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 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.7 Torque Requirements
  • 1.8 Hydraulic Oil
  • 1.9 Major Component Weights
  • 1.10 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
    • 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 Inflation
    • Tire Damage
    • Pneumatic Tires
    • Polyurethane Foam Filled Tires
    • Tire Replacement
    • Wheel Replacement
    • Wheel Installation
  • 3.2 Torque Hub
    • Oil Information
    • Roll and Leak Testing
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Output Carrier Disassembly
    • Input Carrier Disassembly
    • Hub-Spindle Disassembly
    • Spindle-Brake Disassembly
    • Cover Disassembly
    • Cover Assembly
    • Input Carrier Sub-Assembly
    • Output Planet Gear Sub-Assembly
    • Spindle - Brake Sub-Assembly
    • Hub-Spindle Sub-Assembly
    • Cover Sub-Assembly
    • Main Assembly
    • Integral Brake Check
  • 3.3 Free Wheeling Option
    • Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)
    • Engage Drive Motors and Brakes (Normal Operation)
  • 3.4 Drive Motor
    • Description
    • Shaft Seal Replacement
    • Loop Flushing Valve
    • Troubleshooting
    • Disassembly
    • Inspection
    • Assembly
    • Initial Start-up Procedures
  • 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.6 Steer Adjustments
  • 3.7 Swing Drive
    • Gear Backlash
    • Swing Drive Lubrication
    • Motor Control Valve Disassembly
    • Motor and Brake Disassembly
    • Main Disassembly
    • Hub-Shaft Disassembly
    • Carrier Disassembly
    • Hub-Shaft Subassembly
    • Carrier Subassembly
    • Main Assembly
    • Motor and Brake Assembly
    • Motor Control Valve Assembly
  • 3.8 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance
    • Swing Bearing Replacement
    • Swing Bearing Torque Values
  • 3.9 Swing Brake - Mico
    • Disassembly
    • Inspection
    • Assembly
  • 3.10 Rotary Coupling
  • 3.11 Generator
    • Every 250 hours
    • Every 500 hours
    • Overload Protection
    • Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
  • 3.12 Deutz D2.9 L4 Engine
    • Check Oil Level
    • Change Engine Oil
    • Change Oil Filter
    • Change Fuel Filters
  • 3.13 Deutz D2011 Engine
    • Checking Oil Level
    • Changing Engine Oil
    • Changing Oil Filter
    • Replace Fuel Filter
    • Clean Fuel Strainer
  • 3.14 Spark Arrester Cleaning Instructions
  • 3.15 Glow Plugs
  • 3.16 Deutz EMR 2
  • 3.17 Bio Fuel in Deutz Engines
    • General
    • Bio Fuel
    • Biological Contamination In Fuels
  • 3.18 GM Engine General Maintenance
    • Drive Belt Maintenance
    • Engine Electrical System Maintenance
    • Checking/Filling Engine Oil Level
    • Changing Engine Oil
    • Coolant Fill Procedure - Dual Fuel Engine
  • 3.19 GM Engine Dual Fuel System
    • Fuel Filter
    • Direct Electronic Pressure Regulator (DEPR)
    • Air Fuel Mixer
    • Electronic Throttle Control (ETC)
    • Electric Lock Off
    • Engine Control Module (ECM)
    • 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
  • 3.20 GM Engine Fuel System Repair
    • Propane Fuel System Pressure Relief
    • Propane Fuel System Leak Test
    • Propane Fuel Filter Replacement
    • Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
    • Check/Drain Oil Build-Up In 2-Stage Vaporizer
    • Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
    • Exhaust System And Catalytic Converter Inspection And Maintenance
    • Temperature Manifold Absolute Pressure (TMAP) Sensor
    • Throttle Body (ETC) Replacement
    • Mixer Replacement
    • Electronic Pressure Regulator (EPR) Replacement
    • Regulator Replacement
    • Coolant Hose Replacement
    • Vapor Hose Replacement
    • Engine Control Module Replacement
    • Heated Exhaust Gas Oxygen Sensor Replacement
  • 3.21 GM Engine LPG Fuel System Diagnosis
    • