Page 3 - FOREWORD; READ; UNDERSTOOD; before any attempt is made to operate the; YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL; and; NOTE; are defined as follows:
FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion ofproper machine operation for its intended purpose. It is important to over-stress proper machine usage. Allinformation in this manual should be READ and UNDERSTOOD before any attempt i...
Page 5 - – JLG Lift –; INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS; GENERAL
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS 3121190 – JLG Lift – a INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL T h i s s e c t i o n c o n t a i n s t h e g e n e r a l sa f e t y p r e c a u ti on swhich must be observed during maintenance of the aerialplatform. It is of utmost importan...
Page 6 - EFFECTIVITY PAGE; EFFECTIVITY CHANGES
EFFECTIVITY PAGE b – JLG Lift – 3121190 EFFECTIVITY CHANGES March 25, 2004 - Original Issue of Manual February 29, 2008 – Manual Revised
Page 7 - TABLE OF CONTENTS; SECTION 1 - SPECIFICATIONS
3121190 – JLG Lift – i TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aHydraulic System Safety . . . ...
Page 9 - SECTION 3 - TROUBLESHOOTING
3121190 – JLG Lift – iii TABLE OF CONTENTS 2.13 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 10 - LIST OF FIGURES; LIST OF TABLES; TITLE
iv – JLG Lift – 3121190 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . . . . 1-2 1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 11 - SECTION 1. SPECIFICATIONS; WET; TORQUE REQUIREMENTS
SECTION 1 - SPECIFICATIONS 3121190 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Hydraulic Oil Reservoir DC Models – 5 qts. U.S. (4.7 ltr.) 1.2 COMPONENT DATA Hydraulic Pump/Electric Motor Assembly DC Models - 12 Volt DC motor/pump Motor - 12v - DC Standard Duty Pump Displacement – .098 ...
Page 12 - Hydraulic Oil; HYDRAULIC PRESSURE ADJUSTMENT; clockwise, increases system; CYLINDER SPECIFICATIONS; Screw Located at Base of Pump Motor
SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3121190 1.5 LUBRICATION Hydraulic Oil Hydraulic oils must have anti-wear qualities at least to APIService Classification GL-3, and sufficient chemical stabil-ity for mobile hydraulic system service. JLG Industries,recommends Mobilfluid 424 hydraulic oil, w...
Page 15 - SECTION 2 - SERVICE PROCEDURES; SECTION 2. SERVICE PROCEDURES; AND MAINTENANCE; General
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-1 SECTION 2. SERVICE PROCEDURES 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby those personnel that are responsible to place themachine in operation readiness and maintain its...
Page 16 - PREVENTIVE MAINTENANCE AND
SECTION 2 - SERVICE PROCEDURES 2-2 – JLG Lift – 3121190 2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE (See Table 2-2.) The preventive maintenance and inspection checks arelisted and de fined in the fo llowing tabl e. This table isdivided into two basic parts, the “AREA” to be inspectedand the “...
Page 17 - INTERVAL
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-3 Table 2-2. Preventive Maintenance & Inspection Schedule. AREA ON MACHINE INTERVAL PRE-START (1) INSPECTION 3 MONTH PREVENTATIVE MAINTENANCE 6 MONTH PREVENTATIVE MAINTENANCE PRE-DELIVERY (2)OR FREQUENT (3) INSPECTION ANNUAL (4) (YEARLY) INSP...
Page 19 - SERVICING AND MAINTENANCE
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-5 2.3 GENERAL This section provides general information to assist in thep e r f o r m a n c e o f m a i n t e n a n c e o n t h e p e r s o n n e l l i f t .Descriptions, techniques and specific procedures aredesigned to provide the safest and mo...
Page 20 - Chain Size
SECTION 2 - SERVICE PROCEDURES 2-6 – JLG Lift – 3121190 and thickness. Be sure to cut holes in the right location, asblank gaskets can cause serious system damage. Bolt Usage and Torque Application Use bolts of proper length. A bolt which is too long willbottom before the head is tight against its r...
Page 21 - Protruding or Turned Pins:; Chain Anchors and Sheaves:; LUBRICATION INFORMATION; Hydraulic System
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-7 Tight Joints: All joints in the leaf chain should flex freely. On leaf chains, tight joints are usually caused by rust/cor-rosion, or the inside plates “walking” off the bushing. Lim-ber up rusty/corroded chains (after inspecting carefully) wit...
Page 22 - General Information
SECTION 2 - SERVICE PROCEDURES 2-8 – JLG Lift – 3121190 2.6 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY - (DC POWERED MACHINES ONLY) General Information DO NOT ATTEMPT TO DISASSEMBLE THE BATTERY CHARGERIF MACHINE IS STILL UNDER WARRANTY. OPENING THE BAT-TE RY CHARGER WH ILE TH E MACH INE IS UNDER WA ...
Page 23 - Transformer Replacement; Printed Circuit Board Replacement; DC Circuit Breaker Replacement
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-9 Transformer Replacement 1. Disconnect the wiring connecting the transformer toother components within the charger assembly. 2. Remove the four nuts from the cap screws securingthe transformer brackets to the base of the chargerchassis. 3. Remov...
Page 25 - FENNER BRAND PUMP - Brush Replacement; Motor Cap Installation
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-11 2.7 HYDRAULIC LIFT PUMP - SERVICING Remove hydraulic pump from machine. FENNER BRAND PUMP - Brush Replacement Motor Cap/Motor Installation Motor Brush Installation Motor Cap Installation 1. Cap Assembly Screws 2. Cap Assembly Motor Installatio...
Page 26 - Brush Housing Final Assembly Tips; New Brush Installation; Brush Final Positioning
SECTION 2 - SERVICE PROCEDURES 2-12 – JLG Lift – 3121190 Once brush housing has been removed, inspect the rotorcommutator for excessive wear before installing a newbrush set. The rotor commutator surface when new, is approximately1/8 in. (3mm) in thickness. Brush Housing Final Assembly Tips It is ea...
Page 27 - MONARCH BRAND PUMP - Brush Replacement
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-13 MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks Motor/Brush Cover - Remove/Install Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and va...
Page 29 - Tank Installation
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-15 TANK AND PUMP REMOVAL - (All Pumps) Tank Installation Filter Screen Installation Pump Installation Tank Installation 1. Tank Assembly 3. O-Ring Seal 2. Tank Screws (4) 4. Use Screwdriver to pry tank away from pump head. Filter Screen Installat...
Page 30 - Pressure Adjust Valve Installation; Pressure Check Valve Installation
SECTION 2 - SERVICE PROCEDURES 2-16 – JLG Lift – 3121190 Pressure Adjust Valve Installation Pressure Check Valve Installation Pressure Adjust Valve Installation 1. Adjust Valve Cap 4. Valve Ball 2. Adjustment Screw 5. Adjust Valve Por t 3. Valve Spring 6. Extend (Pressure) Por t (Shown Plugged) Note...
Page 31 - REMOVAL, INSPECTION AND REBUILD; Cylinder Disassembly; Cylinder Rod
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-17 2.8 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULICFLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATEMEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE INTHE CYLINDER BEFORE DISCONNECTI...
Page 32 - Piston
SECTION 2 - SERVICE PROCEDURES 2-18 – JLG Lift – 3121190 event that an unacceptable condition occurs, the headshould be replaced. Piston Visually inspect the outside surface for scratches or pol-ishing. Deep scratches are unacceptable. Polishing indi-cates uneven loading and when this occurs, the di...
Page 33 - Cylinder Assembly
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-19 Cylinder Assembly (See Figure 2-1.) 1. Rinse the inside of the tube with hydraulic fluid andallow to drain. A high-pressure rinse followed by awipe with a lint-free rag is preferable. Clean all inter-nal components of any foreign material. 2. ...
Page 34 - MAST ASSEMBLY AND DISASSEMBLY; Mast Disassembly Procedure; Model; TOP
SECTION 2 - SERVICE PROCEDURES 2-20 – JLG Lift – 3121190 2.9 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES The AMI personnel lift mast sections are contructed ofextruded aluminum, protected with an anodized surfacefinish. The mast sections rails are interlocked into eachothe r when asse mbl e d and ar e ...
Page 35 - Mast Section 4 Removal; Mast Section 3 Removal
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-21 Mast Section 4 Removal 6. Remove chain adjust nuts from threaded ends ofchain attached to the chain anchor plate on BOT-TOM end of mast section-4. Push threaded ends ofcable through anchor plate. 7. At TOP of mast section-4, pull chains out an...
Page 38 - Mast Section 1 - Assembly; Mast Section 2 - Assembly
SECTION 2 - SERVICE PROCEDURES 2-24 – JLG Lift – 3121190 2.10 MAST ASSEMBLY (See Figure 2-3., & Figure 2-4.) Mast Section 1 - Assembly NOTE: Apply Krytox lubricant (JLG P/N-3020041) to theINSIDE front and rear wear surfaces of ALL slidepad rails on each mast section just before assembly.Spray on...
Page 39 - Mast Section 3 - Assembly
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-25 side clearance to prevent any strain on the sides ofthe mast when the bolts are tightened. 13. New Design Cylinder Mount: Install the cylinder mounting plates at the bottom of the mast section-1.Mount plates two each side, using the the (2) tw...
Page 40 - Mast Section 4 - Assembly
SECTION 2 - SERVICE PROCEDURES 2-26 – JLG Lift – 3121190 flathead cap screws, each side. Coat threadswith Loctite #171 and tighten. NOTE: When sliding mast sections together, be careful notto scratch or score the anodized finish in the slidepad channels. 28. Carefully slide mast section-3 into secti...
Page 41 - Platform Mounting Section - Assembly
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-27 42. Thread slide pad attaching bolts, two (2) 1/4"-20UNC x 3/8" long hex head bolts, place a flatwasher under head of each bolt, through holes inoutside rail on top of mast section-3 and into theslide pad inserts. Thread in enough to h...
Page 42 - MAST TO BASE FRAME INSTALLATION; MAST CHAINS AND SEQUENCING; Mast Chain Adjustment
SECTION 2 - SERVICE PROCEDURES 2-28 – JLG Lift – 3121190 chains. Check that chains are seated in their sheavewheels at top of mast assembly. 54. Assemble the mini covers to the top of each mastsection and the sequencing cables and hardware tothe side of the mast assembly. Mast assembly should now be...
Page 43 - MAST SIDE PROFILE
SECTION 2 - SERVICE PROCEDURES 3121190 – JLG Lift – 2-29 4. To adjust, elevate the platform until the chain anchoradjust nuts are accessible at the front and bottom ofeach mast section. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT-FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENTBY BLOCKING OR O...
Page 44 - Sequencing Cable Adjustment; SEQUENCE CABLE REPLACEMENT KIT; Remove Old Cable
SECTION 2 - SERVICE PROCEDURES 2-30 – JLG Lift – 3121190 the other. The threaded end (stud) of the chain mayneed to be restrained while tightening the adjust nutto keep the chain from twisting. 7. Retract the mast all the way and check if the top ofthe mast sections appear as shown in Figure 2-5. 8....
Page 47 - SECTION 3. TROUBLESHOOTING; TROUBLESHOOTING INFORMATION; HYDRAULIC CIRCUIT CHECKS; Grounding
SECTION 3 - TROUBLESHOOTING 3121190 – JLG Lift – 3-1 SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to beused for locating and correcting most of the operatingproblems which may develop in the aerial platform. If aproblem should develop which is not presente...
Page 48 - Polarity; Procedure
SECTION 3 - TROUBLESHOOTING 3-2 – JLG Lift – 3121190 Polarity F i n d i n g a n e g a t i v e v o l t a g e o r c u r r e n t r e a d i n g w h e nexpecting a positive reading frequently means the leadsare reversed. Check what reading is expected, the loca-tion of the signal and that the leads are c...
Page 49 - Voltage Measurement
SECTION 3 - TROUBLESHOOTING 3121190 – JLG Lift – 3-3 Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads ...
Page 50 - Continuity Measurement
SECTION 3 - TROUBLESHOOTING 3-4 – JLG Lift – 3121190 Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4. Current Measurement (DC) • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing...
Page 51 - ELECTRICAL SWITCH TESTING
SECTION 3 - TROUBLESHOOTING 3121190 – JLG Lift – 3-5 3.5 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioningproperly, not the circuit in which the switch is placed. Aswitch is functioning properly when there is continuitybetwee n th e correct terminals o...
Page 52 - UNIT LEAKING HYDRAULIC OIL
SECTION 3 - TROUBLESHOOTING 3-6 – JLG Lift – 3121190 Table 3-1. DC Unit - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM DOES NOT RISE Power source is OFF or unplugged. Check power source or Ground Station Key Switch. Red emergency stop button is engaged (PUSHED IN) on either ground control ...
Page 59 - CALIFORNIAN PROPOSITION 65; BATTERY WARNING; WASH HANDS
CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!
Page 60 - JLG Worldwide Locations
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda.Rua Eng. Carlo...
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