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 Tires
  • 1.5 Engine Data
  • 1.6 Major Component Weights
  • 1.7 Hydraulic Oil
  • 1.8 Maintenance and 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 and Wheels
    • Tire Damage
    • Wheel and Tire Replacement
    • Wheel Installation
  • 3.2 Axle Extension System
  • 3.3 Drive Orientation System
  • 3.4 Steering Control System
  • 3.5 Drive/Steering Speed Control
  • 3.6 Traction Control System
  • 3.7 Drive Assembly
  • 3.8 Drive Hub
    • Disassembly
    • Assembly
  • 3.9 Free Wheeling Option
    • Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel)
    • Engage Drive Motors & Brakes (Normal Operation)
  • 3.10 Gear Hub Oil Service
    • Check Oil Level
    • Change Gear Hub Oil
  • 3.11 Drive Motor
    • Description
    • Shaft Seal Replacement
    • Loop Flushing Valve
    • Troubleshooting
    • Disassembly
    • Inspection
    • Assembly
    • Initial Start-up Procedures
  • 3.12 Procedure for Setting Swing Gear Backlash
  • 3.13 Swing Control System
  • 3.14 Chassis Tilt Indicator System
  • 3.15 Auxiliary Power System
• Section 4. Boom & Platform
  • 4.1 Boom Systems
    • Broken Cable Indicator System
    • Transport Position Sensing System
    • Beyond Transport - Drive Speed Cutback System
    • Drive/Steer - Boom Function Interlock System (CE/ AUS ONLY)
    • Jib Stow System
    • Envelope Control System
    • Moment Control System
    • Boom Control System (BCS) Functional Check (Push to Test) System
    • Controlled Arc System
    • Controlled Boom Angle System
    • Envelope Tracking
    • Slow Down System
    • Dual Capacity System
    • Swing Speed Proportioning
    • Platform Load Sensing System
    • Electronic Platform Leveling
    • Boom Control Select
  • 4.2 Boom Removal and Installation
    • Removal
    • Installation
  • 4.3 Boom Assembly
    • Assembly
  • 4.4 Telescope Cylinder
    • Removal
  • 4.5 Boom Shimming Procedure
  • 4.6 Boom Lubrication Application
  • 4.7 Boom Cleanliness Guidelines
  • 4.8 Hose Adjustment Procedure
  • 4.9 Jib
    • Removal
    • Installation
  • 4.10 JIB
    • Jib Straight Shimming Procedure
    • Stowed Jib Shimming Procedure
  • 4.11 Wire Rope
    • Inspection
    • Three Month Inspection
    • Eight Year Inspection
    • Replacement Criteria
  • 4.12 Wire Rope Tensioning Adjustment
    • Boom Preparation for Section Repositioning
    • Wire Rope Tensioning Procedure
    • Confirm Proper Boom Deployment Function
    • Re-Assembly
    • Boom Calibration
  • 4.13 Broken Boom Cable Proximity Switch
    • Adjusting the Proximity Switch
  • 4.14 Powertrack Maintenance
    • One Piece Bracket Maintenance
    • Two Piece Bracket Maintenance
    • Snap Rings and Screws
• Section 5. Basic Hydraulic information & Hydraulic Schematics
  • 5.1 Lubricating O-Rings in the Hydraulic System
    • Cup and Brush
    • Dip Method
    • Spray Method
    • Brush-on Method
  • 5.2 Hydraulic Cylinders
    • Axle Extend Cylinder
    • Jib Level (Slave) Cylinder
    • Platform Level Cylinder
    • Boom Lift Cylinder
    • Jib Lift Cylinder
    • Jib Lock Cylinder
    • Steer Cylinder
    • Jib Telescope Cylinder
    • Boom Telescope Cylinder
  • 5.3 Cylinder Length Sensor
    • Removal
    • Installation
  • 5.4 Oil Sampling
    • Procedure
  • 5.5 Pressure Setting Procedure
    • 1. Setup of the Function Pump
    • 2. Adjustments Made at the Main Valve Bank
    • 3. Adjustments Made at the Frame Valve Bank
    • 4. Adjustments Made at the Platform Valve Bank
    • 5. Adjustments Made at Jib Valve
    • 6. Adjustments Made in Traction Circuit
  • 5.6 Drive Pumps
    • Troubleshooting Procedure
    • Charge Pressure Relief Valve Adjustment
    • Mechanical Centering of Pump
    • Hydraulic Centering of Control Modules
    • High Pressure Relief Valve Adjustments
    • Removal and inspection of charge pump
    • Routine Maintenance
    • Removal and Installation of Shaft Seal
  • 5.7 Function Pump
    • Pump Operation
    • Load Sensing (LS) control with Pressure Compensator (PC)
    • Control Adjustment
    • Troubleshooting
    • Disassemble Pump
    • Inspection
    • Assembly
  • 5.8 Drive & Function Pump Start Up Procedures
    • Start-Up Procedure
• 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
    • Level Vehicle Description
  • 6.2 Machine Personality Settings and Function Speeds
  • 6.3 MACHINE ORIENTATION WHEN SETTING Function SPEEDS
    • Test Notes
  • 6.4 CANbus Communications
  • 6.5 Calibration Instructions
  • 6.6 Control System Boom Sensors
    • Sensor #1 - Load Pin (1)
    • Sensor #2 - Main Boom Angle Sensors (2)
    • Sensor #3 - Main Boom Length Sensor (1)
    • Sensor #4 - Main Boom Cylinder Angle Sensor (1)
    • Sensor #5 - Main Boom Transport Length Switch (1)
    • Sensor #6 - Jib Level Angle Sensor (1)
    • Sensor #7 - Jib Lock Pin Proximity Sensor (1)
    • Sensor #8 - Jib Stow Angle Sensor (1)
    • Sensor #9 - Jib Lift Angle Sensor (1)
    • Sensor #10 - Dual Capacity / Jib Transport Length Switches (2)
    • Sensor #11 - Platform Level Angle Sensor (1)
    • Sensor #12 - Platform Level Angle Gravity Sensors (2)
    • Sensor #13 - Turntable Swing Angle (1)
    • Sensor #14 - Steer Angle Sensor (4)
    • Sensor #15 - Axle extend/retract Sensor (4)
    • Sensor #16 - Brake-Two Speed Pressure Sensor (1)
    • Sensor #17 - Chassis Tilt Sensor (Externally mounted) (1)
    • Sensor #18 - Tilt Sensor (1)
    • Sensor #19 - Warm up Switch (1)
    • Sensor #20 - Main Valve Pressure Transducer (1)
    • Sensor #21 - Main Lift Cylinder Pressure Transducer (1)
  • 6.7 System Test
    • Test from the Platform
    • Test from the Ground Station
  • 6.8 Calibration Procedures
    • Axle Calibration
    • Boom Sensor Calibration
  • 6.9 Electronic Platform Leveling
    • Platform Leveling Fault Warning
    • Fault Response
• Section 7. Basic Electrical Information & Electrical 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
    • Installation of Dielectric Grease
    • Deutsch HD, DT, DTM, DRC Series
    • AMP Seal
    • AMP Mate-N-Lok
    • DIN Connectors
    • Exclusions
  • 7.4 AMP Connector
    • 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
  • 7.6 Wiring Harness Connector Labels
    • Connector Labels
    • Component Labels