesses in distributor, item 22, using a
small amount of mineral based grease to hold
springs in position.
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JLG Lift
3-35

Motor Type
Item 29 No. of
Item 53 No. of
MCR5
MCR10
12
MCR15
MCR20
MCR40
MCR3
Item 53 Torque
Item 39 Torque
150-155 Nm (111-114 ft.lbs.)
40-45 Nm (29-33 ft.lbs.)
12
117-122 Nm (86-90 ft.lbs.)
40-45 Nm (29-33 ft.lbs.)
282-300 Nm (208-221 ft.lbs.)
75-80 Nm (55-59 ft.lbs.)
14
16
282-300 Nm (208-221 ft.lbs.)
150-160 Nm (111-118 ft.lbs.)
16
16
282-300 Nm (208-221 ft.lbs.)
150-160 Nm (111-118 ft.lbs.)
16
16
282-300 Nm (208-221 ft.lbs.)
150-160 Nm (111-118 ft.lbs.)
3. Insert distributor seals, items 47 to 51 as depicted in

Figure 3-36., Figure 3-37. & Figure 3-38., into correct
grooves with minimum distortion of seals.
4. MCR5 Single speed & MCR10 only. Fit O-ring item
33, to stop pin, item 28. MCR5 Single speed A0M
only. Fit capscrew, item 35, to stop pin, item 28.
5. MCR20 & 40 only. Assemble circlip, item 32, onto
stop pin, item 28.
6. All motor except MCR5 Single speed & MCR10.
Insert stop pin, item 28, into correct distributor stop
pin hole stamped L & R, per motor code, see page
4.
7. Using special tool 11, fit and align distributor, item
27, into rear case, item 26, in line with stop pin hole
in rear case.
8. MCR5 Single speed & MCR10 only. Insert stop pin,
item 28, into rear case, item 26, ensuring the stop
pin fully engages with the correct distributor slot per
motor code, see page 4.
9. Insert plug assembly, item 100, and secure with
Allen key.
NOTE: Steps 10 thru 13 are for Two Speed Motors, code 2L/
2R only. See Figure 3-39.
Figure 3-39. Code 2L/2R Two Speed Only

10. Fit circlip, item 58, and washer, item 56, onto spool,
item 55.
11. Insert spring, item 57, into rear case, item 26.
12. Insert O-ring, item 59, into cover or brake housing,
item 38.
13. Oil spool and fit spool assembly, items 55, 56 and
58, into rear case, item 26 (Check that assembly is
free to move).
NOTE: Steps 14 thru 18 are for Two Speed Motors, code
2W, only. See Figure 3-40.
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19. Ensure the correct combination of washer and

spring is selected before assembly. Fit circlip, item
58, and washer, item 56, onto spool, item 55.
21. Insert O-ring, item 59, into cover or brake housing,
item 38.
22. Oil spool and fit shuttle valve assembly, items 55, 56,
58 and 76 into rear case, item 26 (Check that assembly is free to move).
NOTE: Steps 23 and 24 are for MCR10, 15, & 20 Single
Speed Motors only. See Figure 3-42. and Figure 343.
Figure 3-40. Code W Two Speed Only

14. Fit circlip, item 58, and washer, item 56, onto spool,
item 55.
16. 2W Figure 3-40. only. Insert spring, item 71, and
poppet, item 76, into spool valve, item 55.
17. Insert O-rings, item 59 and item 60 into seal ring,
item 54 and fit seal ring to brake housing or end
cover, item 38.
18. Oil spool and fit shuttle valve assembly, items 55, 56,
58, 71 and 76 into rear case, item 26 (Check that
assembly is free to move).
Figure 3-42. MCR 20 Single Speed Only
NOTE: Steps 19 thru 22 are for Two Speed Motors, code

2W, Alternative design only. See Figure 3-41.
Figure 3-43. MCR 10 & 15 Single Speed Only

Figure 3-41. Code W Two Speed Only - Alternative
Design
23. Assemble plug, item 62, into spool bore using loctite
542 and torque plug to 42-45 Nm.
24. Assemble plug, item 63 (x2 on MCR20), into spool
bore(s) and torque to 79-85 Nm.
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3-37
7. Torque capscrews, item 53, as per Table 3-5, Motor

Torque Table 3. Tighten opposites to maintain
squareness.
NOTE: Step 25 is for MCR40 Single Speed Motors only. See

fFigure 3-44.
8. Check drive shaft to ensure motor rotates freely.

9. A_M or C_M motors only. Remove plug, item 100,
from rear case, item 26, and fill motor with clean
hydraulic system oil. Replace plug, item 100.
Reassembly of Park Brake (B-M Motor Only)

See Figure 3-45.
Figure 3-44. MCR 40 Single Speed Only

25. Fit circlip, item 58, onto spool, item 55. Insert O-ring,
item 59, into cover or brake housing. Oil spool and
fit into rear case.
NOTE: A0M C-M Motors only.
26. Place end cover, item 38, onto rear case, item 26.
27. Insert capscrews, item 39, into rear case, item 26.
Start bolts by hand.
28. Torque capscrews, item 39, per Table 3-5, Motor
Torque Table 3. Tighten opposites to maintain
squareness.
Motor Assembly
debris.
2. Fit face O-ring, item 41, to front casing assembly,
item 2.
Figure 3-45. Low Displacement, Single Speed, B-M
3. Fit rotating assembly to front casing assembly,

being careful not to damage splines on shaft, item 1,
or cylinder block, item 20. Position cam, item 25, on
front casing assembly, aligning reference marks
made before disassembly.
4. Fit O-ring, item 41, to rear casing assembly and
position rear case assembly on cam, aligning reference marks.
5. Put Loctite 243 on capscrews, item 53.

debris.
2. If bush, item 94, has been removed, press fit new
bush to shaft, item 66 (or brake piston, item 67, on
MCR15, 20 & 40). Ensure bush is assembled fully
home in shaft, item 66 (or brake piston, item 67, on
MCR15, 20 & 40).
3. Insert brake shaft, item 66, through distributor, item
27, to cylinder block, item 20. Ensure shaft fully
enters cylinder block, item 20.
6. Fit capscrews, item 53, to assembly and start all

capscrews by hand before tightening.
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4. Assemble brake discs, items 77 & 78 (see Table 3-6,

Park Brake Assembly Information), into a pack.
Clamp pack in vice. Ensure inner discs, item 77,
alternates with outer discs, item 78, and an outer
disc is placed at each end of the pack. MCR5 only.
Washer, item 61, is to be included when assembling
the pack.
5. Check pack height adding shims, items 79 & 80, as
required to obtain a pack height as per Table 3-6,
Park Brake Assembly Information. An extra outer
plate is preferred to reduce the number of required
shims. Shims should be placed at end of pack in
contact with rear case, item 26 (or washer, item 61).
6. MCR5 only. Fit washer, item 61, to rear case, item
26.
7. Fit brake housing, item 65, to rear casing assembly.
Aligning reference marks made prior to disassembly.
8. Apply Loctite 243 to socket head capscrews, item 88
(see Table 3-6, Park Brake Assembly Information).
Fit capscrew, item 88, with washers, item 89, to rear
case, item 26. Start each screw by hand then tighten
as per Table 3-6, Park Brake Assembly Information.
Tighten opposites to maintain squareness.
10. Fit outer seal, item 70, to brake housing, item 65,
ensuring correct orientation of seal to groove. (On
latest motors this seal has been revised and may
required a tool for assembly).
11. Fit piston seal, item 82, to piston, item 67.
12. Fit piston, item 67, and seal, item 82, to brake
assembly. Oil seals prior to fitting and ensure no
damage to seals occurs on assembly.
13. Fit disc spring, item 92. Ensure contact surfaces are
coated with S1 grease.
14. Place end cover, item 72, and gasket item 74, onto
brake housing, item 65.
15. Insert bolts, item 90 (see Table 3-6, Park Brake
Assembly Information), into brake housing, item 65.
Start bolts by hand.
16. Torque bolts, item 90, as per Table 3-6, Park Brake
Assembly Information. Tighten opposites to maintain squareness.
17. Refit plug assembly, item 73, and tighten.
18. Close all openings with plugs.
19. Remove plug, item 100, from rear case, item 26, and
fill motor with clean hydraulic system oil. Replace
plug, item 100.
9. Fit brake pack, items 77, 78, 79 & 80 to brake shaft,

item 66.
Table 3-6. Park Brake Assembly Information
Motor Type
Pack Height
No of
Item 77
No of
Item 78
No of
Item 90
No of Item
88 & 90
MCR3
28.2 0.1
15
13
12
MCR5
36.45 0.05
16
14
24
35-39 Nm (26-29 ft.lbs.)
70-77 Nm (52-57 ft.lbs.)
MCR10
41 0.1
19
17
24
70-77 Nm (52-57 ft.lbs.)
117-122 Nm (86-90 ft.lbs.)
MCR15
39.7 0.1
19
17
24
70-77 Nm (52-57 ft.lbs.)
282-300 Nm (208-221 ft.lbs.)
MCR20
48.5 0.1
20
18
24
117-122 Nm (86-90 ft.lbs.)
282-300 Nm (208-221 ft.lbs.)
Item 90 Torque
14-16 Nm (10-12ft.lbs.)
Item 88 Torque
70-77 Nm (52-57 ft.lbs.)
MCR40
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3-39
Park Brake Test (B-M Motor Only)
Flushing Valve
See Figure 3-45., Low Displacement, Single Speed, B-M

1. Increase pressure to brake port until motor shaft just
begins to move by hand. This brake release pressure should not exceed 15 bar g (217 psi g).
2. With 250 bar (3625 psi) differential pressure applied
to motor, and zero brake release pressure, the brake
should hold the motor torque.
See Figure 3-46.
DISASSEMBLY
NOTE: Motor may require to be disassembled prior to starting work.
1. Remove plug, item 106, and O-ring, item 107, from
rear case, item 26.
Figure 3-46. Flushing Valve
3-40
JLG Lift
3121813
3. Remove poppet, item 104, and shim, item 103, if fitted.
Appendix A
See Figure 3-47. for special tools
4. Remove plug, item 43, and O-ring, item 44, from rear
case, item 26.
6. Remove flushing spool, item 100 and washer, item
102.
7. Remove spring, item 108, from rear case spool bore.
8. Inspect spool and poppet for any damage, scores or
debris. If necessary replace.
REASSEMBLY
1. Fit spring, item 108, into rear case spool bore.
2. Oil and insert flushing spool, item 100, into rear case
spool bore. Ensure that it is free to move.
3. Fit flushing washer, item 102.
4. Fit spring, item 109.
5. Fit plug and O-ring, items 43 and 44.
6. Torque plug to 35-40 Nm.
7. Assemble shim (if required), item 103, and spring,
item 105, to poppet, item 104, before inserting poppet in to rear case.
8. Oil and insert poppet assembly items 103, 104 and
105.
9. Fit plug and O-ring, items 106 and 107.
10. Torque plugs to 12-15 Nm.
Figure 3-47. Special Assembly Tools

NOTE: Special tools can be obtained from Mannesmann
Rexroth (Scotland). State full motor code, tool
description and number required.
GENERAL EQUIPMENT (ASSEMBLY AND

DISASSEMBLY)
1. Allen key set and double ended ring spanner set.
2. Soft mallet.
3. Torque wrench covering the ranges:
a. 14-19 Nm (10-12 ft.lbs.)
b. 35-39 Nm (26-29 ft.lbs.)
c. 40-45 Nm (30-33 ft.lbs.)
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3-41
d. 70-77 Nm (52-57 ft.lbs.)
Appendix C
e. 75-80 Nm (55-59 ft.lbs.)
Fault Finding
f. 117-122 Nm (86-90 ft.lbs.)
1. Motor does not rotate:
g. 150-160 Nm (111-118 ft.lbs.)
Confirm there is pressure and oil flow supplied to the

motor and the return line is clear.
h. 170-176 Nm (129-134 ft.lbs.)

i. 282-300 Nm (208-260 ft.lbs.)
Disconnect motor from mechanical load \(ensure no

pressure is applied to motor during disconnection\).
Then confirm motor rotates.
j. 560-580 Nm (426-441 ft.lbs.)

4. Soft steel drift.
Check motor case drain leakage is within datasheet

recommendations.
5. Small screwdriver (no sharp edges).

6. Bench press max load at least 4 tonnes.
If still jammed confirm pump is outputting correct oil

flow.
7. Slip gauges & mechanical (or hydraulic) puller.
Strip and inspect motor for damage.
Appendix B
2. External oil leaks:
Grease Specification
Codetype
Check oil cleanliness and motor pressure.
S1 Lithium-base high temperature grease containing

molybdenum disulphide (Mo S2) for specific high load/
temperature use. Only to be used where specifically
called out on drawing. eg. B.P. Energrease L21-M, Castrol
LMM, Esso Multipurpose Grease Moly, Shell Retinax M
Confirm leakage line is unblocked and case drain pressure is less than 10 bar (145 psi).
G3 A high performance industrial grease of medium/hard

consistency (NLG1 No 3). Temperature range -30C to
150C.(-22F to 302) eg. Shell Alvania G3
3. High temperature/noisy operation:
Strip and inspect motor. Replace seals.

Ensure all bolts are torqued to correct setting.
Check case drain pressure is less than 10 bar (145

psi).
Check charge pressure is above case drain pressure
and in accordance with datasheet recommendations
for operation as a pump.
Check motor mounting is correct (see installation).
Strip motor and inspect cam, rollers, pistons and main
bearings for wear.
4. Motor speed incorrect:
Check pump flow is sufficient for desired motor speed.
Check motor leakage flow. If higher than maximum
specified in data sheet, inspect motor.
Check motor differential pressure is correct.
3-42
JLG Lift
3121813
3.5 DRIVE BRAKE - MICO
4. Install shaft assembly and retaining ring (17) in

cover (21).
Disassembly
NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.
1. Remove pressure plate (3) from cover (21) by

removing the capscrews (1) and washers (2).
5. Install dowel pins (20), spring retainer (16) and

springs (5) in cover plate (21).
6. Position plate (14) on springs (15). NOTE: Disc (13
&11) and plate (14) must remain dry during
installation. No oil residue must be allowed to
contaminate disc surfaces.
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 1500 LBS (680 KGF). THE FOUR CAP SCREWS SHOULD
BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 3000 LBS (1361 KGF) MINIMUM, THE
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING
THE CAP SCREWS AND WASHERS
7. Press the speed sensor ring (12) onto the rotor disc
(13).
8. Place a new rotor disc (13) on the shaft (10) until it
contacts the plate (14). Install stator disc (11).
2. Remove case seal (4) from cover (21).

3. Remove piston (7) from pressure plate (3).
9. Install new o-ring (5), new back-up ring (6), new oring (8) and new back-up ring (9) on piston (7). Note
order of o-rings and backup rings. Insert piston (7)
into pressure plate (3). Be careful not to shear orings or back-up rings.
4. Remove o-ring (5), back-up ring (6), o-ring (8) and

back-up ring (9) from piston (7).
10. Install new case seal (4) in cover (21).
IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED,

THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SENSOR RING IS NOT AVAILABLE AS A SERVICE PART.
5. Remove stack assembly, consisting of stator disc
(11), sensor ring (12), rotor disc (13), and plate (14)
from cover (21).
11. Position pressure plate (3) on cover (21) aligning

dowel pins (20) with holes in pressure plate.
NOTE: A hydraulic press will simplify installation of pressure
plate on cover. Clamp pressure plate in position
while tightening the cap screws.
6. Remove dowel pins (20), springs (15) and spring

retainer (16) from cover (21).
12. Install capscrews (1) and washers (2) and tighten

evenly to draw pressure plate (3) to cover (21).
Torque capscrews to 55 ft.lbs. (74.6 Nm).
NOTE: Note number and pattern of springs for reassembly

purposes.
7. Remove retaining ring (17) from cover (21).
8. Remove shaft (10) by pressing or using a soft mallet
on male end of the shaft.
9. Remove retaining ring (19) and bearing (18) from
shaft (10).
10. Press rotary oil seal (20) from cover (18).
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE

BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE
USED FOR SUPPLEMENTAL CLAMPING.
Bleeding
I
1. Install brake in system and connect pressure lines.
Assembly
NOTE: Lubricate all rubber components from the repair kit
with clean type fluid used in the system.
2. Bleed pressure release section of brake by pressurizing side inlet port and allowing air to escape from
top port. Pressure should not exceed 100 psi (6.9
bar) during bleeding.
3. Apply sufficient pressure to release brake and check
for proper operation in system.
1. Clean all parts thoroughly before assembly.

2. Press new rotary seal (22) into cover (21). Note
direction of seal
3. Install new bearing (18) and retaining ring (19) on
shaft (10).
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JLG Lift
3-43
1.
2.
3.
4.
5.
6.
Capscrew
Washer
Pressure Plate
Case Seal
O-ring
Backup Ring
7.
8.
9.
10.
11.
12.
Piston
O-ring
Backup Ring
Shaft
Stator Disc
Sensor Ring
13.
14.
15.
16.
17.
18.
Rotor Disc
Plate
Spring
Spring Retainer
Retaining Ring
Bearing
19.
20.
21.
22.
23.
Retaining Ring
Dowel Pin
Cover
Rotary Oil Seal
Gasket
Figure 3-48. Drive Brake
3-44
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3121813
Table 3-7. Drive Brake Diagnosis

Problem
Brake slips
Brake drags or runs

hot
Brake will not release
3121813
Cause
Explanation
Corrective
Action
Excessive pressure In hydraulic

system
If there is back pressure in the actuation line of the

brake, holding torque will be reduced.
Check filters. hose size, restrictions

in other hydraulic components.
Oil In brake if designed for dry

use
Wet linings generate 67% of the dry torque rating. If

the brake has oil In it, check the type of oil hydraulic
or gearbox.
1. Gearbox oil
2. Hydraulic oil
Replace oil seal in brake. Check

motor seal. Check piston seals.
Note: Internal components will
need to be inspected, cleaned, and
replaced as required.
Disc plates worn
The thickness of the disc stack sets the torque level.

A thin stack reduces torque.
Check disc thickness.
Springs broken or have taken a

permanent set
Broken or set springs can cause reduced torque rare occurrence.
Check release pressure.

(See spring replacement)
Low actuation pressure
The brake should be pressurized to minimum of

1.38 bar (20 psi) over the full release pressure under
normal operating conditions. Lower pressures will
cause the brake to drag thus generating heat.
Place pressure gauge in bleed port

& check pressure with system on.
Bearing failure
If the bearing should fall. a large amount of drag can

be generated.
Replace bearing.
Stuck or clogged valve
Brakes are designed to come on when system pressure drops below stated release pressure. If pressure cannot get to brake, the brake will not release.
Place pressure gauge in bleed port

- check for adequate pressure.
Replace defective line or component.
Bad O-rings
f release piston will not hold pressure, brake will not

release.
Replace o-rings.
Discs frozen
These brakes are designed for only limited dynamic

braking. A severe emergency stop or prolonged
reduced release pressure operation may result in
this type of damage.
Replace disc stack.
JLG Lift
3-45
3.6 SPEED SENSOR ADJUSTMENT

IF BOTH SPEED SENSORS ARE INSTALLED WRONG, THE CONTROLLER WILL THINK THE MACHINE IS ON A HILL AND WILL GO
INTO FULL SPEED MODE IMMEDIATELY WHEN DRIVE IS
SELECTED. THE MACHINE WILL NOT STOP UNLESS THE FOOTSWITCH IS RELEASED OR THE EMS IS PUSHED IN.
IF ONLY ONE SENSOR IS INSTALLED WRONG, THE CONTROLLER
SENSES A PROBLEM AND THE MACHINE WILL ONLY DRIVE AT
CREEP SPEED. IF BOTH SENSORS ARE ADJUSTED TOO FAR OUT,
THE CONTROL SYSTEM CONTROLLER WILL NOT DRIVE THE
MACHINE.
Adjustment Procedure
1. Back off the locking nut and o-ring.
For proper drive operation, the speed sensors must be

properly installed and adjusted. The sensor operates on a
leading pulse to show direction. If installed wrong, the
sensor will not be able to sense the proper direction.
2. Thread the sensor in until it bottoms out (dont use

excessive force).
3. Back-off 1-2 turns and align the notch with the axis
of the brake. Refer to Figure 3-49., Speed Sensor
Orientation.
4. Use a 1/2" wrench to hold the sensor and a 11/16"
wrench to snug the lock nut to the brake.
3-46
JLG Lift
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Figure 3-49. Speed Sensor Orientation
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3-47
Figure 3-50. Drive Components
3-48
JLG Lift
3121813
Speed Sensor Installation Verification
Verification w/ Analyzer Procedure
The motor controller averages the readings from the right

and left speed sensors and therefore, it can be difficult to
detect if the speed sensors are adjusted properly. When
the positrac keeps coming in and out while on level surfaces, this is a sure indication that one of the speed sensors is not adjusted properly.
The worse case condition of speed sensor misadjustment
occurs when both sensors are installed in a manner that
allows them to indicate the exact opposite direction that
the machine is traveling. This situation causes the controller to believe that the machine is rolling in opposite direction than that selected by the operator. The controllers
reaction to this situation is to put more power into the
drive motors to attempt to overcome the fact that it
believes the machine is rolling backwards. This presents
itself as uncontrolled movement in the direction selected
by the operator until the controller recognizes that it is
placing maximum power in the motors and the controller
and the speed sensors are still reporting movement in the
opposite direction. The controller responds by shutting
down drive and reporting flash code 5/5- Vehicle Runaway
Check Speed Encoders.
Below is a procedure using the Analyzer that will verify

that the speed sensors are installed correctly.
THIS PROCEDURE REQUIRES A LARGE SPACE CLEAR OF

OBSTRUCTIONS. THE OPERATOR SHOULD BE FAMILIAR WITH
JLG EQUIPMENT AND BE PREPARED TO USE THE FOOTSWITCH
TO STOP THE MACHINE. READ AND UNDERSTAND THIS ENTIRE
PROCEDURE PRIOR TO BEGINNING.
If either speed sensor is disconnected or faulty, the controller will recognize this condition and immediately report
flash code 5/5 - Left or Right speed Encoder Faulty.
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JLG Lift
1. Before beginning this procedure, insure that there is

at least 10 ft (3m)in front and back of machine. Be
sure that all other personnel stand clear of the
machine during this procedure.
2. Unplug the left speed sensor from the posi-trac tilt
module.
3. Power up the machine in platform mode and plug in
the Analyzer in the platform.
4. Use the right and left cursor keys on the analyzer to
highlight "DIAGNOSTICS" and press enter.
highlight "DRIVE" and press enter.
3-49
6. Use the right and left cursor keys to display SPEED

