SECTION 2 - GENERAL
3121623
– JLG Lift –
2-3
Bearings
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 bearings 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 bearings until they are
ready to install.
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.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate
a gasket, use gasket material or stock of equivalent
material and thickness. Be sure to cut holes in the right
location, as blank gaskets can cause serious system
damage.
Bolt Usage and Torque Application
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 is too short, there will not be
enough thread area to engage and hold the part
properly. When replacing bolts, use only those hav-
ing 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 Torque Chart Section 1.)
Hydraulic Lines and Electrical Wiring
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.
Hydraulic System
1. Keep the system clean. If evidence of metal or rub-
ber 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.
Lubrication
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants
are not available, 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 corrosion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section
1.
2.3
LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is con-
tamination. Contaminants enter the system by vari-
ous means, e.g., using inadequate hydraulic oil,
allowing moisture, grease, filings, sealing compo-
nents, sand, etc., to enter when performing mainte-
nance, or by permitting the pump to cavitate due
to insufficient system warm-up or leaks in the
pump supply (suction) lines.
2. 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 opera-
tion. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci-
fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or
corrosion. If this condition occurs, the system must
be drained, flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is
operating, are recommended for use.
NOTE:
Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing compo-
nents.
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