Document Outline

• Section A. Introduction - Maintenance Safety Precautions
  • A.A General
  • A.B Hydraulic System Safety
  • A.C Maintenance
• Section 1. Specifications
  • 1.1 Specifications
  • 1.2 Capacities
  • 1.3 Engines
  • 1.4 Tires
  • 1.5 Machine Dimensions
  • 1.6 Pressure Settings
  • 1.7 Serial Number Locations
  • 1.8 Sensors
  • 1.9 Cylinder Specifications
  • 1.10 Major Component Weights
  • 1.11 Critical Stability Weights
  • 1.12 Lubrication Specifications
  • 1.13 Operator Maintenance
    • Draining Oil Build Up From The Propane Regulator
    • Propane Fuel Filter Replacement
    • Propane Fuel System Pressure Relief
  • 1.14 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 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 Preventive Maintenance and Inspection Schedule
• Section 3. Chassis & Scissor Arms
  • 3.1 Operating Characteristics
    • Leveling Jacks
    • Power Deck
    • Generator
    • Lift
    • Drive
  • 3.2 Calibrations
    • Elevation Sensor Calibration (Prior to Software P1.20)
    • Elevation Sensor Calibration (Software P1.20 & Higher)
    • Joystick Calibration (Software P1.20 & Higher)
    • Tilt Sensor Calibration:
  • 3.3 Level Sensor and Analyzer Connections
    • Tilt Sensor, JLG P/N 4000006:
    • Tilt Sensor, JLG P/N 4000021:
  • 3.4 Integrated Torque/drive hub
    • Roll Test
    • Leak Test
    • Disconnect Mechanism
    • Gearbox Disassembly
    • Gearbox Assembly
    • Motor Disassembly
    • Motor Assembly
  • 3.5 Dual Fuel/LPG System
    • Changing From Gasoline to LP Gas
    • Changing From LP Gas to Gasoline
    • Using Liquid Petroleum (LP) Gas
  • 3.6 Ford EFI Engine
    • Performing Diagnostics
    • EFI Diagnostics
    • ECM and Sensors
    • Fuel System
  • 3.7 Generator - Ford Engine
  • 3.8 Deutz EMR 2 (S/N 0200138634 to Present)
  • 3.9 Generator - Duetz Engine
  • 3.10 GM Engine General Maintenance
    • Maintenance of the Drive Belt
    • Engine Electrical System Maintenance
    • Checking/Filling Engine Oil Level
    • Changing The Engine Oil
  • 3.11 Generator - GM Engine
  • 3.12 GM Engine Dual Fuel System
    • Fuel Filter
    • Electric Lock Off
    • EPR Assembly
    • Low Pressure Regulator (LPR)
    • Air Fuel Mixer
    • Electronic Throttle Control (ETC)
    • Engine Control Module
    • Heated Exhaust Gas Oxygen Sensor
    • Gasoline Multi Point Fuel Injection System (MPFI)
    • Gasoline Fuel Pump
    • Gasoline Pressure And Temperature Sensor Manifold
    • Fuel Filter
    • Fuel Injector Rail
    • Fuel Injector
  • 3.13 GM Engine Fuel System Repair
    • Propane Fuel System Pressure Relief
    • Propane Fuel System Leak Test
    • Propane Fuel Filter Replacement
    • Electronic Pressure Regulator (EPR) Assembly Replacement
    • Temperature Manifold Absolute Pressure (TMAP) Sensor
    • Electronic Throttle Control Replacement
    • Mixer Replacement
    • Coolant Hose Replacement
    • Vapor Hose Replacement
    • Engine Control Module Replacement
    • Heated Exhaust Gas Oxygen Sensor Replacement
  • 3.14 GM Engine LPG Fuel System Diagnosis
    • Fuel System Description
    • Diagnostic Aids
  • 3.15 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
  • 4.3 Component Functional Description
    • Piston Hydraulic Pump
    • Gear Hydraulic Pump
    • Manual Descent Valve
  • 4.4 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Steer Cylinder
    • Cylinders With Single Counterbalance Valve
    • Oscillating Axle Lockout Test
  • 4.5 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 4.6 Drive Pump Start-up Procedure
  • 4.7 Hydraulic Component Start-Up Procedures and Recommendations
  • 4.8 Hydraulic Gear Pump
    • Pump Disassembly
    • Parts Inspection
    • Pump Reassembly
  • 4.9 Main Valve
    • Pressure Setting Procedures
  • 4.10 Drive Header Valve (2WD)
  • 4.11 Drive Header Valve (4WD)
  • 4.12 Header Valves (4WD)
  • 4.13 dIRECTIONAL vALVE
    • Pressure Setting Procedure
  • 4.14 pOWER dECK sANDWICH vALVE
  • 4.15 Power Deck Manifold Valve
  • 4.16 Hydraulic Pump
    • Auxiliary Pump Motor
  • 4.17 Cylinder Assemblies
    • Oscillating Axle Bleeding Procedure
• Section 5. JLG Control System
  • 5.1 Hand Held Analyzer
    • 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
  • 5.2 Flash Codes and Descriptions
• Section 6. General Electrical Information & Schematics
  • 6.1 General
  • 6.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 6.3 Applying Silicone Dielectric Compound To Amp Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 6.4 Working With Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly
  • 6.5 Switches
    • Basic check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 6.6 Schematics