Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A.A General
  • A.B Hydraulic System Safety
  • A.C Maintenance
• Section 1. specifications
  • 1.1 Capacities
• Hydraulic Oil Tank
• Hydraulic System (Including Tank)
• Fuel Tank
• Engine Crankcase
  • 1.2 Component Data
• Gasoline Engine
• Diesel Engine
• Drive/Steer System
  • 1.3 Performance Data
• Travel Speed
• Gradeability
• Turning Radius (Inside)
• Lift Speed
• Platform Capacity - Fixed Platform
• Platform Extension Capacity
• Machine Weight
• Machine Height (Fully Extended)
• Machine Platform Height (Platform Lowered)
• Machine Length
• Machine Width
  • 1.4 Torque Requirements
  • 1.5 Lubrication
• Lubrication Specifications
  • 1.6 Pressure Settings
  • 1.7 Serial Number Locations
  • 1.8 Limit Switches
  • 1.9 Cylinder Specifications
  • 1.10 Major Component Weights
  • 1.11 Critical Stability Weights
• Section 2. procedures
  • 2.1 General
  • 2.2 Servicing and Maintenance Guidelines
• General
• Safety and Workmanship
• Cleanliness
• Components Removal and Installation
• Component Disassembly and Reassembly
• Pressure-Fit Parts
• Bearings
• Gaskets
• Bolt Usage and Torque Application
• Hydraulic Lines and Electrical Wiring
• Hydraulic System
• Lubrication
• Batteries
• Lubrication and Servicing
  • 2.3 Lubrication Information
• Hydraulic System
• Hydraulic Oil
• Changing Hydraulic Oil
• Lubrication Specifications
  • 2.4 Cylinders - Theory of Operation
  • 2.5 Valves - Theory of Operation
• Solenoid Control Valves (Bang-Bang)
• Proportional Control Valves
• Relief Valves
• Crossover Relief Valves
  • 2.6 Component Functional Description
• Hydraulic Pump
• Lift Cylinder Counterbalance/Manual Descent Valve
  • 2.7 Wear Pads
• Sliding Pads
  • 2.8 Cylinder Checking Procedures
• Cylinder w/o Counterbalance Valves - Steer Cylinder
• Cylinders w/Single Counterbalance Valves - Lift Cylinder
  • 2.9 Lift Cylinder Removal and Installation
• Removal
• Installation
  • 2.10 Lift Cylinder Repair
• Disassembly
• Cleaning and Inspection
• Assembly
  • 2.11 Steer Cylinder Repair
• Removal
• Disassembly
• Cleaning and Inspection
• Assembly
• Installation
  • 2.12 Oscillation Cylinder Bleeding
  • 2.13 Magnetic Speed Pickup Cleaning Procedure
  • 2.14 Pressure Setting Procedures
• Lift Relief Adjustments
• Steer Relief Adjustment
  • 2.15 Limit Switch Adjustment
• Speed Cutout Switch
• Drive Cutout Switch (400 CRT)
  • 2.16 Automatic Choke - Field Adjustment (DF-750)
• Inspection
• Adjustments
• Reassembly
• Diesel Engine
  • 2.17 Electronic Control System
• To Connect the Hand Held Analyzer:
• Using the Analyzer:
• Changing the Access Level of the Hand Held Analyzer:
  • 2.18 Flash Codes and Descriptions
  • 2.19 Preventive Maintenance and Inspection Schedule
• Section 3. Troubleshooting
  • 3.1 General
  • 3.2 Troubleshooting Information
  • 3.3 Hydraulic Circuit Checks
• Corporate Office
• JLG Industries, Inc.
• 1 JLG Drive
• McConnellsburg PA. 17233-9533
• USA
• Phone: (717) 485-5161
• Fax: (717) 485-6417