Document Outline

• Section A. Introduction - Maintenance Safety Precautions
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Specifications
  • 1.2 Capacities
  • 1.3 Component Data
    • Engine
    • Tires
    • Pumps
    • Steer/Drive System
    • Hydraulic Filter - Inline
    • Torque Requirement
  • 1.4 Lubrication
    • Hydraulic Oil
  • 1.5 Lubrication Specifications
  • 1.6 Cylinder Specifications
  • 1.7 Pressure Settings
  • 1.8 Limit Switches
  • 1.9 Major Component Weights
  • 1.10 Critical Stability Weights
  • 1.11 Serial Number Locations
  • 1.12 Torque Charts
• Section 2. Procedures
  • 2.1 General
  • 2.2 Servicing and Maintenance 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
    • Batteries
    • Lubrication and Servicing
  • 2.3 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinders - Theory of Operation
  • 2.5 Valves - Theory of Operation
    • Solenoid Control Valves (Bang-Bang)
    • Proportional Control Valves
    • Relief Valves
    • Crossover Relief Valves
  • 2.6 Component Functional Description
    • Hydraulic Pump
    • Lift Cylinder Counterbalance/Manual Descent Valve
  • 2.7 Wear Pads
    • Sliding Pads
  • 2.8 Cylinder Checking Procedures
    • Cylinder w/o Counterbalance Valves - Steer Cylinder
    • Cylinders w/Single Counterbalance Valves - Lift Cylinder
  • 2.9 Lift Cylinder Removal and Installation
    • Removal
    • Installation
  • 2.10 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 2.11 Steer Cylinder Repair
    • Removal
    • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Installation
  • 2.12 Limit Switch Adjustment
    • Platform Limit Switch
  • 2.13 Pressure Setting Procedures
    • Main Pressure Adjustment
    • Lift Relief Adjustments
    • Steer Relief Adjustment
    • Leveling Jack Relief Adjustment
    • Main Valve Components
    • Leveling Jacks Directional Valve
  • 2.14 Drive Pump Start-up Procedure
  • 2.15 Automatic Choke - Field Adjustment (DF-750)
    • Inspection
    • Adjustments
    • Reassembly
    • Diesel Engine
  • 2.16 Joystick Controller
  • 2.17 Tilt Sensor
    • Tilt Sensor, JLG P/N 4000006:
    • Tilt Sensor, JLG P/N 4000021:
  • 2.18 Calibrations
    • Tilt Sensor Calibration:
    • Joystick Calibration (Software 1.5 and Higher and Higher)
  • 2.19 Electronic Control System
    • Hand Held Analyzer
    • To Connect the Hand Held Analyzer
    • Using the Analyzer
    • Changing the Access Level of the Hand Held Analyzer
    • Adjusting Parameters Using the Hand Held Analyzer
    • Machine Setup
  • 2.20 Flash Codes and Descriptions
  • 2.21 Machine Model Adjustment
  • 2.22 Machine Configuration Programming Information
  • 2.23 Preventive Maintenance and Inspection Schedule
• Section 3. General Electrical Information & Schematics
  • 3.1 General
  • 3.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 3.3 Applying Silicone Dielectric Compound To Amp Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 3.4 Working With Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly
  • 3.5 Switches
    • Basic check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 3.6 Troubleshooting
    • General
    • Troubleshooting Information
    • Hydraulic Circuit Checks