A - 830P, 1030P - JLG - Service - English

Service and Maintenance Manual
Models
1030P
830P
SN P900004871 to Present
31215863
January 29, 2021 - Rev A

INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A. GENERAL
This section contains the general safety precautions which
must be observed during maintenance of the Mobile Elevat-
ing Work Platform. It is of utmost importance that mainte-
nance 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
established by a qualified person and must be followed to
ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE

AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFAC-
TURED IS A SAFETY VIOLATION.
C. MAINTENANCE
The specific precautions to be observed during machine main-
tenance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD
when servicing hydraulic and larger machine component RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY
parts. VIOLATION.
Your safety, and that of others, is the first consideration when
engaging in the maintenance of equipment. Always be con- • Remove all rings, watches, and jewelry when performing
scious of component weight and never attempt to move any maintenance.
heavy parts without the aid of a mechanical device. Do not • Do not wear long hair unrestrained, or loose fitting cloth-
allow heavy objects to rest in an unstable position. When raising and neckties which are apt to become caught on or
ing a portion of the equipment, ensure that adequate support entangled in equipment.
is provided.
• Observe and obey all danger, warning, caution and other
instructions on machine and in service manual.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD • Keep standing surfaces and hand holds free of oil, grease,
INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE RESPONSIBILITY water, etc.
OF THE OWNER/OPERATOR. • Never work under an elevated platform until platform has
been safely restrained from any movement by blocking or
overhead sling.
B. HYDRAULIC SYSTEM SAFETY
• Before making adjustments, lubricating or performing any
1. It should be particularly noted that the machines other maintenance, shut off all power controls.
hydraulic systems operate at extremely high and poten-
tially dangerous pressures. Every effort should be made • Battery should always be disconnected during replace-
to relieve any system pressure prior to disconnecting or ment of electrical components.
removing any portion of the system. • Keep all support equipment and attachments stowed in
2. Relieve system pressure by lowering the platform com- their proper place.
pletely to direct any line pressure back into the return • Use only approved, nonflammable cleaning solvents.
line to the reservoir. Pressure feed lines to system com-
ponents can then be disconnected with minimal fluid • Ensure replacement parts or components are identical or
loss. equivalent to original parts or components.
31215863 A-1
INTRODUCTION
REVISON LOG
Original Issue A - January 29, 2021
A-2 31215863
TABLE OF CONTENTS
SECTION 1 - MACHINE SPECIFICATIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Working Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Working Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Serial Number Plate Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
830P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1030P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAE Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION 2 - GENERAL MAINTENANCE INFORMATION
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Servicing and Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Hydraulic System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION 3 - COMPONENTS ASSEMBLY
3.1 830P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Mast Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 1030P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SECTION 4 - ELECTRICAL/HYDRAULIC INFORMATION AND MACHINE SCHEMATICS
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
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TABLE OF CONTENTS
4.3 Electrical System - Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Electrical Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Electrical/Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
1030P - Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
1030P - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
830P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
1030P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.7 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
830P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
1030P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
SECTION 5 - MACHINE MAINTENANCE AND SERVICE
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Castor Wheel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Battery/Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
830P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.4 830P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Rear Axle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Contactor Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 1030P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Emergency Lowering Valve Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Gate Spring Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Inspect Main Boom Pivot Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Inspect Main Boom Pivot Pin Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Replace Main Pivot Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Replace the Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Replace a Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
2 31215863
SECTION 1. MACHINE SPECIFICATIONS

1.1 GENERAL
Working Specifications
DESCRIPTION 830P 1030P

Maximum Working Height 14.76 ft (4.50 m) 16.73 ft (5.10 m)
Maximum Platform Height 8.20 ft (2.50 m) 10.17 ft (3.10 m)
Weight 628 lb (285 kg) 775 lb (352 kg)
Platform Dimensions 3.28 ft x 2.39 ft (1 m x 0.73 m) 4.99 ft x 2.46 ft (1.52 m x 0.75 m)
Working Footprint 3.90 ft x 2.46 ft (1.19 m x 0.75 m) 5.31 ft x 2.56 ft (1.62 m x 0.78 m)
Maximum Platform Capacity (1 person + Tools) 440 lb (200 kg) 551 lb (250 kg)
Maximum Manual Side Force 45 lb (200 N) 45 lb (200 N)
Maximum Allowable Operating Slope 0.5° 0.5°
Maximum Wind Force Indoor use only Indoor use only
Maximum Ground Bearing Pressure 174 psi (12.23 kg/cm2) 489 psi (34.38 kg/cm2)
Maximum Wheel Load 345 lb (157 kg) 430 lb (195 kg)
Dimensions Battery Charger
DESCRIPTION 830P 1030P DESCRIPTION 830P 1030P

Length 3.92 ft (1.195 m) 5.31 ft (1.62m) AC Input Voltage 90-135V AC 90-135V AC
Width 2.46 ft (0.75 m) 2.56 ft (0.78 m) Frequency 45-65 Hz 45-65 Hz
Height 5.11 ft (1.56 m) 6.07 ft (1.85 m) Output 12V DC, 7A 12V DC, 7A
Power Source Hydraulic Oil

• Grade 32 Mineral Oil
DESCRIPTION 830P 1030P
Battery Standard 12V DC Standard 12V DC
Electric Motor Standard 12V DC Standard 12V DC
Hydraulic Pump 1.66cc/rev 3.1cc/rev
Hydraulic Pressure Relief 942 psi/65 bar 1595 psi/110 bar
31215863 1-1
Working Envelope 1.2 SERIAL NUMBER PLATE IDENTIFICATION
16.4 ft
(5.0m)
13.1 ft
(4.0m)
9.84 ft
(3.0m)
6.56 ft
(2.0m)
3.28 ft
(1.0m)
0 OAR0060
830P 830P
16.4 ft
(5.0 m)
13.1 ft
(4.0 m)
9.84 ft
(3.0 m)
6.56 ft
(2.0 m)
0"%
1030P
1030P
1-2 31215863
1.3 BATTERY CHARGER At the ground control box, the battery charge indicator dis-
plays a series of red LEDs. One LED is lit at a time to indicate
830P battery charge.
AC POWER SUPPLY CIRCUIT SHOULD BE PROTECTED WITH A BREAKER

CIRCUIT. ONLY CHARGE BATTERY IN A WELL-VENTILATED AREA.
The battery charger is located under the base frame cover
beneath the platform.
1
1. Full Battery Charge
On the battery charger inside in the chassis, the charge level
can be monitored on the side of the charger.
OA
Plug in the charger to an available power supply and ensure

the "low" LED illuminates. A flashing LED indicates a fault. Dis-
connect and reconnect to the power supply. If flashing contin-
ues, check electrical connections and wires. If connections and
1. Charger Assembly wires are secure and undamaged, check battery and battery
charger assemblies for damage.
The charging AC input cable is located on the right side of the
machine base. Plug into a compatible AC power supply. The LEDs will illuminate in sequence. When the "full" LED is
illuminated, charging is complete.
The battery charger can be connected to the AC power supply
at any time or left for extended periods.
1 OA
1. AC Input Cable
The battery charge level can be monitored at the ground con-
trol box or by observing the LEDs on the front of the battery
charger.
31215863 1-3
1030P
AC POWER SUPPLY CIRCUIT SHOULD BE PROTECTED WITH A BREAKER

CIRCUIT. ONLY CHARGE BATTERY IN A WELL-VENTILATED AREA.
0"3
The battery is located under the base frame cover next to the
OAR00100
battery isolator switch. It should be checked daily for secure
The battery charger is located under the ground control con- connections and any damage or corrosion.
sole cover. Plug the AC input cable into a compatible AC
power supply. The battery charger can be connected to an AC To charge the battery, plug in the charger to an available
power supply at any time or left for extended periods. power supply. The LEDs will illuminate in sequence. When the
top LED is illuminated, charging is complete.
NOTE: Ensure the battery isolator is on when charging the
machine.
At the ground control box, the battery charge indicator dis-
plays a series of red LEDs. One LED illuminates at a time to indi-
cate battery charge.
Battery charge level is also indicated by LEDs on the battery

charger. Plug in the charger to an available power supply. The
LEDs will illuminate in sequence. When the top LED is illumi-
nated, charging is complete.
1-4 31215863
1.4 LUBRICATION INTERVALS
INTERVAL (b)
ITEM COMPONENT LUBE POINTS LUBE TYPE/METHOD (a) 1 6 1 COMMENTS
MONTH MONTHS YEAR
HO - Check hydraulic oil level.
1 Hydraulic Oil Reservoir Fill to line on reservoir. HO - Change hydraulic oil.  Check fluid level every day. (b)
2 Pivots (1030P Only) 12 pivots MPG - Apply.  Apply MPG to each of the 12 pivots every month.
Lubrication Types:
• HO - Hydraulic Oil, Grade 32 Mineral Oil
• MPG - Multipurpose Grease having a minimum dripping point of 350°. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40
pounds minimum.)
NOTES: (a) Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions (i.e., high number of cycles, harsh environment, corro-
sive/dirty environment, etc.), lubricating requirements must be adjusted accordingly.
(b) Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on
the hydraulic reservoir. Only check the oil level when the machine is in the stowed position.
31215863 1-5
1
1 OAR00651
OAR00780
830P 1030P
1 - Hydraulic Oil Reservoir
4
2 3
5 12
1 11
6 10
9
8
7 OAD00530
1030P
2 - Pivots (12)
1-6 31215863
1.5 TORQUE CHARTS

SAE Fasteners
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Clamp Torque Torque
Size TPI Bolt Dia (Loctite® 242™ or 271™ or (Loctite® 262™ or
Stress Area Load (Dry) Lubricated
Vibra-TITE™ 111 or 140) Vibra-TITE™ 111)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
31215863 1-7
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque (Loctite® 242™ or 271™ or
Tensile Stress (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
1-8 31215863
Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Size TPI Bolt Dia Clamp Load (Dry)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
31215863 1-9

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
1-10 31215863

SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
31215863 1-11
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
1-12 31215863
Metric Fasteners
CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or (Loctite® 242™ or 271™ or
Size Pitch Torque (Lube)
Area See Note 4 (Dry or Loctite® 263™)
Vibra-TITE™ 131) Vibra-TITE™ 111 or 141)
Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
31215863 1-13

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5*
Torque Torque
Torque (Lube or Loctite® 242™ or 271™
Tensile Clamp Load (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™)
Stress Area See Note 4 or Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
1-14 31215863
Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Torque (Loctite® 262™ or
Tensile Clamp Load (Lube or Loctite® 242™ or 271™
Stress Area See Note 4 or Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.16 K=0.15
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
31215863 1-15
Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE*
Torque Torque
Torque (Lube or Loctite® 242™ or 271™
Tensile Clamp (Loctite® 262™ or
Stress Area Load See Note 4 or Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.17
K=0.18 K=0.15
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
1-16 31215863
SECTION 2. GENERAL MAINTENANCE INFORMATION

2.1 MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventative Maintenance Schedule
MAINTENANCE for items requiring inspection during the performance of
This section provides the necessary information needed by these inspections. Reference the appropriate areas of this
those personnel that are responsible to place the machine in manual for servicing and maintenance procedures.
operation readiness and maintain its safe operating condition.
For maximum service life and safe operation, ensure that all Annual Machine Inspection
the necessary inspections and maintenance have been com-
JLG recommends that the Annual Machine Inspection be per-
pleted before placing the machine into service. With proper
formed by a Factory-Trained Service Technician on an annual
care, maintenance, and inspections performed per JLG’s rec-
basis, no later than thirteen (13) months from the date of the
ommendations with any and all discrepancies corrected, this
prior Annual Machine Inspection. JLG Industries, Inc. recog-
product will be fit for continued use.
nizes a Factory-Trained Service Technician as a person who has
successfully completed the JLG Service Training School for the
Preparation, Inspection, and Maintenance subject JLG product model. Reference the machine Service
It is important to establish and conform to a comprehensive and Maintenance Manual and appropriate JLG inspection
inspection and preventive maintenance program. The Preven- form for performance of this inspection.
tive Maintenance and Inspection Schedule (Section 2.2) out- Reference the JLG Annual Machine Inspection Form and the
lines the periodic machine inspections and maintenance Inspection and Preventative Maintenance Schedule for items
recommended by JLG Industries, Inc. Consult your national, requiring inspection during the performance of this inspec-
regional, or local regulations for further requirements for tion. Reference the appropriate areas of this manual for servic-
Mobile Elevating Work Platforms (MEWP). The frequency of ing and maintenance procedures.
inspections and maintenance must be increased as environ-
ment, severity and frequency of usage requires. For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
Pre-Start Inspection information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of the current
It is the User’s or Operator’s primary responsibility to perform a machine ownership.
Pre-Start Inspection of the machine prior to use daily or at
each change of operator. Reference the Operation and Safety Preventative Maintenance
Manual for completion procedures for the Pre-Start Inspec-
tion. The Operation and Safety Manual must be read in its In conjunction with the specified inspections, maintenance
entirety and understood prior to performing the Pre-Start shall be performed by a qualified JLG equipment mechanic.
Inspection. JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized
Pre-Delivery Inspection and Frequent Inspection degree, certificate, extensive knowledge, training, or experi-
ence, has successfully demonstrated the ability and profi-
The Pre-Delivery Inspection and Frequent Inspection shall be ciency to service, repair, and maintain the subject JLG product
performed by a qualified JLG equipment mechanic. JLG Indus- model.
tries, Inc. recognizes a qualified JLG equipment mechanic as a
Refer to the Preventive Maintenance and Inspection Schedule
person who, by possession of a recognized degree, certificate,
and the appropriate areas of this manual for servicing and
extensive knowledge, training, or experience, has successfully
maintenance procedures. The frequency of service and main-
demonstrated the ability and proficiency to service, repair, and
tenance must be increased as environment, severity and fre-
maintain the subject JLG product model.
quency of usage requires.
The Pre-Delivery Inspection and Frequent Inspection proce-
dures 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; 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 fre-
quency of usage requires.
31215863 2-1
Inspection and Maintenance Table

PRIMARY SERVICE
TYPE FREQUENCY REFERENCE
RESPONSIBILITY QUALIFICATION
Pre-Start Prior to use each day; or
User or Operator User or Operator Operation and Safety Manual
Inspection At each Operator change.
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or Service and Maintenance Manual
Qualified JLG Mechanic
Inspection rental delivery. User and applicable JLG inspection form.
In service for 3 months; or Out of service for a
Frequent Owner, Dealer, or Service and Maintenance Manual
period of more than 3 months; or Purchased Qualified JLG Mechanic
Inspection User and applicable JLG inspection form.
used.
Annual JLG Factory-Trained
Annually, no later than 13 months from the Owner, Dealer, or Service and Maintenance Manual
Machine Service Technician
date of the prior inspection. User and applicable JLG inspection form.
Inspection (Recommended)
Preventative At intervals as specified in the Service and Owner, Dealer, or
Qualified JLG Mechanic Service and Maintenance Manual
Maintenance Maintenance Manual. User
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING
SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 31215863
2.2 PREVENTIVE MAINTENANCE AND INSPECTION the interval column represent the applicable inspection code
for which that component is to be checked.
SCHEDULE
The checks and services listed in this schedule are not
The preventive maintenance and inspection checks are listed intended to replace any local or regional regulations that may
and defined in the following table. This table is divided into pertain to this type of equipment nor should the lists be con-
two basic parts, the “AREA” to be inspected and the “INTER- sidered as all inclusive. Variances in interval times may occur
VAL” at which the inspection is to take place. Under the “AREA” due to climate and or conditions and depending on the loca-
portion of the table, the various systems along with the com- tion and use of the machine.
ponents that make up that system are listed. The “INTERVAL”
portion of the table is divided into two columns representing
the various inspection time periods. The numbers listed within
INTERVAL
AREA ON MACHINE Pre-Delivery1 or Frequent 2 Annual3
(Quarterly) (Yearly)
Inspection Inspection
MAST AND PLATFORM ASSEMBLY
Mast Sections 2, 3 2, 3
Slide Pads 1, 2 1, 2
Platform, Platform Gate, and Latches 1, 3 1, 3
Guard Rails 1, 2 1, 2
Covers and Shields 1, 5 1, 5
Floor 1, 2 1, 2
Lanyard Anchorage Point 1, 2, 6 1, 2, 6
Tool Tray (830P Only) 1 1
CHASSIS AND BASE ASSEMBLY
Castor Wheel Assembly 1, 2 1, 2
Rear Axle Brake Assembly 1, 2 1, 2
Brake Release 3 3
Wheel Locking Nut 150 150
Covers and Shields 1, 5 1, 5
Static Strap 1 1
Wheel and Tire Assemblies 1, 2 1, 2
Bubble Level 1 1
FUNCTIONS AND CONTROLS
Controls Operate Properly, Return to Neutral/Off When Released 3, 9 3,9
Emergency Stop Switches (Ground and Platform) 1, 3 3
Ground Controls Override Platform Controls 3, 7 3
Emergency Lowering Valve 1, 3 1, 3
Function Control Locks, Guards, or Detents 3 3
POWER SYSTEM
Battery Fluid Level Correct 1, 2 1, 2
Motors Free of Damage 2 2
All Electrical Connections Tight, Free of Frays and Corrosion 1, 4 1, 4
Batteries 1, 2, 4, 8 1, 2, 4, 8
Battery Charger 3 3, 5
Instruments, Gauges, Switches, Lights, Horn 1, 3 3, 5
HYDRAULIC SYSTEM
Hydraulic Pump 1, 2, 4 1, 2, 3, 4, 5
Hydraulic Cylinder 2, 4, 5 2, 4, 5
Hydraulic Hoses, Lines, and Fittings 1, 4 1, 4
Hydraulic Reservoir, Cap, and Breather 3, 5 3, 5
31215863 2-3
INTERVAL
AREA ON MACHINE Pre-Delivery1 or Frequent 2 Annual3
(Quarterly) (Yearly)
Inspection Inspection
Hydraulic Filter 1, 4, 5 1, 4, 5
Hydraulic Fluid 4 4
Hydraulic Valve 1, 2, 4 1, 2, 4
GENERAL
No Unauthorized Modifications or Additions 9 9
General Structural Condition and Welds 2 2
Paint and Appearance 5 5
Notify JLG of Machine Ownership 9 9
Annual Machine Inspection Due - 9
All Relevant Safety Publications Incorporated 9 9
All Decals/Placards Installed, Secure, Legible 9 9
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Function Test of All Systems 9 9
Stamp Inspection Date on Frame - 9
Footnotes:
1
Prior to each sale, lease, or delivery
2 In service for 3 months; Out of service for 3 months or more; Purchased used
3 Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating
body
50 Indicates a 50 hour interval required to perform task after initial use of machine. This only occurs once in machine life
Performance Codes:
1 - Check for proper and secure: installation, adjustment, or torque
2 - Visual inspection for damage: (cracks, corrosion, abrasions, distortion, excessive wear, broken welds, gouges, chafing and threads showing)
3 - Proper operation
4 - Check for proper sealing, signs of leakage and fluid level
5 - Clean and free of debris
6 - Decals installed and legible
7 - Check for proper tolerances, routing, and lubrication
8 - Fully Charged
9 - Verify/Perform
2-4 31215863
2.3 SERVICING AND MAINTENANCE GUIDELINES Components Removal and Installation

Use adjustable lifting devices, whenever possible, if mechani-
General cal assistance is required. All slings (chains, cables, etc.) should
The following information is provided to assist you in the use be parallel to each other and as near perpendicular as possible
and application of servicing and maintenance procedures to top of part being lifted.
contained in this chapter. 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
WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CON- the component becomes less than 90 degrees.
TAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGU- If a part resists removal, check to see whether all nuts, bolts,
LARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED cables, brackets, wiring, etc., have been removed and that no
GUIDANCE OBTAINED BEFORE WORK IS RESUMED. adjacent parts are interfering.
Safety and Workmanship Component Disassembly and Reassembly

Your safety, and that of others, is the first consideration when When disassembling or reassembling a component, complete
engaging in the maintenance of equipment. Always be con- the procedural steps in sequence. Do not partially disassemble
scious of component weight. Never attempt to move heavy or assemble one part, then start on another. Always recheck
parts without the aid of a mechanical device. Do not allow your work to assure that nothing has been overlooked. Do not
heavy objects to rest in an unstable position. When raising a make any adjustments, other than those recommended, with-
portion of the equipment, ensure that adequate support is out obtaining proper approval.
provided.
Pressure-Fit Parts
When assembling pressure-fit parts, use an “anti-seize” or
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS molybdenum disulfide base compound to lubricate the mat-
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR ing surface.
OVERHEAD SLING.
Cleanliness Bearings
When a bearing is removed, cover it to keep out dirt and abra-
The most important single item in preserving the long service
sives. Clean bearings in nonflammable cleaning solvent and
life of a machine is to keep dirt and foreign materials out of the
allow to drip dry. Compressed air can be used but do not spin
vital components. Precautions have been taken to safeguard
the bearing.
against this. Shields, covers, seals, and filters are provided to
keep the wheel bearings, mast sections and oil supply clean; Discard bearings if the races and balls (or rollers) are pitted,
however, these items must be maintained on a scheduled scored, or burned.
basis in order to function properly.
If bearing is found to be serviceable, apply a light coat of oil
At any time when oil lines are disconnected, clear adjacent and wrap it in clean (waxed) paper. Do not unwrap reusable or
areas as well as the openings and fittings themselves. As soon new bearings until they are ready to install.
as a line or component is disconnected, cap or cover all open-
Lubricate new or used serviceable bearings before installation.
ings to prevent entry of foreign matter.
When pressing a bearing into a retainer or bore, apply pres-
Clean and inspect all parts during servicing or maintenance, sure to the outer race. If the bearing is to be installed on a
and assure that all passages and openings are unobstructed. shaft, apply pressure to the inner race.
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.
31215863 2-5
Gaskets 2.4 HYDRAULIC SYSTEM INFORMATION

Check that holes in gaskets align with openings in the mating
parts. If it becomes necessary to hand-fabricate a gasket, use
Hydraulic Lines and Electrical Wiring
gasket material or stock of equivalent material and thickness. Clearly mark or tag hydraulic lines and electrical wiring, as well
Be sure to cut holes in the right location, as blank gaskets can as their receptacles, when disconnecting or removing them
cause serious system damage. from the unit. This will assure that they are correctly rein-
stalled.
Bolt Usage and Torque Application
Use bolts of proper length. A bolt which is too long will bot-
Hydraulic System
tom before the head is tight against its related part. If a bolt is Keep the system clean. If evidence of metal or rubber particles
too short, there will not be enough thread area to engage and is found in the hydraulic system, drain and flush the entire sys-
hold the part properly. When replacing bolts, use only those tem.
having the same specifications of the original, or one which is
equivalent. Disassemble and reassemble parts on clean work surface.
Clean all metal parts with non-flammable cleaning solvent.
Unless specific torque requirements are given within the text, Lubricate components, as required, to aid assembly.
standard torque values should be used on heat-treated bolts,
studs, and steel nuts, in accordance with recommended shop The primary enemy of a hydraulic system is contamination.
practices. 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.
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.
2-6 31215863
Lubrication and Servicing 1030P
Components and assemblies requiring lubrication and servic- To drain the oil from the tank, fully elevate the platform. Dis-
ing are shown in the Lubrication Chart. Service applicable connect the "P" connection at the pump manifold and hold
components with the amount, type, and grade of lubricant open end over a container suitable for hydraulic oil.
recommended in this manual, at the specified intervals. When NOTE: Use a container with a capacity of approximately 5 L. To
recommended lubricants are not available, consult your local prevent oil from splashing while draining, fill the container
supplier for an equivalent that meets or exceeds the specifica- with approximately 2 L of oil before placing the open end
tions listed. of the hose inside.
Cloudy oils indicate a high moisture content which permits
organic growth, resulting in oxidation or corrosion. If this con- At the ground controls, press the lift down button until the
dition occurs, the system must be drained, flushed, and refilled platform is returned to the stowed position. Secure the hose,
with clean oil. then refill tank at the fill cap with 1-2 L of hydraulic oil.
It is not advisable to mix oils of different brands or types, as 830P

they may not contain the same required additives or be of The only practical method to remove the oil from the tank is to
comparable viscosities. Good grade mineral oils, with viscosi- use a syringe suitable for hydraulic oil, which is easily obtain-
ties suited to the ambient temperatures in which the machine able, or a vacuum system for hydraulic oil. Refill to proper level
is operating, are recommended for use. with fresh oil. Cycle the mast up and down a few full cycles,
NOTE: Metal particles may appear in the oil of new machines due then recheck oil level.
to the wear-in of meshing components. The hydraulic steel pipe connection to the cylinder must not
be disconnected, unless by a competent person. If the connec-
Changing Hydraulic Oil tion has been disconnected, then a full pressure test of the sys-
tem must be conducted prior to placing the machine back
Hydraulic oil must be replaced on an annual basis, otherwise into service
premature wear and component failure may occur.
PRESSURE AND LEAK CHECK
Use every precaution to keep the hydraulic oil clean. If the oil
must be poured from the original container into another, be 1. Check that the hydraulic oil level is at the FULL mark on
sure to clean all possible contaminants from the service con- the pump reservoir.
tainer. 2. Place a pressure gauge on the existing test port at the
While the unit is shut down, a good preventive maintenance hydraulic pressure line from pump to the cylinder.
measure is to make a thorough inspection of all hydraulic Gauge must be capable of reading greater than the set
components, lines, fittings, etc., as well as a functional check of hydraulic pressure.
each system, before placing the machine back in service. 3. Fully extend and retract the mast through two or three
Follow these guidelines when servicing the hydraulic system: lift cycles. Recheck the pump reservoir oil level.
• Refill with grade 32 mineral oil. 4. Elevate platform to maximum height and check the
pump line pressure while pump is running. Should be
• Check the oil level only when the platform is in the stowed approximately 1100 psi @ normal operating tempera-
position. ture.
• Do not overfill the reservoir (refer to the line indicated on 5. Check the lines and fittings for any hydraulic oil leaks.
the side of the reservoir). Repair if needed.
• Ensure hydraulic connections around the pump and base of
6. Top off the pump reservoir oil level to FULL if needed.
cylinder are tight, undamaged, and without leaks.
31215863 2-7
2-8 31215863
SECTION 3. COMPONENTS ASSEMBLY

3.1 830P
NOTE: For a more thorough description of machine parts, refer to
the associated Illustrated Parts Manual.
Chassis
124 - 3/4 Washer A2 211 - Castor Wheel Assembly 225 - Base Frame Cover
148 - 3/4 UNC Nyloc Nut BZP 212 - Rear Wheels 226 - Platform Cable Guide
172 - Chassis Assembly 213 - Bubble Level Indicator 252 - Brake Actuator Bar
180 - Static Strap 223 - Buffer Wheels 253- Rear Axle Arm
31215863 3-1
Platform
173 - Platform Rails Assembly 177 - Platform Gates 231 - Manual Box
174 - Platform 230 - Gas Strut
3-2 31215863
Electrical
161 - Battery Charge Indicator 193 - Pump Solenoid 208 - Lift Down Switch
170 - Battery Isolator 203 - Battery Charger 209 - Hourmeter
182 - Platform Control Console 205 - Emergency Stop Switch 210 - Audible Alarm
183 - Ground Control Console 206 - Ground/Off/Platform Key Selector Switch 259 - Battery
190 - Enable Switch (Platform) 207 - Lift Up Switch
31215863 3-3
Hydraulic
168 - Lift Cylinder 195 - 12V Power Pack Solenoid Valve

191 - O-Ring
178 - Hydraulic Pipe 196 - Emergency Lowering Valve
192 - O-Ring
179 - Power Pack 221 - Cylinder Seal Kit
3-4 31215863
Mast Disassembly 13. Loosen the two slide pads, one each side, at the top of
the inner mast section and slide as far rearward as possi-
The 830P mast is extended by a hydraulic cylinder pressurized ble and hand tighten in place.
by a hydraulic pump. The mid and outer mast sections are
removable. The inner mast section is stationary and welded to 14. Remove the roller guide at the bottom front of the mid
the base assembly. mast section.
1. Lower the platform to stowed position. Turn off the bat- 15. Using suitable lifting equipment, carefully and slowly lift
tery isolator. the mid mast section off the inner mast assembly.
2. Remove the tool tray. NOTE: The mid mast section weighs approximately 66 lb.
3. Remove the platform assembly. 16. If removing the hydraulic cylinder, remove the access
panel at the bottom rear of the mast assembly. Discon-
4. Remove the frame cover. nect and cap the hydraulic line attached to the bottom
5. Disconnect the positive (+) battery terminal at the bat- of the cylinder.
tery. 17. Carefully remove the cylinder from the inner mast sec-
6. Remove the mast top cap bolts on the sides of the outer tion. Protect cylinder rod from damage.
mast section. Carefully pull/pry up on the top cap to
manually extend the hydraulic cylinder rod. Mast Assembly Notes
7. Remove counter sunk hex head screw attaching the Assemble the mast by reversing the disassembly steps.
hydraulic cylinder rod to the mast top cap. Remove the Mast components requiring lubrication, anti-seize compound,
mast top cap and lay aside. or threadlocking compound during assembly:
NOTE: It may be necessary to restrain the cylinder rod from turn- Threadlocking Compound:
ing when removing the screw attaching it to the mast top
cap. If gripping the rod surface, protect it from severe dam- •Apply to threads of fitting on bottom of lift cylinder (5).
age, grip as close to the bottom of the top cap as possible, •Apply to threads of hydraulic line fitting on bottom of lift
as this area does not retract into the cylinder barrel. cylinder (5).
NOTE: If only removing the lift cylinder, proceed to steps 16 and •Apply to threads of mast cap to cylinder rod screw (4).
17.
•Apply to threads of mast cap to outer mast section screws
8. Loosen the lock nuts on all the wear screws around the (4).
base of the outer mast section. Loosen wear screws until
Anti-Seize Compound:
flush with mast inside surface.
• Coat the surface of the spring dampener block and
9. Loosen the two slide pads, one each side, at the top of
approximately one inch around it (10).
the mast mid section and slide as far rearward as possi-
ble and hand tighten in place. • On a level surface verify each mast section is plumb with
vertical level as they are assembled. Use the slide pads at
10. Remove the roller guide at the bottom front of the outer the top of the mast section and wear screws at the bot-
mast section. tom of the mast section to adjust the sections vertically
11. Using suitable lifting equipment, carefully and slowly lift on the mast.
the outer mast section off the mid mast section assem- • Do not overtighten wear screws and slide pads against
bly. mast surface. Run in until contact is made to take out any
NOTE: The outer mast section weighs approximately 77 lb. side to side or front to back movement, when plumbed
vertical, then tighten large nut. Gap between screw and
NOTE: In order to slide the mid mast section off of the inner mast mast should be no more than 0.008 in to 0.019 in (0.2 mm
section, the mid mast section must be pushed rearward to to 0.5 mm).
create clearance between the spring dampening bar stop
mounted on the inside of the lower half of the mid mast • Once mast is completely assembled, set machine up for
section and the spring dampening assembly mounted operation and check that mast assembly extends and
three quarters the way up on the outside of the inner mast retracts correctly.
section.
12. Loosen the lock nuts on all the wear screws around the
base of the mid mast section. Loosen wear screws until
flush with mast inside surface.
31215863 3-5
1. Inner Mast Section (Welded to Base) 5. Hydraulic Lift Cylinder 9. Wear Screws
2. Mid Mast Section 6. Inner and Mid - Mast Slide Pads 10. Spring Damper and Stop
3. Outer Mast Section 7. Inner and Mid - Mast Rear Guide Roller
4. Mast Top Cap, Mounting and Cylinder Screws 8. Mid and Outer - Mast Front Guide Roller
3-6 31215863
3.2 1030P
NOTE: For a more thorough description of machine parts, refer to
the associated Illustrated Parts Manual.
Chassis
160 - Static Strap 218 - Battery Cover 226 - Brake Axle Assembly
216 - Castor Wheel Assembly 219 - Ground Control/Power Pack Cover 228 - Chassis
217 - Rear Wheel 220 - Bubble Level Indicator 230 - Step Plate
31215863 3-7
Boom
101 - Serial Number Plate

102 - Pivot Pin Screw 168 - Pivot Pin (115 mm) 223 - Upper Boom Assembly
156 - Grease Nipple (12) 171 - Knuckle Assembly 224 - Lower Boom Assembly
166 - Chassis Cylinder Pin Assembly 173 - Pivot Pin (210 mm) 225 - Tie Bar Assembly
167 - Pivot Pin (166 mm)
3-8 31215863
Platform
105 - Gate Spring 180/181 - Left and Right Side Rails 237 - Lanyard Attach Point
124 - Gate Pivot Bolt 231 - Gate 243 - Manual Box
174 - Base Frame 235 - Platform
31215863 3-9
Electrical
142 - Ground Control Console/Emergency Stop/Audible 188/189 - Battery Charger 199 - Battery Isolator
Alarm 190/191 - 12V DC Battery 200 - Platform Cable
143 - Platform Control Console
3-10 31215863
SECTION 4. ELECTRICAL/HYDRAULIC INFORMATION AND MACHINE SCHEMATICS

4.1 GENERAL Backprobing
This section contains basic electrical and hydraulic informa- To "backprobe" means to take the measurement by accessing
tion to be used for locating and correcting most of the operat- a connector’s contact on the same side as the wires, the back
ing problems that may develop in this machine. If a problem of the connector. Readings can be done while maintaining cir-
should develop that is not present in this section or is not cor- cuit continuity this way. If the connector is the sealed type,
rected by listed corrective actions, technically qualified guid- great care must be taken to avoid damaging the seal around
ance should be obtained before proceeding with any the wire. It is best to use probes or probe tips specifically
maintenance. designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
4.2 HYDRAULIC CIRCUIT CHECKS tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
The first reference for improper function of a hydraulic system, connector by backprobing both sides of a connector terminal
where the cause is not immediately apparent, should be the and measuring resistance. Do this after giving each wire a gen-
Troubleshooting Chart. The best place to begin the problem tle pull to ensure the wires are still attached to the contact and
analysis is at the power source (pump). Once it is determined contacts are seated in the connector.
that the pump is serviceable, then a systematic check of the
circuit components, beginning with the control, would follow. Min/Max
4.3 ELECTRICAL SYSTEM - MULTIMETER BASICS Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
A wide variety of multi-meters or Volt Ohm Meters (VOM) can while alone. For example, you can read the voltage applied to
be used for troubleshooting your equipment. A digital meter a solenoid when it is only operational while a switch, far from
with reasonable accuracy (within 7%) is recommended for the the solenoid and meter, is held down.
measurements in these procedures. This section shows dia-
grams of a common, digital VOM configured for several differ- Polarity
ent circuit measurements. Instructions for your VOM may vary.
Please consult the meter operator’s manual for more informa- Finding a negative voltage or current reading when expecting
tion. a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
Grounding that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the ground
"Grounding the meter" means to take the black lead (which is or negative side of the signal and the lead on the other port
connected to the COM (common) or negative port) and touch goes to the positive side of the signal.
it to a good path to the negative side of the voltage source.
31215863 4-1
Scale Procedure
M = Mega = 1,000,000 * (Displayed Number) Test multimeter leads resistance. Subtract this value from the
measured resistance of the wires to get a more accurate mea-
k = kilo = 1,000 * (Displayed Number)
surement.
m = milli = (Displayed Number) / 1,000
Consult the circuit schematic to determine which wires to use
µ = micro = (Displayed Number) / 1,000,000 in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in
Example: 1.2 k = 1200  the same connectors as the wire under test or are within reach
Example: 50 mA = 0.05 A of the jumper.
Continuity Measurement Over Long Distances 1. Disconnect all connections associated with the wire
under test and the two additional wires. If harness is
When trying to determine continuity of a harness or wire, lon- not completely isolated disconnect battery terminals
ger than the reach of standard instrument leads, is possible to also, as a precaution.
perform the check without excessively long leads. Using the
other wires in the harness one can determine the condition of 2. Measure continuity between all three wires, the wire
a particular wire in the harness. under test, wire #1 and wire #2. These should be open.
If not, repair the shorted wires or replace the harness.
Requirements 3. On one side, jumper from contact of wire #1 and wire
• Harness with at least three separate wires including the wire #2.
under test. 4. Measure continuity between wire #1 and wire #2. If
• These wires must be able to be isolated from other wires, there is continuity, both wires are good and can be
etc. used for this test. If there is not continuity, either wire
could be bad. Check connections and measurement
• Jumper or method to connect contacts on one side of har- setup. Redo measurement. If still no continuity, repair
ness. wires or consult schematic for other wires to use for
• Meter that can measure resistance or continuity. test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire
under test is good. Resistance of a wire increases as
the length increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at
once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the
problem, start at step 1 and use the entire procedure.
4-2 31215863
Voltage Measurement Resistance Measurement
• If meter is not auto ranging, set it to the correct range (See • First test meter and leads by touching leads together. Resis-
multimeter’s operation manual) tance should read a short circuit (very low resistance)
• Use firm contact with meter leads • Circuit power must be turned OFF before testing resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range (See
multimeter’s operation manual)
• Use firm contact with meter leads
31215863 4-3
Continuity Measurement Current Measurement
• Some meters require a separate button press to enable • Set up the meter for the expected current range
audible continuity testing
• Be sure to connect the meter leads to the correct jacks for
• Circuit power must be turned OFF before testing continuity the current range you have selected
• Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See
multi meter’s operation manual)
• First test meter and leads by touching leads together. Meter
should produce an audible alarm, indicating continuity
4-4 31215863
4.4 ELECTRICAL SWITCH TESTING 2. Reconnect harness if it was disconnected for step 1,
and turn on machine.
Basic Check 3. Hold switch away from metal and observe switch state
in the control system diagnostics using the Analyzer.
The following check determines if the switch is functioning See vehicle or control system documentation on how
properly, not the circuit in which the switch is placed. A switch to do this.
is functioning properly when there is continuity between the
correct terminals or contacts only when selected. 4. Place sensing face of switch on the object to be
sensed by the switch. If that is not available, use a
1. De-energize the circuit. piece of ferrous metal physically similar to it. The
2. Isolate the switch from the rest of the circuit if possi- switch state in the control system diagnostics should
ble. If not possible, keep in mind it may affect read- change.
ings. 5. When reinstalling or replacing switch be sure to follow
3. Access the terminals to the switch. 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. Automatic Switches
b. Change the switch position. If the switch is actuated automatically, by temperature or pres-
c. Measure resistance again with the leads in the sure for example, find a way to manually actuate the switch to
same positions. If the meter was reading short, it test it. Do this either by applying heat or pressure, for example,
should read an open. If the meter was reading to the switch. These switches may need to be energized to
open it should read short. actuate.
5. If the switch has more than two terminals, consult the 1. Connect instrumentation to monitor and/or control
schematic or switch diagram to determine what ter- the parameter the switch is measuring.
minals will be connected. The test is similar to testing
2. Observe switch state in control system with the Ana-
a switch with two terminals.
lyzer. See vehicle or control system documentation on
a. Place one meter lead on the common contact how to do this.
and the other on a different contact in the same
3. Operate system such that the switch actuates. This
circuit.
could be going over a certain pressure or tempera-
b. Cycle through all positions of the switch. The ture, for example. The state indicated in the control
meter should read short only when the switch system should change.
connects the two terminals and open otherwise.
c. If the switch has more than one common contact Switch Wiring - Low Side, High Side
repeat the process for that circuit.
When controlling a load, a switch can be wired between the
Limit Switches positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to
Limit switches are used to control movement or indicate posi- the load. When a switch is wired between the negative side of
tion. Mechanical limit switches are just like manually operated the power source and the load, it is a "low side" switch. The
switches except that the moving object operates the switch. switch provides the ground to the load.
These switches can be tested the same way as a standard
A low side switch will allow voltage to be present on the load.
switch by manually operating the sensing arm.
No power is applied because the switch is stopping current
Another type of limit switch used by JLG is the inductive prox- flow. This voltage can be seen if the measurement is taken
imity switch, also referred to as a "prox switch". Inductive prox- with one test lead on the load and the other on the battery
imity switches are actuated only by ferrous metal (metal that negative side or grounded to the vehicle. What is actually
contains Iron, such as steel) near the switch. They do not being measured is the voltage drop across the switch. This
require contact, and must be energized to actuate. These could mislead a technician into thinking the load is receiving
types of switches can be used to detect boom or platform power but not operating. To produce an accurate picture of
position, for example. These switches have a sensing face power or voltage applied to the load, measure voltage across
where the switch can detect ferrous metal close to it. To find the load’s power terminals. Also, the technician can measure
the sensing face, take note how the switch is mounted and the voltage at both power terminals with respect to battery
how the mechanisms meet the switch. Test this type of switch ground. The difference between those two measurements is
as follows: the voltage applied to the load.
1. Remove prox switch from its mount.
31215863 4-5
4.5 ELECTRICAL/HYDRAULIC COMPONENTS

1030P - Hydraulic
141 - Pressure Switch 206 - Valve Cartridge 211 - Solenoid and Valve
157 - Pipe Union 207 - Cylinder 212 - Breather Cap
161 - Emergency Lowering Valve Spindle 208 - Valve Cartridge 213 - Flow Control Valve
177 - Motor Coupling 209 - Cylinder Seal Kit 214 - Motor Start Solenoid
205 - 12V DC Power Pack 210 - Pressure Hose Kit 215 - Lower Solenoid and Valve
4-6 31215863
1030P - Electrical
163 - Hourmeter 192 - Emergency Stop Switch (Platform) 199 - Battery Isolator
183 - Enable Switch 193 - Emergency Stop Switch (Ground) 200 - Platform Cable
186 - Horn/Alarm 194 - Ground/Off/Platform Key Selector Switch 203 - Battery Indicator
187 - Overload Indicator 195 - Lift Up Switch 204 - Audible Alarm
188/189 - Battery Charger 196 - Lift Down Switch 214 - Motor Start Solenoid
190/191 - 12V DC Battery
31215863 4-7
4-8
4.6
830P

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31215863
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31215863 4-9
4.7 HYDRAULIC SCHEMATICS

830P
4-10 31215863
1030P
1001260478 B
OAR00710
31215863 4-11
4-12 31215863
SECTION 5. MACHINE MAINTENANCE AND SERVICE

5.1 GENERAL Some typical signs of impact which would require castor and
fixing replacement may include:
This section contains machine information to be used for ser-
vicing the machine. If a problem should develop that is not
present in this section or is not corrected by listed corrective
actions, technically qualified guidance should be obtained
before proceeding with any maintenance. 1
5.2 CASTOR WHEEL MAINTENANCE

In order to ensure the castors are maintained in safe, service-
able condition, regular inspection is required, especially in
harsh conditions. When inspecting the castor to determine its 2
serviceability, pay attention to the swivel bearing head and
the boss/rivet, which goes through the center of the swivel
bearing and clamps the assembly together.
• 1 & 2: This foot pedal distortion is a result of a significant

impact. It is likely the top plate and bearing will also be dis-
1 torted.
• 3: This mounting plate distortion is a result of a single signif-
1. Castor Mounting Bolt icant impact or multiple lower level impacts.
2. Swivel Bearing Head (free to rotate, not loose)
If visible distortion is evident, it is likely a significant impact
has occurred. Under these conditions, the castor wheel assem- IT MAY BE THOUGHT FEASIBLE TO REPAIR THE CASTOR IN THESE SITUATIONS,
bly must be replaced. BUT SERIOUS STRUCTURAL DAMAGE MAY HAVE OCCURRED TO THE HEAD
BEARING AND CASTOR ASSEMBLY, AS WELL AS POSSIBLE DAMAGE TO THE
MAIN FIXING BOLT. EVEN IF THE REST OF THE CASTOR IS IN GOOD CONDITION,
THE CASTOR AND FIXING BOLT MUST BE REPLACED.
NOTE: Ensure the castor fixing bolt is torqued to 120 Nm.
NOTE: Ensure the castor axle bolt is torqued to 40 Nm.
31215863 5-1
5.3 BATTERY/BATTERY CHARGER 5.4 830P

830P Troubleshooting Table
Check the battery fluid levels and charge in a well-ventilated The troubleshooting procedures applicable to the 830P are
area, only if lead acid batteries are fitted (not required for listed and defined in the table below.
maintenance-free AGM batteries).
Each malfunction within an individual group or system is fol-
The battery charger is located under the base frame cover and lowed by a listing of probable causes that will enable determi-
the charging lead is located on the exterior of the machine nation of the applicable remedial action. The probable causes
base, and the remedial action should be checked, when possible, in
the order listed in the table.
The input voltage is located on the exterior of the machine
base, It should be noted there is no substitute for a thorough knowl-
edge of the equipment and related systems.
Plug the charger into an available power supply and ensure
the "low" LED illuminates. If flashing, a fault is indicated. Dis- It should be recognized the majority of the problems arising in
connect and reconnect to the power supply. If flashing contin- the machine will be centered in the hydraulic and electrical
ues, seek technical support. systems. For this reason, every effort has been made to ensure
that all likely problems in these areas are given the fullest pos-
The LEDs will illuminate in sequence and when the "full" LED is
sible treatment. In the remaining machine groups, only those
illuminated the charge is complete.
problems that are symptomatic of greater problems that have
Additionally the battery charge indicator on the ground con- more than one probable cause and remedy are included. This
trol panel will indicate charge level. The charge is complete means that problems for which the probable cause and rem-
when the two green LEDs are illuminated. edy may be immediately obvious are not listed in this section.
The battery charger can be connected to the power supply at The first rule for troubleshooting any circuit that is hydrauli-
any time or left for extended periods. cally operated and electrically controlled is to determine if the
circuit is lacking hydraulic oil and electrical control power. This
All mains supply should be protected with a suitable RCD. can be ascertained by overriding the bypass valve (mechani-
cally or electrically) so that oil is available to the function valve,
then overriding the function valve mechanically. If the func-
tion performs satisfactorily, the problem exists with the con-
trol circuit.
5-2 31215863
TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.
Red emergency stop button is engaged on control station. Disengage red emergency button until it pops out.
Press and hold Enable button while operating platform up
Enable button on platform control not pressed in.
or down buttons.
Control relay not functioning. Replace control relay.
Motor start relay not functioning. Replace motor start relay.
Unit wiring not properly grounded. Check all ground connections in the wiring.
Unit lowers by itself.
Manual descent valve open. Close manual descent valve.
Hydraulic hose and/or fittings loose causing a hydraulic
Tighten hydraulic hose and/or fittings.
pressure leak.
Lift down solenoid valve not functioning. Replace lift down solenoid valve.
Unit leaking hydraulic oil.
Hydraulic hose and/or fittings loose. Tighten hydraulic hose and/or fittings.
Valve and/or plug loose. Tighten valve and/or plug.
Breather cap on tank is saturated or clogged with oil. Replace breather cap on tank.
Hydraulic oil tank overfilled. Lower oil level to full mark on dipstick.
Unit lowers very slowly.
Lift down solenoid valve not functioning. Replace lift down solenoid valve.
31215863 5-3
Rear Axle Adjustment This may need adjustment if when moving the machine, the
wheel is dragging on the frame stop weldment (6) with the
The 830P rear axle brake assembly is actuated by a pivoting platform fully lowered. Or the frame stop weldment (6) doesn’t
lever bar. When the platform is raised the lever bar is allowed engage the wheel (1) at all, when the platform is elevated.
to raise at the front, this lowers the frame at the rear and pivots
the tire up until it makes contact with the stop weldment on Adjusting the actuator bar higher in the L bracket slots pushes
the frame. That along with the front caster brakes helps hold the Pivoting Lever Bar (2) down further in the front and raises
the machine in place while the platform is elevated. the frame higher at the rear, thereby increasing the gap
between the wheel (1) and the frame stop weldment (6).
Adjusting the Brake Actuator Bar (5)
Adjusting the actuator bar lower in the L bracket slots raises
The brake actuator bar (5) is adjustable within the slots at the the Pivoting Lever Bar (2) up in the front and lowers the frame
top of the L side brackets. Moving the actuator bar up or down at the rear, thereby decreasing the gap between the wheel (1)
allows the amount of pivoting action of the frame assembly. and the frame stop weldment (6).
1. Wheel Assembly 4. Lever Bar Pivot Snap Ring

2. Pivoting Lever Bar 5. Brake Actuator Bar and Bracket
3. Lever Bar Pivot Point 6. Frame Stop Weldment
Contactor Solenoid Replacement 5. Remove the mounting bolts and nuts from the contac-
tor solenoids.
1. Place machine in a clear work area.
6. Replace the contactor solenoid, install reversing the
2. Rotate the platform up into the machine maintenance steps above.
position and lock the gas strut. Remove the base frame
cover.
3. Disconnect machine power by removing the battery (+)
positive terminal from the battery (+) positive post.
4. Disconnect the motor contactor 1 and/or motor contac-
tor 2 cables and wiring from the contactor solenoids.
5-4 31215863
5.5 1030P Gate Spring Mechanism

When the gate is closed, the "U" pin should rest evenly within
Emergency Lowering Valve Spindle the jaw of the gate latch. If the "U" pin is too low, the spring
The spindle on the emergency lowering valve can become can be adjusted to correct the issue.
bent, which prevents it from sliding into the housing correctly.
NOTE: Turn off the battery isolator and wear the appropriate per-
sonal protective equipment.
3
1. Locate the spindle on the cylinder.
2 1
OAR00750
1. "U" Pin 3. Pivot Bolt

2. Lock Nut and Washer 4. Lower Hinge
1. Ensure the gate is closed.

OAR00720
2. Remove the lock nut and washer (2) at the bottom of the
2. Remove the red cap. Identify the direction of the bend hinge. Lift the pivot bolt (3) slightly above the lower
and use pliers to gently straighten the bend. hinge (4).
3. Replace the red cap. 3. Place enough M10 washers to close the gap in the lower
4. Verify proper operation of the emergency lowering hinge.
valve. 4. Push the pivot bolt through the lower hinge and addi-
tional washers. Secure with locknut (2).
5. Open and close the gate to verify proper latching of the
gate. If a gap exists and the "U" pin (1) is still too low, add
more washers.
31215863 5-5
Inspect Main Boom Pivot Pins 1. Remove the plastic end caps from both sides of the
pivot pin. Remove the two M12 bolts that secure the tie-
NOTE: Wear the appropriate personal protective equipment. bar to the pin.
Ensure the machine is positioned on a smooth, firm surface

within the limits of the maximum operating slope and the cas-
tor wheels are locked before elevating the platform to inspect
the main boom pivot pins.
1. Elevate the platform to full height using the ground con-
trols. Turn off the battery isolator.
2. Remove the black plastic pin cap on the boom-to-chas-
sis pivot pin.
2
3. Stand by the side of the machine and place a hand on 1
the boom just above the middle knuckle post. Push the
boom sideways, back and forth, several times.
OAR00730
4. Observe the end of the boom-to-chassis pivot pin for

signs of movement within the hole. 1. M12 bolts (2) 2. Tiebar
5. If there is movement, measure the gap. It should be no
more than 0.5 mm, although 0.25 -0.3 mm is acceptable. 2. Slide off the tiebars on each side.
6. If the movement is above the tolerance, the pin must be 3. Remove the M6 pivot locking screws. Use a suitable rod
replaced. (30 mm diameter) or another pin to push out the old
pin.
NOTE: Apply a small amount of high strength threadlocking com-
4. Align the new pin to the hole on the chassis. Tap into
pound when replacing the plastic pin caps.
place with a mallet.
Inspect Main Boom Pivot Pin Screws

Check if the M6 pivot pin locking screws and ensure they are
tight. If they are loose, remove and apply a small amount of
high strength threadlocking compound and tighten to 0.5
Nm.
Replace Main Pivot Pin

Fully lower the platform and lock the castor wheels. Ensure the
machine is positioned on a smooth, firm surface within the
limits of the maximum operating slope. OAR00740
NOTE: Some components removed for clarity.
5. Replace the M6 pivot locking screws.

pound to the screws.
6. Replace the tiebars.

7. Replace the M12 bolts and plastic end caps.
NOTE: Apply a small amount of low strength threadlocking com-

pound on the bolts.
5-6 31215863
Replace the Lift Cylinder

Ensure the machine is positioned on a smooth, firm surface

within the limits of the maximum operating slope and the cas-
tor wheels are locked before replacing the lift cylinder.
1. Fully lower the platform to the stowed position.
2. Drain the emergency lowering valve. 2
a. Remove the cover of the power pack. Pull and twist 1
the red knob counterclockwise, then release to
open the valve. OAR00730
b. Press and hold the red knob on the lift cylinder for a
minute or two to drain the valve. 1. M12 bolts (2) 2. Tiebar
c. Close the valve by twisting the red knob counter-
clockwise on the power pack. 6. Remove the two M12 bolts and two M6 locking screws
at one end of the cylinder. Drift out the cylinder base
end-pin, followed by the rod end-pin.
7. Repeat step 6 at the other end of the cylinder.
8. Remove the cylinder.
9. Install the new cylinder by reversing steps 7 through 4.
2
pound when replacing the M12 bolts.
10. Reconnect the hydraulic hoses and electrical connec-

tions to the cylinder.
1
11. Verify proper operation of the new cylinder by raising
and lowering the platform several times from the
ground controls. Check for smooth elevation and lower-
ing of the platform.
Replace a Rear Wheel

1. Use a suitable hoist or forklift to raise the machine off

the ground.
OAR00090
1. Red Knob (Power Pack) 2. Red Knob (Lift Cylinder 2. Remove the lock nut. Remove the wheel and bearing
from the axle.
3. Install the new wheel and replace the lock nut.
3. Disconnect the hydraulic hoses and electrical connec-
tions from the cylinder. 4. Apply a small amount of high strength threadlocking
compound to the lock nut and torque to 30 Nm. Ensure
4. Remove the plastic end cap from one side of the pivot the wheel spins freely.
pin. Remove the two M12 bolts that secure the tiebar to
the pin.
5. Slide off the tiebar.
31215863 5-7
5-8 31215863
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations.

www.jlg.com

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Service and Maintenance Manual

January 29, 2021 - Rev A

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE

Original Issue A - January 29, 2021

SECTION 1 - MACHINE SPECIFICATIONS

4.3 Electrical System - Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SECTION 1. MACHINE SPECIFICATIONS

DESCRIPTION 830P 1030P

Dimensions Battery Charger

DESCRIPTION 830P 1030P DESCRIPTION 830P 1030P

Power Source Hydraulic Oil

Working Envelope 1.2 SERIAL NUMBER PLATE IDENTIFICATION

AC POWER SUPPLY CIRCUIT SHOULD BE PROTECTED WITH A BREAKER

Plug in the charger to an available power supply and ensure

AC POWER SUPPLY CIRCUIT SHOULD BE PROTECTED WITH A BREAKER

Battery charge level is also indicated by LEDs on the battery

1.4 LUBRICATION INTERVALS

1.5 TORQUE CHARTS

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

Values for Magni Coating Fasteners (Ref 4150701)

Values for Magni Coating Fasteners (Ref 4150701)

Values for Magni Coating Fasteners (Ref 4150701)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

Sq mm KN [N.m] [N.m] [N.m]

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

Values for Magni Coated Fasteners (Ref 4150701)*

Values for Magni Coated Fasteners (Ref 4150701)*

SECTION 2. GENERAL MAINTENANCE INFORMATION

Inspection and Maintenance Table

2.3 SERVICING AND MAINTENANCE GUIDELINES Components Removal and Installation

Safety and Workmanship Component Disassembly and Reassembly

Gaskets 2.4 HYDRAULIC SYSTEM INFORMATION

Lubrication and Servicing 1030P

It is not advisable to mix oils of different brands or types, as 830P

SECTION 3. COMPONENTS ASSEMBLY

168 - Lift Cylinder 195 - 12V Power Pack Solenoid Valve

101 - Serial Number Plate

SECTION 4. ELECTRICAL/HYDRAULIC INFORMATION AND MACHINE SCHEMATICS

Voltage Measurement Resistance Measurement

Continuity Measurement Current Measurement

1. Remove prox switch from its mount.

4.5 ELECTRICAL/HYDRAULIC COMPONENTS

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4.7 HYDRAULIC SCHEMATICS

SECTION 5. MACHINE MAINTENANCE AND SERVICE

5.2 CASTOR WHEEL MAINTENANCE

• 1 & 2: This foot pedal distortion is a result of a significant

NOTE: Ensure the castor fixing bolt is torqued to 120 Nm.

NOTE: Ensure the castor axle bolt is torqued to 40 Nm.

5.3 BATTERY/BATTERY CHARGER 5.4 830P

TROUBLE PROBABLE CAUSE REMEDY

1. Wheel Assembly 4. Lever Bar Pivot Snap Ring

5.5 1030P Gate Spring Mechanism

1. "U" Pin 3. Pivot Bolt

1. Ensure the gate is closed.

Ensure the machine is positioned on a smooth, firm surface

4. Observe the end of the boom-to-chassis pivot pin for

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