Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Capacities
  • 1.2 Engine Data
  • 1.3 Drive/Steer System
  • 1.4 Performance Data
  • 1.5 Function Speeds
  • 1.6 Lubrication
  • 1.7 Torque Requirements
  • 1.8 Pressure Settings - PSI (Bar)
  • 1.9 Major Component Weights
  • 1.10 Critical Stability weights
  • 1.11 Serial Number Locations
  • 1.12 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 & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Drive Torque Hub
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present
    • Disassembly
    • Inspection
    • Assembly
  • 3.5 Free Wheeling Option
    • To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
    • To Engage Drive Motors and Brakes (Normal Operation)
  • 3.6 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Replacement and Devcon Application Procedures
    • Swing Bearing Torque Values
  • 3.7 Swing Torque Hub
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.8 Swing Brake - Ausco - Machines Built To 1992
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.9 Swing Brake - Mico - Machines Built To 1992
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.10 Swing Brake - Machines Built 1992 To Present
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 3.11 Swing Motor
    • Disassembly
    • Assembly
  • 3.12 PQ Controllers
    • TRIM Adjustment
    • RAMP Adjustment
  • 3.13 Pump Coupling Conversion Procedures
    • Lovejoy Coupling
    • Hayes Coupling
  • 3.14 Tilt Alarm Switch
    • Manual Adjustment
    • Voltmeter Adjustment
  • 3.15 Throttle Checks and Adjustments
• SECTION 4. Boom & Platform
  • 4.1 Boom Maintenance
    • Boom Mounted Limit Switches and Valves
    • Main Boom Removal
    • Tower Boom Removal
    • Main Boom Disassembly
    • Tower Boom Disassembly
    • Inspection
    • Main Boom Assembly
    • Tower Boom Assembly
    • Tower Boom Installation
    • Main Boom Installation
  • 4.2 Boom Chains
    • Adjusting Procedures - Main Boom
    • Inspection Procedure
  • 4.3 Wear Pads
  • 4.4 Platform Rotator Brake
• SECTION 5. Hydraulics
  • 5.1 Valves - Theory of Operation
    • Solenoid Control Valves (Bang-Bang)
    • Proportional Control Valves - Vickers
    • Relief Valves
    • Crossover Relief Valves
  • 5.2 Cylinders - Theory of Operation
  • 5.3 Cylinder Checking Procedures
    • Cylinders w/o Counterbalance Valves - Front and Rear Steer Cylinders, Front and Rear Frame Lift Cylinders, Upper Master Cylinder, Lower Master Cylinder, Front and Rear Axle Extension Cylinders
    • Cylinders w/Single Counterbalance Valves - Main Lift Cylinder, Tower Telescope Cylinder
    • Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Level Cylinder
  • 5.4 Cylinder Removal and Installation
    • Tower Telescope Cylinder Removal
    • Tower Telescope Cylinder Installation
    • Tower Lift Cylinder Removal
    • Tower Lift Cylinder Installation
    • Main Telescope Cylinder Removal
    • Main Telescope Cylinder Installation
    • Main Lift Cylinder Removal
    • Main Lift Cylinder Installation
    • Lower Master Level Cylinder Removal
    • Lower Master Level Cylinder Installation
    • Upper Master Level Cylinder Removal
    • Upper Master Level Cylinder Installation
  • 5.5 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.6 Pressure Setting Procedures
    • Low Drive System
    • 5 Stack Directional Control Valve (Internal Relief Adjustment)
    • 5 Stack Directional Control Valve (External Relief Adjustment Screws)
    • Two Stack Directional Control Valve
    • Three Stack Directional Control Valve
    • Four Stack Directional Control Valve
  • 5.7 Hydraulic Gear Pump
    • Disassembly
    • Assembly
    • Wear Guide for Replacement
    • Recommended Start-up Procedure for New or Rebuilt Pump
    • Recommended Test Procedure
• SECTION 6. Schematics
  • 6.1 General
  • 6.2 Troubleshooting
  • 6.3 Hydraulic Circuit Checks