0%" on the analyzer.
highlight drive and press enter.
7. While watching the analyzer display, select drive forward. Be ready to remove your foot from the footswitch if the machine lunges forward.
17. Use the right and left cursor keys to display "speed
0%" ON THE ANALYZER.
8. The analyzer display should read the following if the

RIGHT speed sensor is adjusted properly: "SPEED
20% FWD".
9. If the speed sensor is adjusted improperly, the analyzer will display "SPEED 20%REV" and the machine
will lunge forward.
10. Adjust the right speed sensor using the preceding
Adjustment Procedure until the analyzer displays
"SPEED 20% FWD" when forward is selected at the
platform. The percentage displayed is not critical,
just the direction.
11. After obtaining the display in step 10, operate the
machine in both forward and reverse directions. The
machine should be controllable in both directions
and will only drive at a maximum of creep speed.
The display on the analyzer should match the direction selected.
18. while watching the analyzer display, select drive forward. Be ready to remove your foot from the footswitch if the machine lunges forward.
19. The analyzer display should read the following if the
left speed sensor is adjusted properly: "SPEED 20%
FWD".
20. If the left speed sensor is adjusted improperly, the
analyzer will display "SPEED 20% REV", and the
machine will lunge forward.
21. Adjust the left speed sensor using the preceding
Adjustment Procedure until the analyzer displays
"SPEED 20% FWD" when forward is selected in the
platform. The percentage displayed is not critical,
just the direction.
12. After completing adjustment of the right sensor, plug

the left sensor into the posi-tilt module.
22. After obtaining the display in step 10, operate the

machine in both the forward and reverse directions.
The machine should be controllable in both directions and will only drive at a maximum of creep
speed. The display on the analyzer should match
the direction selected.
13. Unplug the right sensor from the power module.
23. Plug in the right sensor to the power module.
14. Power up the machine in platform mode and plug in

the analyzer in the platform.
24. Test the machine. The machine should now have

maximum drive speed available in both directions
and should be controllable in both directions. The
analyzer display should match the direction
selected.
15. Use the right left cursor keys on the analyzer to highlight diagnostics and press enter.
3-50
JLG Lift
3121813
Figure 3-51. Oscillating Axle
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JLG Lift
3-51
Figure 3-52. Axle Oscillation Lockout Valve
3-52
JLG Lift
3121813
3.7 OSCILLATING AXLE LOCKOUT TEST (IF

EQUIPPED)
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.
NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test.
13. If lockout cylinders do not function properly, have

qualified personnel correct the malfunction prior to
any further operation.
3.8 OSCILLATION CYLINDER BLEEDING

NOTE: The oscillating axle must be checked daily for proper
operation.
Bleeding Procedure
1. Run one side wheel onto a ramp or block of wood.
On the other side, the lockout cylinder should be
extended.
1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.
2. Block the rear wheels and disconnect the drive

hubs.
2. From platform control station, start engine

3. Place the Drive control lever to the forward position
and carefully drive machine up ascension ramp until
left front wheel is on top of block.
NOTE: Step three is only for models with all wheel drive.
3. Next, unplug the 4 wheel assist valve under the
frame.
4. Carefully activate Swing control lever and position

boom over right side of machine.
4. Have an assistant activate drive forward and telescope in from the platform. Open up the bleeder
screws on the extended side lockout cylinder. Let
the hydraulic oil run out until all the air bubbles are
out of the cylinder. Then close the bleeder screws.
5. With boom over right side of machine, place Drive

control lever to Reverse and drive machine off of
block and ramp.
6. Have an assistant check to see that left front or right
rear wheel remains elevated in position off of
ground.
7. Carefully activate Swing control lever and return
boom to stowed position (centered between drive
wheels). When boom reaches center, stowed position, lockout cylinders should release and allow
wheel to rest on ground, it may be necessary to activate Drive to release cylinders.
Checking Oscillation Cylinders

After bleeding the lockout cylinders, check to see that
they are holding their position when oscillated.
8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel.
9. Place Drive control lever to Forward and carefully
drive machine up ascension ramp until right front
wheel is on top of block.
10. With boom over left side of machine, place Drive
control lever to Reverse and drive machine off of
block and ramp.
11. Have an assistant check to see that right front or left
rear wheel remains elevated in position off of
ground.
1. Reconnect the drive hubs and 4-wheel assist valve.

2. Run one wheel onto a ramp or a block of wood,
mark the retracted cylinder with a marker, swing the
turntable off of the cam valve.
3. Back the unit off of the ramp, check the retracted
cylinder for drive no more than " (12.7 mm).
4. Repeat this procedure for the other side. If the lockout cylinders do not hold, repeat the bleeding procedure or check for the following:
a. Air in lockout system.
b. Bad cylinder seals.
c. Bad holding valves.
12. Carefully activate Swing control lever and return

boom to stowed position (centered between drive
wheels). When boom reaches center, stowed position, lockout cylinders should release and allow
wheel to rest on ground, it may be necessary activate Drive to release cylinders.
3121813
JLG Lift
3-53
3.9 SWING DRIVE

Roll, Leak and Brake Testing
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure that
the units gears, bearings and seals are working properly.
The following information briefly outlines what to look for
when performing these tests.
NOTE: The brake must be released and hydraulic lines to
motor removed before performing the roll test.
ROLL TEST
The purpose of the roll test is to determine if the units
gears are rotating freely and properly. You should be able
to rotate the gears in your unit by applying constant force
to the roll checker. If you feel more drag in the gears only
at certain points, then the gears are not rolling freely and
should be examined for improper installation or defects.
Some gear packages roll with more difficulty than others.
Do not be concerned if the gears in your unit seem to roll
hard as long as they roll with consistency.
LEAK TEST (MAIN UNIT)
1. Tighten (but do not torque) bolt A" until snug.
The purpose of a leak test is to make sure the unit is air

tight. You can tell if your unit has a leak if the pressure
gauge reading on your air checker starts to fall after the
unit has been pressurized and allowed to equalize. Leaks
will most likely occur at the pipe plugs, the main seal or
wherever o-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap
and water solution around the main seal and where the orings or gaskets meet on the exterior of the unit, then
checking for air bubbles. If a leak is detected in a seal, oring or gasket, the part must be replaced, and the unit
rechecked. Leak test at 10 psi for 20 minutes.
2. Go to the opposite side of the bolt circle and tighten

bolt "B" until equally snug.
BRAKE TEST
The brake test should be performed prior to disassembly
and after reassembly to ensure that the brake functions
properly and does not leak. The brake test procedure can
be found in the Motor-Brake Subassembly section of this
manual.
3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply the specified
torque to bolt "A".
5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the remaining bolts.
Motor Control Valve Disassembly

1. Place unit on bench with the motor end up.
2. Remove Hydraulic Tubing Assembly (20) by loosening Fittings (18) on both ends of tube with a wrench.
NOTE: Items (18) & (19) are included on Item (20) when
ordering a replacement Tubing Assembly.
NOTE: Failure to perform this test may result in damaged or

ineffective brake parts.
Tightening and Torquing Bolts
3. Using a wrench, loosen jam nut on Elbow Fitting

(17) and remove fitting from Motor Control Valve
(31).
If an air impact wrench is used to tighten bolts, extreme

care should be taken to ensure that the bolts are not tightened beyond their specified torque.
4. Using a wrench, remove Fitting (21) from Brake

Housing.
The following steps describe how to tighten and torque

bolts or socket head cap screws in a bolt circle.
5. Remove Motor Control Valve (31) from Motor (10) by

removing the four Bolts (34) and washers (33).
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JLG Lift
3121813
17.
18.
19.
20.
21.
Elbow Fitting
Fittings
Ferrule
Tubing Assembly
Fitting
29.
31.
33.
34.
Plug
Motor Control Valve
Washers
Bolts
Figure 3-53. Motor Control Valve Disassembly
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JLG Lift
3-55
Motor and Brake Disassembly
5A. O-ring
11. Thrust Washer
12. Hex Bolts
Figure 3-54. Motor and Brake Disassembly
1. With unit resting on bench with Motor (10) end up,

loosen Hex Bolts (12) and remove Brake/Motor Subassembly from the Housing (1G) (See assembly
drawing).
2. Remove O-Ring (5A) from between Brake/Motor
Subassembly and Housing (1G) (See assembly
drawing).
3-56
JLG Lift
3. Remove Thrust Washer (11) from between Brake/

Motor Subassembly and Carrier.
4. Remove one O-Ring Plug (13) from Motor (10) and
one O-Ring Plug (13) from Brake Housing (6).
5. Remove O-Ring Plug (4) from Brake Housing (6).
3121813
6. Remove Motor (10) from Brake Housing (6) by

removing four Bolts (15) incrementally until spring
pressure is relieved.
9. Remove Brake Piston (8-2) from Brake Housing (6)

by slowly pressurizing brake port in Brake Housing
(6) with air.
7. Remove O-Ring (26) from between Motor (10) and

Brake Housing (6).
10. Remove O-Rings (8-1A) & (8-1C) and Backup Rings

(8-1B) & (8-1D) from Brake Piston (8-2).
8. Remove Springs (8-6) & (8-7) from Brake Piston (82).
11. Remove Sun Gear (9).
WEAR EYE PROTECTION DURING THE NEXT STEP OF THIS PROCEDURE.
4.
O-ring Plug
6.
Brake Housing
8-1A. O-ring
8-1B. Backup Ring
8-1C. O-ring
8-1D. Backup Ring
12. Remove Outer Plates (8-3) and Inner Plates (8-4)

from the Brake Housing (6).
13. Remove the Thrust Spacer (8-5).
8-2. Brake Piston

8-3. Outer Plates
8-4. Inner Plates
8.5. Thrust Spacer
8-6. Spring
8.7. Spring
9.
10.
13.
15.
26.
Sun Gear
Motor
O-ring Plug
Bolts
O-ring
Figure 3-55. Brake Disassembly
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JLG Lift
3-57
Main Disassembly
3. Remove O-ring (5) from between Ring Gear (2) and

Housing Subassembly.
1. With the unit resting on the Output Shaft (Pinion)

(1A), remove the Carrier Subassembly.
4. Remove four Dowel Pins (14) from Housing Subassembly.
2. Remove Ring Gear (2) from Housing Subassembly.
2. Ring Gear
5. O-Ring
14. Dowel Pins
28. Input Spacer
Figure 3-56. Main Disassembly
3-58
JLG Lift
3121813
Hub-shaft Disassembly
4. Remove the Bearing Cone (1D) from the Housing

(1G).
1. Using retaining ring pliers, remove Retaining Ring

(1I) from groove in Output Shaft (1A) and discard.
5. Invert the Housing (1G) and remove the Lip Seal

(1B) if not already removed when Output Shaft (1A)
was pressed out of Housing (1G).
6. Using a bearing puller, remove the Bearing Cone
(1F) from the Output Shaft (1A).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

2. Remove Thrust Washer (1H).
7. Bearing Cups (1C & 1E) will remain in Housing (1G).
3. While supporting the Housing (1G) on the Output

Shaft (1A) end, press the Output Shaft (1A) out of
the Housing (1G).
NOTE: If bearing replacement is necessary, the Bearing

Cups (1C & 1E) can be removed with a slide hammer puller or driven out with a punch.
NOTE: The Lip Seal (1B) may or may not be pressed out of
the Housing (1G) by the Bearing Cone (1D) during
this step.
1A.
1B.
1C.
1D.
1E.
Output Shaft
Lip Seal
Bearing Cup
Bearing Cone
Bearing Cup
1F. Bearing Cone

1G. Housing
1H. Thrust Washer
1l. Retaining Ring
Figure 3-57. Hub Shaft Disassembly
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JLG Lift
3-59
Carrier Disassembly
3. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A).
1. Using a 1/4" punch, drive the Roll Pin (3G) which

holds the Planet Shaft (3E) in the Carrier (3A) down
into the Planet Shaft (3E) until it bottoms.
4. Remove both rows of Needle Bearings (3C) and the

Spacer (3D) from the bore of the Planet Gear (3F).
5. Using a 1/4" punch, drive the Roll Pin (3G) out of the
Planet Shaft (3E).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, damage to the carrier could occur when the
Planet Shaft is removed.
6. Repeat Steps 1 through 5 for the remaining two

Planet Gears (3F).
2. Remove the Planet Shaft (3E) from the Carrier (3A).
3A.
3B.
3C.
3D.
Carrier
Thrust Washers
Needle Bearings
Spacer
3E. Planet Shaft

3F. Planet Gear
3G. Roll Pin
Figure 3-58. Carrier Disassembly
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JLG Lift
3121813
Hub-Shaft Sub-Assembly
Carrier Sub-Assembly
(See Figure 3-57., Hub Shaft Disassembly)
(See Figure 3-58., Carrier Disassembly)
1. Press Bearing Cup (1E) into Motor end of Housing

(1G) using an appropriate pressing tool.
1. Apply a liberal coat of grease to the bore of Planet

Gear (3F). This will enable the Needle Rollers (3C) to
be held in place during assembly.
2. Invert Housing (1G) and press Bearing Cup (1C) into

Housing (1G) using an appropriate pressing tool.Set
Bearing Cone (1F) onto Bearing Cup (1E).
2. Install the first row of 16 Needle Rollers (3C) into the

bore of Planet Gear (3F).
3. Using an appropriate pressing tool, press Seal (1B)

into Housing (1G) until it is flush with the end of the
Housing (1G).
3. Insert Spacer (3D) into bore of Planet Gear (3F) on

top of the Needle Rollers (3C).
4. Place second row of Needle Rollers (3C) into bore of
Planet Gear (3F) against Spacer (3D) and remove
Planet Shaft (3E).
4. Apply liberal amount of grease to lip of Seal (1B).

5. Invert Housing (1G) and lower onto Output Shaft
(1A).
5. Place Carrier (3A) on bench so that one of the Roll

Pin (3G) holes is straight up.
NOTE: Be careful not to damage seal while lowering Housing onto Output Shaft.
6. Paying attention to the location of the Roll Pin (3G)

hole in the Planet Shaft (3E), start Planet Shaft (3E)
through the hole in Carrier (3A). Using ample grease
to hold it in position, slide one Thrust Washer (3B)
over the Planet Shaft (3E) with the tang resting in the
cast slot of the Carrier (3A).
6. Press Bearing Cone (1D) onto Output Shaft (1A)

until it seats against the bearing shoulder.
7. Place Thrust Washer (1H) onto Bearing Cone (1D).
7. Place the Planet Gear (3F) into position in Carrier

(3A) and push Planet Shaft (3E) through the Planet
Gear (3F) without going all the way through.
EYE PROTECTION SHOULD BE WORN DURING THE NEXT STEP

OF THIS PROCEDURE.
8. Slide the second Thrust Washer (3B) between the

Planet Gear (3F) and the Carrier (3A) with the tang of
the washer located in the cast slot of the Carrier
(3A). Finish sliding the Planet Shaft (3E) through the
Thrust Washer (3B) and into the Carrier (3A).
NOTE: Retaining Ring (1I) should never be reused in a

repair or rebuild.
8. Using retaining ring pliers, install Retaining Ring (1I)
into groove in Output Shaft (1A). If Retaining Ring
(1I) will not seat completely into groove, use an
appropriate pressing tool to press down on Bearing
Cone (1D) while rotating Housing (1G). Reinstall
Thrust Washer (1H) and Retaining Ring according to
preceding procedures. Tap the Retaining Ring (1I)
with a soft metal punch to ensure that the Retaining
Ring (1I) is completely seated in the groove of the
Output Shaft (1A).
9. Using a soft face hammer, hit the end of the Shaft
(1A) to remove the bearing preload.
10. Install O-ring Plug (1J) and torque to 23 to 24 ft-lbs.
9. Position the non-chamfered side on the Planet Shaft

(3E) roll pin hole so that it is in line with the hole in
the Carrier (3A) using a 1/8 inch diameter punch.
NOTE: If Planet Shaft (3E) has a flat on the end, position the
flat toward the center of the Carrier (3A).
10. After using a 1/4" punch to align the Roll Pin (3G)
holes in the Carrier (3A) and the Planet Shaft (3E),
drive the Roll Pin (3G) through Carrier (3A) and into
the Planet Shaft (3E) until the Roll Pin (3G) is flush
with the bottom of the cast tang slot in the Carrier
(3A). Use a 1/4" pin punch to make sure the Roll Pin
(3G) is flush in the slot.
NOTE: On 6:1 Ratios of S1C"s, the pin must be 0.125
below the surface of the outside diameter.
11. Repeat Steps 1 through 10 for the remaining two
Planet Gears (3F).
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JLG Lift
3-61
Main Assembly
(See Figure 3-56., Main Disassembly)
1. With the Housing-Shaft Subassembly resting on the
Shaft (1A) install one Dowel Pin (14) into each of the
four counter-bored holes in the Housing (1G) (See
assembly drawing) until they bottom out. Also at this
time, mark the four Dowel Pin (14) holes on the O.D.
of the Housing (1G) (See assembly drawing). This is
for identification later in the assembly.
NOTE: Be sure that Backup Rings (8-1B) & (8-1D) are

located as tightly into the grooves in the Piston (8-2)
as possible to prevent them from being shaved
when Piston (8-2) is installed into Brake Housing (6).
5. Apply grease sparingly to Piston (8-2) O.D. and the
cylinder bore of Brake Housing (6). Insert Piston (82) into cylinder of Brake Housing (6), be sure not to
cut the O Rings (8-1A) & (8-1C) or Backup Rings (81B) & (8-1D).
6. Install Compression Springs (8-6) into spring pockets in Piston (8-2).
2. Install Thrust Spacer (28) into counter-bore in

splined end of the Output Shaft (1A).
7. Install Compression Springs (8-7) into Compression

Springs (8-6) in spring pockets in Piston (8-2).
3. Place O-Ring (5) into Housing (1G) counter-bore.

Use grease to hold O-ring in place.
8. Grease O-Ring (26) and install into counter-bore in

Brake Housing (6).
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE
SEATING THIS O-RING.
4. Install Carrier Subassembly with splined end down
so that the spline of the Carrier Subassembly is in
mesh with the spline of the Housing-Shaft Subassembly. Rotate carrier in assembly to check for freedom of rotation.
5. With large shoulder side of Ring Gear (2) facing
down, place Ring Gear (2) onto Housing-Shaft Subassembly with gear teeth in mesh with the Planet
Gears (3f) in the Carrier (3A). The side of the Ring
Gear (4) with an "X" or punch mark stamped on it
should be up and the marked hole should be at a
Dowel Pin (14) location.
Motor-Brake Subassembly
9. Assemble Test Cover (See Tools at back of manual

for drawing) to Brake Housing (6) using four Bolts
(15) evenly tightening Bolts (15) to 80-100 ft-lbs.
10. Check the brake for release. Apply pressure to
brake port in side of Brake Housing (6) while trying
to rotate Sun Gear (9) by hand. The brake should
release between 200-255psi. Remove Test Cover.
11. Assuming that Brake passed the Brake Test, place
Motor (10) into Brake Housing (6) with splines of
Motor (10) meshing with splines of Sun Gear (9).
12. Attach Motor (10) to Brake Housing (6) with four
Bolts (15) and torque to Bolts (15) to 80100 ft-lbs.
13. 13. Install O-Ring Plug (13) and torque to 1315 ftlbs.
Motor-Brake Assembly
(See Figure 3-54., Motor and Brake Disassembly)
(See Figure 3-54., Motor and Brake Disassembly)
1. Place Brake Housing (6) on bench with flange end

down. Either block Brake Housing (6) up or place
over hole in bench large enough for the shoulder of
the Sun Gear (9) to rest on the bottom of the Brake
Housing (6). Then install Sun Gear (9) with gear end
down into Brake Housing (6).
2. Place Spacer (8-5) into Brake Housing (6) in bottom
of small counter bore below splines.
3. Install brake disks, starting with an Outer Plate (8-3),
then alternating Inner Plates (8-4) and Outer Plates
(8-3) into splined bore.
1. Grease Thrust Washer (11) and install into counterbore of Carrier Subassembly, which should already
be installed into the Main Subassembly.
2. Grease O-Ring (5A) and install into counter-bore of
the Brake Housing (6) in the Motor-Brake Subassembly.
3. Install Motor-Brake Subassembly onto Main Assembly using twelve Bolts (12). Torque bolts to 23 27 ftlbs.
4. Grease the O Rings (8-1A) & (8-1C) and Backup

Rings (8-1B) & (8-1D), and place them in their
respective grooves in the Piston (8-2). Make sure the
backup-rings are correctly positioned as per the
assembly print.
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JLG Lift
3121813
Motor Control Valve Assembly
Procedure for Setting Gear Backlash
(See Figure 3-53., Motor Control Valve Disassembly)

1. Lay assembly down with motor ports facing up.
Remove the two plastic plugs in the motor ports on
new motors, being careful not to loose the O ring in
each port. Assemble the Motor control Valve (31)
onto the Motor (10) with Bolts (34) and Washers
(33). Torque Bolts (34) to 23-27 ft-lbs.
NOTE: Be sure to align the holes in the control valve with
the motor ports and make sure o-ring is in hole.
2. Install Straight Fitting (21) into Brake Housing (6)
and torque to 13-15 ft-lbs.
3. Install Elbow Fitting (17) into Motor Control Valve
(31) with chamfered end of fitting pointing towards
straight Fitting (21). Thread fitting all the way in until
in the correct position, then torque jam nut to 13-15
ft-lbs.
4. Assemble Tubing (20) Nuts (18) and Ferrules (19)
per the procedures below.
Tube Fitting Assembly Procedures
1.
2.
3.
4.
NOTE: Be sure the tube is inline with the fitting. If required,

gently modify the tube bends to be inline.
Shoulder Screw
Capscrew
Setscrew
Jam Nut
1. Assemble nut onto tubing with threaded end toward

the assembled end of the tube.
Figure 3-59. Setting Gear Backlash
2. Assemble ferrule onto tube with the large tapered

end into the nut.
NOTE: The bearing high spot will be marked with yellow

paint.
3. Place tube tight against the flared fitting in the

assembly.
1. Place a shim, JLG P/N 4071009, between the pinion

and bearing high spot.
4. Lubricate threads and fitting end with hydraulic oil.

