Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Operating Specifications
  • 1.2 Dimensional Data
  • 1.3 Capacities
  • 1.4 Tires
  • 1.5 Hydraulic Oil
  • 1.6 Major Component Weights
  • 1.7 Function Speeds
    • Test Notes
    • Machine Orientation When Doing Speed Tests
  • 1.8 Operator Maintenance
• Section 2. General
  • 2.1 Machine Preparation, Inspection, and Maintenance
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Service and 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
    • Battery
    • Lubrication and Servicing
  • 2.3 Lubrication and Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinder Drift Test
    • Platform Drift
    • Cylinder Drift
  • 2.5 Pins and Composite Bearing Repair Guidelines
  • 2.6 Welding on JLG Equipment
    • Do the Following When Welding on JLG Equipment
    • Do NOT Do the Following When Welding on JLG Equipment
• Section 3. Chassis & Turntable
  • 3.1 Tires and Wheels
    • Tire Wear and Damage
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Spindle
    • Setting Wheel Bearing End Play
    • Specifications
    • Checking
    • Greasing Requirements
  • 3.3 Drive Hub
    • Roll and Leak Testing
    • Main Disassembly
    • Output Carrier Disassembly
    • Input Carrier Disassembly
    • Hub-Spindle Disassembly
    • Cover Disassembly
    • Input Carrier Assembly
    • Output Planet Gear Assembly
    • Output Carrier Assembly
    • Hub-Spindle Assembly
    • Cover Subassembly
    • Main Assembly
  • 3.4 Drive Brake - Mico
    • Disassembly
    • Assembly
    • Bleeding
  • 3.5 Speed Sensor Adjustment
    • Adjustment Procedure
    • Speed Sensor Installation Verification
    • Verification w/ Analyzer Procedure
  • 3.6 Positrac/Tilt module
  • 3.7 Swing Motor
    • Preparation Before Disassembly
    • Disassembly and Inspection
    • Assembly
    • One Piece Stator Construction
    • Two Piece Stator Construction
    • Final Checks
    • Installation Torque
  • 3.8 Swing Drive
    • Disassembly
    • Assembly
  • 3.9 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Replacement of Swing Bearing
    • Swing Bearing Torque Value
  • 3.10 Battery Maintenance And Charging
    • Battery Maintenance, Quarterly
    • Battery Charging, Daily
  • 3.11 Battery Charger
    • Operating Instructions
    • Maintenance Instructions
    • Battery Charger Fault Codes
    • Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
    • Checking/Changing the Battery Charger Algorithm
  • 3.13 Drive Orientation System
  • 3.14 Hoods
• Section 4. Boom & Platform
  • 4.1 Boom Maintenance
    • Removal of the Main Boom
    • Disassembly of the Main Boom
    • Inspection
    • Assembly of the Main Boom
    • Installation of the Main Boom
  • 4.2 Powertrack Maintenance
    • Removing a Link
    • Installing a New Link
    • Replacing Fixed End Brackets
    • Replacing Moving End Brackets
  • 4.3 Boom Cleanliness Guidelines
  • 4.4 Tilt Sensor Check
  • 4.5 Footswitch Adjustment
  • 4.6 Boom Limit Switches
  • 4.7 Rotary Actuator
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Installation and Bleeding
    • Troubleshooting
• Section 5. Hydraulics
  • 5.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 5.2 Hydraulic Cylinders
    • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Phase Check Cartridge
  • 5.3 Pressure Setting Procedure
    • Adjustments made at the Main Valve Bank
    • Adjustments made at the Boom Function Valve Bank
  • 5.4 Initial Hydraulic Pump Start-Up Procedure
    • Procedure
• Section 6. JLG Control System
  • 6.1 JLG Control System Analyzer Kit Instructions
    • Introduction
    • To Connect the JLG Control System Analyzer
    • Using the Analyzer
    • Changing the Access Level of the Hand Held Analyzer
    • Adjusting Parameters Using the Hand Held Analyzer
    • Machine Setup
    • Level Vehicle Description
    • System Self Test
• Section 7. Basic Electrical Information & Schematics
  • 7.1 General
  • 7.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Voltage Measurement
    • Resistance Measurement
    • Continuity Measurement
    • Current Measurement
  • 7.3 Applying Silicone Dielectric Compound to Electrical Connections
    • Installation of Dielectric Grease
    • Deutsch HD, DT, DTM, DRC Series
    • AMP Seal
    • AMP Mate-N-Lok
    • DIN Connectors
    • Exclusions
  • 7.4 AMP Connector
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.5 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly