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 Engine
  • 1.5 Tires
  • 1.6 Torque Requirements
  • 1.7 Sensors
    • 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 Sensors
    • Oscillating Axle Limit Switch
  • 1.8 Pressure Setting
  • 1.9 Major Component Weights
  • 1.10 Critical Stability Weights
  • 1.11 Lubrication
  • 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 Operator Maintenance
  • 2.5 Cylinder Drift Test
    • Platform 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
    • Wheel Installation
  • 3.3 Drive Motor
    • Motor Disassembly
    • Motor Assembly
  • 3.4 Steering Assembly
  • 3.5 Rear Axle
    • Limit Switches
  • 3.6 Outrigger Cylinder Removal
  • 3.7 Engine Compartment
    • Hood Assembly
    • Deutz Engine
    • Engine Tray Slide
    • Glow Plugs
    • Engine Solenoid Fuse
    • Hydraulic Pump Assembly
    • Hydraulic Pump
    • Exhaust Pipe Assembly
    • Air Filter Assembly
    • Engine Removal
    • Hydraulic Tank
    • Pressure Filter
  • 3.8 Fuel Tank
  • 3.9 Ground Control Panel
  • 3.10 Battery Removal
  • 3.11 Platform
    • Platform Control Box
    • Joystick Controller
    • Receptacles
    • Main Platform Side Rails
    • Main Platform End Rails
    • Platform Extension Side Rails
    • Platform Extension End Rail
    • Platform Removal
  • 3.12 Ladder Installation
  • 3.13 Beacon Installation (Option)
  • 3.14 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
    • Drive Valve
    • Main Valve Block
    • Pump Engage/Disengage Valve
    • Hand Pump
    • Load Holding Valve
    • 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
    • Oscillating Axle Limit Switches
    • 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