5. Slide ferrule and nut against fitting and hand tighten
nut to the fitting.
6. Mark nut in relation to the fitting.
7. Hold tube tight against fitting and tighten nut 1-1/4
turns of the nut past the marked location.
NOTE: Be sure to align the holes in the control valve with
the motor ports.
8. Pressure test brake, tube and control valve connections by applying 3000psi pressure to the brake
bleed port and holding for 1 minute. Check for leaks
at the control-valve-motor interface and the tube
connections. Release pressure.
2. Torque the shoulder screw (1) to 420 ft.lbs. (588 Nm)

with Loctite #271.
3. Remove the turntable lock pin.
4. Pre-torque the 3/4 inch capscrews (2) to 120 ft.lbs.
(168 Nm) with Loctite #271.
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JLG Lift
3-63
5. Tighten the setscrew (3) until the pinion is completely snug against the shim and bearing and then
back off the setscrew.
4. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.
5. Swing the turntable 90 degrees, and check some
selected bolts at the new position.
6. Torque the setscrew to 50 ft.lbs. (70 Nm).

7. Tighten the jam nut (4).
6. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in
all quadrants.
8. Torque the four 3/4 inch capscrews (2) to 420 ft.lbs.

(588 Nm).
7. Lower the boom to horizontal and fully extend the

boom.
9. Remove and discard the shim.
8. Swing the turntable over the side.
3.10 SWING BEARING
9. On the frame, at the front of the turntable, try to

insert the 0.0015" feeler gauge between the bolt
head and hardened washer at the indicated position.
Turntable Bearing Mounting Bolt Condition

Check
NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for
looseness.
all quadrants.
Check the turntable to bearing. Attach bolts as follows:
Check the frame to bearing. Attach bolts as follows:
1. Elevate the fully retracted boom to full elevation and

rotate the platform 90o.
2. Swing the turntable over the side.
1. Elevate the fully retracted boom to full elevation and

rotate platform 90o.
2. Swing turntable over the side.
3. At turntable rear, try and insert the 0.0015" feeler

gauge between the bolt head and hardened washer
at the arrow indicated position.
3. On the frame, at the rear of the turntable, try to insert

the 0.0015" feeler gauge between the bolt head and
hardened washer at the indicated position. (Figure
3-60., Swing Bearing Feeler Gauge Check)
3-64
JLG Lift
3121813
Wear Tolerance
1. With the boom positioned over the side of the
machine, the Boom horizontal with telescope fully
extended, using a magnetic base dial indicator,
measure and record the distance between the swing
bearing and turntable front.

all quadrants.
2. With the boom positioned over the side of the

machine, the Boom fully elevated, retracted, and
platform rotated 90o, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable rear.
.0015" Feeler Gauge

Figure 3-60. Swing Bearing Feeler Gauge Check
7. Lower the boom to horizontal and fully extend the
boom.
Figure 3-61. Swing Bearing Tolerance Measuring Point
8. At turntable front, try and insert the 0.0015" feeler

gauge between the bolt head and hardened washer
at the arrow indicated position.
3. If a difference greater than 0.057 in. (1.40 mm) is

determined, the swing bearing should be replaced.
4. If a difference less than 0.057 in. (1.40 mm) is determined, and any of the following conditions exist, the
bearing should be removed.

a. Metal particles in the grease.
all quadrants.
c. Noise.
b. Increased drive power.

d. Rough rotation.
5. If bearing inspection shows no defects, reassemble
bearing and return to service.
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JLG Lift
3-65
Figure 3-62. Swing Drive and Bearing Installation
3-66
JLG Lift
3121813
Replacement of Swing Bearing

Removal of the swing bearing is as follows:
1. Attach an adequate support sling to the boom and
draw all slack from sling. Prop or block the boom if
feasible.
NOTE: If Mobiltac 375NC is not available, Tribol Molub-Alloy

936 Open Gear Compound or Mobilith SHC Bearing
Grease or Multi-Purpose Grease (MPG) can be substituted, however the service interval will be shorter.
4. Using suitable lifting equipment, install bearing/
assembly to frame with soft spot (red) 90 degree relative to load axis. If reusing old bearing, ensure that
scribed line of outer race of the bearing aligns with
the scribed mark on the frame.
2. Tag and disconnect hydraulic lines running through

center of turntable and frame. Use a suitable container to retain any residual hydraulic fluid. Cap lines
and ports.
3. Attach suitable overhead lifting equipment to the
base of turntable weldment.
4. Use a suitable tool to scribe a line on the inner race
of the swing bearing and on the underside of the
turntable. This will aid in aligning the bearing upon
installation. Remove bolts, nuts and washers which
attach the turntable to the bearing inner race. Discard nuts and bolts.
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8

BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
WITH NEW GRADE 8 NUTS AND BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND
TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT
HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG
HARDWARE IS HIGHLY RECOMMENDED.
5. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure
that no damage occurs to the turntable, bearing or
frame mounted components.
6. Carefully place the turntable on a suitably supported
trestle.
NOTE: The bearing weighs approximately 100 lbs. (45 kg.).
7. Use a suitable tool to scribe a line on the outer race
of the swing bearing and the frame. This line will aid
in aligning the bearing upon installation. Remove the
bolts and washers which attach the outer race of the
bearing to the frame. Discard the bolts. Use suitable
lifting equipment to remove the bearing from the
frame; move to a clean, suitably supported work
area.
5. Apply a light coating of Loctite 271 to the new bearing bolts and loosely install the bolts and washers
through the frame and outer race of bearing.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT

WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
BE CHECKED PRIOR TO USE.
6. Following the torque sequence diagram shown in
Figure 3-63., Swing Bearing Torque Sequence,
tighten the bolts to an initial torque of 175 ft. lbs.
(237 Nm). Then following the same sequence,
tighten to a final torque of 240 ft. lbs. (336 Nm).
7. Remove lifting equipment from bearing.
Installation of the swing bearing is as follows:
8. Use suitable lifting equipment to carefully position

the turntable assembly above the machine frame.
1. Install bearing to turntable with two capscrews, so

the grease hose is on the forward side of the frame
as close to the centerline of the turntable as the bolt
pattern will allow. Do not tighten capscrews.
2. Line up high spot (marked with yellow paint) of bearing with center tooth of bull gear. Set backlash to
0.008 - 0.012 inch (0.20 - 0.30 mm). Refer to Swing
Drive Installation. Tighten capscrews as shown in
Figure 3-63., Swing Bearing Torque Sequence
9. Carefully lower the turntable onto the swing bearing.

Ensure that the scribed line of the inner race of the
bearing aligns with the scribed mark on the turntable. If a new swing bearing is used, ensure that the
filler plug fitting is at 90 degrees from the fore and aft
centerline of the turntable.
10. Apply a light coating of Loctite 271 to the new bearing bolts and install through the turntable and inner
race of bearing.
3. Grease bearing with Mobilith SHC Bearing Grease.

Grease fitting is on inside wall of inner race of bearing.
3121813
JLG Lift
3-67
11. Following the torque sequence shown in Figure 363., Swing Bearing Torque Sequence tighten the
bolts to an initial torque of 175 ft. lbs. (237 Nm).
Then following the same sequence, tighten the bolts
to 240 ft. lbs (326 Nm).
Swing Drive Installation

1. Coat the threads of the socket head bolts securing
the swing drive to the mounting plate with Loctite
#271 and torque to 120 ft.lbs. (168 Nm).
12. Remove the lifting equipment.
2. Position swing drive to location of bearing gear max

eccentric tooth. High spot is marked with yellow
paint in tooth.
13. Route hydraulic lines through center of turntable and

frame and connect as tagged prior to removal.
3. With the mounting plate pivoting about the shoulder

bolt, adjust backlash between the pinion and bearing gear teeth to 0.008 to 0.012 inch backlash
(0.20mm to 0.30mm).
14. Using all applicable safety precautions, activate the

hydraulic system and functionally check swing system for proper and safe operation
.
4. Tighten the adjusting bolt, jam nut, and shoulder

bolt to prevent the swing drive from moving. Coat
the threads of the shoulder bolt with Loctite #271
and torque to 420 ft.lbs. (588 Nm).
5. Coat the threads of the mounting plate bolts with
Loctite #271 and torque to 420 ft.lbs. (588 Nm).
Setting Backlash
1. Place a shim (JLG P/N 4071009) between pinion
and bearing on high spot of bearing.
2. After applying Loctite #271 to the shoulder bolt,
torque to 420 foot-pounds (588 Nm).
3. Remove the lock pin on the turntable.
4. After applying Loctite #271, torque the four "
socket head bolts to 120 foot-pounds (168 Nm).
5. Tighten the setscrew until the pinion is snug against
the shim and bearing.
6. Torque the setscrew to 50 foot-pounds (70 Nm).
Figure 3-63. Swing Bearing Torque Sequence
7. Tighten the jam nut.
Swing Bearing Torque Value
8. Torque the four " socket head bolts to 420 footpounds (588 Nm).
Install with Loctite - 240 ft. lbs. (326 Nm).
9. Recover the shim and throw it away.
3-68
JLG Lift
3121813
3.11 BATTERY MAINTENANCE AND

CHARGING
Optional On Board Generator

EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY.
IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH

AT LEAST 115 POUNDS (52 KG). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT IN A
TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY
OR DEATH.
Battery Maintenance, Quarterly

1. Open battery compartment cover to allow access to
battery terminals and vent caps.
WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE

PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE
GROUND EMERGENCY STOP SWITCH IN ON (PULLED OUT), THE
GENERATOR WILL START AUTOMATICALLY WHEN THE BATTERIES REACH A LOW-CHARGE STATE AUTOMATICALLY CHARGING
THE BATTERIES.
NOTE: The engine will automatically shut down under the
following conditions:
WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS
ELECTROLYTE COVERS THE PLATES.
Charged Batteries
High Engine Oil Temperature
Low Engine Oil Pressure
Engine Overspeed
Generator Overvoltage
NOTE: When adding distilled water to batteries, non-metallic

containers and/or funnels must be used.
To avoid electrolyte overflow, add distilled water to
batteries after charging.
When adding water to the battery, fill only to level
indicated or 3/8" above separators.
2. Remove all vent caps and inspect electrolyte level of
each cell. Electrolyte level should be to the ring
approximately one inch from top of battery. Fill batteries with distilled water only. Replace and secure
all vent caps.
TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR

ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.
Battery Charging (On Board Charger)

1. For maximum battery life:
a. Avoid completely discharging the batteries.
b. Fully charge the batteries each day the machine
is used.
3. Remove battery cables from each battery post one

at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or
ammonia) and wire brush. Replace cables and/or
cable clamp bolts as required.
c. Charge the batteries at available times between

charging.
d. Be sure the battery fluid covers the battery
plates before charging, but to avoid overflow, do
not top off the fluid level until charging.
4. Clean battery post with wire brush then re-connect

cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly.
2. To charge the batteries, connect the charger to a

115 volt source with a 15 amp minimum capacity.
5. When all cables and terminal posts have been

cleaned, ensure all cables are properly positioned
and do not get pinched. Close battery compartment
cover.
3. The charge cycle is complete when the 100% LED is

lit. Any other reading indicates the charge cycle is
not complete.
6. Start hydraulic system and ensure that it functions

properly.
4. The Charger will shut off automatically when the batteries are fully charged.
Depleted batteries will take approximately 23 hours to
charge.
3121813
JLG Lift
3-69
Removing the Battery Box

To remove the battery box, perform the following steps.
NOTE: The battery box and batteries complete weigh

approximately 668 pounds (303 kg).
1. Pull the pull ring to disconnect the batteries at the

battery disconnect beside the box.
3. Using a forklift, lift the battery box up enough to

clear the notch on the battery box rails and remove
the battery box from the machine.
2. Remove the two attachment bolts that secure the

battery box to the turntable.
Figure 3-64. Battery Cable Routing
3-70
JLG Lift
3121813
Figure 3-65. Batteries and Battery Charger
3121813
JLG Lift
3-71
15
12
19
7
14
13
20
18
1
2
1
17
4
10
6
9
11
NOTE: Charger Cover removed for clarity.

Item #5 Not Shown.
1.
2.
3.
4.
5.
6.
20 Amp Circuit Breaker

Connector
PC Board
DC Cord
Fuse Holder
80 Amp DC Fuse
7.
8.
9.
10.
11.
12.
Harness
Harness
Fuse Holder
AC Inlet Plug
DC Plug
Rectifier
13.
14.
15.
16.
17.
18.
SCR
Relay
Shunt Assembly
Strain Relief
Transformer
Varistor
Figure 3-66. Battery Charger
3-72
JLG Lift
3121813
INTERLOCK CONNECTOR
(SEE D13552-1 ASSY DWG)
SOLDER CONNECTION
RELAY
BLK
DC NEG
BLACK
BLK
AC FUSE OR
CIRCUIT BREAKER
CON.
1
AC BLK
OR BRN
A
WHT
SCR
GROUND
SCREW
TX
PRI
CAP
AC GRN OR
YLW/GRN
VARISTOR
.001
OHM
SHUNT
HEATSINK
NUT & BOLT

CONN
* DC FUSE OR
CIRCUIT BREAKER
CAP
DC POS
RED
D
SCR
*OPTIONAL* CAPACITORS REQUIRED IN CE CHARGERS
WHT
7
7
GRN
WHT
REMOTE
LIGHT BOARD
1
2
3
4
1
2
3
4
BLACK
WHITE
GREEN
RED
1 BLK
WHT
2 GRN
3 RED
4
YELL
ORG
ORG
NOTE: ON CE CHARGERS VARISTOR LEADS MUST

BE COVERED WITH VARFLEX
10
11
15
16
17
BLUE
GRN
13
WHT
12
12
BLK
12
WHT
14
14
HEATSINK
YELL
WHT
BLK
AC GRN
OR BLUE
WHITE
N.C.
N.O.
CIRCUIT
BOARD
HARNESS
13
3
4 3 2 1
TO 4POS CONN
OF MAIN BOARD
PIN 1
PIN 2
PIN 3
PIN 4
RED
GRN
WHT
BLK
* IN SOME CHARGERS
THIS MAY BE AN
AUTOMOTIVE FUSE.
CONNECTORS ARE SAME.
J-2
CONNECTOR
Figure 3-67. Battery Charger Schematic
3121813
JLG Lift
3-73
3.12 GENERATOR (PRIOR TO S/N 88375)
Start Control Relay
NOTE: Throughout the Generator section, the abbreviations

RBS and CTS are used. RBS stands for Rotary Battery System, which is the generator system. CTS
stands for Call To Start, which is the electronic inputs
which signal the generator to start and charge the
batteries.
The generator consists of a drive engine, controller, and
related components.
Alternator
The alternator is a brushless, DC output alternator. The 3
phase output of the alternator is full wave rectified and
directed to the output terminator.
The output rating is 58 volts DC at 45 amps. Voltage regulation and current limiting is provided by the Engine/Generator Controller.
The rectifier diodes and output current sensor are located
in the alternator end.
Dynamo and Dynamo Voltage Regulator
The engine is equipped with a 12 Volt, 15 Amp DC output
dynamo.
Dynamo Output Fuse
The dynamo output fuse is used to protect the output of
the dynamo. This fuse is rated at 20 Amps DC, slow blow
and is located on the left side of the engine.
Control Fuse
This fuse provides power to the engine/generator and the
relays for start control, fuel control, and pre-heater. This
fuse is rated at 15 Amps DC and is located on the right
side of the engine.
Start Battery
A 12 volt lead-acid battery is utilized to provide starting
power for the generator and power for the generator controls. This battery is charged by the engine dynamo and
dynamo regulator when the engine is running.
Engine Starter
Fuel Control Relay

The fuel control relay energizes the hold coil of the fuel
solenoid. The fuel control relay is energized by the
engine/generator controller.
Fuel Solenoid
The fuel solenoid actuates the run/stop lever of the
engine. This solenoid has a pull and hold coil. The pull coil
is energized by the start control relay and the hold coil is
energized by the fuel control relay.
Engine Oil Temperature Sensor
The engine oil temperature sensor is used to sense the
temperature of the oil in the sump of the engine. This sensor provides a signal to the engine/generator controller for
high engine temperature shutdown.
Alternator Output Current Sensor
The alternator output current sensor provides a signal proportional to the output current of the alternator to the
engine/generator controller. This signal is used by the
controller to regulate the current output of the alternator.
The output current is regulated at 55 Amps DC. The alternator output current sensor is located inside the rear
cover of the alternator.
Engine Speed Sensor
The engine speed sensor provides a signal proportional
to the rotational speed of the engine to the engine/generator controller. This signal is used by the controller to determine starter cut-out, overspeed fault, and underspeed
fault. This signal has failsafe protection, if it is not present
at the controller, the unit will fault with a loss of speed signal indication. The engine speed sensor is located inside
the recoil starter cover at the front of the engine.
Engine Low Oil Pressure Switch
The engine is equipped with a 12 Volt DC starter. This

starter provides mechanical power to crank the engine.
Electrical power for the starter is provided by the start battery. The starter is energized by the start control relay.
3-74
The start control relay energizes the solenoid of the

engine starter and the pull coil of the engine fuel solenoid.
The start control relay is located on the fuel solenoid
bracket on the right side of the engine. The start control
relay is energized by the engine/generator controller.
The engine is equipped with a low oil pressure switch. The

switch is closed when the oil pressure is below 14.2 psi (1
Bar).
JLG Lift
3121813
Figure 3-68. Generator Components
3121813
JLG Lift
3-75
Timing Sequences
6. Time Delay Bypass (TDBP)
RBS Prestart Sequence
Once the engine starts, TDBP must elapse before

low oil pressure and underspeed shutdowns are
activated. This allows the engine to come up to normal operating conditions before enabling these
shutdowns are monitored.
1. Time Delay Engine Start (TDES)

TDES is the period which the RBS waits to verify that
the CTS is valid rather than a transient condition.
2. Time Delay Pre-Heat (TDPH)
Table 3-9. RBS Startup Sequence

Crank Time -> Rest Time
(Until Engine Start or # of
Crank Cycles)
TDPH, if enabled, occurs after TDES has elapsed

and the engine temperature is below the factory set
engine preheat temperature setting. The engine preheater will be energized for the factory set preheat
delay period.
TDBP Bypass
Normal Running Operation
Table 3-8. RBS Prestart Sequence

RBS Shutdown Sequence
CTS (Call to Start)
Once all CTS conditions have been removed, the RBS will
begin the shutdown sequence. If a CTS condition is initiated during the shutdown sequence, the RBS will return to
normal running operation until the CTS is removed.
TDES (Engine Start)

Preheat Delay
RBS Startup Sequence
1. Time Delay Engine Run (TDER)

RBS Startup Sequence
3. Crank Time
The RBS will crank for a period up to the crank time
or until the engine starts.
4. Rest Time
If the engine does not successfully start, the RBS will
wait for the rest time before attempting to crank the
engine again.
5. Crank Cycles
The RBS will attempt to start the engine up until the
number of crank cycles is reached. If the RBS does
not start, an Overcrank fault is indicated.
Once the CTS condition is removed, the TDER

period begins. This period ensures that no further
CTS conditions occur prior to the cooldown period.
2. Time Delay Cooldown (TDC)
Once the TDER period ends, the alternator output is
reduced to a minimal level in order to allow the
engine to cool down for the TDC period. If a CTS is
received during the TDC period, the CTS must last
for at least the TDES period for the RBS to return to
normal running operation.
Table 3-10. RBS Shutdown Sequence
Remove CTS
TDER Engine Run
TDC Cooldown
Engine Stop
3-76
JLG Lift
3121813
To Connect the JLG Control System Analyzer

to the Generator
The JLG Control System Analyzer can be used to monitor
generator settings and conditions. Connect the analyzer
as follows:
1. Connect the four pin end of the cable supplied with
the analyzer, to the connector behind the ground
control module located on the left side of the
machine next to the ground control station and connect the remaining end of the cable to the analyzer.
The ground control module contains the settings for
the generator.
NOTE: The cable has a four pin connector at each end of

the cable; the cable cannot be connected backwards.
2. Power up the Analyzer by pulling out the ground station EMS and positioning the Generator Enable
switch on the platform control box to the "on" position. Refer to Figure 3-69., Generator System Analyzer Flow Chart
Alarms and Fault Flash Codes

In the event of an RBS alarm, a flash code will be issued
and an alarm indicated on the analyzer.
NOTE: Alarms must be reset once the fault has been corrected.
Table 3-11. Generator System Flash Codes

Code
Alarm
Description
1-1
Low Oil Pressure
Shutdown due to low engine

oil pressure
1-2
High Engine Temperature
Shutdown due to high engine

oil temperature
1-3
Engine Overspeed
Shutdown due to high engine

speed
1-4
Engine Underspeed/Overcrank
Shutdown due to engine

overcrank or underspeed
1-5
No Speed Signal
Shutdown due to loss of

speed signal
2-1
Overvoltage
Shutdown due to high output

voltage
2-2
Engine Starting
System fault
Alarm not a shutdown; Indicates problem with the

engine starting system
2-3
Not Used
Not Used
2-4
L o s s o f Vo l t a g e
Sense
Shutdown due to loss of voltage sensing
Continuous
Unit Disabled
No Faults. RBS enabled and

can respond to any CTS
Off
Unit Disabled
RBS off or disabled; Will not

respond to any CTS
Low Oil Pressure

Enabled once TDBP (time delay bypass) period has
elapsed after engine startup. If the low engine oil pressure
switch closes, the engine will stop immediately and a low
oil pressure alarm will be indicated.
High Engine Temperature
If the engine oil temperature exceeds the high engine temperature setting, the engine will stop immediately and a
low oil pressure alarm will be indicated.
Overspeed
If the engine speed exceeds the overspeed limit, the
engine will stop immediately and an overspeed alarm will
be indicated.
3121813
JLG Lift
3-77
Figure 3-69. Generator System Analyzer Flow Chart
3-78
JLG Lift
3121813
Output Current and Voltage Settings
Underspeed
Enabled once TDBP (time delay bypass) period has
elapsed after engine startup. If the engine speed drops
below the underspeed limit, the engine will stop immediately and an engine underspeed alarm will be indicated.
Overcrank
Normal/Extended Output Voltage

The normal/extended output voltage setting is the voltage
at which the alternator changes under normal operating
conditions.
Current Limit
If the engine fails to start after a set number of start

attempts, the RBS will cease attempts to restart and an
engine overcrank alarm will be indicated.
The current limit setting determines the maximum alternator output current.
High Voltage Shutdown Level
No Speed Signal
In the event of a loss of speed signal, the RBS will shutdown and an engine no speed signal alarm will be indicated. This shutdown is delayed by a factory set period to
ensure the fault was not momentary.
Overvoltage
If the voltage measured at the alternator output exceeds
the high voltage setting, the RBS will stop immediately
and an RBS high output alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault
was not caused by a transient condition. This feature protects the batteries and load from high DC voltages.
Engine Starting System Fault
Indicates a problem with either the engine start battery,
engine magneto, or magneto voltage regulator.
This setting determines the alternator output voltage at

which the high voltage shutdown occurs. This protects the
load from abnormally high voltages.
Finish Charging Current
The finish charging current determines the level of the current alternator output must drop below for a low battery
voltage CTS to be removed. This ensures that the batteries have accepted sufficient charge prior to shutting down
the RBS. This level is used along with the low battery voltage remove CTS level to determine when the RBS
removes the CTS after a low battery voltage CTS. If the
charging current falls below the finish charging current
while another CTS is active, the RBS will continue to operate at the normal/extended output voltage until all CTSs
are removed.
Loss Of Voltage Sense

If the voltage measured at the alternator output is less
than half of the system nominal voltage, the RBS will stop
immediately and an RBS loss of voltage sense alarm will
be indicated. This feature protects the batteries and load
from high DC voltages due to a loss of output control.
Run Inhibited
The RBS unit is disabled by the run inhibited input.
3121813
JLG Lift
3-79
Priming the Fuel Line
5. Clean up any spilled fuel and try to start the generator engine.
The following procedure is for re-priming the fuel line on

the generator engine in the event fuel system components
have been replaced or the unit has been run dry of fuel.
6. If the engine still doesnt start, remove the steel line

from the fuel injector pump.
1. Make sure the fuel line isnt blocked or kinked.
7. Once fuel starts to flow, re-connect the fuel line to

the fuel injector pump.
2. Make sure fuel tank has fuel.
8. Clean up any spilled fuel and try to start the generator engine.
3. Disconnect the rubber fuel line at the fuel injector

pump.
9. If no fuel flows there are some possibilities:

a. There is no fuel getting to the injector pump. No
fuel in tank, or obstruction in fuel line, or clogged
inline fuel filter.
b. The engine/camshaft rotation is not opening the
injection fuel pump. Using the recoil starter,
rotate the engine 1/3 of a turn and fuel should
spill from the fuel injector pump.
10. Engine might run rough for 20 seconds or so, but it
will clean out.
4. When fuel starts to flow out of the rubber line, reconnect the fuel line to the fuel injector pump.
3-80
JLG Lift
3121813
3.13 GENERATOR (S/N 88375 TO PRESENT)
Dynamo and Dynamo Voltage Regulator
NOTE: Throughout the Generator section, the abbreviation

RBS is used. RBS stands for Rotary Battery System,
which is the generator system.
The engine-driven generator is designed to produce a DC
output directly without the need of a separate rectifier.
Included in the RBS unit is the engine, generator, engine/
generator controller, harness and related components.
Engine
Peak rating:
Continuous rating:
6.2 HP
0.6 HP at 3600 RPM
The engine is equipped with a dynamo and dynamo voltage regulator.
Refer to the Engine Manual for a complete description of

the engine.
Dynamo output: 12V

7A DC
Refer to the Engine Manual for a complete description of
the dynamo and dynamo voltage regulator.
Alternator
Dynamo Output Fuse
The RBS is equipped with a brushless DC output alternator.

The 3-phase AC output of the alternator is full wave rectified and presented to the output terminals.
Output rating: 58.0V at 45A
Voltage regulation and current limiting is provided by the
RBS Engine/Generator Controller.
The rectifier diodes and output current sensor are located
in the alternator endbell.
3121813
This fuse protects the dynamo output; it is located on the

left side of the engine.
Rating: 20ADC
Control Fuse
The control fuse provides power to the engine/generator
controller and the relays for start control, fuel control and
glow plug.
Rating: 15ADC
This fuse is located on the right side of the engine.
JLG Lift
3-81
13
10
12
11
7
8
8.
9.
10.
11.
12.
13.
Temperature Sensor
Voltage Regulator
Alternator
Starter
Starter Solenoid
Oil Filter
10
1.
2.
3.
4.
5.
6.
7.
Glow Plug Relay

Fuel Control Relay
Start Control Relay
Fuel Solenoid
Fuel Filter
Low Oil Pressure Switch
Glow Plug
12
13
3
2
Figure 3-70. Generator
3-82
JLG Lift
3121813
Start Battery
Start Control Relay
The RBS requires a 12V lead-acid start battery (not supplied with the system), which provides starting power and
power for the RBS controls.
This battery is charged by the engine dynamo and
dynamo regulator when the engine is running.
Engine Starter
The start control relay energizes the solenoid of the
engine starter and the pull coil of the engine fuel solenoid.
The start control relay is energized by the engine/generator controller from pin J2-4.
The start control relay is located on the fuel solenoid
bracket on the right side of the engine.
The engine is equipped with a 12VDC starter, which provides the mechanical power to crank the engine. Electrical
power for the starter is provided by the start battery.
The starter is energized by the start control relay.
3121813
JLG Lift
3-83
Fuel Control Relay
Glow Plug Control Relay
The fuel control relay energizes the hold coil of the fuel
solenoid.
The glow plug control relay energizes the glow plug. It is

energized by the engine/generator controller, pin J2-27.
The fuel control relay is energized by the engine/

generator controller from pin J2-3.
The glow plug control relay is located on the fuel solenoid

The fuel control relay is located on the fuel solenoid

Glow Plug
The glow plug is a resistive heating element located in the
combustion chamber. It is used during starting at temperatures below 32F (0C).
The heater is energized by the glow plug control relay.
3-84
JLG Lift
3121813
Fuel Pump
Engine Low Oil Pressure Switch
The fuel pump runs in parallel with the fuel solenoid hold
coil which is run by the fuel control relay.
The pump runs whenever the engine runs, and keeps the
fuel filter filled. Excess fuel flows through the return line
back to the fuel tank.
The fuel pump is located on the right side of the engine.
Fuel Solenoid
The engine is equipped with a low oil pressure switch.

This switch is closed when the oil pressure is below 7psi.
It is mounted on the side cover.
Engine Oil Temperature Sensor
The fuel solenoid actuates the run/stop lever of the

engine. This solenoid has a pull coil energized by the start
control relay and a hold coil energized by the fuel control
relay.
The fuel solenoid is located on the right side of the engine.
3121813
The engine oil temperature sensor is used to sense the

temperature of the oil in the sump of the engine.
This sensor provides an analog signal to the engine/generator controller. The primary use of this signal is for high
engine temperature shutdown 248F (120C) for the
JLG Lift
3-85
engine. The signal is also used in determining if the air

glow plug should be energized.
The engine oil temperature sensor is connected to the
engine/generator controller at pins J2-8 and J2-19.
The engine oil temperature sensor is located on the left
side of the engine.
RBS Engine/Generator Controller

The control system enclosure houses the RBS engine/
generator controller, which performs all control tasks
associated with the RBS.
The engine/generator controller interface is via a J2 35-pin
connector.
Alternator Output Current Sensor
Table 3-12. Controller Interface Pin Assignments
The alternator output current sensor provides a signal proportional to the output current of the alternator to the
engine/generator controller. The output current is regulated at 45ADC.
The alternator output current sensor is connected to the
engine/generator controller at pins J2-21, J2-31 and J232.
The alternator output current sensor is located inside the
rear cover of the alternator.
Engine Speed Sensor
PIN
FUNCTION
System 48VDC
System 0V DC
Fuel solenoid
Starter Solenoid
Manual call to start
Low oil pressure
Not used
Engine oil temperature
Speed sensing input
10
RS-232 +12V
11
RXD
12
TXD
13
LED Driver GND
14
LED Driver +48V
15
Speed sensor GND
16
Not used
17
Not used
18
- Output voltage
The engine speed sensor provides a signal proportional

to the rotational speed of the engine to the engine/generator controller. This signal is used by the engine/generator
controller to determine starter cut-out, overspeed fault and
underspeed fault. If the signal is not present at the engine/
generator controller, the unit will fault with a loss of speed
signal indication.
19
Engine oil temperature/ambient temp. + 8V
20
Speed Sensing + 8V
21
Output current sensor (GND)
22
Not used
23
RS-232 GND
24
- Field drive
The engine speed sensor is connected to the engine/generator controller at pins J2-9, J2-15 and J2-20.
25
+ Start battery
26
- Start battery
The engine speed sensor is located inside the recoil

starter cover at the front of the engine.
27
Pre-heat
28
Inhibit run
3-86
JLG Lift
29
Engine temp. switch
30
+ Output voltage
31
Speed sensing + 5V
32
Output current sense
33
Not used
34
Not used
35
Field Drive
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Warnings and Safety Precautions
System Settings
CALL TO START SETTINGS
THE RBS MAY START WITHOUT WARNING.
MORE THAN ONE LIVE CIRCUIT IS USED INSIDE THE RBS CONTROL PANEL. EXERCISE CAUTION WHEN THE CONTROL PANEL
IS OPEN, EVEN WHEN THE RBS IS NOT RUNNING.
System Controls
Low battery voltage call to start level
48.0 VDC
Low battery voltage remove call to start level
54.0 VDC
Low temperature call to start level
5C
Low temperature remove call to start level
8C
Low start battery voltage call to start level
12.2 V
Low start battery voltage remove call to start level
12.9 V
CURRENT AND VOLTAGE SETTINGS
INHIBIT RUN INPUT
Normal output voltage level
58.0 VDC
The inhibit run input prevents the RBS from starting, clears
any existing calls to start and stops the engine immediately. To return to normal operating mode, the inhibit run
input must be removed.
Extend output voltage level
58.0 VDC
Current limit level
45 ADC
High voltage shutdown level
63 ADC
MANUAL CALL TO START
Finish charging current level
30 ADC
The manual call to start input initiates an automatic run of

the RBS unit.
TIME DELAY SETTINGS
RS232 PORT
TD engine start
30s
The RS232 allows the RBS to be monitored and controlled

using an analyzer.
TD purge
0s
System Status and Performance Monitoring

System status and performance can be monitored by the
analyzer.
TD bypass
10s
TD engine run
1800s
TD cool-down
30s
TD high volts
2s
CRANK SETTINGS
Crank time
15s
Reset time
15s
Crank cycles
SPEED TIME AND GLOW PLUG SETTINGS
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TD no speed signal
5s
TD DC sensing fault
10s
Starter disconnect
1000 Hz
Overspeed shutdown
3800 RPM
Underspeed shutdown
2000 RPM
Glow plug on temperature
5C
Glow plug on time
15s
JLG Lift
3-87
RBS Start
Call to start
RBS shutdown
Manual
48V DC applied to the input
Call to start removed
Automatic
1 Low battery voltage (below

48VDC)
2 Low engine temperature
(below 5C)
RBS waits to verify that call to

start is valid (not a transient condition).
Preheat delay
- if engine temperature is below

32F (0C)
Crank time
(Rest time)
RBS will crank and rest until

engine starts, or Overcrank fault
is indicated after 3 failed crank
cycles.
Time delay bypass
RBS waits until normal engine

operating conditions are
reached before Low oil pressure
and Underspeed faults are monitored.
3-88
Inhibit run input applied
Automatically:
1 Battery voltage above

54VDC and finish charging current below 30ADC
2 Engine temperature above
8C
3 Low start battery voltage

(below 12.2V)
Engine start time
delay
Manually
3 Start battery voltage above

12.9V and finish charging current below 30ADC
Engine run time delay
This period ensures that no further call to start conditions

occur prior to cool-down period.
Cool-down period
Alternator output is reduced to a

minimal level to allow the engine
to cool down.
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3121813
RBS Alarms and Flash Codes

In the event of an RBS alarm, a flash code will be issued
and an alarm indicated on the analyzer.
Table 3-13. RBS Alarms and Flash Codes
Flash Code
Problem
RBS Condition
1-1
Low Oil Pressure 1
Below 7psi
Shutdown
1-2
High Engine Temp.
Over248F(120C)
Shutdown
1-3
Overspeed
Over 3800 RPM
Shutdown
1-4
Underspeed 1
Below 2000 RPM
Shutdown
Overcrank
3 failed crank cyclesCall to start removed
Call to start removed
1-5
No Speed Signal2
2-1
Overvoltage 3
Shutdown
Over 63VDC
Shutdown
2-2
Engine Starting System fault 4
2-4
steady
Unit Enabled, no faults
Unit can respond to any call to start
Unit Off / Disabled
Unit will not respond to any call to start
Alarm
Alternator output less than 1/2 of the system Shutdown
nominal voltage (58VDC)
Notes:
1 Enabled once time delay bypass period has elapsed after engine startup.
2 Delayed to ensure the fault was not momentary.
3 Measured at the alternator output, shutdown is delayed by a factory set period to ensure the fault was not caused by a transient condition.
4 Indicates a problem with the engine start battery, engine magneto or magneto-voltage regulator.
Alarms must be reset once the fault has been corrected
(see below).
Maintenance Schedule
Check oil level every 24 hours
Resetting the RBS Controller
Change engine oil and filter every 150 hours
The RBS can be reset using the analyzer or by disabling

and re-enabling the RBS controller. This will clear any current fault condition with the controller.
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JLG Lift
3-89
Troubleshooting
Table 3-14. Troubleshooting
Flash Code
-
Problem
Solution
Unit Off / Disabled (engine will not Check position of selector switch.
crank)
Verify that the inhibit run is released.
Check the warning LED. Remedy fault if present and restart the RBS.
Check the start battery voltage.
Check control fuse.
Check for loose wiring or connection.
1-1
Low Oil Pressure
Check oil level.

Check oil supply lines.
Refer to Kubota Workshop manual WSM OC60/80/95.
Verify correct operation of oil pressure switch with a test gauge.
1-2
High Engine Temp.
Check for obstructions in the cooling airflow to the engine.

Check that the ambient temperature is within the design limits of the engine.
Verify correct operation of engine temperature sensor.
1-3
Overspeed
Verify setting of governor lever. Readjust, if required.

Refer to Kubota Workshop manual WSM OC60/80/95.
1-4
Underspeed
Ensure there is an adequate supply of fuel to the engine.

Ensure there is an adequate supply of combustion air to the engine. Check air
cleaner.
Verify setting of governor lever. Readjust if required.
Refer to Kubota OC60 Engine Manual.
Overcrank
Check fuel level.

Check fuel connections.
Verify operation of fuel solenoid and fuel pump.
Check the start battery voltage.
If the engine exhaust contains white smoke then fuel is entering the engine but
the engine is not firing. Refer to the Kubota OC60 Engine Manual for further
checks.
If the ambient temperature is low, verify that the heater and/or glow plug are
operating.
1-5
No Speed Signal
Check wiring connections.
2-1
Overvoltage
Check alternator output voltage.
3-90
JLG Lift
3121813

Flash Code
2-2
Problem
Engine Starting System fault
Solution
Check engine start battery charging system for current output.
Check for failed engine start battery.
2-4
APU Engine Start Battery Boosting

Always connect the POSITIVE (+) of the booster battery
to the POSITIVE (+) of the APU start battery, and the NEGATIVE (-) of the booster battery to the ground of the
engine block.
DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID

LEVEL IN THE BATTERY.
WARNINGS:
ALWAYS SHIELD YOUR EYES AND AVOID LEANING OVER THE

BATTERY WHENEVER POSSIBLE.
DO NOT ALLOW BATTERY ACID TO CONTACT EYES OR SKIN.

FLUSH ANY CONTACTED AREA WITH WATER IMMEDIATELY.
SEEK MEDICAL ATTENTION IF IRRITATION PERSISTS.
STARTING BATTERIES GENERATE EXPLOSIVE GASES. KEEP

SPARKS, FLAME AND LIGHTED CIGARETTES AWAY FROM BATTERIES.
IMPROPER USE OF A BOOSTER BATTERY TO START AN APU MAY

CAUSE AN EXPLOSION.
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THE VOLTAGE OF THE BOOSTER BATTERY MUST BE RATED AT

12V. THE AMP-HOUR CAPACITY OF THE BOOSTER BATTERY
MUST NOT BE LOWER OR SUBSTANTIALLY HIGHER THAN THAT
OF THE DISCHARGED BATTERY. USE OF BATTERIES OF DIFFERENT VOLTAGE OR SUBSTANTIALLY DIFFERENT AMP-HOUR RATING MAY CAUSE AN EXPLOSION OR PERSONAL INJUR Y.
APPLYING A HIGHER VOLTAGE WHILE BOOSTING WILL ALSO
CAUSE DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS.
A CHARGING SYSTEM (BATTER Y CHARGER OR BATTER Y

CHARGING ALTERNATOR) MUST NEVER BE ENERGIZED WHILE
BOOSTING. DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS
WILL RESULT.
THE MAIN BATTERY OF THE LIFT MUST NEVER BE USED TO

BOOST THE APU. DAMAGE TO SENSITIVE ELECTRONIC COMPONENTS WILL RESULT.
JLG Lift
3-91
3.14 SUPPLEMENTARY FUSE FOR ENGINE

GENERATOR CONTROLLER
2. Find where the harness attaches to the rear cover of

the generator and the connection point for the new
inline fuse.
The purpose of this section is to describe the procedure to

add a supplementary fuse for the Engine Generator Controller for the APU.
Tools And Material

- Weather proof fuse holder - JLG P/N 2400081
- AGC1, 1 Amp fuse - JLG P/N 2400080
- 45 cm of #16 AWG wire - JLG P/N 4920019
- 2 X insulated butt splice connectors - JLG P/N
4460035
- 6 X medium length wire ties - JLG P/N 4240033
- Wire/Side cutters
- 5/32 Allen Key
- Crimping tool
3. Remove the socket head drive screw with a 5/32
Allen key. Next remove the cable clamp from the
harness.
Procedure
BEFORE BEGINNING THIS PROCEDURE, ENSURE THAT ALL
SOURCES OF POWER ARE DISCONNECTED FROM THE APU!
This procedure is common for all applications of the APU.
The photos contained in this document illustrate the modification performed to an APU supplied in a JLG M450 lift.
1. Locate the harness at the rear of the APU.
4. Cut and remove the Wire Ties holding the Harness

label to the harness. Next, remove the Wire Ties so
3-92
JLG Lift
3121813
that the cable sleeve can be moved, exposing the

conductors of the harness.
6. Re-install the harness with the new fuse in place.
7. Reconnect the lift and APU start battery. The APU is

now ready for use.
5. Cut wire 106 going to the Engine/Generator Controller after the existing connection point and install the
conductors that lead to the new inline fuse holder.
Use insulated butt splice connectors for these conductors.
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JLG Lift
3-93
NOTES:
3-94
JLG Lift
3121813
SECTION 4. BOOM & PLATFORM

4.1
BOOM
Removal
1. Raise the boom to horizontal and make sure that it is
adequately supported with a lifting device or blocking.
2. Tag and disconnect the electrical leads at the platform and the platform valve.
3. Tag and disconnect all hydraulic lines on the platform valve and rotator. Cap or plug all openings.
4. Remove the hardware attaching the platform and
platform support and remove the platform.
NOTE: Steps 5 and 6 are only applicable if the machine is
equipped with a jib.
5. If equipped with a jib, place the jib in a horizontal
position and support it with blocking. Tag and disconnect the hydraulic lines running to the jib cylinder. If equipped with a side swing jib, also tag and
disconnect the hydraulic lines running to the jib rotator.
7. Disconnect the hydraulic and electrical lines from

the bulkhead fittings at the rear of the boom.
8. Remove the cover at the rear of the upright.
9. Remove the covers on the side of the upright for the

pivot pins.
6. Remove the jib pivot pin and the slave cylinder pivot
pin and remove the jib.
10. Tag and disconnect the hydraulic lines running to

the telescope cylinder.
11. Tag and disconnect the hydraulic lines running to
the master cylinder.
12. Remove the upper lift cylinder pivot pin.
3121813
JLG Lift
4-1
Figure 4-1. Boom Assembly - Sheet 1 of 3
4-2
JLG Lift
3121813
3121813
JLG Lift
4-3
4-4
JLG Lift
3121813
6. Connect the hydraulic lines running to the master

cylinder as tagged during removal.
7. Connect the hydraulic lines running to the telescope
cylinder as tagged during removal.
8. Install the covers on the side of the upright to conceal the pivot pins.
9. Install the rear cover on to the upright.
10. Connect all the hydraulic and electrical lines at the
bulkhead fitting at the rear of the boom.
NOTE: Steps 10 and 11 are only applicable if the machine is
equipped with a jib.
11. Position the jib to the pivot points and install the jib
pivot pin and the slave cylinder pivot pin.
12. Connect the hydraulic lines running to the jib cylinder as tagged during removal. If equipped with a
side swing jib, connect the hydraulic lines running to
the jib rotator.
13. Install the platform support and platform.
13. Remove the upper master cylinder pivot pin.
14. Install the hydraulic lines to the platform valve and

rotator as tagged during removal.
14. Remove the boom pivot pin.
15. Reconnect the electrical leads at the platform and

platform valve as tagged during disassembly.
15. Remove the boom link pivot pin.

NOTE: The standard boom assembly weighs approximately
1993 lbs. (904 kg).
16. Using an adequate lifting device, remove the boom
from the machine.
Installation
16. Cycle test the boom from the ground station to

ensure all functions operate properly.
17. After verifying that all functions operate properly
from the ground station, cycle test the boom from
the platform station to ensure all functions operate
properly from the platform station as well.
1. Using an adequate lifting/supporting device, position the boom into the proper position on the
upright.
2. Install the boom link pivot pin.
3. Install the boom pivot pin.
4. Install the upper master cylinder pivot pin.
5. Install the upper lift cylinder pivot pin.
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JLG Lift
4-5
Figure 4-4. Boom Limit Switch Adjustment
4-6
JLG Lift
3121813
SWITCH TO ACTIVATE WHEN BOOM

IS EXTENDED 18 1 (46 2.5 CM)
Figure 4-5. Transport Limit Switch (CE Only)
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JLG Lift
4-7
4.2
LOAD CELL CALIBRATION PROCEDURE
13. Remove the weight from the basket.

14. Adjust P2 until the load = 0%.
1. Place the machine in the stowed position.

2. Activate both emergency stop switches and turn the
key switch to the platform position.
3. Remove all loads from the basket including the
operator.
15. Place 500 lbs. (230kg) in the center of the basket.

17. Add 55lbs. (25kg) in center of the basket.
4. Turn P1 clockwise (in) until the potentiometer begins

to click.
18. Verify that the overload lamp lights continuously and

the alarm sounds continuously during an overload
condition.
5. Plug the analyzer into the port in the platform.
19. Remove weight from the basket.
6. Enter the password 33271.
20. Seal Potentiometers with fingernail polish.
7. Select Machine Set-Up/Load Cell/ 1=Warn Only.
21. When an overload condition is reached, the

machine will give an indication by activating the tilt
alarm, lighting the overload light, put all platform
functions into creep, cutout lift up and telescope out
at platform and ground.
The horn will be activated when MTB ground control
switch is selected to ground and overload condition
is reached.
8. Select Diagnostics/System/Load Cell on the Analyzer.

10. Place 455 lbs. in the center of the basket.
12. Verify that the overload lamp lights continuously and
the alarm sounds continuously during an overload
condition.
NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued.
A,B,D
C,D
A
B
C
D
E
Torque to 50 ft.lbs. (68 Nm)

Loctite #242
Torque to 480 ft. lbs. (650 Nm)
Check torque every 150 hours of operation
Torque to 85 ft. lbs. (115 Nm)
Figure 4-6. Platform Support Torque Values
4-8
JLG Lift
3121813
Figure 4-7. Load Sensor
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JLG Lift
4-9
4.3
PLATFORM ROTATOR
Assembly and Testing
Theory of Operation
See Figure 4-9., Platform Rotator Assembly - Cutaway
Fluid entering Port P2 under pressure will bear on the piston (4) and force the piston sleeve (3) upwards. The lefthanded spline of the piston sleeve (3) will combine with
the right- handed spline of the shaft (2A) and cause rapid
counter-clockwise rotation of the shaft and flange (2B)
(looking down). Fluid entering Port P1 will reverse this
rotation.
Displacement and torque are identical for clockwise and
counterclockwise rotation.
The shaft (2A) is integral with the shaft flange (2B) and
bearing tube (2C). The shaft is supported radially by the
large upper radial bearing (19) and the lower radial bearing (18). Axially, the shaft is separated from the housing by
the upper and lower thrust rings (20). The end cap (5) is
adjusted for axial clearance and locked in position by cap
screws (7).
Wash all parts thoroughly in cleaning solvent and blow

dry. Coat all sealing and working surfaces with a good
grade hydraulic oil. Install seals and bearings in the piston
sleeve, piston, shaft, and end cap. The lips of the exclusion seals (16) face outward, and the lips of the high pressure seals face inward.
Place the actuator in a vertical position, install the piston
sleeve (3) in timed relation to the housing, applying firm
pressure as the new seals and bearings enter the housing
and become compressed by the housing chamber.
DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS

IT WILL MAR THE CYLINDER BORE). THE TIMING MARKS (THE
SMALL PUNCH MARKS ON THE FACE OF EACH GEAR), MUST BE
ALIGNED FOR PROPER SHAFT ORIENTATION. REFER TO FIGURE 4-8., TIMING MARKS.
Disassembly and Inspection

Place on a clean workbench with room to place the internal parts as they are removed. Remove all hydraulic fittings Loosen cap screws(7) and unscrew locknut (6) and
end cap (5). The shaft is now free to move up and out of
engagement with the piston sleeve (3). Note the orientation between the spline teeth (see Figure II), as this will
greatly simplify actuator timing upon reassembly.
After removing the shaft, the piston sleeve and the piston
assembly can now be moved down and out of the housing. Remove all seals and bearings from their grooves,
except static piston seals (9) and (11). These seals generally do not require replacement. Clean all parts thoroughly
and inspect for wear. A small amount of wear in the spline
teeth will have little effect on the actuator strength. New
spline sets are manufactured with a backlash of about
0.005 (0.127 mm) per mating set. After long service, a
backlash of about 0.015 (0.381 mm) per set may still be
acceptable in most cases, depending on the required
accuracy of the application.
Item (1) is the integral housing and ring gear. Check the
ring gear for wear and weld damage to the pins. Inspect
the cylinder bore for wear and scratches. The surface finish should be 32 RMS or better; re-hone if necessary. The
radial bearings (18) and (1 9) and the piston bearings (17)
should have a maximum radial clearance of 0.006 (0.152
mm). A clearance in excess of 0.008 (0.203 mm) requires
replacement of the bearings. Rough and grooved shaft
journals require shaft replacement.
4-10
JLG Lift
1. Integral Housing & Ring Gear

2. Shaft
3. Piston Sleeve
Figure 4-8. Timing Marks
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1. Housing & Ring Gear

2A. Shaft
2B. Flange
2C. Bearing Tube
3. Piston Sleeve
4. Piston
5. End Cap
6. Locknut
7. Capscrew
9. Piston Seal
11. Piston Seal
14. O-ring
15. O-ring
16. Exclusion Seals
17. Piston Bearing
18. Radial Bearing
19. Radial Bearing
20. Thrust Bearing
21. O-ring
22. O-ring
P1 Pressure Port
P2 Pressure Port
Figure 4-9. Platform Rotator Assembly - Cutaway
3121813
JLG Lift
4-11
If the actuator is not equipped with grease fittings, the

thrust bearings (20) are coated with good grease before
sliding on the shaft and end cap. The shaft is installed by
again aligning the proper punched timing marks. Temporarily taping the threaded portion of the shaft will help
installation past the shaft seals (masking tape works well).
Apply anti-seize to threaded and surrounding areas of the
end caps. Also, depending on the size of the actuator
(60K and larger), the end cap may need to be installed
with the actuator in a vertical position.
The end cap (5) is torqued to 60-400 ft-lb (84-560 Nm)
depending on the actuator size, such that the actuator
begins rotation at approximately 100 psi (6.9 bar) pressure. The shaft flange cannot be rotated by hand; the
combined backdrive efficiency and friction prevent manual rotation. If the end cap is torqued too high, the actuator may require as much as 300 psi (20.7 bar) to rotate. If
the end cap is not torqued high enough, shaft axial motion
and radial backlash will result. The end cap must be
secured against the shaft by tightening cap screws (7), or
by installing axial setscrews, depending on the
leakage out of Port P2, around shaft flange (2B), and from
ring gear pin welds.
4.4
JIB ROTATOR
Operating Principle
Helacs helical hydraulic rotary actuators use our sliding
spline technology which converts linear piston motion into
powerful shaft rotation. The actuators are composed of a
housing and only two moving parts, the central shaft and
the annular piston. Helical spline teeth machined on the
shaft engage matching splines on the inside diameter of
the piston. The outside diameter of the piston carries a
second set of splines, of opposite hand, which engage
matching splines in the housings ring gear. As hydraulic
pressure powers the piston back and forth within the
housing similar to the operation of a hydraulic cylinder
the splines cause the shaft to rotate.
model. Apply hydraulic pressure and check for breakaway

pressure and shaft axial motion.
To test for leakage, pressurize Port P2 to 3000 psi (206.8
bar). No oil should seep from Port P1 or from around end
cap (5). Repeat test by pressurizing Port P1 and check for
Bars indicate starting positions of piston

and shaft. Arrows indicate direction they
will rotate. The housings ring gear
remains stationary.
As fluid pressure is applied, the piston is

displaced axially while, simultaneously...
... the helical gearing forces the rotation of

the shaft. Note how the double helix
design compounds rotation: shaft rotation
is about twice that of the piston.
Figure 4-10. Operating Principle - Jib Rotator
4-12
JLG Lift
3121813
Disassembly
5. Remove the shaft from the housing assembly by

driving it out with a plastic hammer as seen below.
1. Remove all hydraulic fittings Drain the oil from both

sides of the piston through the pressure ports.
2. Place the actuator horizontally on a clean work
bench with ample room to place the internal parts as
they are removed.
3. Unthread the socket head cap screws (102) from the
lockwasher(05). Remove the lock washer from the
shaft (02).
4. Secure the actuator firmly to the work surface to prevent movement. A pipe vise works well. Insert two
long screws (1/4-20) into the end cap (04) and,
using a pry bar, unthread the end cap from shaft by
turning in a counterclockwise direction as shown
below.
Before the shaft and piston gearing are completely

disengaged, note the orientation between the spline
teeth: small punch marks on the face of the piston
and the root of a spline tooth on the shaft gearing
indicate timing as seen below.
A considerable amount of
torque may be required to
loosen the end cap. Completely filling the length of the
screws with a stack of washers
or a bushing as seen in the
illustration to the right will permit more force to be applied to
the screws and prevent them
from bending be sure to
thread the screws completely
into the endcap. If the end cap
is difficult to break loose, special tooling may be fabricated
according to the drawing
below.
3121813
JLG Lift
Marking the teeth at this time with a permanent felt

tip marker will make the marks easier to see and
greatly simplify actuator timing during reassembly.
For 120 rotation actuators, remove the stop tube
from the shaft before removing the shaft from the
housing. Do not remove the 0-ring from the stoptube. It performs no sealing functions and should be
reused when the actuator is reassembled.
4-13
1. Housing
2. Shaft
3. Piston Sleeve
4. End Cap
5. Lockring
102. Socket Head Capscrew
106. Port Plug
111. Grease Fitting

112. Grease Relief Valve
400. Stop Tube
200. Rod Seal
201. Rod Seal
202. Piston Seal
204. Cap Seal
205. Bearing Seal

206. Exclusion Seal
301. Piston Bearing
302. Shaft Bearing
303. Shaft Bearing
304. Thrust Washer
Figure 4-10. Jib Rotator Assembly
4-14
JLG Lift
3121813
Figure 4-11. Tool for Removing End Cap

6. With the shaft removed, note the orientation of the
timing marks on the piston sleeve and ring gear in
the housing as below.
The adjacent weld can make the ring gear timing

marks difficult to locate; using a light can help.
Again, mark the teeth with a felt tip marker to make
the marks easier to see and to simplify timing during
reassembly. Drive the piston sleeve out of the hous-
ing using the handle of a rubber mallet as shown

below.
Support the piston sleeve as it is removed from the

housing. Great care should be taken to insure that
the gear teeth are not damaged and the piston
sleeve does not damage the housing bore as it is
removed.
7. Remove all seals and bearings from their grooves.
Note the orientation of the sealing lips prior to
removal.
8. Clean all components thoroughly with solvent or in a
parts washer. Be sure to flush all grease and contaminants from the grease fittings and grease relief
passages.
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JLG Lift
4-15
Inspection
3. Lightly coat the thrust washers (304) with grease

and install them on the shaft (02) and end cap (04)
prior to seal installation.
Inspect all parts for wear, damage, cracks, etc.

HOUSING
Inspect the cylinder bore for wear and scratches. The surface finish should be 32 RMS or better. Rehone if necessary. Minor scratches and damage can be repaired by
local polishing. Inspect all bearing contact surfaces for
damage and/or contamination and repair and clean as
necessary. Inspect the exterior of the housing for damage,
cracks, integrity of welds, etc.
SHAFT
Check the sealing surface of the shaft for scratches and
damage. Polish if necessary.
GEAR COMPONENTS
Check gearing for excessive wear. Nominal movement
between gear components in excess of 1.5 degrees can
result in sloppy response.
BEARINGS
All radial bearings are of a reinforced nylon material. If the
thickness measures less than 0.123 in. (3.125 mm), the
bearings should be replaced.
THRUST WASHERS
Manufactured from an orkot material. If the thickness measures less than 0.113 in. (2.870 mm), or if contaminants
are noticed imbedded in the material, the thrust washers
should be replaced.
Reassembly
It is recommended that you first practice assembling the
actuator with the bearings and thrust washers installed
but without the seals. The seals are easily damaged and
their increased friction makes assembly more difficult. Be
sure that the timing marks on the gear components are
engaged in the correct orientation. Mark the timing marks
with a felt tip marker for better visibility to make assembly
easier.
4. Lightly coat all sealing and working surfaces with a

good grade of hydraulic oil.
5. Install all seals in their respective grooves. Refer to
the Assembly Drawing on page 2 to ensure the correct orientation of all seals. Note that the 0-ring energizer should be removed from seal (201) on the
inside diameter of the piston nearest the piston
splines. This prevents pressure from being trapped
between seals (200) and (201).
6. With the housing positioned horizontally and firmly
secured to prevent movement, insert the piston
sleeve into the housing bore until the piston seal
contacts the housing chamfer. Look through the
opposite side (shaft flange side) of the housing bore
and rotate the piston sleeve as necessary to align
the timing marks on the housing ring gear and piston sleeve. While holding the piston sleeve steady to
prevent damage to the cylinder bore, drive the piston sleeve into the housing with a rubber mallet until
the gear teeth engage. This assembly step is difficult
and might require several attempts to successfully
engage the gear teeth. Double check the timing
marks and the engagement of the gear teeth to
insure correct alignment, then drive the piston
sleeve as far as possible into the housing until it
comes to a stop against the ring gear.
7. Install the shaft as seen below in timed relation to
the piston sleeve by aligning the punched timing
marks as shown below. Temporarily taping the
threaded portion of the shaft with masking tape will
make it easier to clear the rod seals and prevent
their damage Once the gear teeth are engaged,
rotate the shaft clockwise until it is bottomed out
against the piston sleeve. Using a rubber mallet,
drive the shaft into the housing until the thrust
1. Wash all parts thoroughly in cleaning solvent and

blow dry.
2. Pump a high quality NLGI-2 lithium based grease
into the grease fittings (111) to flush any contaminants out of the fittings and passages and to insure
the fittings are functioning properly. Replace any
non functioning fittings. Wipe off all excess grease.
The set screws of the relief valves (112) must be
flush with the countersunk bore to ensure proper
tension on the spring as seen in Photo F. If the set
screws are threaded in too far, the seals will be
extruded during greasing and damaged. Secure the
set screws with Loctite# 242.
4-16
JLG Lift
3121813
washer comes to a stop against the housing thrust

surface.
11. Apply a generous amount of anti-seize to the splines

at the end of the shaft. Locate the correct position of
the locknut to align its bolt circle with that of the end
cap. If the bolt circles do not align, unthread the end
cap no more than a half a pitch of the shaft splines.
Insert the cap screws and torque to 108 IN-LB (147
N.m).
12. Grease the thrust washers. Pump a high quality
NLGI-2 lithium based grease into the grease fittings
at both ends of the housing until it begins to ooze
from the grease reliefs. If possible, rotate the shaft
during greasing to ensure even distribution on the
thrust surfaces.
Testing
If the equipment is available, the actuator should be tested
on a hydraulic test bench. The breakaway pressure the
pressure at which the shaft begins to rotate should be
between 200 and 450 PSI (14 to 31 bar). Cycle the actuator at least 25 times at 3000 PSI (210 bar) pressure. At the
end of rotation, increase the pressure to 4500 PSI (315
bar) to check for leaks and cracks. Perform the test again
at the end of rotation in the opposite direction.
TESTING FOR INTERNAL LEAKAGE
8. Remove the masking tape and apply anti-seize to

the shaft threads.
Rotate the shaft the end of rotation at 3000 PSI (210 bar) a
maintain pressure. Remove the hydraulic line from the
non-pressurized side. Continuous oil flow from the open
pressure port indicates internal leakage across the piston.
Replace the line and rotate the shaft to the end of rotation
in the opposite direction Repeat the test procedure outlined above for the other port.
9. Install the stop tube if applicable.

10. Apply a thin film of grease to the seals, then thread
the end cap onto the shaft to a net fit where the end
cap just begins to damp against the thrust washer.
Tighten the end cap to approximately 120 FT-LB
(163 N.m).
3121813
JLG Lift
4-17

Problem
Shaft will not rotate or rotates slower than normal
Possible Cause
Insufficient torque output
Increase Hydraulic Pressure.
Damaged piston and/or rod seals causing internal

leakage
Test for internal leakage. Check for scratches,

gouges, etc., on shaft and internal housing surfaces
that could have damaged seals. Rehone or polish
damaged surfaces. Replace piston and/or rod
seals.
Ports or hydraulic lines are restricted or obstructed

Corrosion buildup on thrust surfaces causing
excessive friction
Improper hydraulic fluid
Operation is spongy, erratic, or faster than normal
Solution
Be sure ports are clear of obstructions and contaminants.

Remove corrosion with sandpaper or wire brush.
Drain system and/or actuator and fill with proper
fluid. The use of synthetic or water-based fluids in
standard actuators will cause seals and bearings to
swell. The actuator must be disassembled and all
seals and bearings replaced.
Air in actuator or insufficient hydraulic fluid
Bleed air from hydraulic system and/or add fluid to

proper levels
Bypass leakage in control valving
Repair or replace valve
Air in hydraulic system.
Bleed air from hydraulic system and/or add fluid to

proper levels
Damaged piston and/or rod seals causing internal

leakage
Test for internal leakage as outlined on page 7.

Check for scratches, gouges etc., on shaft and internal housing surfaces that could have damaged
seals. Rehone or polish damaged surfaces.
Replace piston and/or rod seals.
Bypass leakage in control valving

Improper hydraulic fluid
Repair or replace valve

Drain system and/or actuator and fill with proper
fluid. The use of synthetic or water-based fluids in
standard actuators will cause seals and bearings to
swell. The actuator must be disassembled and all
seals and bearings replaced.
Will not accept grease at grease fittings
4-18
Grease relief not functioning or replaced with

grease fitting or plug
JLG Lift
Clean or replace grease relief valves
3121813
SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE
HYDRAULIC SYSTEM
When assembling connectors in the hydraulic that use oring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.
2. Holding the fitting over the hydraulic oil container,

brush an even film of oil around the entire o-ring in
the fitting, making sure the entire o-ring is completely saturated.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this
manner:
A small container for hydraulic oil
Small paint brush
3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring
is coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush

with the other hand to dip into the container.
Remove excess hydraulic oil from the brush so an
even film of oil is applied on the o-ring.
3121813
JLG Lift
5-1
Dip Method
Spray Method
NOTE: This method works best with Face Seal o-rings, but
will work for all o-ring fitting types.
This method requires a pump or trigger spray bottle.

1. Fill the spray bottle with hydraulic oil.
2. Hold the fitting over a suitable catch can.
The following is needed to correctly oil the o-ring in this

manner:
3. Spray the entire o-ring surface with a medium coat

of oil.
A small leak proof container

Sponge cut to fit inside the container
A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add
hydraulic oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and
drip from the bottom of the fitting. This should signify
an even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.
2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. O-ring Boss type fittings will require more pressure

in able to immerse more of the fitting into the saturated sponge. This will also cause more oil to be dispersed from the sponge.
5-2
JLG Lift
3. Brush hydraulic oil on the entire o-ring, applying an

even coat of oil.
3121813
5.2 CYLINDERS - THEORY OF OPERATION
6-8 drops per minute or more, cylinder repairs must

be made.
Lift, Telescope, Slave, Master, Oscillation (if

equipped), Jib (if equipped), and Steer
A double acting cylinder is one that requires oil flow to
operate the cylinder rod in both directions. Directing oil
(by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward
the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of
the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.
Holding valves are used in the Lift circuits to prevent
retraction of the cylinder rod should a hydraulic line rupture or leak develop between the cylinder and its related
control valve.
5.3 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system
operation is suspected.
Cylinders With Single Counterbalance Valve

Lift Cylinder and Oscillation Cylinder
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION

ONLY.
1. Using all applicable safety precautions, activate
hydraulic system.
WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. IF
WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER
BOOM HALFWAY, FULLY ELEVATE UPPER BOOM AND ATTACH
OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING
APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR
SLING FOR TEST PURPOSES.
Cylinder Without Counterbalance Valves

Steer Cylinder and Master Cylinder
hydraulic system and fully extend cylinder to be
checked. Shut down hydraulic system.
2. Carefully disconnect hydraulic hose from retract port
of cylinder. There will be initial weeping of hydraulic
fluid which can be caught in a suitable container.
After initial discharge, there should be no further
leakage from the retract port.
3. Activate hydraulic system, and activate cylinder
extend function.
4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to retract port
and retract cylinder. If leakage continues at a rate of
6-8 drops per minute or more, cylinder repairs must
be made.
5. With cylinder fully retracted, shut down motor and
carefully disconnect hydraulic hose from cylinder
extend port.
2. After completing the above, shut down hydraulic

system and allow machine to sit for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appropriate cylinder port block.
3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.
4. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.
5. Remove boom prop/overhead crane, activate
hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
6. Activate hydraulic system and activate cylinder

retract function. Check extend port for leakage.
7. If extend port leakage is less than 6-8 drops per
minute, carefully reconnect hose to extend port,
then activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate of
3121813
JLG Lift
5-3
Cylinders With Dual Counterbalance Valve
1. Connect a suitable auxiliary hydraulic power source

to the cylinder port block fitting.
Telescope and Slave Cylinders
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION

ONLY.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

hydraulic system.
2. When working on the platform slave cylinder, stroke
platform slave level cylinder forward until platform
sits at a 45 degree angle.
3. After completing the above, shut down hydraulic
system and allow machine to sit for 10-15 minutes.
This is done to relieve pressure in the hydraulic
lines. Carefully remove hydraulic hoses from appropriate cylinder port block.
2. Operate the hydraulic power source and extend the

cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fixture.
4. There will be initial weeping of hydraulic fluid, which

can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
repairs must be made. If the retract port is leaking,
the piston is leaking, the piston seals are defective
and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
replaced.
5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge there should not be any further leakage from
the ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and
must be replaced.
6. If no repairs are necessary or when repairs have
been made, carefully reconnect hydraulic hoses to
the appropriate ports.
Figure 5-1. Cylinder Barrel Support

5. Mark cylinder head and barrel with a center punch
for easy realignment. Using an allen wrench, loosen
the cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.
7. Remove boom prop/overhead crane, activate

hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
5.4 CYLINDER REPAIR

NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
Disassembly
Figure 5-2. Capscrew Removal
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
5-4
JLG Lift
3121813
1.
2.
3.
4.
5.
Barrel
Not Used
Wear Ring
T-Seal
Wear Ring
6.
7.
8.
9.
10.
O-ring
Backup Ring
Wiper Ring
Seal
Rod
11.
12.
13.
14.
15.
Cap
Washer Ring
Bolt
Counterbalance Valve
Bleeder Valve
16.
17.
18.
19.
20.
Bushing
O-ring Plug
Loctite #242
Locking Primer (Not Shown)
Bushing
Figure 5-3. Axle Lockout Cylinder
3121813
JLG Lift
5-5
1.
2.
3.
4.
5.
6.
Loctite #242 (Not Shown)

Locking Primer
Loctite #RC609 (Not Shown)
Bolt
Tapered Bushing
Bushing
7.
8.
9.
10.
11.
12.
Head
Rod
Barrel
O-ring Plug
O-ring Plug
Not Used
13.
14.
15.
16.
17.
18.
Piston
Wear Ring
Washer Ring
Backup Ring
Wear Ring
Backup Ring
19.
20.
21.
22.
23.
24.
O-ring
O-ring
Setscrew
Bolt
Wiper
Seal
25.
26.
27.
28.
T-Seal
Spacer
Figure 5-4. Level Cylinder
5-6
JLG Lift
3121813
1.
2.
3.
4.
5.
6.

Not Used
Loctite #RC609 (Not Shown)
Bolt
Tapered Bushing
7.
8.
9.
10.
11.
12.
Bushing
Bushing
Head
Barrel
Rod
Washer Ring
13.
14.
15.
16.
17.
O-ring Plug
Piston
Not Used
Backup Ring
Backup Ring
18.
19.
20.
21.
22.
Seal
Wear Ring
Wear Ring
O-ring
O-ring
23.
24.
25.
26.
27.
Seal
Wiper
T-Seal
Bolt
Figure 5-5. Jib Lift Cylinder
3121813
JLG Lift
5-7
1.
2.
3.
4.
5.
6.

Loctite (Not Shown)
Bolt
Tapered Bushing
Bushing
7.
8.
9.
10.
11.
Barrel
Rod
Head
O-ring Plug
Not Used
12.
13.
14.
15.
16.
Piston
Backup Ring
Backup Ring
Washer Ring
Wear Ring
17.
18.
19.
20.
21.
Wear Ring
O-ring
O-ring
Capscrew
Seal
22.
23.
24.
25.
26.
Rod Seal
Wiper
Check Valve
Check Valve
Figure 5-6. Lift Cylinder
5-8
JLG Lift
3121813
1.
2.
3.
4.
5.
6.
Locknut
O-ring
Wear Ring
Piston
Piston Seal
O-ring
7. Spacer
8. Barrel
8A. Bushing
9. Rod
9A. Bushing
10. O-ring
11.
12.
13.
14.
15.
Backup Ring
Setscrew
Guide
Seal
Wiper
Figure 5-7. Master Cylinder
3121813
JLG Lift
5-9
1.
2.
3.
4.

Loctite (Not Shown)
Rod
5.
6.
7.
8.
Barrel
Head
Not Used
Wear Ring
9.
10.
11.
12.
Wear Ring
O-ring
Wiper
Backup Ring
13.
14.
15.
16.
T-Seal
Seal
Washer Ring
Bolt
Figure 5-8. Steer Cylinder
5-10
JLG Lift
3121813
1.
2.
3.
4.
5.
6.

Loctite (Not Shown)
Bolt
Bolt
Tapered Bushing
7.
8.
9.
10.
11.
12.
Barrel
Rod
Head
O-ring Plug
Not Used
Support Pad
13.
14.
15.
16.
17.
18.
Piston
Support Plate
Wear Ring
Backup Ring
Wear Ring
O-ring
19.
20.
21.
22.
23.
O-ring
O-ring
Bolt
Bolt
Backup Ring
24.
25.
26.
27.
28.
Wiper
Seal
Rod Seal
Spacer
Valve
Figure 5-9. Telescope Cylinder
3121813
JLG Lift
5-11
12. Remove the bushing from the piston.
NOTE: Steps 6 applies only to the telescope cylinders.

6. Using a spanner wrench, loosen the end cap or
head retainer, and remove from cylinder barrel.
7. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
8. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
Figure 5-11. Tapered Bushing
13. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.
14. Remove and discard the piston o-rings, seal rings,
and backup rings.
15. Remove piston spacer, if applicable, from the rod.
16. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals,
and wiper seals.
Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.
Figure 5-10. Cylinder Rod Support

9. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.
2. Inspect the cylinder rod for scoring, tapering, ovality,

or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
10. Loosen and remove the cap screw(s), if applicable,

which attach the tapered bushing to the piston.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
11. Insert the cap screw(s) in the threaded holes in the

outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
5-12
JLG Lift
3121813
9. Inspect cylinder head inside diameter for scoring or

other damage and for ovality and tapering. Replace
as necessary.
10. Inspect threaded portion of head for damage. Dress
threads as necessary.
Assembly
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components
prior to assembly.
11. Inspect seal and o-ring grooves in head for burrs

and sharp edges. Dress applicable surfaces as necessary.
1. A special tool is used to install a new rod seal into

the applicable cylinder head gland groove.
12. Inspect cylinder head outside diameter for scoring

or other damage and ovality and tapering. Replace
as necessary.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod/barrel
must be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing.
NOTE: Install pin into the Gar-Max bearing dry. Lubrication
is not required with nickel plated pins and bearings.
Figure 5-13. Rod Seal Installation
WHEN INSTALLING "POLY-PAK" PISTON SEALS, ENSURE SEALS

ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland
groove.
Figure 5-12. Gar-Max Bearing

14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
Figure 5-14. Wiper Seal Installation
3121813
JLG Lift
5-13
3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head.
backup rings are to be positioned so as not to be in

alignment with each other.
Figure 5-15. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
6. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side facing the O-ring is grooved.)
7. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the solid seal.)
Figure 5-16. Piston Seal Kit Installation

8. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as
possible.
NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal.(See magnified insert in Figure 5-16.)The split of seals and
9. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
10. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil.
WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER,

OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED
BUSHING BOLTS, THEN TIGHTEN SECURELY.
11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor cap-
5-14
JLG Lift
3121813
screws) through the drilled holes in the bushing and

into the tapped holes in the piston.
b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces
between the capscrews.
Figure 5-17. Tapered Bushing Installation
Figure 5-18. Seating the Tapered Bearing
12. Tighten the capscrews evenly and progressively in

rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifications.)
14. Retorque the capscrews evenly and progressively in

rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifications.)
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;
15. Remove the cylinder rod from the holding fixture.
a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between
the capscrews.
16. Place new guide locks and seals in the applicable

outside diameter grooves of the cylinder piston.
(See Figure 5-19., Poly-Pak Piston Seal Installation)
Figure 5-19. Poly-Pak Piston Seal Installation
3121813
JLG Lift
5-15
17. Position the cylinder barrel in a suitable holding fixture.
Table 5-1.Cylinder Head and Tapered Bushing Torque

Specifications
Description
Head Torque Value

(Wet)
Tapered Bushing
Torque Value (Wet)
Lift Cylinder
240 ft. lbs

(325 Nm)
35 ft. lbs.
(47 Nm)
Slave Cylinder
30 ft. lbs
(41 Nm)
5 ft. lbs.
(7 Nm)
Telescope Cylinder
N/A
9 ft. lbs.
(12 Nm)
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
18. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
20. Secure the cylinder head gland using the washer
ring and socket head bolts.
Table 5-2. Holding Valve Torque Specifications

Description
SUN - 7/8 HEX M20 X 1.5 THDS.
30-35 ft. lbs.

(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS.
45-50 ft. lbs.

(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS.
Figure 5-20. Rod Assembly Installation
Torque Value
150-160 ft. lbs.

(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS.
50-55 ft. lbs.

(68-75 Nm)
RACINE - 1 3/8 HEX 1 3/16 - 12 THDS.
75-80 ft. lbs.

(102-109 Nm)
RACINE - 1 7/8 HEX 1 5/8 - 12 THDS.
100-110 ft. lbs.

(136-149 Nm)
21. After the cylinder has been reassembled, the rod

should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 5-2, Holding Valve Torque
Specifications).
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON

THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER
A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS
TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING
ROD.
5-16
JLG Lift
3121813
1.
2.
3.
4.
5.
6.
Hydraulic Tank
Filter & Pressure Switch
Suction Strainer
Magnetic Plug
Sight Gauge
Filter Indicator
7.
8.
9.
10.
11.
Tank Strap
Electric Motor
Hydraulic Pump
Contactor Module
Fuel Tank (M Models Only)
Figure 5-21. Hydraulic Tank and Pump (Prior to S/N 51941)
3121813
JLG Lift
5-17
1.
2.
3.
4.
5.
6.
Hydraulic Tank
Filter & Pressure Switch
Suction Strainer
Magnetic Plug
Sight Gauge
Filter Indicator
7.
8.
9.
10.
11.
Tank Strap
Electric Motor
Hydraulic Pump
Contactor Module
Fuel Tank (M Models Only)
Figure 5-22. Hydraulic Tank and Pump (S/N 51941 to Present)
5-18
JLG Lift
3121813
5.5 PRESSURE SETTINGS
Flow Control / Bang Bang Main Relief
Proportional Main Relief - 3200 psi (220 Bar)
1. Connect the pressure gauge at the MP port on the

main valve.
Bang Bang Main Relief - 3000 psi (207 Bar)
2. Activate and bottom out telescope in. Adjust pressure to 3000 psi (207 Bar).
Lift Down - 1100 psi (76 Bar)

Lift Up - 2500 (172 Bar)
Steer
Swing - 2500 psi (172 Bar)

main valve.
Flow Control - 3000 psi (207 Bar)

Steer - 1800 (124 Bar)
2. Activate and bottom out steer right or left. Adjust

pressure to 1800 psi (124 Bar).
Platform Level Up - 2500 psi (172 Bar)

Platform Level Down - 1500 psi (103 Bar)
Platform Level Down
Jib Up - 2300 psi (158.5 Bar)
1. Connect a pressure gauge to the M1 port on the

platform control valve bank.
Jib Down - 2300 psi (158.5 Bar)

NOTE: All functions must be activated from the platform
control station when adjusting pressures at the Platform Control and Main Valve Blocks.
2. Activate and bottom out Platform Level Down. Adjust

to 1500 psi (103 Bar).
Platform Level Up Relief
Proportional Main Relief
1. Connect a pressure gauge to the M1 port on the


main valve and disconnect the lift up coil on the
main valve block.
2. Activate the lift up switch from the platform. Adjust
pressure to 3200 psi (220 Bar).
2. Activate and bottom out Platform Level Up. Adjust to

2500 psi (172 Bar).
Jib Relief
Lift Down
main valve.
2. Activate and bottom out lift down. Adjust pressure to
1100 psi (76 Bar).
1. Connect a pressure gauge at the M1 port on the

2. Activate and bottom out either Jib Up or Down.
Adjust the relief to 2300 psi (158.5 Bar).
Lift Up
main valve.
2. Activate lift up until end of lift cylinder stroke. Adjust
pressure to 2600 psi (179 Bar). If ceiling height will
not allow elevation, disconnect lift up hose (port #8
on valve bank) and cap the port to make the setting.
Swing
main valve.
2. Activate the swing function with the turntable lock
pin engaged. Adjust pressure to 2500 psi (172 Bar).
3121813
JLG Lift
5-19
NOTE: Torque all cartridges to 20 ft. lbs.(28 Nm)

Figure 5-23. Hydraulic Control Valve - Main Valve
5-20
JLG Lift
3121813
Figure 5-24. Hydraulic Control Valve - Platform Valve
3121813
JLG Lift
5-21
NOTES:
5-22
JLG Lift
3121813
SECTION 6. JLG CONTROL SYSTEM

6.1 INTRODUCTION
creep and max.-speed for all boom, drive, and steering

functions.
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON

THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS.
The motor controller will control current output, as programmed for smooth operation and maximum cycle time.
Ground control speeds for all boom functions can also be
programmed into the motor controller. The motor controller also features an adjustable time limit for positive traction.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 48 volt based
motor control unit installed on the boom lift.
The JLG Control System has reduced the need for
exposed terminal strips, diodes and trimpots and provides
simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,
The JLG Control System controller has a built in LED to

indicate any faults. The system stores recent faults which
may be accessed for troubleshooting. Optional equipment includes an hour meter, beacon light, function cutout, and ground alarm. These options may be added later
but must be programmed into the motor controller when
installed.
The Control System may be accessed utilizing a custom
designed, hand held analyzer (Analyzer Kit, JLG part no.
2901443) which will display two lines of information at a
time, by scrolling through the program.
NOTE: Each module has a label with the JLG part number
and a serial number which contains a date code.
The following instructions are for using the hand held analyzer.
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub

Level, and item menus
To return home or
access previous menu
Left & Right Arrow Keys
Up & Down Arrow Keys
Used to move between Top Level,

Sub Level, and item menus
Value Selector
Figure 6-1. Hand Held Analyzer
3121813
JLG Lift
6-1
Figure 6-2. Analyzer Flow Chart - Sheet 1 of 2
6-2
JLG Lift
3121813
Figure 6-3. Analyzer Flow Chart - Sheet 2 of 2
3121813
JLG Lift
6-3
Figure 6-4. Control Module Location
6-4
JLG Lift
3121813
6.2 TO CONNECT THE JLG CONTROL

SYSTEM ANALYZER
The top level menus are as follows:

HELP
DIAGNOSTICS
ACTIVATE TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only)
1. Connect the four pin end of the cable supplied with

the analyzer, to the motor controller module located
in the platform box or at the power module and connect the remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of
the cable; the cable cannot be connected backwards.
2. Power up the Control System by turning the lower
key to the platform or ground position and pulling
both emergency stop buttons on.
If you press ENTER, at the HELP: PRESS ENTER display,

and a fault is present, the analyzer display will scroll the
fault across the screen. If there was no fault detected, the
display will read: HELP: EVERYTHING OK. If powered up
at the ground station, the display will read: GROUND OK.
If ENTER is pressed again, the display moves to the following display:
6.3 USING THE ANALYZER

With the machine power on and the analyzer connected
properly, the analyzer will display the following:
LOGGED HELP
1: STARTUP (2/1)
HELP:
PRESS ENTER
LOGGED HELP
1: STARTUP (2/1)
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
At this point, the analyzer will display the last fault the system has seen, if any are present. You may scroll through
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To
return to the beginning, press ESC. two times. STARTUP
(2/1) indicates a power up.
When a top level menu is selected, a new set of menu
items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
3121813
JLG Lift
6-5
Pressing ENTER with any of the above displayed menus,

will display additional sub-menus within the selected
menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ESC. key.
Once the correct password is displayed, press ENTER.

The access level should display the following, if the password was entered correctly:
MENU:
ACCESS LEVEL 1
6.4 CHANGING THE ACCESS LEVEL OF THE

HAND HELD ANALYZER
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level,
the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 2
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
6-6
JLG Lift
3121813
6.5 ADJUSTING PARAMETERS USING THE

HAND HELD ANALYZER
6.6 MACHINE SETUP
Once you have gained access to level 1, and a personality

item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
When a machine digit item is selected, press the UP or

DOWN arrow keys to adjust its value, for example:
GROUND ALARM:
2=DRIVE
PERSONALITIES:
DRIVE ACCEL 1.0s
GROUND ALARM:
2 = DRIVE
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular personality. If the value does not change when pressing the
up and won arrows, check the access level to ensure you
are at access level 1.
The effect of the machine digit value is displayed along

with its value. The above display would be selected if the
machine was equipped with a ground alarm and you
wanted it to sound when driving. There are certain settings allowed to install optional features or select the
machine model.
When selection the machine model to match the size of
the machine, the personality settings will all default to the
factory recommended setting.
NOTE: Refer to Table 6-2, Personality Ranges/Defaults, and
Table 6-1, Machine Setup Descriptions in this Service Manual for the recommended factory settings.
NOTE: Password 33271 will give you access to level 1,
which will permit you to change all machine personality settings.
3121813
JLG Lift
6-7
There is a setting that JLG strongly recommends that you

do not change. This setting is so noted below:
Table 6-1. Machine Setup Descriptions

MODEL NUMBER...
Displays/adjusts machine model NOTE:

all personalities reset to default when
model number is altered
TILT...
Displays/adjusts tilt sensor function
DRIVE CUTOUT...
Displays/adjusts drive cutout switch

presence/ function
FUNCTION CUTOUT...
Displays/adjusts function cutout switch

presence/function
JIB. . .
Displays/adjusts jib presence
GROUND ALARM...
Displays/adjusts ground alarm presence/

function
PLATFORM ALARM...
Displays/adjusts platform alarm presence/ function
4WD ASSIST...
Displays/adjusts 4WD assist presence
SOFT TOUCH
Displays/adjusts soft-touch system

presence
ELEVATION CUTBACK
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
6-8
JLG Lift
3121813
6.7 MACHINE PERSONALITY SETTINGS
NOTE: Personality settings can be adjusted within the

adjustment range in order to achieve optimum
machine performance.
Table 6-2. Personality Ranges/Defaults

FUNCTION
DRIVE
LIFT
SWING
3121813
PERSONALITY
RANGE
DEFAULTS
ACCELeration
0.5s to 5.0s
1.0
DECELeration
0.1s to 2.0s
0.5
MINimum speed
0 to 25%
MAXimum speed
0 to 100%
72
ELEVATED MAXimum speed
0 to 25%
12
CREEP MAXimum speed
0 to 45%
30
POSITRAC time
0 to 60s
10
POSITRAC current
50-400 A
300A
4WD MINimum
0 to 50%
20
4WD MAXimum
0 to 100%
50
4WD Cutback
0 to 50%
30
ACCELeration
0.5 to 5.0
0.7
DECELeration
0.1 to 3.0
1.0
MlNimum UP speed
0 to 20%
MAXimum UP speed
0 to 100
85
CREEP Maximum UP speed
0 to 50
25
MINimum DOWN speed
0 to 10
MAXimum DOWN speed
0 to 100
53
CREEP maximum DOWN speed
0 to 30
15
ACCELeration
0.5 to 5.0s
0.7
DECELeration
0.1 to 3.0s
1.5
MINimum LEFT speed
0 to 10%
MAXimum LEFT speed
0 to 60%
CREEP maximum LEFT speed
0 to 35%
MINimum RIGHT speed
0 to 10%
MAXimum RIGHT speed
0 to 60%
CREEP maximum RIGHT speed
0 to 35%
JLG Lift
6-9

FUNCTION
TELEscope
BASKET LEVEL
BASKET ROTATE
JIB
STEER
6-10
PERSONALITY
RANGE
DEFAULTS
ACCELeration
0.5 to 5.0
0.7
DECELeration
0.1 to 3.0
0.5
MINimum IN speed
0 to 20
20
MAXimum IN speed
0 to 100
50
MINimum OUT speed
0 to 20
20
MAXimum OUT speed
0 to 100
55
ACCELeration
0.5 to 5.0
1.5
DECELeration
0.1 to 3.0
1.3
MINimum UP speed
0 to 20
MAXimum UP speed
0 to 50
22
MlNimum DOWN speed
0 to 20
MAXimum DOWN speed
0 to 60
12
ACCELeration
0.5 to 5.0
DECELeration
0.1 to 3.0
1.5
MlNimum LEFT speed
0 to 15
MAXimum LEFT speed
0 to 100
10
MINimum RIGHT speed
0 to 15
MAXimum RIGHT speed
0 to 100
10
Lift ACCELeration
0.5 to 5.0
1.5
Lift DECELeration
0.1 to 3.0
0.5
MINimum UP speed
0 to 50
MAXimum UP speed
0 to 100
23
MINimum DOWN speed
0 to 25
MAXimum DOWN speed
0 to 100
15
MINimum LEFT speed
0 to 50
17
MAXimum LEFT speed
0 to 100
30
MINimum RIGHT speed
0 to 50
17
MAXimum RIGHT speed
0 to 100
30
MINimum speed
0 to 100
20
MAXimum speed
0 to 100
30
JLG Lift
3121813

FUNCTION
GROUND MODE
PERSONALITY
RANGE
DEFAULTS
LIFT UP speed
0 to 100
85
LIFT DOWN speed
0 to 100
63
SWING speed
0 to 100
TELEscope speed
0 to 100
60
BASKET ROTATE speed
0 to 100
10
BASKET LEVEL speed
0 to 100
JIB LIFT speed
0 to 100
15
JIB SWING speed
0 to 100
20
4150341-B
3121813
JLG Lift
6-11
6.8 MACHINE CONFIGURATION

PROGRAMMING INFORMATION
Table 6-3. Machine Configuration Programming Information
Configuration Digit
Number
Description
1
MODEL #
E600
M600
Default
Number
1
When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting
2
TILT SENSOR
1
5 degree - reduces the maximum speed of all platform functions to creep when tilted and
above elevation. Reduces drive speed to creep when tilted. (Domestic/Japan)
4 degree - reduces the maximum speed of all platform functions to creep when tilted and above
elevation. Reduces drive speed to creep when tilted. (European/Australian)
4 degree - cuts out drive and reduces boom functions to creep speed when tilted and above elevation. Reduces drive speed to creep when tilted only. (Option)
3 degree - reduces the maximum speed of all boom functions to creep when tilted and above
elevation. Reduces drive speed to creep when tilted. (CE and Australian E600JP, M600JP)
NOTE: Any of the selections above will light the tilt lamp when a tilted condition
occurs and will sound the platform alarm when the machine is tilted
and above elevation.
3
DRIVE CUTOUT
4
FUNCTION
CUTOUT LIMIT
SWITCH
5
JIB
6
GROUND
ALARM
6-12
Battery Charger Cutout - cuts out drive when the battery charger is plugged in
Battery Charger Cutout and Simultaneous Drive and Boom functions disabled above elevation
(European/Australian)
Battery Charger Cutout and Drive Cutout above elevation (Option)
0= No Function Cutout
1= Cuts out all boom functions when switch opens (Option)
2= Cuts out all functions when the switch opens (Option)
No jib installed
Jib installed which has up and down movements only (Option)
Jib installed which has up and down movements and side to side movements
(Option)
No ground alarm installed
Travel Alarm - Sounds when the drive function is active (Option)
Descent Alarm - Sounds when either lift down is active (Option)
Motion Alarm - Sounds when any function is active (Option)
JLG Lift
3121813
Table 6-3. Machine Configuration Programming Information

Configuration Digit
Number
7
PLATFORM
ALARM
Sounds continuously when above elevation and tilted only.
Sounds continuously when above elevation and tilted, and in conjunction with
fault code flashes (Option)
8
SOFT TOUCH
0=No Soft Touch system installed
1= Soft Touch system installed (Option)
No Load Cell Installed
Warn Only
Warn & Cutout
9
LOAD CELL
Description
Default
Number
0
NOTE: The following information is to be used when working with the MACHINE SETUP menu. When configuring the
machine, the machine configuration must be completed before any personality settings can be changed. Changing
the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.
Default settings will be shown in bold type.
4150342-3
3121813
JLG Lift
6-13
6.9 LEVEL VEHICLE DESCRIPTION
Help Descriptions and Fault Flash Codes

Table 6-4. JLG Control System Flash Codes
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE

TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.
Code
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Description
2-1
Faulty Footswitch/EMS
2-2
Drive/Steer inputs/Footswitch Interlocks
2-3
Boom function inputs/Lift-Swing Joystick
2-5
Function Cutout/Drive Cutout
3-1
Contactors miswired/Motors miswired
3-2
Line contactor welded
3-3
Contactor short circuit or valve short circuit
3-5
Brake pressure input
4-2
Controller Overtemperature
4-4
Battery voltage out of range
5-5
Speed Sensor input
6-6
CANbus inputs
7-7
Traction /Pump motor wiring or motor faulty
9-9
Power Module Failure
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2 ENTER confirms that
vehicle is currently level, and zeroes the tilt sensor measurements
6-14
JLG Lift
3121813
Table 6-5. Help Descriptions and Fault Flash Codes
Flash Code
Description
No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is not behaving as
expected.
EVERYTHING OK
The normal help message in platform mode
GROUND MODE OK
The normal help message in ground mode
BATTERY LOW
Battery voltage is below 40V. This is a warning the controller does not shut down (the low battery lamp will light below 45V and flash
below 40V.
BRAKES RELEASED
Indicates manual brake release in ground mode
DRIVING AT CREEP - TILTED
Drive speed is limited to creep because the vehicle is tilted.
FSW OPEN
A drive or boom function has been selected but footswitch is open.
PUMP MOTOR AT CURRENT LIMIT
Pump current has reached controller current limit or safe operating area limit.
RUNNING AT CREEP - CREEP SWITCH OPEN
All function speeds are limited to creep because the creep switch is open.
RUNNING AT CREEP - TILTED & ABOVE ELEVATION
All function speeds are limited to creep because the vehicle is tilted and above elevation.
RUNNING AT CUTBACK - ABOVE ELEVATION
Drive speed is limited to cutback because the vehicle is above elevation.
TESTS ACTIVE - RECYCLE EMS TO END
The system tests have been activated; normal vehicle operation is not allowed.
TILT MODULE FAILURE: BAD TILT SENSOR
There is a problem with the tilt sensor in the positilt module; the controller defaults to massively tilted and does not try to prevent vehicle
roll on the grade.
TRACTION MOTOR AT CURRENT LIMIT
Traction current has reached controller current limit or safe operating area limit.
2/1
Flash code 2/1 indicates problems with footswitch.

FSW FAULTY
The two footswitch signals do not agree.
EMS recycle required.
STARTUP
Neither EMS input is active - the system is just switching on or is discharging the capacitor bank.
A welded line contactor might also cause this.
3121813
JLG Lift
6-15

2/2
Flash code 2/2 indicates problems with drive & steer selection.
DRIVE JOYSTICK FAULTY
The drive joystick center tap is out of valid range, or the wiper is wire-off.
DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FSW
Drive was selected before and during footswitch closure or at EMS switch-on.
FSW INTERLOCK TRIPPED
Footswitch was closed for seven seconds with no function selected.
STEER LOCKED - SELECTED BEFORE EMS/FSW
Steer was selected before and during footswitch closure or at EMS switch-on.
STEER SWITCHES FAULTY
Both steer switches are active together.
WAITING FOR FSW TO BE OPEN
Footswitch was closed when platform mode was selected.
4WD ASSIST DISABLED-NOT AVAILABLE WITH BOOM
4WD Assist has been selected and is not available due to a boom function being operated at the same time.
JOYSTICK FAULTS - CHECK PLATFORM BOX WIRING
There are drive, lift, or swing joystick faults but the exact cause cannot be determined (a short-circuit of any one joystick or the pump
pot could cause this).
2/3
Flash code 2/3 indicates problems with boom function selection.

LIFT/SWING JOYSTICK FAULTY
The lift or swing joystick center tap is out of valid range, or the wiper is wire-off.
LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE EMS/FSW
Platform upper lift or swing was selected before and during footswitch closure.
PUMP POT FAULTY
The pump pot is open-circuit; all platform boom functions except upper lift & swing will run at creep.
PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
A boom function (telescope, basket level, basket rotate, jib) has both directions selected together.
PUMP SWITCHES LOCKED - SELECTED BEFORE EMS/FSW
A boom function (telescope, basket level, basket rotate, jib) was selected before keyswitch or footswitch closure.
PUMP SWITCHED LOCKED - SELECTED BEFORE EMS
A ground boom function (telescope, basket level, basket rotate, jib) was selected before keyswitch.
SWING/LIFT JOYSTICK FAULTY
The swing joystick center tap is out of valid range, or the wiper is wire-off.
6-16
JLG Lift
3121813

2/5
Flash code 2/5 indicates that a function is prevented due to a cutout.

BOOM PREVENTED - DRIVE SELECTED
A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive & boom
operation.
BOOM PREVENTED - FUNCTION CUTOUT ACTIVE
A boom function is selected while function cutout is active and configured to cutout boom functions.
DRIVE & BOOM PREVENTED - FUNCTION CUTOUT ACTIVE
Drive or a boom function is selected while function cutout is active and configured to cutout all functions.
DRIVE PREVENTED - ABOVE ELEVATION
Drive is selected while above elevation and drive cutout is configured to prevent drive.
DRIVE PREVENTED - BOOM MOVEMENT SELECTED
Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED - CHARGER CONNECTED
Drive is selected while the charger is on (indicated by drive cutout being active) and drive cutout is configured to prevent drive.
DRIVE PREVENTED - TILTED & ABOVE ELEVATION
Drive is selected while tilted and above elevation and tilt is configured to cutout drive.
3/1
Flash code 3/1 indicates that a contactor did not close when energized.
LINE & DIRECTION CONTACTORS MISWIRED
When the line contactor was closed traction point A went high (and the capacitor bank charge did not increase to battery supply) - this
occurs if the line contactor coil wiring is swapped with that for a direction contactor coil.
OPEN-CIRCUIT FORWARD CONTACTOR OR TRACTION MOTOR
Traction point A did not go high when forward contactor was energized (this could be due to traction motor open-circuit or a power wiring error).
OPEN-CIRCUIT LINE CONTACTOR
The capacitor bank charge did not increase to battery supply when line contactor was energized (this could be due to a power wiring
error).
OPEN-CIRCUIT REVERSE CONTACTOR OR TRACTION MOTOR
Traction point A did not go high when reverse contactor was energized (this could be due to traction motor open-circuit or a power wiring error).
3/2
Flash code 3/2 indicates that a contactor did not open when deenergized.
WELDED LINE CONTACTOR
The capacitor bank charge did not decrease from battery supply when line contactor was deenergized (this could be due to a power
wiring error).
WARNING: If the line contactor is welded, the controller will not switch off when EMS or keyswitch is turned off.
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3/3
Flash code 3/3 indicates that a contactor coil is short-circuit.

OVERLOADED VALVE SUPPLY-CHECK WIRING
There is a high current draw from the valve supply when no valve is energized; this is probably due to a wiring error at the ground
module.
SHORT-CIRCUIT FORWARD CONTACTOR COIL
The forward contactor was not energized when required, due to coil overcurrent protection.
SHORT-CIRCUIT LINE CONTACTOR COIL
The line contactor was not energized when required, due to coil overcurrent protection.
SHORT-CIRCUIT REVERSE CONTACTOR COIL
The reverse contactor was not energized when required, due to coil overcurrent protection.
3/5
Flash code 3/5 indicates that there is a brake pressure problem.

BRAKES DID NOT LOCK
Brake pressure did not clear when the brake valve was deenergized.
BRAKES DID NOT RELEASE
No brake pressure was detected when running the pump motor and energizing the brake valve and steer speed valve.
4/2
Flash code 4/2 indicates that the controller is overtemperature.

SYSTEM TOO HOT - PLEASE WAIT
The controller heatsink temperature reached 75 degrees. The controller is shut down until it cools to below 70 degrees.
4/4
Flash code 4/4 indicates problems with the battery supply.

BATTERY LOW
Battery voltage is below 40V. This is a warning - the controller does not shut down.
BATTERY TOO HIGH - SYSTEM SHUT DOWN
Battery voltage is above 62V.
BATTERY TOO LOW - SYSTEM SHUT DOWN
Battery voltage is below 33V.
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5/5
Flash code 5/5 indicates problems with vehicle speed or the encoder.
NO VEHICLE MOVEMENT DETECTED AT MAXIMUM POWER
No speed was measured with traction motor full on. This could be due to a traction motor fault, a power wiring error, a speed encoder
fault, the brakes not releasing (although brake pressure is OK) or the vehicle being overloaded so that the motor cannot turn the wheels.
DRIVE PREVENTED - BOTH SPEED ENCODERS FAULTY
Both speed encoder input voltages are out of range.
LEFT SPEED ENCODER FAULTY
The speed encoder on the left wheel (connected to the positilt module) has a short-circuit or open-circuit fault; drive is still possible at
creep speed (automatic positrac is disabled).
RIGHT SPEED ENCODER FAULTY
The speed encoder on the right wheel (connected to the power module) has a short-circuit or open-circuit fault; drive is still possible at
creep speed (automatic positrac is disabled).
SPEED ENCODERS READING INVALID SPEED
One or both speed encoders is indicating an impossible number of pulses. This is probably due to a faulty speed encoder.
TILT MODULE FAILURE: NOT COMMUNICATING
No information is being received from the positilt module (it may be miswired); the system will drive at creep speed using the speed
encoder connected to the power module; the controller defaults to massively tilted and does not try to prevent vehicle roll on the grade.
VEHICLE RUNAWAY - CHECK SPEED ENCODERS
Speed in the wrong direction was measured with traction motor full on. This is probably due to the speed encoder being fitted incorrectly; it could also be due to a speed encoder fault or faults as for NO VEHICLE MOVEMENT DETECTED with the vehicle on a grade.
6/6
Flash code 6/6 indicates problems with the CANbus.

48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING
The power module is not receiving acknowledgements from the platform, ground modules, or positilt modules to transmitted data,
and the protection circuit which supplies the platform, ground, and positilt modules has tripped. This is probably due to wiring problems at the platform, ground, or positilt module.
CANbus FAILURE: GROUND MODULE
The power module is receiving from the platform module but not the ground module. This should not be possible!
CANbus FAILURE: PLATFORM MODULE
The power module is receiving from the ground module but not the platform module. This is probably due to wiring problems between
the platform and ground modules.
CANbus FAILURE: POWER MODULE
The power module is not receiving acknowledgments from the platform, ground, or positilt modules to transmitted data. This is probably due to wiring problems between the power and positilt modules.
GROUND MODULE FAILURE: OBSOLETE ON THIS VEHICLE
The ground module is an old design which is incompatible with the E600 vehicle; it must be replaced (it can be used on E300/M45/E45
vehicles).
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7/7
Flash code 7/7 indicates problems with a motor.

CAPACITOR BANK FAULT - CHECK POWER/MOTOR WIRING
The capacitor bank is not charging. This is probably due to a motor or power wiring error causing illegal current drain; it could also be
due to a very low battery supply.
OPEN-CIRCUIT PUMP MOTOR
Pump point A is collapsing when the pump MOSFETs are pulsed. This is probably due to an open circuit pump motor or a power wiring
error.
WARNING:
If the power wiring between the power module & contactor panel is wrong, this fault can occur any attempt to operate the vehicle
could damage the power module.
OPEN-CIRCUIT DIRECTION CONTACTOR OR TRACTION MOTOR
Traction point A is collapsing when the traction MOSFETs are pulsed. This is probably due to an open circuit traction motor or directional contactor or wiring error.
NOTE: This fault is unlikely to be seen due to interaction with speed control
PUMP POINT A LOW - CHECK POWER / MOTOR WIRING
Pump point A is near 0V when the pump MOSFETs are off. This is probably due to a motor or power wiring error.
STALLED TRACTION MOTOR
The power module traction MOSFET protection circuit is active. This is due to massive current drain and could be a stalled traction
motor or a power wiring error.
7/7
Flash code 7/7 indicates problems with a motor (continued).

STALLED PUMP MOTOR
The power module pump MOSFET protection circuit is active. This is due to massive current drain and could be a stalled pump motor
or a power wiring error.
TRACTION MOTOR OVERLOADED
The traction motor is drawing Excessive current for an extended period of time; the system shuts down to prevent destruction of the
motor or power module.
PUMP MOTOR OVERLOADED
The pump motor has been operating in current limit at a low percentage on for a period of time greater than 10 seconds
TRACTION CURRENT AT ZERO - CHECK SHUNT WIRING
Traction current measurement is at zero. This is probably due to an open-circuit between the current measurement shunt and the
power module.
TRACTION POINT A HIGH - CHECK POWER / MOTOR WIRING
Traction point A is near battery supply when neither direction contactor is energized and the traction MOSFETs are off. This could be
due to a welded direction contactor or a power wiring error.
TRACTION POINT A LOW - CHECK POWER / MOTOR WIRING
Traction point A is near 0V when neither direction contactor is energized and the traction MOSFETs are off. This could be due to a power
wiring error.
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9/9
Flash code 9/9 indicates problems with the controller.

POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1
A contactor remained energized when turned off.
POWER MODULE FAILURE: HWFS CODE 2
The hardware fail-safe tests did not complete because traction point A is not safe, or the hardware fail-safe is permanently tripped.
The hardware fail-safe tests did not complete because a contactor was energized when all should be turned off.
The hardware fail-safe tests did not complete because the hardware fail-safe tripped immediately when the traction MOSFETs were
turned on.
The hardware fail-safe tests failed because the hardware fail-safe did not trip within the allowed test time.
The hardware fail-safe tests failed because the hardware fail-safe tripped too slowly.
The hardware fail-safe tests failed because the hardware fail-safe tripped too quickly.
9/9
Flash code 9/9 indicates problems with the controller. (continued)

The hardware fail-safe tests failed because the hardware fail-safe remained tripped when the traction MOSFETs were turned off.
The hardware fail-safe tests failed because the line contactor could still be energized when the hardware fail-safe was tripped.
The hardware fail-safe tests failed because the contactor drive fail-safe did not trip within the allowed test time.
The hardware fail-safe tests failed because the contactor drive fail-safe tripped too slowly.
The hardware fail-safe tests failed because the contactor drive fail-safe tripped too quickly.
POWER MODULE FAILURE: HWFS TEST STALLED
The hardware fail-safe tests did not complete, but no reason can be determined.
POWER MODULE FAILURE: BAD TEMPERATURE SENSOR
The temperature sensor measurement is invalid; this is probably due to a disconnected wire within the power module. The possibility
of other disconnected wires (which could cause dangerous system function) means that the controller is shut down.
POWER MODULE FAILURE: S/C LINE CONTACTOR DRIVER
The line contactor energized when the footswitch was closed, before it was turned on; this is probably due to a failed driver within the
power module, although it could be due to bad power module wiring.
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6.10 ANALYZER DIAGNOSTICS MENU

STRUCTURE
the next outer level. The LEFT/RIGHT arrow keys move

between items in the same level. The UP/DOWN arrow
keys alter a value if allowed
In the following structure descriptions, an intended item is

selected by pressing ENTER; pressing ESC steps back to
Table 6-6. ADJUSTMENTS - Personality Descriptions
DRIVE
ACCEL
Displays/adjusts drive acceleration
DECEL
Displays/adjusts drive deceleration
MIN
Displays/adjusts minimum drive speed
MAX
Displays/adjusts maximum drive speed
ELEVATED MAX

NOTE: used when elevation cutout switches are limiting maximum speed
CREEP MAX

NOTE: used when creep switch on pump pot is active
TRACTION
Displays/adjusts the amount of time traction control is enabled after each input activation
POSITRAC
Displays/adjusts the maximum traction motor current at which positrac will activate
4WD MIN
Displays/adjusts the minimum 4WD assist speed
4WD MAX
Displays/adjusts the maximum 4WD assist speed
4WD CUTBACK
Displays/adjusts the maximum 4WD assist speed

NOTE: used when elevation cutout switches are limiting maximum speed
LIFT
ACCEL
Displays/adjusts upper lift acceleration
DECEL
Displays/adjusts upper lift deceleration
MIN UP
Displays/adjusts minimum upper lift up speed
MAX UP
Displays/adjusts maximum upper lift up speed
CREEP UP
Displays/adjusts maximum upper lift up speed

MIN DOWN
Displays/adjusts minimum upper lift down speed
MAX DOWN
Displays/adjusts maximum upper lift down speed
CREEP DOWN
Displays/adjusts maximum upper lift down speed

SWING
ACCEL
Displays/adjusts swing acceleration
DECEL
Displays/adjusts swing deceleration
MIN LEFT
Displays/adjusts minimum swing left speed
MAX LEFT
Displays/adjusts maximum swing left speed
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CREEP LEFT
Displays/adjusts maximum swing left speed

MIN RIGHT
Displays/adjusts minimum swing right speed
MAX RIGHT
Displays/adjusts maximum swing right speed
CREEP RIGHT
Displays/adjusts maximum swing right speed

TELE
ACCEL
Displays/adjusts telescope acceleration
DECEL
Displays/adjusts telescope deceleration
MIN IN
Displays/adjusts minimum telescope in speed
MAX IN
Displays/adjusts maximum telescope in speed
MIN OUT
Displays/adjusts minimum telescope out speed
MAX OUT
Displays/adjusts maximum telescope out speed
BASKET LEVEL
ACCEL
Displays/adjusts basket level acceleration
DECEL
Displays/adjusts basket level deceleration
MIN UP
Displays/adjusts minimum basket level up speed
MAX UP
Displays/adjusts maximum basket level up speed
MIN DOWN
Displays/adjusts minimum basket level down speed
MAX DOWN
Displays/adjusts maximum basket level down speed
BASKET ROTATE
ACCEL
Displays/adjusts basket rotate acceleration
DECEL
Displays/adjusts basket rotate deceleration
MIN LEFT
Displays/adjusts minimum basket rotate left speed
MAX LEFT
Displays/adjusts maximum basket rotate left speed
MIN RIGHT
Displays/adjusts minimum basket rotate right speed
MAX RIGHT
Displays/adjusts maximum basket rotate right speed
JIB
Not displayed if JIB = NO
ACCEL
Displays/adjusts jib acceleration
DECEL
Displays/adjusts jib deceleration
MIN UP
Displays/adjusts minimum jib up speed
MAX UP
Displays/adjusts maximum jib up speed
MIN DOWN
Displays/adjusts minimum jib down speed
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6-23

MAX DOWN
Displays/adjusts maximum jib down speed
MIN LEFT
Displays/adjusts minimum jib left speed
MAX LEFT
Displays/adjusts maximum jib left speed
MIN RIGHT
Displays/adjusts minimum jib right speed
MAX RIGHT
Displays/adjusts maximum jib right speed
STEER
MIN SPEED
Displays/adjusts minimum steer speed, which applies when vehicle speed is at maximum
MAX SPEED
Displays/adjusts maximum steer speed, which applies when vehicle speed is at minimum
GROUND MODE
LIFT UP
Displays/adjusts fixed lift up speed
LIFT DOWN
Displays/adjusts fixed lift down speed
SWING
Displays/adjusts fixed swing speed
TELE
Displays/adjusts fixed telescope speed
BASKETLEVEL
Displays/adjusts fixed basket level speed
BASKETROTATE
Displays/adjusts fixed basket rotate speed
JIB (U/D)
Displays/adjusts jib lift speed

JIB (L/R)
Displays/adjusts jib swing speed

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Table 6-7. Diagnostic Menu Descriptions

DRIVE
DRIVE
Displays drive joystick direction & demand
SPEED
Displays vehicle direction & speed
4WD
Displays 4WD status

NOTE: Not Displayed when 4WD ASSIST=NO
POSITRAC
Displays positrac status
STEER
Displays steer switch direction & demand

NOTE: steer demand is inversely proportional to vehicle speed
BRAKES
Displays brake control system status
CREEP
Displays pump pot creep switch status
BOOM
LIFT
Displays lift joystick direction & demand
SWING
Displays swing joystick direction & demand
LEVEL
Displays basket level switch direction & demand

NOTE: demand is controlled by the pump pot
TELE
Displays telescope switch direction & demand

ROTATE
Displays basket rotate switch direction & demand

JIB (U/D)
Displays jib lift switch direction & demand

JIB (L/R)
Displays jib swing switch direction & demand

PUMP POT
Displays pump pot demand
CREEP
Displays pump pot creep switch status
SYSTEM
3121813
TRACTION
Displays measured traction motor current
PUMP
Displays measured pump motor current
VALVE
Displays measured valve (12V supply) current

NOTE: this includes current for the ground alarm & hourmeter, but not
for any lamps
BATTERY
Displays measured battery voltage
TEMPERATURE
Displays measured heatsink temperature
JLG Lift
6-25
Table 6-7. Diagnostic Menu Descriptions

FSW1
Displays footswitch status

NOTE: FSW1 is wired to the power module
FSW2
Displays footswitch status

NOTE: FSW2 is wired to the platform module
DRIVE CUTOUT
Displays drive cutout switch status
ELEV. CUTOUT
Displays elevation cutout switch status
FUNC. CUTOUT
Displays function cutout switch status
BRAKES
Displays brake pressure switch status
MAN.RELEASE
Displays manual brake release switch status
TILT
Displays measured vehicle tilt

The first value indicates tilt in the forward/ reverse direction (pitch)
The second value indicates tilt in the left/ right direction (roll)
DATALOG
MAX.TEMP
Displays maximum measured heatsink temp.
MIN.TEMP
Displays minimum measured heatsink temp.
MAX.BATTERY
Displays maximum measured battery voltage
ON
Displays total controller on (EMS) time
DRIVE
Displays total controller drive operation time
PUMP
Displays total controller pump running time

NOTE: includes all boom functions, steer and brake release
LIFT
Displays total controller lift operation time
SWING
Displays total controller swing operation time
TELE
Displays total controller tele operation time
RENTAL
Displays total controller operation time

NOTE: can be reset
ERASE RENTAL
Not available at password level 2
YES:ENTER, NO:ESC
ENTER resets rental datalog time to zero
VERSIONS
6-26
POWER
Displays power module software version
PLATFORM
Displays platform module software version
GROUND
Displays ground module software version
POSITILT
Displays positrac/tilt module software version
ANALYSER
Displays Analyzer software version
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Table 6-8. Calibration Descriptions

CALIBRATIONS
Not available at password level 2; can be viewed but not changed at level 1
CONTROLLER CALS
TEMPERATURE
Displays/adjusts heatsink temperature calibration

The setting should not be altered from that set during manufacture
TRACTION I
Displays/adjusts traction motor current calibration

PUMP I
Displays/adjusts pump motor current calibration

TILTdelayIN
Displays/adjusts how long the tilt sensor must indicate a tilted condition before it is registered
The setting should be adjusted to optimize controller response to a sudden tilt, while minimizing spurious tilt indications during acceleration & deceleration
TILTdelayOUT
Displays/adjusts how long the tilt sensor must indicate a not-tilted condition before it is registered
The setting should be adjusted to optimize controller response to a sudden tilt, while minimizing spurious tilt indications during acceleration & deceleration
MACHINE CALS
BRAKE
Displays/adjusts brake release speed

The setting should be adjusted to release the brakes in the desired time, with minimal effect on other boom functions
PUMP@0%
Displays/adjusts minimum pump%on

The setting should be adjusted to minimize speed variations when functions are used individually and in combinations
PUMP@100%
Displays/adjusts maximum pump%on

The setting should be adjusted to minimize speed variations when functions are used individually and in combinations
Vflow@0%
Displays/adjusts minimum flow control proportional valve%on
Vflow@100%
Displays/adjusts maximum flow control proportional valve%on
Vlift@0%
Displays/adjusts minimum lift proportional valve%on
Vlift@100%
Displays/adjusts maximum lift proportional valve%on
Vswing@0%
Displays/adjusts minimum swing proportional valve%on
Vswing@100%
Displays/adjusts maximum swing proportional valve%on
SPEEDprop1
Displays/adjusts speed control PID algorithm proportional term in traction mode

The setting should be adjusted to optimize speed control
SPEEDprop2
Displays/adjusts speed control PID algorithm proportional term in plugging mode

SPEEDint
Displays/adjusts speed control PID algorithm integral term in traction & plugging mode
PLUGmax
Displays/adjusts maximum plugging current

The setting should be adjusted to ensure that the vehicle can be safely stopped when being driven down maximum
grade
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Table 6-9. Calibration Ranges/Defaults

Calibration
Range
Defaults
E600
BRAKE
0 to 100
25
PUMP@0%
0 to 50
50 to 100
100
0 to 50
44
FLOW VALVE@100%
50 to 100
60
LIFT VALVE@0%
0 to 100
40
LIFT VALVE@100%
0 to 100
70
SWING VALVE@0%
0 to 100
45
SWING VALVE@100%
0 to 100
52
TEMPERATURE
0 to 100
50
TRACTION I
0.50 to 2.00
1.00
PUMP I
0.50 to 2.00
1.00
SPEEDprop1
0 to 30
SPEEDprop2
0 to 30
16
SPEEDint
0.0 to 2.5
0.3
PLUGmax
30 to 100
75
TILTdelayIN*
0.0 to 5.0
1.0
TILTdelayOUT*
0.0 to 5.0
0.1
PUMP@100%
FLOW VALVE@0%
M600
*NOTE: TiltdelayIN and TILTdelayOUT are adjusted in internal units, not in 0.1s increments.
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6.11 SYSTEM SELF TEST
switch has been closed, it will move on to the next

input, lower lift down LLD. If the switch is faulty or the
wiring is faulty, the controller will not move on to the
next input. The controller will continue to wait for the
closure of the input. If the operator knows the switch
is faulty and wants to continue the tests he must
simply press the enter key on the analyzer to continue.
The system self test is utilized to locate typical problems.

See Table 6-10, System Test Descriptions and Table 6-11,
System Test Messages for information concerning the
tests performed and available messages in this mode.
1. When the keyswitch is in the platform position and
the self test enabled, the self test function will test all
valves, contactors, platform inputs, indicator lamps,
and system alarms for various fault conditions.
3. After the controller has conducted the tests from the

chosen operator station, it will display "TESTS COMPLETE". This indicates that the controller has
checked all inputs and outputs for that station.
When the keyswitch is in the ground position, the

self test function will test all valves, the line contactor, ground control inputs, and the ground alarm output for various fault conditions.
2. In order to test the inputs on the machine, the controller will ask the service technician to perform various tasks at the appropriate operator control station.
An example of this is "Close LLU Switch". The controller expects the operator to close the lower lift up
switch. When the controller sees that the lower lift up
IN ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF

TEST IS COMPLETE, POWER MUST BE RECYCLED USING THE
EMS OR THE KEYSWITCH.
Table 6-10. System Test Descriptions

ACTIVATE TESTS
Not available once tests are activated
YES:ENTER, NO:ESC
ENTER activates system tests

NOTE: cannot be done while controller is in use (footswitch closed) and for a short time afterwards
RUN SYSTEM TEST
ENTER starts system test

Not available until tests are activated
Displays messages while system test runs

Some messages are prompts, requiring user intervention.
ENTER can be pressed if a fault is found, to confirm that the fault has been noted and to continue the system
test.
NOTE: a flashing message is critical, and prevents the system test running
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Table 6-11. System Test Messages

RUNNING
6-30
Initial display when system test is run; certain critical checks are made. Problems which can be reported include:
ONLY 1 ANALYZER!
Do not connect two Analyzers while running the system test.
BAD POWER WIRING
The capacitor bank is not charged or pump point A is low or traction point A is high or low.
Check all power wiring.
LINE CONT WELDED
The capacitor bank is at battery voltage.
Check line contactor.
Check all power wiring.
BATTERY TOO LOW
The system test cannot run with battery voltage below minimum.
BATTERY TOO HIGH
The system test cannot run with battery voltage above maximum.
CHECK CAN WIRING
The system test cant run in platform mode unless data is being received from the platform, ground & positrac/tilt
modules.
The system test cannot run in ground mode unless data is being received from the ground and positrac/tilt modules.
CHECK LEFT SPD.
There is an open- or short- circuit in the left speed encoder wiring.
Check left speed encoder.
CHECK RIGHT SPD.
There is an open- or short- circuit in the right speed encoder wiring.
Check right speed encoder.
CHECK SHUNT
The traction current measurement is open-circuit.
Check wiring between power module and contactor panel.
BAD PUMP WIRING
Pump point A is not high, probably caused by an open-circuit pump motor or wiring.
Check all power wiring. Check pump motor.
BAD POWER MODULE
An internal problem was detected in the power module.
BAD POWER WIRING
Traction point A is high, probably caused by incorrect traction motor wiring.
Check all power wiring. Check traction motor.
HIGH TILT ANGLE
The vehicle is very tilted, or the tilt sensor has been damaged.
Check tilt sensor.
HOT POWER MODULE
The heatsink temperature exceeds 75C; this is only a warning.
BAD I/O PORTS
The controller detected a problem with its internal circuits at switchon.
If other problems are also detected, the controller may need replacing.
SUSPECT EEPROM
The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
WAIT:CAPBANK HI
This message can be displayed if the system test is run shortly after the vehicle was used; after a short wait, it should
clear.
OPEN FSW
In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW
In platform mode, the footswitch must be closed when this message is displayed; the footswitch MUST BE KEPT
CLOSED during the valve & contactor tests.
BAD FSW
The two footswitch signals are not changing together, probably because one is open-circuit. One footswitch signal
(FSW1) is routed to the power module, the other (FSW2) is routed to the platform module. Check footswitch &
wiring.
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TESTING VALVES
VALVE TEST DONE
Indicates that the valve test is beginning.

Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils.
NOTE: in platform mode, the footswitch must be closed.
NOTE: jib valves are not tested if JIB = NO
NOTE: left/right jib valves are not tested unless JIB = SIDESWING.
Problems which can be reported include:
CANT TEST VALVES
There is a wiring problem which prevents the valve test from functioning correctly.
Check valve wiring.
Check ground alarm & hourmeter wiring.
valvename S/C
The named valve is drawing too much current so is presumed to be short-circuit.
Check valve wiring.
valvename O/C
The named valve is drawing too little current so is presumed to be open-circuit.
Check valve wiring.
Indicates that the valve test is complete (with or without faults).
TESTING CONTS
Indicates that the contactor test is beginning.

In platform mode, the forward & reverse direction contactors are energized and de-energized; checks are made that
they
close & open correctly and for short-circuit coils.
In platform and ground mode, the line contactor is energized and de-energized; checks are made that it closed &
opened
correctly and for a short-circuit coil.
In platform mode, the positrac contactors are energized and de-energized; checks are made for short-circuit and
open-circuit coils.
CANT TEST CONTS
There is a wiring problem which prevents the contactor test from functioning correctly.
Check power wiring.
Check contactor wiring.
BAD CONT WIRING
There is a wiring problem which caused the capacitor bank to be charged when a direction contactor was energized;
probably the wiring to the contactor coils is incorrect.
Check power wiring.
contname WELDED
The named contactor appears to have not opened.
Check named contactor.
Check power wiring.
contname COIL O/C
The named contactor coil did not load its driver circuit so is presumed to be open-circuit.
contname COIL S/C
The named contactor coil overloaded its driver circuit so is presumed to be short-circuit.
contname DIDNT CLOSE
The named contactor appears to have not closed.
Check power wiring.
CONT TEST DONE
Indicates that the contactor test is complete (with or without faults).
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CHECKING INPUTS
Indicates that the inputs test is beginning.

Every input is checked to ensure that it is in its normal position; function switches should be open, cutout switches
should
be closed, joysticks should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are reported.
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: switches which are not in use (due to the settings of machine digits) are not checked.
NOTE: the pump pot is checked only for a wire-off condition; it can be at any demand from creep to maximum.
CHECK switchname
The named switch is not in its normal position.
Check switch & wiring.
CHECK switchname JOY.
The named joystick appears to be faulty.
Check joystick.
INPUTS DONE
Indicates that the inputs test is complete (with or without faults).
TESTING LAMPS
Indicates that the lamps test is beginning.

Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit - ENTER must be pressed to continue
the test.
NOTE: lamps which are not in use (due to the settings of machine digits) are not checked.
NOTE: lamps are only tested in platform mode.
lampname S/C
A short-circuit condition appeared while the named lamp was being tested, presumably because it is short-circuit.
LAMP TEST DONE
Indicates that the lamps test is complete.
TESTING ALARMS
Indicates that the alarms test is beginning.

Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding - ENTER must be pressed to
continue the test.
NOTE: the platform alarm is only tested in platform mode.
NOTE: the ground alarm is not tested if GROUND ALARM = NO.
alarmname S/C
A short-circuit condition appeared while the named alarm was being tested, presumably because it is short-circuit.
ALARM TEST DONE
Indicates that the alarms test is complete.
6-32
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TEST ALL INPUTS?
Prompts whether to check every operator input. If ESC is pressed, the system test ends.
If ENTER is pressed, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: the jib switches are not tested if JIB = NO.
NOTE: left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test include:
CLOSE switchname
The named switch should be closed.
OPEN switchname
The named switch should be opened.
joystickname direction TO MAX
The named joystick should be pushed to its full extent in the named direction.
joystickname direction TO MIN
The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX
The pump pot should be turned to maximum.
PUMP POT TO MIN
The pump pot should be turned to minimum.
MULTIPLE CLOSURE
More than one operator input is closed; if only one has been operated, there could be a short between two inputs.
TESTS COMPLETE
Indicates that the system test is complete. Any problems reported should have been noted and should now be rectified.
Press ESC to return to the RUN SYSTEM TEST Analyzer menu.
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6-33
NOTES:
6-34
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SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5
GENERAL
This section contains basic electrical information andschematics to be used for locating and correcting most of
the operating problems which may develop. 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.
7.6
tion of the signal and that the leads are connected to the
device under test correctly. Also check that the lead on the
"COM" port goes to the Ground or negative side of the signal 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)
MULTIMETER BASICS
m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM)

can be used for troubleshooting your equipment. This
section shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the meter
operators manual for more information.
= micro = (Displayed Number) / 1,000,000

Example: 1.2 k = 1200
Example: 50 mA = 0.05 A
Voltage Measurement
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 connectors 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 connector 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 technique, especially on sealed connectors. Whenever possible insert probes into 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 connector 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 contact and contacts are seated in the connector.
Figure 7-1. Voltage Measurement (DC)

If meter is not auto ranging, set it to the correct
range (See multimeters operation manual)
Min/Max
Use of the "Min/Max" recording feature of some meters
can help when taking measurements of intermittent conditions 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.
Use firm contact with meter leads
Polarity
Getting a negative Voltage or current reading when
expecting a positive reading frequently means the leads
are reversed. Check what reading is expected, the loca-
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7-1
Resistance Measurement
Continuity Measurement
Figure 7-3. Continuity Measurement

Some meters require a separate button press to
enable audible continuity testing
Circuit power must be turned OFF before testing
continuity
Figure 7-2. Resistance Measurement

First test meter and leads by touching leads
together. Resistance should read a short circuit
(very low resistance)
Circuit power must be turned OFF before testing
resistance
Disconnect component from circuit before testing

First test meter and leads by touching leads
together. Meter should produce an audible alarm,
indicating continuity
Disconnect component from circuit before testing

range (See multimeters operation manual)
7-2
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Current Measurement
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.
c. If the 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.
Figure 7-4. 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
range (See multi meters operation manual)
7.7
CHECKING SWITCHES
Another type of limit switch used by JLG is the inductive

proximity switch, also referred to as a "prox switch". Inductive 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 face 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:
1. Remove prox switch from its mount.
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 possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
2. Reconnect harness if it was disconnected for step a,

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 documentation 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 follow mounting instructions and properly set the gap
between the switch and object sensed.
4. If the switch has two terminals:

a. Measure resistance across the terminals.
b. Change the switch position.
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7-3
Automatic Switches
7.8
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 pressure, 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.
APPLYING SILICONE DIELECTRIC

COMPOUND TO ELECTRICAL
CONNECTIONS
Silicone Dielectric Compound must be used on all electrical connections for the following reasons:
2. Observe switch state in control system with the Analyzer. 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 temperature, for example. The state indicated in the control
system should change.

Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Silicone grease should not be applied to connectors with
external seals.
1. To prevent oxidation, silicone grease must be
packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.
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 loads power terminals. Also,
the technician can measure the voltage at both power terminals with respect to battery ground. The difference
between those two measurements is the voltage applied
to the load.
NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed
around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the connector should also be sealed.
NOTE: This condition is especially common when machines
are pressure washed since the washing solution is
much more conductive than water.
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to
the contacts only.
NOTE: Curing-type sealants might also be used to prevent
shorting and would be less messy, but would make
future pin removal more difficult.
7-4
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7.9
AMP CONNECTOR
Assembly
Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-5.). Proceed as follows:
Applying Silicone Dielectric Compound to

AMP Connectors
Silicone Dielectric Compound must be used on the AMP
connections for the following reasons:
Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely
around male and female pins on the inside of the
connector after the mating of the housing to the
header. This is easily achieved by using a syringe to
fill the header with silicone dielectric compound, to a
point just above the top of the male pins inside the
header. When assembling the housing to the
header, it is possible that the housing will become
air locked, thus preventing the housing latch from
engaging.
Figure 7-5. Connector Assembly Figure 1
2. Pierce one of the unused wire seals to allow the

trapped air inside the housing to escape.
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7.).
3. Install a hole plug into this and/or any unused wire

seal that has silicone dielectric compound escaping
from it.
2. Pull back on the contact wire with a force of 1 or 2

lbs. to be sure the retention fingers are holding the
contact (See Figure 7-7.).
Figure 7-6. AMP Connector
3121813
JLG Lift
7-5

3. After all required contacts have been inserted, the
wedge lock must be closed to its locked position.
Release the locking latches by squeezing them
inward (See Figure 7-8.).
4. Slide the wedge lock into the housing until it is flush

with the housing (See Figure 7-9.).
7-6
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3121813
Figure 7-10. Connector Disassembly
Disassembly
Service - Voltage Reading
1. Insert a 4.8 mm (3/16") wide screwdriver blade

between the mating seal and one of the red wedge
lock tabs.
2. Pry open the wedge lock to the open position.
3. While rotating the wire back and forth over a half
turn (1/4 turn in each direction), gently pull the wire
until the contact is removed.
NOTE: The wedge lock should never be removed from the
housing for insertion or removal of the contacts.
Wedge Lock
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

It has been common practice in electrical troubleshooting
to probe wires by piercing the insulation with a sharp
point. This practice should be discouraged when dealing
with the AMPSEAL plug assembly, or any other sealed
connector system. The resulting pinholes in the insulation
will allow moisture to invade the system by traveling along
the wire strands. This nullifies the effectiveness of the connector seals and could result in system failure.
The wedge lock has slotted openings in the forward, or

mating end. These slots accommodate circuit testing in
the field, by using a flat probe such as a pocket knife. DO
NOT use a sharp point such as an ice pick.
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JLG Lift
7-7
Figure 7-11. Connector Installation
7-8
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3121813
7.10 DEUTSCH CONNECTORS
DT/DTP Series Disassembly
DT/DTP Series Assembly
A
A
D
Figure 7-12. DT/DTP Contact Installation
Figure 7-13. DT/DTP Contact Removal
1. Grasp crimped contact about 25mm behind the contact barrel.

2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly
locked in place.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular
wedges are not oriented. Thy may go in either way.
1. Remove wedgelock using needlenose pliers or a

hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards,
while at the same time releasing the locking finger
by moving it away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact
may displace the seal.
NOTE: The receptacle is shown - use the same procedure

for plug.
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7-9
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Figure 7-14. HD/HDP Contact Installation
Figure 7-16. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact

crimp barrel.
1. With rear insert toward you, snap appropriate size

extractor tool over the wire of contact to be
removed.
2. Hold connector with rear grommet facing you.

3. Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm that it is
properly locked in place.
2. Slide tool along into the insert cavity until it engages

contact and resistance is felt.
3. Pull contact-wire assembly out of connector.
Figure 7-15. HD/HDP Locking Contacts Into Position

NOTE: For unused wire cavities, insert sealing plugs for full
environmental sealing
7-10
Figure 7-17. HD/HDP Unlocking Contacts

NOTE: Do Not twist or insert tool at an angle.
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This page left blank intentionally.
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7-11
Figure 7-18. Electrical Components Installation - Sheet 1
7-12
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3121813
Figure 7-19. Electrical Components Installation - Sheet 2
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7-13
Figure 7-20. Electrical Schematic - Sheet 1 of 4
7-14
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3121813
1870226 A
3121813
JLG Lift
7-15
7-16
JLG Lift
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1870226 A
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7-17
Figure 7-24. Hydraulic Schematic - Sheet 1 of 2
7-18
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2792459 A
Figure 7-25. Hydraulic Schematic - Sheet 2 of 2
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7-19
NOTES:
7-20
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3121813
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
+61 2 65 811111
JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
+55 19 3295 1025
+61 2 65 810122
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
JLG Industries (UK) Ltd

Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0)161 654 1000
JLG France SAS

Z.I. de Baulieu
47400 Fauillet
France
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
+44 (0)161 654 1001

JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
(852) 2639 5783
JLG Industries (Italia) s.r.l.

Via Po. 22
20010 Pregnana Milanese - MI
Italy
JLG Europe B.V.

Polaris Avenue 63
2132 JH Hoofddorp
The Netherlands
+39 029 359 5210
+31 (0)23 565 5665
+39 029 359 5845
+31 (0)23 557 2493
(852) 2639 5797

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
+48 (0)914 320 245
+48 (0)914 358 200
JLG Industries (Scotland)

Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland
+44 (0)141 781 6700
+44 (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
www.jlg.com
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534

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Service and Maintenance Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

This section contains the general safety precautions

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A

REMOVE ALL RINGS, WATCHES AND JEWELRY

HYDRAULIC SYSTEM SAFETY

DO NOT WEAR LONG HAIR UNRESTRAINED, OR

Relieve system pressure by cycling the applicable control

- August 10, 2000

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

SECTION 3 - CHASSIS & TURNTABLE

Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Drive Hub (front 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

SECTION 4 - BOOM & PLATFORM

Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

SECTION 6 - JLG CONTROL SYSTEM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Low Displacement, Single Speed, B-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Table 1-2. Operating Specifications

Table 1-1. Capacities

13 gallons (49.2 liters)

500 lb (230 kg)

30 ft. 11 5/16 in. (9.43 m)

Table 1-4. Battery Charger

120V - 240V Auto Seeking

17 amps at start of charging

1.5 DRIVE/STEER SYSTEM

48 VDC, 12.5 H.P. @ 3200 rpm. continuous, rotation - reversible

spring-applied, hydraulically released

15 ft. 3 in. (4.65 m)

Maximum Tire Load:

7700 lbs. (3500 kg)

Maximum Ground Bearing Pressure

52 psi (3.7 kg/cm2)

55 psi (4.0 Bar)

3.0 mph (1.3 m/s)

Maximum Hydraulic System Pressure

3200 psi (221 Bar)

Maximum Wind Speed

28 mph (12.5 m/s)

Dynamo Output Fuse

Table 1-5. Drive System

Electrical System Voltage

1.4 BATTERY CHARGER

Maximum Drive Speed:

10W30 (Refer to Engine Manual)

Tilt Alarm Setting (See Section 3)

Turning Radius (inside)

Turning Radius (outside)

Maximum Travel Grade (Side Slope) with

Maximum Horizontal Platform Reach

RPMs under max. load