SECTION 2 - GENERAL SERVICE INFORMATION
3121741 – JLG Lift – 2-5
Bolt Usage and Torque Application
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 origi-
nal, or one which is equivalent.
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 rec-
ommended shop practices. (See Torque Chart in Section-1
of this manual.)
2.4 HYDRAULIC SYSTEM INFORMATION - (830P
Only)
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
Keep the system clean. If evidence of metal or rubber par-
ticles is found in the hydraulic system, drain and flush the
entire system.
Disassemble and reassemble parts on clean work surface.
Clean all metal parts with non-flammable cleaning sol-
vent. Lubricate components, as required, to aid assembly.
The primary enemy of a hydraulic system is contamina-
tion. Contaminants enter the system by various means,
e.g., using inadequate hydraulic oil, allowing moisture,
grease, filings, sealing components, sand, etc., to enter
when performing maintenance, or by permitting the
pump to cavitate due to insufficient system warm-up or
leaks in the pump supply.
The design and manufacturing tolerances of the compo-
nent working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a sys-
tem can cause wear or damage to the components and
generally results in faulty operation. Every precaution
must be taken to keep hydraulic oil clean, including
reserve oil in storage.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart, (See Section-
1). 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.
Cloudy oils indicate a high moisture content which per-
mits organic growth, resulting in oxidation or corrosion. If
this condition occurs, the system must be drained,
flushed, and refilled with clean oil.
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 of new
machines due to the wear-in of meshing compo-
nents.
Hydraulic Oil
For best performance, JLG recommends the use of Grade
32, Mineral oil. Refer to Section-1 for recommended
hydraulic oils.
Changing Hydraulic Oil
To drain the hydraulic tank, the mast must be in the trans-
port position, and the platform tilted to allow access to
the motor/pump unit. The only practical method to
remove the oil from the tank is to use a syringe suitable for
hydraulic oil, which are easily obtainable, or a vacuum sys-
tem for hydraulic oil. The hydraulic steel pipe connection
to the cylinder must not be disconnected, unless by a
competent person. If the connection has been discon-
nected, then a full pressure test of the system must be
conducted prior to placing the machine back into service.
See Hydraulic System - Pressure and Leak Check on page
3-14, no leaks must be evident when the pressure test is
conducted.
Use every precaution to keep the hydraulic oil clean. If the
oil must be poured from the original container into
another, be sure to clean all possible contaminants from
the service container.
While the unit is shut down, a good preventive mainte-
nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a func-
tional check of each system, before placing the machine
back in service.
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