Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. specifications
  • 1.1 Capacities
    • Fuel Tank
    • Hydraulic Oil Tank
    • Hydraulic System (Including Tank)
    • Torque Hub, Drive
    • Engine Crankcase
  • 1.2 Component Data
    • Engine - Diesel (Liquid-Cooled)
    • Drive System
    • Steer System
    • Swing System
    • Hydraulic Gear Pump (at 1800 RPM)
    • Auxiliary Power Pump
    • Hydraulic Filter - In-line
  • 1.3 Performance Data
    • Turning Radius (Outside)
    • Turning Radius (Inside)
    • Boom Elevation
    • Machine Weight approximately
    • Machine Height (Stowed)
    • Machine Length (Stowed)
    • Machine Width
    • Wheel base
  • 1.4 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.5 Torque Requirements
  • 1.6 Lubrication
    • Ford LRG425 Engine
    • Deutz F3M1011F Engine
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.7 Pressure Settings
    • Rexroth Valve
  • 1.8 Cylinder Specifications
  • 1.9 Major Component Weights
  • 1.10 Critical Stability Weights
  • 1.11 Serial Number Locations
• 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
  • 2.7 Applying Silicone Dielectric Compound to Electrical Connections
  • 2.8 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
• Section 3. Chassis & Turntable
  • 3.1 Torque Hub, Drive
    • Disassembly
    • Cleaning and Inspection
    • Repair
    • Assembly
  • 3.2 Torque Hub, Drive (Auburn Gear)
    • Disassembly
    • Assembly
  • 3.3 Drive Brake - Ausco
    • Disassembly
    • Inspection
    • Assembly
  • 3.4 Drive Brake - Mico
    • Disassembly
    • Assembly
    • Bleeding
  • 3.5 Drive Motor (Prior to S/N 85132)
    • Spare Parts Kits
    • Replacing the Drive Shaft Seal
    • Disassembly and Assembly
    • Assembly Notes
    • Taper Roller Bearing Initial Tension
    • Testing and Setup
  • 3.6 Drive Motor Adjustment Procedure (PRior to S/N 85132)
  • 3.7 Drive Motor (S/N 85132 to Present)
    • Description
    • Shaft Seal Replacement
    • Loop Flushing Valve
    • Troubleshooting
    • Disassembly
    • Inspection
    • Assembly
    • Initial Start-up Procedures
  • 3.8 Free Wheeling Option
    • To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
    • To Engage Drive Motors and Brakes (Normal Operation)
  • 3.9 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.10 Steer Adjustments
  • 3.11 Swing Hub
    • Adjustment Procedures
  • 3.12 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Replacement
    • Swing Bearing Torque Value
  • 3.13 Swing Brake - Ausco
    • Disassembly
    • Inspection
    • Assembly
  • 3.14 Swing Motor
    • Disassembly
    • Reassembly
    • Motor Timing
  • 3.15 Tilt Alarm Switch (Machines with External Tilt Sensor)
    • Manual Adjustment
  • 3.16 Spark Arrester Cleaning Instructions
  • 3.17 Dual Fuel System
    • Changing from Gasoline to LP Gas
    • Changing from LP Gas to Gasoline
  • 3.18 Electric Governor Installation and Adjustments - Ford Engine
    • General
    • Quick-start Installations
    • Mounting-Actuator
    • Linkage
    • Mounting-Controller
    • Wiring
    • Check-Out and Initial Start-Up Procedures
    • Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout)
    • Single-Turn Adjustment (Gain, Factory Adjust)
    • Troubleshooting
  • 3.19 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306)
    • General
    • Procedure
    • Controller Status
    • Failure Modes
  • 3.20 Automatic Choke Adjustment - Ford Engine
  • 3.21 Cold Weather Starting Difficulty
    • Checking the Carburetor
    • Checking the Ignition
  • 3.22 Checking the Fuel
  • 3.23 Ford EFI Engine (machines after S/N 58209)
    • Performing Diagnostics
    • EFI Diagnostics (S/N 58209 to S/N 60188)
    • Engine Module and Sensors
    • Fuel System
• Section 4. Boom & Platform
  • 4.1 Boom Maintenance
    • Removal
    • Disassembly Boom Sections
    • Inspection
    • Assembly
    • Installation
  • 4.2 Boom Rope Torquing Procedures
    • Torque Procedures
  • 4.3 Wear Pads
    • Main Boom
  • 4.4 Wire Rope
    • Inspection
    • Three Month Inspection
    • Eight Year Inspection
    • Replacement Criteria
  • 4.5 Limit Switches and Cam Valve Adjustment
    • Limit Switch Functional Check
  • 4.6 Rotator - Helac
    • Disassembly
    • Inspection
    • Assembly
  • 4.7 Drive Card Setup Procedures
    • Lift, Swing, and Drive Cards
    • Flow Control Card
  • 4.8 Foot Switch Adjustment
• Section 5. Hydraulics
  • 5.1 Cylinders - Theory of Operation
    • Systems Incorporating Double Acting Cylinders
    • Systems Incorporating Holding Valves
  • 5.2 Valves - Theory of Operation
    • Solenoid Control Valve - Rexroth
    • Relief Valves
  • 5.3 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    • Cylinders With Dual Counterbalance Valves
  • 5.4 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.5 Cylinder Removal and Installation
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Boom Lift Cylinder Removal
    • Boom Lift Cylinder Installation
  • 5.6 Variable Displacement pump (M46 series)
    • Troubleshooting
    • Inspections and Adjustments
    • Minor Repair and Replacement
  • 5.7 Pressure Setting Procedures
    • Main Relief, Steer, Swing and Lift Down
    • Platform Level
    • 4 Wheel Steer (If Equipped)
  • 5.8 Directional Control Valve
  • 5.9 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
  • 5.10 Hydraulic Component Start-Up Procedures and Recommendations
• Section 6. JLG CONTROL SYSTEM (ADE)
  • 6.1 Introduction
  • 6.2 To Connect the JLG Control System Analyzer
  • 6.3 Using the Analyzer
  • 6.4 Changing the Access Level of the Hand Held Analyzer
  • 6.5 Adjusting Parameters Using the Hand Held Analyzer
  • 6.6 Machine Setup
  • 6.7 Level Vehicle Description
  • 6.8 Machine Personality Settings
  • 6.9 Analyzer Diagnostics Menu Structure
• Section 7. schematics
  • 7.1 General
  • 7.2 Troubleshooting
  • 7.3 Hydraulic Circuit Checks