Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Operating Specifications
    • Operating Specifications
    • Dimensional Data
    • Capacities
    • Tires
    • Engine Data
    • Hydraulic Oil
    • Major Component Weights
  • 1.2 Function Speeds
  • 1.1 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 Replacement
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Drive Orientation System
  • 3.3 Drive System
  • 3.4 Steer Cylinder
    • Removal
    • Installation
  • 3.5 Drive Hub
    • Removal
    • Installation
  • 3.6 Drive Motor
    • Removal
    • Disassembly
    • End Cover Disassembly
    • Cleaning
    • Measuring And Replacement
    • Lubrication
    • Assembly
    • Assembly of End Cover
    • Installation
  • 3.7 Swing Drive Hub
    • Disassembly
    • Tightening and Torquing Bolts
    • Assembly
    • Brake Test
    • Roll and Leak Test
  • 3.8 Procedure for Setting Swing Gear backlash
  • 3.9 Swing Bearing
    • Wear Tolerance
    • Turntable/Swing Bearing Removal
    • Installation
    • Swing Bearing Torque Values
  • 3.10 Chassis Tilt Indicator System
  • 3.11 Cold Start System
  • 3.12 Engine Operating States
  • 3.13 Engine Start Conditions
  • 3.14 Engine RPM Levels
    • Engine Stop RPM
    • Idle RPM
    • Cold Idle RPM
    • Mid Engine RPM
    • High Engine RPM
    • Generator RPM
  • 3.15 Engine controls
    • Alternator Excitation
    • Glow Plugs
    • Ambient Air Temperature Sensor
  • 3.16 Auxiliary Pump
    • Removal
    • Installation
  • 3.17 Counterweight
• Section 4. Boom & Platform
  • 4.1 Platform Control Enable System
  • 4.2 Function Speed Control System
  • 4.3 Transport Position Sensing System
  • 4.4 Boom Telescope Speed
    • Extend Function
    • Retract Function
  • 4.5 Beyond Transport Position - Drive Speed Cutback System
  • 4.6 Drive/Steer – Boom Function Cutout System (Optional)
  • 4.7 Emergency Descent System
  • 4.8 Platform Load Sensing System (JAPAN)
  • 4.9 Main Boom
    • Dissassembly
    • Assembly
  • 4.10 Lower Boom
    • Disassembly
    • Assembly
  • 4.11 Telescope Cylinder
    • Removal
    • Installation
  • 4.12 Hose Adjustment Procedure
  • 4.13 Platform Control Enable System
• 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
    • Platform Slave Level Cylinder
    • Master Cylinder
    • Steer Cylinder
    • Lift Cylinder
    • Telescope Cylinder
  • 5.3 Sauer Danfoss Pump
    • New Pump Startup Procedure
    • Troubleshooting
    • General Adjustment Practices
    • Charge Pressure Relief Valve Adjustment
    • Pressure Limiter Adjustments
    • Engaging the Bypass Function
    • Displacement Limiter Adjustment
    • Control Neutral Adjustment
    • Mechanical Neutral Adjustment
    • Standard Procedures, Removing the Pump
    • Electric Control Module
    • Control Solenoids
    • Shaft Seal, Roller Bearing and Shaft Replacement
    • Charge Pump
    • Charge Check / HPRV
    • Charge Pressure Relief Valve
    • Pressure Limiter Valve Replacement
  • 5.4 Hydraulic Drive Pump Pre-fill Procedure
  • 5.5 Pressure Setting Procedure
• Section 6. JLG Control System
  • 6.1 JLG Control System Analyzer Kit Instructions
    • Introduction
  • 6.2 analyzer Menu Structure
  • 6.3 using the hand held analyzer
    • 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
  • 6.4 System Fault Messages
• 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