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 Tires
  • 1.5 Engine Data
    • Hydraulic Oil
    • Major Component Weights
  • 1.6 Function Speeds
    • Test Notes
  • 1.7 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 Tires and Wheels
    • Tire Replacement
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Drive Orientation System
  • 3.3 Beyond Transport Position - Drive Speed Cutback System
  • 3.4 Drive/Steer - Boom Function Interlock System (CE ONLY)
  • 3.5 Drive System
  • 3.6 Drive Motor
    • Disassembly
    • Assembly
  • 3.7 Drive Hub
    • Roll, Leak and Brake Testing
    • Tightening and Torquing Bolts
    • Measuring Rolling Torque
    • Main Disassembly
    • Housing-Spindle Disassembly
    • Spindle-Brake Subassembly Disassembly
    • Cover Disassembly
    • Planet Gear Subassembly
    • Spindle-Brake Subassembly
    • Housing-Spindle Subassembly
    • Housing-Ring Gear Subassembly
    • Cover Subassembly
    • Main Assembly
    • Integral Brake Check Procedure
  • 3.8 Oscillating Axle System
    • Oscillating Axle Bleeding Procedure
  • 3.9 Chassis Tilt Indicator System
  • 3.10 Swing Motor
    • Removal
    • Preparation Before Disassembly
    • Disassembly and Inspection
    • Assembly
    • One Piece Stator Construction
    • Two Piece Stator Construction
    • Final Checks
    • Installation
  • 3.11 Swing Drive
    • Removal
    • Installation
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Torque Value
    • Disassembly
    • Assembly
  • 3.12 Engine Operating States
  • 3.13 Engine Start Conditions
  • 3.14 Engine rPM Levels
    • Engine Stop RPM
    • Idle RPM
    • Mid Engine RPM
    • Multi-Function RPM
    • High Engine RPM
    • Generator RPM
  • 3.15 Engine controls
    • Ambient Air Temperature Sensor
    • Fuel Level Sensor
  • 3.16 Engine Startup Procedure (Kubota)
  • 3.17 Kubota Engine
    • Engine Oil Pressure Switch
    • Engine Speed Sensor
    • Coolant Sensor
    • Glow Plugs
    • Engine Speed Actuators
    • Engine Start
    • Alternator Excitation
    • Fuel Pump
    • Shutdown
  • 3.18 GM Dual Fuel Engine
    • Communications with the JLG Control System
    • Engine Start
    • Oil Pressure
    • Engine Speed
    • Coolant Temperature
    • Fuel Select
  • 3.19 Fuel Reserve / Cut-Out System
  • 3.20 Cold Start System (Diesel Engine)
  • 3.21 Generator
  • 3.22 Counterweight
• Section 4. Boom & Platform
  • 4.1 Platform Control Enable System
  • 4.2 Transport Position Sensing System
  • 4.3 Boom Maintenance
    • Disassembly of the Main Boom
    • Inspection
    • Assembly of the Main Boom
  • 4.4 Boom Cleanliness Guidelines
  • 4.5 Rotary Actuator
    • Theory of Operation
    • Tools Required
    • Disassembly
    • Inspection
    • Assembly
    • Greasing Thrust Washers
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Installation and Bleeding
    • Troubleshooting
• 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
    • Disassembly and Assembly Instructions
    • General Information
    • Standard of Maintenance
    • Inspection After Assembly
    • Disassembly Procedure
    • Assembly
  • 5.3 Drive Pump
    • Description
    • The System Circuit
    • High Pressure Relief Valve (HPRV) and Charge Check
    • Charge Pressure Relief Valve
    • Electrical Displacement Control (EDC)
    • Disassembly
    • Inspection
    • Assembly
    • Port Locations and Gauge Installation
    • Fastener Size and Torque Chart
    • Plug Size and Torque Chart
    • Initial Startup Procedures
    • Troubleshooting
    • Pump Adjustment
    • Displacement Limiter Adjustment
    • Control Neutral Adjustment
    • Mechanical Neutral Adjustment
    • Removing the Pump
    • Electric Control Module
    • Control Solenoids
    • Shaft Seal, Roller Bearing and Shaft Replacement
    • Charge Check / HPRV
    • Charge Pressure Relief Valve
    • Pressure Limiter Valve Replacement
  • 5.4 Gear Pump
    • Disassembly
    • Troubleshooting
  • 5.5 Pressure Setting Procedure
  • 5.6 Oil Sampling
    • 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 Operator Controls and Switches
    • Ground Control Switches
    • Platform Control Switches
  • 6.5 Control System Startup Checks
  • 6.6 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
  • 7.4 AMP 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