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 Capacities
  • 1.3 Battery Charger
  • 1.4 Drive System
  • 1.5 Hydraulic Pump/Electric Motor Assembly
  • 1.6 Generator
  • 1.7 Tires
  • 1.8 Dimensional Data
  • 1.9 Function Speeds
    • Machine Orientation When Doing Function Tests
  • 1.10 Torque Specifications
  • 1.11 Cylinder Specifications
  • 1.12 Major Component Weights
  • 1.13 Critical Stability Weights
  • 1.14 Pressure Settings
  • 1.15 Serial Number Locations
  • 1.16 Lubrication
    • Lubrication Specifications
  • 1.17 Operator Maintenance & 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
    • 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 & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Spindle
    • Setting Wheel Bearing End Play
    • Specifications
    • Checking
    • Greasing Requirements
  • 3.3 Drive Hub (Part No. 2780236)
    • Dissembling
    • Disassembly
    • Disassembly of the first stage planetary assembly (7)
    • Disassembly of second stage planet gears (1)
    • Assembly of first stage planetary assembly (7)
    • Assembly of end cover unit (8)
    • Final Assembly
    • Initial Start-up And After Repairs
    • Maintenance
    • Oil Change Interval-Gear Drive
    • Setting of Tapered Roller Bearings
    • Securing of the Shaft Nut
  • 3.4 Drive Brake - Mico
    • Disassembly
    • Assembly
    • Bleeding
  • 3.5 Speed Sensor Adjustment
    • Adjustment Procedure
    • Speed Sensor Installation Verification
    • Verification w/ Analyzer Procedure
  • 3.6 Positrac/Tilt module
  • 3.7 Swing Motor - S/N 0300135649 to Present
    • Preparation Before Disassembly
    • Disassembly and Inspection
    • Assembly
    • One Piece Stator Construction
    • Two Piece Stator Construction
    • Final Checks
  • 3.8 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Replacement of Swing Bearing
    • Swing Bearing Torque Value
    • Checking Worm Gear End Play
    • Adjusting End Play
  • 3.9 Battery Maintenance and Charging
    • Battery Maintenance, Quarterly
    • Charging Sequence of Remote LED Card
    • Battery Charging (On Board Charger)
    • Optional On Board Generator
  • 3.10 Battery Charger (S/N 0300059350 to Present)
    • Operating Instructions
    • Maintenance Instructions
    • Battery Charger Fault Codes
    • Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
    • Checking/Changing the Battery Charger Algorithm
  • 3.11 Generator (Prior to S/N 88539)
    • Alternator
    • Dynamo and Dynamo Voltage Regulator
    • Dynamo Output Fuse
    • Control Fuse
    • Start Battery
    • Engine Starter
    • Start Control Relay
    • Fuel Control Relay
    • Fuel Solenoid
    • Engine Oil Temperature Sensor
    • Alternator Output Current Sensor
    • Engine Speed Sensor
    • Engine Low Oil Pressure Switch
    • 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
  • 3.12 Generator (S/N 88539 to Present)
    • Engine
    • Alternator
    • Dynamo and Dynamo Voltage Regulator
    • Dynamo Output Fuse
    • Control Fuse
    • Start Battery
    • Engine Starter
    • Start Control Relay
    • Fuel Control Relay
    • Glow Plug Control Relay
    • Glow Plug
    • Fuel Pump
    • Fuel Solenoid
    • Engine Low Oil Pressure Switch
    • Engine Oil Temperature Sensor
    • Alternator Output Current Sensor
    • Engine Speed Sensor
    • RBS Engine/Generator Controller
    • Warnings and Safety Precautions
    • System Controls
    • System Status and Performance Monitoring
    • System Settings
    • RBS Start
    • RBS shutdown
    • RBS Alarms and Flash Codes
    • Resetting the RBS Controller
    • Maintenance Schedule
    • Troubleshooting
    • APU Engine Start Battery Boosting
  • 3.13 Supplementary fuse for apu
    • Tools And Material
    • Procedure
• Section 4. Boom & Platform
  • 4.1 Boom Maintenance
    • Removal
    • Disassembly
    • Inspection
    • Assembly
    • Installation
  • 4.2 Upper (Main) Boom Lift Cylinder
    • Removal
    • Installation
  • 4.3 Mid Boom Lift Cylinder
    • Removal
    • Installation
  • 4.4 Lower Boom Lift Cylinder
    • Removal
    • Installation
  • 4.5 Upper Boom Telescope Cylinder
    • Removal
    • Installation
  • 4.6 Mid and Lower Lift Cylinder Bleeding Procedure
  • 4.7 Wear Pads
  • 4.8 Boom Synchronizing Procedure
  • 4.9 Articulating Jib Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
  • 4.10 Footswitch Adjustment
  • 4.11 Boom Limit Switches
  • 4.12 Helac Rotary actuator
    • Theory Of Operation
    • Tools Required for Assembly/Disassembly
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Installation and Bleeding
    • Troubleshooting
  • 4.13 Powertrack Maintenance
    • Removing a Link
    • Installing a New Link
    • Replacing Fixed End Brackets
    • Replacing Moving End Brackets
• Section 5. Hydraulics
  • 5.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 5.2 Cylinders - Theory of Operation
    • Double Acting Cylinder
  • 5.3 Cylinder Checking Procedures
    • Cylinder Without Counterbalance Valves
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valve
  • 5.4 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.5 Pressure Setting Procedures
    • Main Relief
    • Upper Lift Down Relief
    • Lower Lift Down Relief
    • Telescope Relief
    • Platform Level Up Relief
    • Platform Level Down Relief
    • Steer Relief
    • Jib Lift (Up and Down) Relief
    • Jib Swing Relief
    • Releveling Valve Relief
• Section 6. JLG Control System
  • 6.1 JLG Control System Analyzer Kit Instructions
    • 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
    • Machine Personality Settings
    • Machine Configuration Programming Information
    • Level Vehicle Description
    • Help Descriptions and Fault Flash Codes
    • Analyzer Diagnostics Menu Structure
    • System Self Test
• Section 7. Basic Troubleshooting, Electrical Information, & Schematics
  • 7.1 General
  • 7.2 Troubleshooting
  • 7.3 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Voltage Measurement
    • Resistance Measurement
    • Continuity Measurement
    • Current Measurement
  • 7.4 Checking Switches
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 7.5 Applying Silicone Dielectric Compound to Electrical Connections
  • 7.6 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.7 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly