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 Engine Data
  • 1.5 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.6 Torque Requirements
  • 1.7 Hydraulic Oil
  • 1.8 Major Component Weights
  • 1.9 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
    • Preventive 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 Chassis Components and Servicing
    • Service Notes
    • Track and Chain
      • Track Shoes
      • Track Pin
      • Track Bushing (Bearing)
    • Replace Track
      • Remove Track
      • Links, Pin, and Bushing Wear Measurement
      • Install Track
    • Track tensioning
    • Rubber Track Pad Installation
    • Rollers
      • Rollers are “lifetime” lubricated and under normal working conditions no further lubrication is required. Idlers should be randomly checked while working to protect against destruction should a seal be damaged.
      • Roller Seals
      • Track Roller Disassembly
      • Track Roller Assembly
      • Bottom Track Roller Installation
    • Idler Roller Assembly
      • Track Tension and Idler Roller Disassembly
      • Track Tension and Idler Roller Reassembly
      • Idler Roller Disassembly
      • Idler Roller Assembly (See Figure 25)
      • Idler Roller and Track Tensioner Removal and Replacement to Side Frame
      • Install Shock
  • 3.2 Drive Motor
    • Disassembly
      • Preparation
      • Base Plate
      • Brake Piston
      • Cylinder Block
      • Gear Box
      • Hydraulic Motor Parts Replacement Criteria
    • Assembly
      • Gear Box
      • Motor Section
      • Base Plate
    • Install Motor Assembly
    • Rotary Coupling
  • 3.3 Swing Drive
    • Gear Backlash
    • Swing Drive Lubrication
    • Motor Control Valve Disassembly
    • Motor and Brake Disassembly
    • Main Disassembly
    • Hub-Shaft Disassembly
    • Carrier Disassembly
    • Hub-Shaft Subassembly
    • Carrier Subassembly
    • Main Assembly
    • Motor and Brake Assembly
    • Motor Control Valve Assembly
  • 3.4 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Replacement
      • Removal
      • Installation
    • Swing Bearing Torque Values
    • See Figure 3-34. Swing Bearing Torque Sequence.
  • 3.5 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
      • inspecting brush position
      • inspecting brushes
      • CLEANING SLIP RINGS
  • 3.6 Deutz D2.9 L4 Engine
    • Check Oil Level
    • Change Engine Oil
    • Change Oil Filter
    • Change Fuel Filters
  • 3.7 Deutz D2011 Engine
    • Checking Oil Level
    • Changing Engine Oil
    • Changing Oil Filter
    • Replace Fuel Filter
    • Clean Fuel Strainer
  • 3.8 Spark Arrester Cleaning Instructions
  • 3.9 Glow Plugs
  • 3.10 Deutz EMR 2
  • 3.11 Bio Fuel in Deutz Engines
    • General
    • Bio Fuel
      • Permitted bio-diesel fuels
      • approved engines
      • Basic conditions to be observed
      • Plant oil
    • Biological Contamination In Fuels
      • Symptoms
      • Cause
      • Preventive measures
      • Fuel additives
• Section 4. Boom & Platform
  • 4.1 Boom Systems
    • Removal
  • 4.2 Wear Pads
  • 4.3 Boom Disassembly/Assembly & Cable Replacement
    • Boom Section Disassembly
  • 4.4 Wire Rope
    • Inspection
    • Three Month Inspection
    • Eight Year Inspection
    • Replacement Criteria
  • 4.5 Wire Rope Tensioning Adjustment
    • Wire Rope Tensioning Procedure
    • Inspection
    • Assembly
    • Installation
  • 4.6 Articulating Jib Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
  • 4.7 Limit Switches and Cam Valve Adjustment
  • 4.8 Boom Cleanliness Guidelines
  • 4.9 Rotary Actuator
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing Actuator
    • Testing Actuator for Internal LeakS
    • Installation and Bleeding
    • Troubleshooting
  • 4.10 Foot Switch Adjustment
  • 4.11 Platform
    • Platform Support Torque Settings
    • Replace Platform Sections
  • 4.12 Powertrack Maintenance
    • Remove Link
    • Install New Link
    • Replace Fixed End Brackets
    • Replace Moving End Brackets
• Section 5. Hydraulics
  • 5.1 O-Ring Lubrication
    • Cup and Brush
    • Dip
    • Spray
    • Brush-On
  • 5.2 Cylinders - Theory of Operation
    • Systems With Double Acting Cylinders
    • Systems With Holding Valves
  • 5.3 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valves
  • 5.4 Cylinder Removal and Installation
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
  • 5.5 Cylinder Repair
    • Disassembly
    • Cylinder Locations
    • Main Lift Cylinder
      • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Master Cylinder
      • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Telescope Cylinder
      • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Platform Level (Slave) Cylinder
      • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Jib Lift Cylinder (SJC Only)
      • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.6 Hydraulic Pump (Gear)
    • Disassembly
    • Inspect Parts For Wear
    • General Information
    • Reverse Shaft Rotation of Pump
    • Assembly
    • Placing Pump Back Into Service
  • 5.7 Variable Pump
    • Ports and Pressure Gauges
    • NFPE Control
    • Remove and Install FNR and NFPE Modules
    • Remove and Install FNR and NFPE Control Orifices
    • Charge Relief Valve
    • Shaft Seal and Shaft Replacement
    • Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
    • Charge Pump
  • 5.8 Hydraulic Component Start-Up
  • 5.9 Pressure Setting Procedures
    • Main Relief
    • Lift Down
    • Swing
    • Platform Level Up
    • Platform Level Down
    • Jib Up
    • Jib Down
• Section 6. JLG Control System
  • 6.1 Introduction
    • Connect JLG Control System Analyzer
    • Using Analyzer
    • Changing Access Level
    • Adjust Parameters
    • Machine Setup
    • Level Vehicle Description
  • 6.2 Machine Personality Settings
  • 6.3 Machine Orientation When Setting Function Speeds
    • Test Notes
  • 6.4 CANbus Communications
• 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
    • Dielectric Grease Application
    • Deutsch HD, DT, DTM, DRC Series
    • AMP Seal
    • AMP Mate-N-Lok
    • DIN Connectors
    • Exclusions
      • Brad Harrison/Phoenix Contact M12
      • AMP Junior Timer
  • 7.4 AMP Connector
    • Contact Assembly
    • 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