Service Manual Instruction Manual

SECTION 2 - GENERAL
3121616 – JLG Lift – 2-3
Component Disassembly and Reassembly
Complete procedural steps in sequence when disassembling
or reassembling a component. Do not partially disassemble or
assemble one part, then start on another. Always recheck your
work to ensure nothing is overlooked. Do not make any
adjustments, other than those recommended, without obtain-
ing proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use a molybdenum disul-
fide base compound or equivalent to lubricate the mating sur-
face.
Bearings
1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol-
vent and allow to drip dry. Compressed air can be used,
but do not spin the bearing.
2. Discard bearings if races and balls (or rollers) are pitted,
scored, or burned.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until ready to install.
4. Lubricate new or used serviceable bearings before
installation. Apply pressure to the outer race when
pressing a bearing into a retainer or bore. Apply pres-
sure to the inner race If bearing is installed on a shaft.
Gaskets
Check holes in gaskets align with openings in mating parts. If
it is necessary to hand-fabricate a gasket, use gasket material
or stock of equivalent material and thickness. Be sure to cut
holes in the correct location. Blank gaskets can cause serious
system damage.
Bolt Usage and Torque Application
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1. Always use new replacement hardware when installing
locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.
2. Unless specific torque requirements are given within the
text, use standard torque values on heat-treated bolts,
studs, and steel nuts, in accordance with recommended
shop practices. (See Torque Chart in Section 1.)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, and
their receptacles, when disconnecting or removing them from
the unit. This ensures correct reinstallation.
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 sur-
face. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components as needed to aid assem-
bly.
Lubrication
Service applicable components with the amount, type, and
grade of lubricant recommended in this manual at the speci-
fied intervals. When recommended lubricants are not avail-
able, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.
Battery
Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
sion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and servic-
ing are shown in the Lubrication Chart in Section 1.