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Technical Tips

Get expert advice from our factory-trained technicians who share a new tech tip every month in the Ground Support e-newsletter.

Proper Method for Checking Transmission Fluid

JLG® telehandler models equipped with the ZF TSC transmission are also equipped with a thermal bypass valve in the cooling circuit to facilitate faster warm-up of the transmission.

JLG® telehandler models equipped with the ZF TSC transmission are also equipped with a thermal bypass valve in the cooling circuit to facilitate faster warm-up of the transmission. When the transmission cooling circuit is below operating temperature, this valve may be fully or partially closed, affecting the amount of fluid in the transmission. It is necessary to check the fluid level with the valve fully open to ensure the proper amount of fluid is present in the system. Improper fluid levels can contribute to premature failure of the transmission.

Download the ZF Transmission Fluid Level Check PDF (163KB PDF) for step-by-step instructions.

Please contact your Regional Service Manager or a JLG® service representative if further information is required.

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Pressure Washing and Electronics

Today’s lifts are equipped with electronics that can be sensitive to pressure and water. See how JLG Industries recommends washing equipment areas containing sensitive components.

A rugged job site can make pressure washing your machines a necessity, but today’s lifts are equipped with sophisticated electronics that can be sensitive to pressure and water. Beyond avoiding washing electrical or electronic components, JLG Industries recommends the following in the event that you need to wash an area containing sensitive components:

  • Use a maximum pressure of 750 psi (52 BAR)
  • Maintain a minimum distance of 12 inches away from these components
  • Avoid directly spraying components, and limit any secondary water exposure to brief periods to avoid saturation
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Raised Outrigger Binding Issue

Based on feedback from the field, outriggers used on the machines listed above may bind, in some instances, in the raised position, preventing the outrigger from being lowered into position when required.
Models Affected: JLG Models G10-43A; G10-55A; and G12-55A Telehandlers

Based on feedback from the field, outriggers used on the machines listed above may bind, in some instances, in the raised position, preventing the outrigger from being lowered into position when required. To resolve this issue, JLG has developed a field service kit (P/N 1001180818) which provides stop blocks that will limit the distance the outrigger arms can be raised. These stop blocks are installed by welding, and the kit contains installation instructions as well as parts to update one machine. 

Warranty: JLG recommends the installation of the stop block kit (P/N 1001180818) at your next service maintenance interval. JLG will reimburse your account the cost of the part and two (2) hours for labor for each unit completed and up to three (3) hours for travel time. 

This part can only be ordered by a local servicing entity of JLG products. This servicing entity must have a JLG account and be capable of purchasing parts and filing warranty claims. When ordering a kit, the servicing entity will be charged (debited) for the cost of each kit. Reference SL 15-09 on your warranty claim. The warranty coverage for this bulletin will expire 12 months after the date on this letter.
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Torque Value of Check Valve Used on Unloader Valve P/N 1001103151

The supplier of the Unloader Valve Assembly (ref. page 8-2 of JLG Service Manual 31200796 for location) has notified JLG of a torque value change on Check Valve Assembly P/N 70022716.
Models Affected: SkyTrak® Telehandlers 6036 and 6042 with Serial Numbers 0160037836 through 0160058296 

The supplier of the Unloader Valve Assembly (ref. page 8-2 of JLG Service Manual 31200796 for location) has notified JLG of a torque value change on Check Valve Assembly P/N 70022716. The revised torque specification is 120 ft-lbs. If you are experiencing an issue, such as a leak, with the check valve assembly on a machine with the serial number range listed above, follow the steps outlined in the full bulletin (32 KB PDF). 

Part Number: 1001103151 

Refer to our latest tech bulletin (32 KB PDF) for more information and procedures.
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SkyTrak Brake Valve: Incorrect O-Ring on Fittings/Adapters

JLG has determined that certain SkyTrak brake valves, P/N 1001106836, may have incorrect O-rings installed on the adapter fittings, which could result in a fluid leak at the brake valve.
JLG has determined that certain SkyTrak brake valves, P/N 1001106836, may have incorrect O-rings installed on the adapter fittings, which could result in a fluid leak at the brake valve. Brake performance is not affected by this leak. To resolve this, JLG has worked with fitting manufacturers to ensure that the correct O-ring is being installed, but we recommend replacing brake valve fittings to prevent potential leaks. 

A Brake Valve Fittings Service Kit (P/N 1001171117) is available, and it includes SkyTrak Brake Valve Fittings Installation Instructions (P/N 31212000). 

Warranty: JLG recommends the installation of this service kit at your next maintenance interval. JLG will reimburse your account the cost of the service kit, and one (1.0) hour labor for each unit completed. No travel will be paid in accordance with this Service Letter. This bulletin will expire 12 months after the date of distribution. Please reference SL 14-02 (PDF 32 KB) on your warranty claim. 

This service kit can only be ordered by a local servicing entity of JLG products. This servicing entity must have a JLG account and be capable of purchasing parts and filing warranty claims. When ordering a kit, the servicing entity will be charged (debited) for the cost of each kit.
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Tips for Winter Weather

With cold, wintry weather upon us, here are a few quick checks that should help keep your JLG machines operating smoothly throughout the season.

With cold, wintry weather upon us, here are a few quick checks that should help keep your JLG machines operating smoothly throughout the season.

  • If your AWP is a diesel and has glow plugs, check in the machine set up menu of your analyzer to ensure they are turned on. If they are not set to the appropriate setting, your glow plugs will not activate.
  • Be sure all of your battery and battery connections are corrosion-free and tight.
  • Check all cannon plugs for moisture and apply a small amount of dialectic grease to help ward off moisture.
  • Inspect all of your toggle switches and joysticks at both platform and ground for boot damage. Introducing water/ice into one toggle switch can render your machine inoperative and cause you a service call.
  • Be sure you are using the proper lubricants and fuel specified for your machine and your ambient working temperatures per the service manual.

These tips, along with the regular recommended service program, should help keep your machines up and running.

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Transmission Oil Level Check on Telehandler

In order to prevent premature transmission failures, transmission fluids and levels should be checked daily.

In order to prevent premature transmission failures, transmission fluids and levels should be checked daily. Here’s a simple way to check the oil level. Consult machine’s Operator Manual for specific machine operation hours.

  • Apply park brake, shift transmission to "Neutral" and lower forks or attachment to the ground.
  • Check transmission oil level with engine at idle and oil at normal operating temperature.
  • Remove the transmission dipstick (1) and check oil level. The oil level should be within the "HOT" zone (2).
  • If oil is low, add hydraulic fluid to bring oil up to the "HOT" zone.
  • Replace transmission dipstick.
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Keeping Hydraulic Oil Clean

Hydraulic oil is the lifeblood of any construction machine, and the cleanliness of the oil is just as important as the proper amount of hydraulic oil.

Hydraulic oil is the lifeblood of any construction machine, and the cleanliness of the oil is just as important as the proper amount of hydraulic oil. Dirty or contaminated hydraulic oil can damage internal components and void the manufacturer’s warranty.

JLG recommendations for hydraulic oil cleanliness levels are based on the three-digit ISO code for 4 micron/6 micron/14 micron particle sizes found in 1 ml of fluid (reference ISO 4406:199(E). The acceptable level is 19/17/14 or below; anything higher requires system cleaning and filter replacement. (It’s important to note that the human eye can only distinguish particles down to 40 microns – smaller particles that are sampled are not visible.) Reference the JLG Service Manual for the appropriate maintenance intervals based on the hours of operation. If your equipment is exposed to extremely dirty or hostile conditions, more frequent service may be required. Always use original JLG filters to assure necessary filtration requirements are met.

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Separation of Windshield Wiper Circuit from the Alternator Excitation Circuit Fusing

It has been brought to JLG’s attention that certain machines equipped with enclosed cabs may experience an issue with the fuse for the alternation excitation circuit when operating in extreme cold conditions.
Models Affected: SkyTrak® Telehandlers 6036 and 6042 with Serial Numbers 0160045066 through 0160065889, SkyTrak Telehandlers 8042, 10042 and 10054 with Serial Numbers 160045250 through 0160065887

It has been brought to JLG’s attention that certain machines equipped with enclosed cabs may experience an issue with the fuse for the alternation excitation circuit when operating in extreme cold conditions. The circuit currently is tied into the windshield wiper circuit, and if the wipers are activated while frozen to the windshield, the increased current draw may blow the fuse. Because the same fuse is being used to protect the alternator, the charging function of the machine will cease to work. 

JLG has created a Service Kit, P/N 1001191738, for customers who are experiencing a problem with the fuse prematurely blowing. The kit contains all necessary parts along with detailed instructions to reroute the alternator excitation wire, and eliminate the potential problem.

Download technical information bulletin 15-11 to learn more. (17 KB PDF)

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Fuel Filter P/N 70024315 (Also Included in Filter Kits 1001150521 & 1001150522)

Cummins Inc. has advised JLG that the bond attaching the filter shell to the filter nut plate may fail, resulting in a potential separation of the shell from the fuel filter nut plate.
Models Affected: JLG G10-55A and JLG G12-55A Telehandlers

Cummins Inc. has advised JLG that the bond attaching the filter shell to the filter nut plate may fail, resulting in a potential separation of the shell from the fuel filter nut plate. If this occurs, the engine will stall without warning and will not restart until the fuel filter is replaced. Download service letter 15-04 (41 KB PDF) to learn more about this issue and how to resolve it.
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SIB 14-08 Brake Pedal Enhancement for SkyTrak Machines

Based on feedback from our customers regarding brake application resistance, JLG has developed a SkyTrak® Brake Pedal enhancement kit (14 KB PDF), which can be installed to increase brake pedal travel.
Based on feedback from our customers regarding brake application resistance, JLG has developed a SkyTrak® Brake Pedal enhancement kit (14 KB PDF), which can be installed to increase brake pedal travel. The enhancement helps reduce operator fatigue while performing common braking functions. The kit consists of all the necessary fittings and hoses to allow the brake valve pressure line to be routed to a different supply source. 

Kit P/N 1001167008 is available for 6036 and 6042 telehandler models. 

Kit P/N 1001167009 is available for 8042, 10042 and 10054 telehandler models. 

Follow installation instructions P/N 31212003B to ensure proper kit installation. No warranty consideration will be allowed for this installation.
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Wheel Rim Stability Requirements

The rims installed on each JLG product model have been designed for stability requirements, which consist of track width, tire pressure and load capacity.

The rims installed on each JLG product model have been designed for stability requirements, which consist of track width, tire pressure and load capacity. Size changes, such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendation may result in an unsafe condition regarding stability. Consult your Operator Manual for wheel and tire replacement requirements.

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Troubleshooting Tire Damage

A common question heard in the JLG call center is, “When should a damaged tire be replaced?” 

A common question heard in the JLG call center is, “When should a damaged tire be replaced?” The following is a guideline that will help you make that decision.

Pneumatic tires: If there are any cuts, rips or tears that expose sidewall or tread area cords in the tire, remove the tire from service immediately. Arrangements must be made for replacement of the tire or tire assembly.

Polyurethane foam filled tires: Remove the tire from service immediately and make arrangements for replacement of the tire or tire assembly when any of the following conditions are discovered:

  • A smooth, even cut through the cord plies which exceeds 3 inches (7.5 cm) in total length
  • Any tears or rips (ragged edges) in the cord plies which exceed 1 inch (2.5 cm) in any direction
  • Any punctures which exceed 1 inch in diameter
  • Any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to ensure the damage has not propagated beyond the allowable criteria.

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MaxTrax Rubber Tracks are high quality, properly fitting, affordable rubber tracks designed to offer better handling and excellent ride quality. Find the right tracks for your compact loader and mini excavator fleets right here.   

Shop MaxTrax Rubber Tracks

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JLG Industries, Inc. is the world's leading designer, manufacturer and marketer of access equipment. The Company's diverse product portfolio includes leading brands such as JLG® aerial work platforms; JLG, SkyTrak® and Lull® telehandlers; and an array of complementary accessories that increase the versatility and efficiency of these products. JLG is an Oshkosh Corporation Company [NYSE: OSK].
An Oshkosh Corporation Company