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39MT STARTERS HARDWARE PACKAGES Guide
User manual for 39MT STARTERS HARDWARE PACKAGES
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Table of contents
Document Outline
Section A. Introduction - Maintenance Safety Precautions
A. General
B. Hydraulic System Safety
C. Maintenance
Section 1. Specifications
1.1 Specifications
Platform Capacities
Dimensional Data
Tires
Batteries
Battery Quick-Disconnect - (If Equipped)
Electrical System
Motors
Travel Speed
Lift Speed
1.2 CRITICAL STABILITY WEIGHTS
1.3 Lubrication
Hydraulic Oil
Pressure Settings
1.4 Limit Switches
Tilt Alarm
High Drive Speed Cutout
1.5 Cylinder Specifications
1.6 Major Component Weights
1.7 Torque Requirements
Torque Charts
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 Preventive Maintenance and Inspection Schedule
Maintenance and Inspection Schedule Codes:
Footnotes:
2.3 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
2.4 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.5 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.6 Pins and Composite Bearing Repair Guidelines
Section 3. Chassis & Scissor Arms
3.1 Machine Component Covers
3.2 Battery Removal/Maintenance
Battery Quick-Disconnect - (If Equipped)
Battery Maintenance and Safety Practices
3.3 Battery Charger
3.4 BATTERY CHARGING
Battery Charger Fault (LED Flash)
Battery Charger Maintenance
Battery Charger Troubleshooting
3.5 DC to AC Inverter (if equipped)
Inverter Location on Machine
Inverter Operation
Inverter Troubleshooting
Inverter Specifications
3.6 Ground Control Station
Components Location
Removal (All Models)
Installation
3.7 Main Power Contactor Relay
3.8 ELEVATION Limit Switch Assembly
Location
Installation
Switch Adjustment
3.9 LSS - Scissor Arm Angle Sensor - location
3.10 Tilt Sensor Replacement
Tilt Sensor Removal
Tilt Sensor Installation
Tilt Sensor Switch - Adjustment Procedure
3.11 Traction System
Theory of Operation
Common Traction System Difficulties
3.12 Power Control Module - ZAPI
ZAPI Power Module Electrical Evaluation
3.13 Drive Motor Servicing
Drive Motor Troubleshooting
Drive Motor Electrical Evaluation
Servicing Guidelines
Brake - Manual Disengage Procedure
Drive Motor Removal
Drive Motor Disassembly
Drive Motor Inspection and Service
Drive Motor Reassembly
Drive Motor Installation
3.14 Torque Hub Servicing
Roll Test
Leak Test
Oil Check/Fill Procedure
Main Gearbox Disassembly
Input Carrier Disassembly
Hub Disassembly
Spindle Disassembly
Tightening and Torquing Bolts
Assembly Tools
Spindle Assembly
Hub Assembly
Input Carrier Assembly
Main Gearbox Assembly
3.15 Steer Assembly Components
3.16 Arms and Platform Positioning and Support
3.17 Platform Removal
3.18 Scissor Arms Removal
Removing scissor arm assembly as a complete unit:
Removing/Installing scissor arms individually:
3.19 Platform Control Station
Installation/Removal
Control Station Harness Installation to Scissor Arms
Control Station Disassembly
Overview of Control Station Components
Joystick Controller
Section 4. Hydraulics
4.1 Cylinders - Theory of Operation
4.2 Valves - Theory of Operation
Solenoid Control Valves (Bang-Bang)
Relief Valves
Crossover Relief Valves
Proportional Valve
Manual Descent Valve
4.3 Pump/Motor
Pump Motor Electrical Evaluation
Hydraulic Oil Check Procedure
Pump/Tank Disassembly
Pump Motor Removal
4.4 Lift Pressure Setting Procedure
4.5 Cylinder Checking Procedure
4.6 Lift Cylinder Removal
4.7 Cylinder Repair
Disassembly
Steer Cylinder Piston Removal
Cleaning and Inspection
Assembly
Lift Cylinder - LSS Pressure Sensor Location (If Equipped)
Section 5. JLG Control System
5.1 Hand Held Analyzer
Diagnostic Port
To Connect the Hand Held Analyzer:
Using the Analyzer:
Changing the Access Level of the Hand Held Analyzer:
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
Joystick Calibration
Updating Software
5.2 Machine Model Adjustment
5.3 Machine ConfiguRation Programming Information
Section 6. Diagnostic Trouble Codes
6.1 Introduction
System Fault/DTC Indication
6.2 DIAGNOSTIC TROUBLE CODES (DTC)
6.3 X-CONNECTOR REFERENCES
6.4 DTC Index
6.5 DTC Check Tables
Section 7. General Electrical Information & Schematics
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements:
Procedure
7.3 Applying Silicone Dielectric Compound To Amp Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
7.4 Working With Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
7.5 Switches
Basic check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side
7.6 Circuit Boards: Inputs and Outputs
7.7 Electrical Schematics and Layouts
Electrical Schematic - 1870164G - Sheet 1 of 2
Electrical Schematic - 1870164G - Sheet 2 of 2
Electrical Schematic - 1870205B - Sheet 1 of 2
Electrical Schematic - 1870205B - Sheet 2 of 2
7.8 Hydraulic Schematic
Hydraulic Schematic - 2792599C
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