Service Manual Instruction Manual
Table Of Contents
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires And Wheels
- 3.2 Torque Hub
- Oil Information
- Roll and Leak Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Output Carrier Disassembly
- Input Carrier Disassembly
- Hub-Spindle Disassembly
- Spindle-Brake Disassembly
- Cover Disassembly
- Cover Assembly
- Input Carrier Sub-Assembly
- Output Planet Gear Sub-Assembly
- Spindle - Brake Sub-Assembly
- Hub-Spindle Sub-Assembly
- Cover Sub-Assembly
- Main Assembly
- Integral Brake Check
- 3.3 Free Wheeling Option
- 3.4 Drive Motor
- 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.6 Steer Adjustments
- 3.7 Swing Drive
- 3.8 Swing Bearing
- 3.9 Swing Brake - Mico
- 3.10 Rotary Coupling
- 3.11 Generator
- 3.12 Deutz D2.9 L4 Engine
- 3.13 Deutz D2011 Engine
- 3.14 Spark Arrester Cleaning Instructions
- 3.15 Glow Plugs
- 3.16 Deutz EMR 2
- 3.17 Bio Fuel in Deutz Engines
- 3.18 GM Engine General Maintenance
- 3.19 GM Engine Dual Fuel System
- Fuel Filter
- Direct Electronic Pressure Regulator (DEPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Electric Lock Off
- Engine Control Module (ECM)
- Heated Exhaust Gas Oxygen Sensor
- Gasoline Multi Point Fuel Injection System (MPFI)
- Gasoline Fuel Pump
- Gasoline Pressure And Temperature Sensor Manifold
- Fuel Filter
- Fuel Injector Rail
- Fuel Injector
- 3.20 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
- Check/Drain Oil Build-Up In 2-Stage Vaporizer
- Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
- Exhaust System And Catalytic Converter Inspection And Maintenance
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Throttle Body (ETC) Replacement
- Mixer Replacement
- Electronic Pressure Regulator (EPR) Replacement
- Regulator Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.21 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- 5.1 O-Ring Lubrication
- 5.2 Cylinders - Theory of Operation
- 5.3 Cylinder Checking Procedure
- 5.4 Cylinder Removal and Installation
- Cylinder Locations
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Boom Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- 5.5 Hydraulic Cylinder repair
- Tower Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Upright Level Cylinder
- Cleaning and Inspection
- Assembly
- Master Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Tower Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Platform Level (Slave) Cylinder
- Cleaning and Inspection
- Assembly
- Jib Lift Cylinder (AJ Only)
- Cleaning and Inspection
- Assembly
- Steer Cylinder
- Cleaning and Inspection
- Assembly
- Axle Lockout Cylinder
- 5.6 Hydraulic Pump (Gear)
- 5.7 Variable Pump
- 5.8 Hydraulic Component Start-Up
- 5.9 Pressure Setting Procedures
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics

SECTION 1 - SPECIFICATIONS
1-12 – JLG Lift – 3121616
Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)
Size TPI Bolt Dia
Tensile
Stress Area
Clamp Load
In Sq In
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
28 0.2500 0.0364
In Sq In
5/16 18 0.3125 0.0524
24 0.3125 0.0580
3/8 16 0.3750 0.0775
24 0.3750 0.0878
7/16 14 0.4375 0.1063
20 0.4375 0.1187
1/2 13 0.5000 0.1419
20 0.5000 0.1599
9/16 12 0.5625 0.1820
18 0.5625 0.2030
5/8 11 0.6250 0.2260
18 0.6250 0.2560
3/4 10 0.7500 0.3340
16 0.7500 0.3730
7/8 9 0.8750 0.4620
14 0.8750 0.5090
1 8 1.0000 0.6060
12 1.0000 0.6630
1 1/8 7 1.1250 0.7630
12 1.1250 0.8560
1 1/4 7 1.2500 0.9690
12 1.2500 1.0730
1 3/8 6 1.3750 1.1550
12 1.3750 1.3150
1 1/2 6 1.5000 1.4050
12 1.5000 1.5800
NO. 5000059 REV. J
3. * ASSEMBLY USES HARDENED WASHER
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
1320 43 5
1580 60 7
1800 68 8
2860 143 16 129 15
3280 164 19 148 17
LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
4720 25 35 20 25 20 25
5220 25 35 25 35 20 25
7000456040 553550
7900 50 70 45 60 35 50
9550 70 95 65 90 50 70
10700 80 110 70 95 60 80
12750 105 145 95 130 80 110
14400 120 165 110 150 90 120
16400 155 210 140 190 115 155
18250 170 230 155 210 130 175
20350 210 285 190 260 160 220
23000 240 325 215 290 180 245
30100 375 510 340 460 280 380
33600 420 570 380 515 315 430
41600 605 825 545 740 455 620
45800 670 910 600 815 500 680
51500 860 1170 770 1045 645 875
59700 995 1355 895 1215 745 1015
68700 1290 1755 1160 1580 965 1310
77000 1445 1965 1300 1770 1085 1475
87200 1815 2470 1635 2225 1365 1855
96600 2015 2740 1810 2460 1510 2055
104000 2385 3245 2145 2915 1785 2430
118100 2705 3680 2435 3310 2030 2760
126500 3165 4305 2845 3870 2370 3225
142200 3555 4835 3200 4350 2665 3625
Torque
(Loctite® 242
TM
or 271
TM
OR Vibra-TITE
TM
111 or
140) K=.18
Torque
(Loctite® 262
TM
or Vibra-
TITE
TM
131)
K=0.15
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque
(Dry or Loctite® 263)
K= 0.20