Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. Specifications
  • 1.1 Capacities
  • 1.2 Operating specifications
  • 1.3 Generator
  • 1.4 Battery Charger
  • 1.5 Drive/Steer System
  • 1.6 Tires
  • 1.7 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.8 Pressure Settings
  • 1.9 Torque Requirements
  • 1.10 Major Component Weights
  • 1.11 Serial Number Location
  • 1.12 Hydraulic Oil
  • 1.13 Operator Maintenance
• 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
  • 2.7 Applying Silicone Dielectric Compound to Electrical Connections
• Section 3. Chassis & Turntable
  • 3.1 Tires & Wheels
    • Tire Inflation
    • Tire Damage
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Drive Hub -REAR (Prior to S/N 0300112585)
    • Disengaging for Towing
    • Engaging after Towing is Complete
    • Disassembly
    • Disassembly of Cover
    • 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
    • Oil Change Interval-Gear Drive
  • 3.3 Drive Hub (S/N 115723 to Present)
    • Roll and Leak Testing
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Output Carrier Disassembly
    • Input Carrier Disassembly
    • Hub-Spindle Disassembly
    • Cover Disassembly
    • Input Carrier Assembly
    • Output Planet Gear Assembly
    • Output Carrier Assembly
    • Hub-Spindle Assembly
    • Cover Subassembly
    • Main Assembly
  • 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 Oscillating Axle Lockout Test (If Equipped)
  • 3.7 Oscillation Cylinder Bleeding
    • Bleeding Procedure
    • Checking Oscillation Cylinders
  • 3.8 Swing Drive
    • Roll, Leak and Brake Testing
    • Tightening and Torquing Bolts
    • Motor Control Valve Disassembly
    • Motor and Brake Disassembly
    • Main Disassembly
    • Hub-shaft Disassembly
    • Carrier Disassembly
    • Hub-Shaft Sub-Assembly
    • Carrier Sub-Assembly
    • Main Assembly
    • Motor-Brake Subassembly
    • Motor-Brake Assembly
    • Motor Control Valve Assembly
    • Tube Fitting Assembly Procedures
    • Procedure for Setting Gear Backlash
  • 3.9 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Replacement of Swing Bearing
    • Swing Bearing Torque Value
    • Swing Drive Installation
    • Setting Backlash
  • 3.10 Battery Maintenance and Charging
    • Battery Maintenance, Quarterly
    • Optional On Board Generator
    • Battery Charging (On Board Charger)
    • Removing the Battery Box
  • 3.11 Generator (Prior to S/N 88375)
    • 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 88375 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 Engine Generator Controller
    • Tools And Material
    • Procedure
• Section 4. Boom & Platform
  • 4.1 Boom
    • Removal
    • Installation
  • 4.2 Load Cell Calibration Procedure
  • 4.3 Platform Rotator (Prior to S/N 0300130810)
    • Theory of Operation
    • Disassembly and Inspection
    • Assembly and Testing
  • 4.4 Platform Rotator (S/N 0300130810 to Present)
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
  • 4.5 Jib Rotator
    • Operating Principle
    • Disassembly
    • Inspection
    • Reassembly
    • Installing Counterbalance Valve
    • Testing the Actuator
    • Installation and Bleeding
    • Troubleshooting
• 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
    • Lift, Telescope, Slave, Master, Oscillation (if equipped), Jib (if equipped), and Steer
  • 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 settings
    • Proportional Main Relief
    • Lift Down
    • Lift Up
    • Swing
    • Flow Control / Bang Bang Main Relief
    • Steer
    • Platform Level Down
    • Platform Level Up Relief
    • Jib Relief
• Section 6. JLG Control System
  • 6.1 Introduction
  • 6.2 To Connect the JLG Control System Analyzer
  • 6.3 Using the Analyzer
  • 6.4 Changing the Access Level of the Hand Held Analyzer
  • 6.5 Adjusting Parameters Using the Hand Held Analyzer
  • 6.6 Machine Setup
  • 6.7 Machine Personality Settings
  • 6.8 Machine Configuration Programming Information
  • 6.9 Level Vehicle Description
    • Help Descriptions and Fault Flash Codes
  • 6.10 Analyzer Diagnostics Menu Structure
  • 6.11 System Self Test
• Section 7. Basic Electrical Information & Schematics
  • 7.6 General
  • 7.7 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Voltage Measurement
    • Resistance Measurement
    • Continuity Measurement
    • Current Measurement
  • 7.8 Checking Switches
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 7.9 Applying Silicone Dielectric Compound to Electrical Connections
  • 7.10 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.11 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly