Document Outline

• Service & Maintenance Manual
  • 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 Engine
      • Battery
    • 1.5 Tires
    • 1.6 Torque Requirements
    • 1.7 Limit Switches
      • Platform Stowed/Jacks Retract Limit Switch
      • High Drive Speed Cutout Limit Switch
      • Maximum Drive Height/Maximum Height without Outriggers Limit Switch
      • Maximum Height Limit Switch
      • Tilt Sensor
      • Outrigger Interlock Sensors
    • 1.8 Pressure Setting
    • 1.9 Major Component Weights
    • 1.10 Critical Stability Weights
    • 1.11 Lubrication
  • 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 Operator Maintenance
    • 2.5 Cylinder Drift Test
      • Lift Cylinder Drift
    • 2.6 Preventive Maintenance and Inspection Schedule
  • Section 3. Chassis, Platform & Scissor Arms
    • 3.1 Operating Characteristics
      • Leveling Jacks
    • 3.2 Wheel Assembly
      • Drive System
      • Drive Hub
      • Roll Test
      • Leak Test
      • Lubricant
      • Tire Replacement
      • Wheel Replacement
      • Drive Motor
      • Motor Disassembly
      • Motor Assembly
    • 3.3 Steering Assembly
    • 3.4 Rear Axle Assembly
    • 3.5 Outrigger Cylinder Removal
    • 3.6 Engine Compartment
      • Hood Assembly
      • Deutz Engine
      • Engine Tray Slide
      • Glow Plugs
      • Engine Solenoid
      • Gear Pump Assembly
      • Exhaust Pipe Assembly
      • Air Filter Assembly
      • Engine Removal
      • Hydraulic Tank
      • Pressure Filter
    • 3.7 Fuel Tank
    • 3.8 Ground Control Panel
    • 3.9 Battery Removal
    • 3.10 Platform
      • Platform Control Box
      • Joystick Controller
      • Receptacles
      • Extension End Rails
      • Extension Side Rails
      • Main Platform End Rails
      • Main Platform Side Rails
      • Platform Removal
    • 3.11 Ladder Installation
    • 3.12 Beacon Installation (Option)
    • 3.13 Scissor Arms
      • Limit Switches
      • Scissor Arm Assembly Removal
      • Lift Cylinder Removal
      • Scissor Arms Disassembly
  • Section 4. Hydraulics
    • 4.1 Cylinders - Theory of Operation
      • Deck Extension Cylinder:
      • Lift Cylinder:
      • Outrigger Cylinders:
      • Steer Cylinder:
    • 4.2 Valves - Theory of Operation
      • Solenoid Control Valves (Bang-Bang)
      • Relief Valves
      • Crossover Relief Valves
      • Proportional Valve
    • 4.3 Cylinder Checking Procedure
    • 4.4 Cylinder Repair
      • Disassembly
      • Cleaning and Inspection
      • Assembly
    • 4.5 Valves
      • Valve Compartment
      • Pressure Switch, Drive Enable
      • Brake Valve
      • Main Valve Block
      • Steering Valve
      • Drive Valve
      • Hand Pump
      • Lift/Lower Valve Block
      • Platform Lower Flow Valve
      • Outrigger Safety Valves
  • Section 5. JLG Control System
    • 5.1 Main Terminal Box Circuit Boards
    • 5.2 Control Card Complex 2
      • General Description of Components and Functions
    • 5.3 Nivolux - Automatic Self-Leveling System
      • Introduction
      • The System
      • Operation
      • NIVOLUX Board LED’s
      • Setting and Adjustment of the NIVOLUX Board
    • 5.4 PNP5 Circuit Board
      • System
      • Operation
      • Adjustment
    • 5.5 Trigger Control Circuit Card
      • Relay K1
      • Relay K2
      • Relay K3
    • 5.6 Limit Switch & Sensor Operation
      • Height Limit Switches
      • Tilt Switch
      • Outrigger Limit Switches
      • Pressure Switch
    • 5.7 Engine Control System
      • Functional Description
  • 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
    • Electrical Schematic
    • Electrical Diagram
    • Hydraulic Diagram
    • Hydraulic Schematic