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 Pressure Settings
  • 1.4 Component Data
    • Battery Charger
    • Batteries (8)
    • Drive System
    • Steer System
    • Hydraulic Pump/Electric Motor Assembly
  • 1.5 Torque Specifications
  • 1.6 Lubrication
    • Lubrication Specifications
  • 1.7 Cylinder Specifications
  • 1.8 Major Component Weights
  • 1.9 Critical Stability Weights
  • 1.10 Lubrication
  • 1.11 Serial Number Locations
  • 1.12 Torque Charts
• 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 Preventive Maintenance and Inspection Schedule
• Section 3. Chassis & Scissor Arms
  • 3.1 Calibrations
    • Elevation Sensor Calibration (Prior to Software V13.6)
    • Elevation Sensor Calibration (Software V13.6 and Higher)
    • Speed Sensor
    • Tilt Sensor Calibration:
    • Joystick Calibration (SW V13.5 & Higher and P1.0 & Higher)
  • 3.2 Tilt Sensor
    • Tilt Sensor, JLG P/N 4000006:
    • Tilt Sensor, JLG P/N 4000021:
  • 3.3 Battery Maintenance and Charging
    • Battery Maintenance, Quarterly
    • Optional On Board Generator
    • Battery Charging (On Board Charger) (MAC)
    • Charging Sequence of Remote LED Card
    • Battery Charger (Delta-Q)
    • Battery Charger Maintenance
    • Battery Charger Troubleshooting
    • Battery Temperature Sensor
    • Removing the Battery Box
  • 3.4 Generator
    • Timing Sequences
    • To Connect the JLG Control System Analyzer to the Generator
    • Alarms and Fault Flash Codes
    • Output Current and Voltage Settings
    • Priming the Fuel Line
  • 3.5 Supplementary Fuse For APU
    • Tools And Material
    • Procedure
  • 3.6 Joystick Controller
    • Power Controller
  • 3.7 Torque Hub
    • Disengaging for Towing
    • Engaging after Towing is Complete
  • 3.8 Drive Hub
    • Disassembly
    • Disassembly of Cover Unit (8)
    • Disassembly of First Stage Planetary Assembly
    • Disassembly of the Second Stage Planet Gears (1)
  • 3.9 Drive Brake - MICO
    • Disassembly
    • Assembly
    • Bleeding
  • 3.10 Torque Hub
    • Roll Test
    • Leak Test (Main Unit)
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Output Carrier Disassembly
    • Input Carrier Disassembly
    • Hub-Spindle Disassembly
    • Cover Disassembly
    • Input Carrier Sub-Assembly
    • Output Carrier Sub-Assembly
    • Hub-Spindle Sub-Assembly
    • Cover Sub-Assembly
    • Main Assembly
• Section 4. Hydraulics
  • 4.1 Servicing and Maintenance Guidelines
    • General
    • Safety and Workmanship
    • Cleanliness
    • Component 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
  • 4.2 Lubrication Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 4.3 Cylinders - Theory of Operation
  • 4.4 Valves - Theory of Operation
    • Control Valves
  • 4.5 Component Functional Description
    • Hydraulic Pump
    • Manual Descent
  • 4.6 Wear Pads
  • 4.7 Motor Controller - Modes of Operation
    • Traction Motor (Drive)
    • Pump Motor (LIft)
  • 4.8 Features
    • Traction Mode
  • 4.9 Cylinder Checking Procedures
    • Cylinder Without Counterbalance Valves (Steer)
    • Cylinders With Single Counterbalance Valve (Lift Cylinder)
    • Cylinders with Duel Counterbalance Valves (Oscillating Cylinders)
  • 4.10 Cylinder Removal and Installation
    • Lift Cylinder Removal
    • Lift Cylinder Installation
  • 4.11 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 4.12 Steer Cylinder Removal
  • 4.13 Oscillation Cylinder Bleeding
    • Bleeding Procedure
    • Checking Oscillation Cylinders
    • Oscillating Axle Lockout Test (If Equipped)
  • 4.14 Cylinder Assemblies
  • 4.15 Pressure Setting Procedures
    • Main Relief at Pump
    • Lift Relief
    • Steer Relief
  • 4.16 Drive Torque Hub
    • Disassembly
    • Assembly
  • 4.17 Drive Assist Valve
• Section 5. JLG Control System
  • 5.1 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
  • 5.2 PC Boards
  • 5.3 Flash Codes/DTC’s and Descriptions
  • 5.4 Ground Control Circuit Board
    • Software Version 13.6
    • Software Version P1.0
• Section 6. General Electrical Information & Schematics
  • 6.1 General
  • 6.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 6.3 Applying Silicone Dielectric Compound To Amp Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 6.4 Working With Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly