Grove JLG VM 3242E VM 2642E Service & Maintenance Manual PN 31210043 – PDF DOWNLOAD

Service and Maintenance Manual

Model VM 3242E VM 2642E P/N - 31210043 November 08, 2007

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SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A

GENERAL

C

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION. The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual.

These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR.

B

MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION. • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT. • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS. • NEVER WORK UNDER AN ELEVATED STRUCTURE U N T I L S T RU C T U R E H A S B E E N S A F E LY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING. • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS. • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high, potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

Relieve system pressure by cycling the applicable control several times, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

31210043

– JLG Lift –

A-1

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISON LOG Original Issue

A-2

- November 08, 2007

– JLG Lift –

31210043

TABLE OF CONTENTS

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - SPECIFICATIONS 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Major Components Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

SECTION 2 - GENERAL 2.1 2.2 2.3 2.4 2.5

Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

SECTION 3 - CHASSIS 3.1 3.2 3.3 3.4 3.5

Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Steering Knuckles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 Non Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3 Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

SECTION 4 - TURNTABLE AND VERTICAL MAST 4.1 4.2 4.3 4.4 4.5 4.6 4.7

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Swing Gear Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Mast Profile Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Lifting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Pulley - Pulley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 Mast Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

SECTION 5 - JIB AND PLATFORM 5.1

Jib Cylinder Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

SECTION 6 - HYDRAULICS 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14

31210043

Main Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Steering Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Hydraulic Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3 Hydraulic Pump / Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 Functions Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Motor Supply Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 Differential Locking Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 Brake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 "Free wheel" Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Swing Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

– JLG Lift –

1

TABLE OF CONTENTS (Continued)

SECTION 7 - BATTERY / CHARGER 7.1 7.2 7.3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Battery Discharge Controller Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

SECTION 8 - ELECTRIC - CONTROL SYSTEM 8.1 8.2 8.3 8.4 8.5 8.6

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Motor Speed Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Synoptical Switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7 Drive Management Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Circuits Protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15 "Clipper" Connector Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17

SECTION 9 - SCHEMATICS 9.1 9.2 9.3 9.4 9.5 9.6

2

Electrical Power Circuit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Harness Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 Platform Console - Panel Mounted Components Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 Ground Console - Panel Mounted Components Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

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31210043

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS 1.1

Turning Radius

CAPACITIES

Inside - 0 ft (0 m) Outside - 5.8 ft (1.75 m)

Hydraulic Oil Tank - Main 5.8 gallons (22 liters)

Mast Speed

Hydraulic System

Lift up - 24-27 seconds Lift down - 20-29 seconds

Approximately 8 gallons (30 liters)

Jib Speed

Hydraulic Oil Tank - Steering Unit

Lift up : 10-16 seconds Lift down : 15-24 seconds

0.25 gallon ( 1 liter)

Hydraulic System - Steering

Turntable Swing Speed (Left and Right)

Approximately 0.4 gallon (1.5 liter)

1.2

From rest to rest : 50-65 seconds

Machine Weight

COMPONENT DATA

7720 lbs (3500 kg)

Battery - Battery Charger Battery : 3 battery packs of 8 volts, 560 ampHour (5 hour rate) (each pack is composed of 4 two volts cells).

Charger : Input, 110-220 VAC, 50-60 Hz - Output, 24 VDC (65 Amps) NOTE: *Refer to the appropriate section in this manual for further information.

Ground Bearing pressure 200 PSI (14 kg/cm²)

Machine Height (Stowed) 6.5 ft (1.99m)

Machine Length (Stowed)

Main Hydraulic Pump / Electric Motor Assembly

10.5 ft (3.20m)

Motor - 24 VDC, 3 kW.

42 in (1.06 m)

Machine Width

Pump - 0.49 cu.in/rev (8 cm³/t) Pump Output, 3.1 gpm (12 l/mn) at 2000 psi (138 bar)

Wheel base

Steering Hydraulic Pump / Electric Motor Assembly

4.26 ft (1.30 m)

Up and Over Platform Height

Motor - 24 VDC, 0.8 kW

22 ft (6.70 m)

Pump - 0.03 cu.in/rev (0.5 cm³/t)

1.3

Horizontal Reach Up and Over 9.5 ft (2.90 m)

PERFORMANCE DATA

Max. Platform Height

Travel speed (Forward and Reverse) High drive - 2.3 m.p.h. (3.8 km/h) [28-32 sec / 100 ft] Drive w / mast raised - 0.4 m.p.h. (0.7 km/h) [35-38 sec / 50 ft]

26.6 ft (8.10 m)

Gradeability 20%.

31210043

– JLG Lift –

1-1

SECTION 1 - SPECIFICATIONS

1.4

TORQUE CHART Torque values for bolts. nuts and studs Grade

8.8 10.9 12.9

Tensile strength Mpa / Psi 785 113854 981 142281 1177 170709

Unit

M4 x70

M5 x80

M6 M8 M10 M12 M14 x100 x125 x150 x175 x200

M16 x200

M18 x250

M20 x250

M22 x250

M24 x300

M27 x300

M30 x350

N.m lbf ft N.m lbf ft N.m lbf ft

2.7 2 3.9 2.9 4.6 3.4

5.2 3.8 7.7 5.7 9 6.6

9.1 6.7 13.4 9.9 15.7 11.6

189 139 278 205 325 239

261 192 384 283 449 331

370 272 544 408 637 469

509 375 748 551 875 645

637 469 936 690 1095 807

944 696 1386 1022 1622 1196

1280 944 1880 1386* 2200 1622

22 44 76 16.2 32.5 56 32 64 111 23.6 47.2 81.9 38 75 130 28 55.3 95.9

121 89.2 178 131 209 154

Torque values for fittings JIC JIC 7/16 JIC 9/16 JIC 3/4 JIC 7/8

1.5

Nm / lb ft 15 11.1 30 22.1 50 36.9 69 50.9

BSPP BSPP 1/4 BSPP 3/8 BSPP 1/2 BSPP 3/4

N.m / lbf ft 14.8 10.9 34 25.1 60 44.3 115 84.8

Metric M14x150 M18x150

N.m / lbf ft 38 28 51 37.6

of metal or rubber particles. If evidence of metal or rubber particles are found, drain and flush the entire system.

LUBRICATION

General

Recommended hydraulic oil

EXERCISE EXTREME CARE AROUND PRESSURIZED HYDRAULIC SYSTEMS WHILE IN OPERATION OR UNTIL ALL PRESSURE IS RELEASED.

HIGH PRESSURE OIL COULD PENETRATE SKIN AND CAUSE INJURIES OR BURNS. LOOSEN FITTINGS OR COMPONENTS SLOWLY TO ALLOW OIL PRESSURE TO DROP GRADUALLY. When servicing the hydraulic system, use a container to collect the oil from hydraulic lines or components and prevent it from spilling on the work platform or on the ground.

NOTE: Used oils and filter cartridges must be disposed of according to regulation in force.

Contaminants in the hydraulic system will affect operation and will result in serious damage to components working parts. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. If the oil must be poured from the original container into another, be sure to clean all contaminants from the service container.

Before disconnecting a hydraulic line or removing a component, clean fittings and adjacent area. As soon as a hydraulic line is disconnected or a component removed, plug, cap or cover all openings to prevent entry of foreign matter.

NERVOL VERVOFLUID VG32

MOBIL DTE 13M

32

32

Cinematic Viscosity at 4°F (-20°C)

1213 mm²/s (cSt)

1250 mm²/s (cSt)

Cinematic Viscosity at 32°F (0°C)

254 mm²/s (cSt)

250 mm²/s (cSt)

Cinematic Viscosity at 104°F (+40°C)

34 mm²/s (cSt)

33,3 mm²/s (cSt)

Pour paint, max

-42°F (-41°C)

-51°F (-46°C)

Flash paint, min

437°F (225°C)

331°F (166°C)

Viscosity index

148

144

ISO 6743-4 Classification

HV

HV

ISO VG VISCOSITY GRADE

NOTE: Aside from JLG recommendations, it is not advisable to mix oils from different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other then those recommended, contact JLG Industries for proper recommendations.

Disassemble and reassemble parts on clean work surface. Hydraulic system filters should be replaced at the specified intervals. Examine filter cartridges for evidence

1-2

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31210043

SECTION 1 - SPECIFICATIONS

Lubrication Chart

Component

Number / Type Lube points

Interval Hours

Lube

125

250 X

Comments

1000

1

Swing Bearing Race

1 grease fitting

B

2

Swing Bearing Teeth

By brush

C

3

Wheel Hub Bearing

2 grease fittings

B

4

Mast Profiles

By brush

B

X

Remove old grease first

5

Lifting Chains

Spray on or by brush

D

X

Lubricate before first 50 hours

6

Hydraulic Oil

Fill through return filter cap

A

7

Hydraulic Pressure Filter

N/A

N/A

X

Change after first 50 hours

8

Hydraulic Return Filter

N/A

N/A

X

Change after first 50 hours

X

Need swing gear box assembly removal

X

X

Check level daily. Change at least every 2 years

Table 1-1. Lubrication Chart NOTE: Lubrication intervals are based on machine operation under normal condition. For machines used in multi shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

(*) to be adapted to the machine’s working conditions.

Refer to the corresponding section in this manual.

NOTE: Refer to the corresponding sections in this manual for specific lubrication procedures.

Lube Specifications Table 1-2. Lube Specifications Lube

Specifications Nervol NERVOFLUID VG32 Mobil DTE 13M

A

Hydraulic Oil

B

Extreme Pressure - Multi Purpose Grease

Mobil MOBILUX EP2 Mobil COMPLEX EP2

C

Open Gear Lube

Mobil MOBILTAC 81

D

Non Detergent Mineral Oil*

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Mobil DTE 16M

– JLG Lift –

1-3

SECTION 1 - SPECIFICATIONS

1.6

MAJOR COMPONENTS WEIGHT

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF SAFELY SUPPORTING WEIGHT. Table 1-3. Major Component Weight COMPONENT

lbs

kg

Platform & Support (*)

154

70

Jib Assembly w/Cylinder

174

79

Jib Cylinder

66

30

Mast Assembly (4 mast sections)

860

390

Mast Cylinder

99

45

Mast Section #1 Assembly

595

270

Chassis Assembly

1565

710

Steering Knuckle (each)

68

31

Drive Motor (each)

70

32

Counterweight

2800

1270

Wheel (*)

55

25

560 Ah Battery pack (each) (*)

437

198

NOTE: (*) Items critical to stability.

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

1.7

SERIAL NUMBER LOCATIONS

For machines identification, a serial number plate is affixed to the platform. If the serial number plate is damaged or missing, the machine serial number is stamped on the front beam of the frame.

1-4

– JLG Lift –

31210043

SECTION 2 - GENERAL

SECTION 2. GENERAL 2.1

2. At any time when hydraulic oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. as soon as a line or component is disconnected, cap or cover all opening to prevent entry of foreign matter.

MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation 1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

The maintenance procedures included consist of servicing and component removal and installation, disassembly, and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

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SERVICING AND MAINTENANCE GUIDELINES

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc. have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy object to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Bearings

Cleanliness 1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components.

Precautions have been taken to safeguard against this. Shields, covers, seals and filters are provided to keep oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

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1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearing if the races and balls (or rollers) are pitted, scored or burned.

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearing until they are ready to be installed.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

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SECTION 2 - GENERAL

Care and Installation of Teflon Coated Bushings

2. Slightly oil the outside diameter of the bushing to facilitate insertion.

Bushings :

3. Keep driver, bushing and housing correctly align during assembly.

1. No jiffy wheels or reaming of any kind can be used on teflon coated bushings.

4. Blocking must be used on parts that will receive two bushings to prevent damage to the lower bushing flange.

2. Once the coating on the bushing is damaged, it cannot be used and must be replaced.

Pins : 1. Any rough or damaged surface on a pin will cause the teflon coating of the bushing to be damaged.

2. All rust or masking residue must be cleaned from the pin prior to assembly.

3. Never dry "Arcor" treated pins (black colored). This will reduce corrosion resistance property of pin coating.

Bushings and Pin : 1. Coat inside diameter of bushing with specified lubricant prior to pin installation.

2. Properly align pin and bushing so that the coating does not get damaged when installing the pin.

Bolt Usage and Torque Application

3. Pins have chamfered or rounded end to prevent damage to the coating of the bushing during pin installation.

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt if too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat treated bolts, studs and steel nuts, in accordance with recommended shop practices (See § 1.4).

Hydraulic Lines and Electrical Wiring

Bushing installation : 1. Use an appropriate driver (soft steel) to insert bushing in its housing.

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled. Coat contacts of electrical connectors with anti-corrosion compound.

Always disconnect battery plug prior to working on the electrical system.

Hydraulic System 1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

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– JLG Lift –

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SECTION 2 - GENERAL

Welding on Work Platform When welding on the work platform, disconnect battery plug and all electronic components. When welding on the chassis, connect the welder ground wire to the machine chassis as close as possible to the area bering welded.

When welding on the superstructure, connect the welder ground wire to the machine superstructure as close as possible to the area being welded. This is to prevent arcing inside the swing bearing or the lifting chains.

Lubrication Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified interval. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Lubrication Chart.

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– JLG Lift –

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