Document Outline

• Section 1. Specifications
  • 1.1 Operating specifications
  • 1.2 Specifications and Performance Data
  • 1.3 Capacities
  • 1.4 Component Data
    • Engine Data
    • Battery
  • 1.5 Tires
  • 1.6 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.7 Torque Requirements
  • 1.8 Lubrication
    • Hydraulic Oil
  • 1.9 Pressure Settings
  • 1.10 Major Component Weights
  • 1.11 Operator Maintenance
    • Draining Oil Build Up From The Propane Regulator
    • Propane Fuel Filter Replacement
    • Propane Fuel System Pressure Relief
  • 1.12 Serial Number Location
• 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 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 & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Wheel Drive Assembly, 2WD
    • Removal and Disassembly
    • Assembly and Installation
  • 3.3 Drive Motor - 2WD (Prior to S/N 83331)
    • Replacing the Drive Shaft Seal
    • Disassembly
    • Assembly
  • 3.4 Drive Motor (S/N 83331 to Present)
    • Description
    • Shaft Seal Replacement
    • Loop Flushing Valve
    • Troubleshooting
    • Disassembly
    • Inspection
    • Assembly
    • Initial Start-up Procedures
  • 3.5 Torque Hub
    • Disassembly
    • Cleaning and Inspection
    • Repair
    • Assembly
  • 3.6 Wheel Drive Assembly, 4WD
    • Removal and Disassembly
    • Assembly and Installation
  • 3.7 Torque Hub (4WD Machines W/ Integral Brake)
    • Roll, Leak and Brake Testing
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Input Carrier Disassembly
    • Output Carrier Disassembly
    • Housing-Spindle Disassembly
    • Spindle-Brake Disassembly
    • Input Carrier Sub-Assembly
    • Output Carrier Sub-Assembly
    • Spindle-Brake Sub-Assembly
    • Housing-Spindle Sub-Assembly
    • DW2B Integral Brake Check
    • Main Assembly
  • 3.8 Drive Brake, 2WD - Mico (Prior to S/N 83331)
    • Disassembly
    • Assembly
    • Bleeding
  • 3.9 Re-Aligning torque hub input coupling
    • Equipment Required
    • Procedure
  • 3.10 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.11 Swing Drive Hub
    • Disassembly
    • Main Assembly Procedure
    • Hub Shaft Sub-Assembly
    • Carrier Sub-Assembly
  • 3.12 Swing Brake - Mico (Prior to S/N 66417)
    • Disassembly
    • Assembly
    • Bleeding
  • 3.13 Swing Motor (Prior to S/N 66417)
    • Disassembly
    • Inspection and Cleaning
    • Assembly
    • Timing Procedure
  • 3.14 Swing Motor (S/N 66417 to Present)
    • Disassembly and inspection
    • Assembly
    • One Piece Stator Construction
  • 3.15 Procedure For Setting Gear Backlash
  • 3.16 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Removal
    • Swing Bearing Installation
    • Swing Bearing Torque Values
  • 3.17 Rotary Coupling
  • 3.18 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
  • 3.19 Ford EFI Engine
    • Performing Diagnostics
    • EFI Diagnostics
    • ECM and Sensors
    • Fuel System
  • 3.20 Deutz EMR 2 (S/N 85332 to Present)
  • 3.21 GM Engine General Maintenance
    • Maintenance of the Drive Belt
    • Engine Electrical System Maintenance
    • Checking/Filling Engine Oil Level
    • Changing The Engine Oil
    • Coolant Fill Procedure - Dual Fuel Engine
  • 3.22 GM Engine Dual Fuel System
    • Fuel Filter
    • Electric Lock Off
    • EPR Assembly
    • Low Pressure Regulator (LPR)
    • Air Fuel Mixer
    • Electronic Throttle Control (ETC)
    • Engine Control Module
    • Heated Exhaust Gas Oxygen Sensor
    • Gasoline Multi Point Fuel Injection System (MPFI)
    • Gasoline Fuel Pump
    • Gasoline Pressure And Temperature Sensor Manifold
    • Fuel Filter
    • Fuel Injector Rail
    • Fuel Injector
  • 3.23 GM Engine Fuel System Repair
    • Propane Fuel System Pressure Relief
    • Propane Fuel System Leak Test
    • Propane Fuel Filter Replacement
    • Electronic Pressure Regulator (EPR) Assembly Replacement
    • Temperature Manifold Absolute Pressure (TMAP) Sensor
    • Electronic Throttle Control Replacement
    • Mixer Replacement
    • Coolant Hose Replacement
    • Vapor Hose Replacement
    • Engine Control Module Replacement
    • Heated Exhaust Gas Oxygen Sensor Replacement
  • 3.24 GM Engine LPG Fuel System Diagnosis
    • Fuel System Description
    • Diagnostic Aids
• Section 4. Boom & Platform
  • 4.1 Boom Maintenance
    • Removal
    • Boom Disassembly
    • Inspection
    • Assembly
    • Installation
    • Telescope Cylinder/Boom Cable Removal
    • Telescope Cylinder/Boom Cable Installation
    • Lift Cylinder Removal
    • Lift Cylinder Installation
  • 4.2 Wire Rope
    • Inspection
    • Three Month Inspection
    • Seven Year Inspection
    • Replacement Criteria
  • 4.3 Boom Rope Torquing Procedures
    • Torque Procedures
  • 4.4 Elevation & Capacity Switches - 800S
  • 4.5 Elevation, Dual Capacity, & Transport Switch - 860SJ
  • 4.6 Electronic Platform Leveling
    • Description
    • Normal Operation
    • Platform Leveling Fault
    • CAN Errors
    • Replacing the Level Sensors
    • Additional Platform and Jib Valves
    • Platform Leveling Calibration Procedure
  • 4.7 Powertrack Maintenance
    • One Piece Bracket Maintenance
    • Two Piece Bracket Maintenance
    • Snap Rings and Screws
  • 4.8 Helac Rotary actuator
    • Theory of Operation
    • Tools Required for Assembly/Disassembly
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Installation and Bleeding
    • Troubleshooting
  • 4.9 Load Sensing device
    • Calibrating the Load Sensor
• Section 5. Hydraulics
  • 5.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 5.2 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
    • Steer Cylinder Seal Repair Instructions
  • 5.3 Pressure Setting Procedure
    • Set Up of the Function Pump
    • Adjustments Made at the Main Valve Block
    • Adjustments Made at the Platform Valve Assembly
  • 5.4 Start Up Procedures
    • Start Up After Overhaul or Replacement of Components
• Section 6. JLG Control System
  • 6.1 Introduction
    • 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
    • Machine Personality Settings
    • Analyzer Diagnostics Menu Structure
• 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
  • 7.4 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • 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