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 Electric Power Unit
  • 1.4 Tires
  • 1.5 Engine
    • Battery
  • 1.6 Dimensional Data
  • 1.7 Lubrication
    • Hydraulic Oil
  • 1.8 Major Component Weights
  • 1.9 Pressure Settings
  • 1.10 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
    • 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 Breaking-in a New Trailer
    • Retighten Lug Nuts at First 10, 25 & 50 Miles
    • Adjust Brake Shoes at First 200 Miles
    • Synchronizing the Brake Systems
  • 3.2 Trailer inspection and Service Instructions
    • Fasteners and Frame Members
    • Brake Shoes and Drums
    • Manually Adjusting Brake Shoes
  • 3.3 Electric Brakes
    • Brake Controller
    • Brake Cleaning and Inspection
    • Shoes and Linings
  • 3.4 Hydraulic (Surge) Brakes
    • Self Adjusting Mechanism
    • Parking Brake
    • General Maintenance
  • 3.5 Hubs, Drums, Wheel Bearings
    • Hub Removal
    • Brake Drum Inspection
    • Bearing Inspection
    • Bearing Lubrication
    • Seal Inspection and Replacement
    • Bearing Adjustment
  • 3.6 Tires & Wheels
    • Tire Inflation
    • Tire Wear
    • Tire Replacement
    • Wheel and Tire Replacement
    • Wheel Installation
    • Lug Nuts (Bolts)
  • 3.7 Hydraulic brake Coupler
    • Troubleshooting
    • Bleeding the Brake System
    • Towing
    • Backing Up
    • Maintenance
    • Extended Storage Instructions
    • Proper Towing Checklist
  • 3.8 Combination Coupler
    • Bleeding the Brake System
    • General Maintenance
    • Servicing the Emergency Lever
  • 3.9 Hitch Coupler & Axle (CE Only)
    • Ball Coupler
    • Coupling Head Maintenance
    • Damper Maintenance
    • Brake Maintenance
    • Adjustment and Readjustment of the Overrun Braking System
    • Troubleshooting
  • 3.10 Coupler Assembly (S/N 0030002099 to Present)
    • Engaging Manual Lockout Lever
    • Servicing the Breakaway Assembly
    • Actuator Maintenance
    • Coupler Maintenance
  • 3.11 Trailer Jack (Solid wheels)
    • Installation
    • Operation
    • Maintenance
    • Assembly
  • 3.12 Swing Motor (Prior to S/N 0030000960)
    • Removal
    • Disassembly
    • Assembly
    • Shaft Timing Procedure
    • Installation
  • 3.13 Swing Motor (S/N 0030001050 to Present)
    • Removal
    • Disassembly and inspection
    • Assembly
    • One Piece Stator Construction
    • Installation
  • 3.14 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Removal
    • Swing Bearing Installation
    • Swing Bearing Torque Values
  • 3.15 Engine
    • Throttle & Choke Adjustment
    • Fuel Valve Lever
    • Checking RPM Level
    • Choke Actuator
    • Checking Oil Level
  • 3.16 Outrigger cylinder and Stabilizer
    • Removal
    • Installation
  • 3.17 Outrigger Limit SwitchEs
    • Adjustment
  • 3.18 Procedure For Retracting Outriggers Using Service Harness (Optional)
  • 3.19 Leveling, Tilt sensor calibration
    • When Machine Is on a Firm Level Surface
    • Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure:
  • 3.20 Drive & Set
    • Drive & Set Interlocks
  • 3.21 Drive Motor
    • Disassembly and inspection
    • Assembly
    • One Piece Stator Construction
  • 3.22 Batteries (Electric Machines)
    • Quarterly Battery Maintenance
  • 3.23 Battery Charger
    • Removal
    • Cover Removal
    • Transformer Replacement
    • Printed Circuit Board Replacement
    • Shunt Assembly Replacement
    • Interlock Relay Replacement
    • SCR Rectifier Replacement (Either Side)
    • AC Circuit Breaker Replacement
    • DC Circuit Breaker Replacement
  • 3.24 Battery Charger
    • Operating Instructions
    • Maintenance Instructions
    • Battery Charger Fault Codes
• Section 4. BOOM & PLATFORM
  • 4.1 Boom and Cylinder AssemblY
    • Removal
    • Installation
  • 4.2 Main Boom
    • Removal
    • Disassembly
    • Assembly
    • Installation
  • 4.3 Master Cylinder
    • Removal
    • Installation
  • 4.4 Slave Cylinder
    • Removal
    • Installation
  • 4.5 Jib Cylinder
    • Removal
    • Installation
  • 4.6 Boom Sensors
    • Boom Elevation Limit Switch
• 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
    • Inspection
    • Assembly
    • Testing
  • 5.3 Pressure Setting Procedure
    • Main Relief
    • Telescope In
    • Telescope Out
    • Platform Level Up
    • Platform Level Down
    • Swing Right
    • Swing Left
    • Outrigger Up
  • 5.4 Hydraulic Oil Fill at Startup
  • 5.5 Hydraulic Hoses
  • 5.6 Hydraulic Filter and Breather
• 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 System Test
    • Platform Test
    • Ground Test
  • 6.8 User Fault Codes
  • 6.9 Machine Orientation When Setting Speeds
    • Test Notes
• 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 Checking Switches
    • Basic Check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 7.4 Applying Silicone Dielectric Compound to Electrical Connections
  • 7.5 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.6 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly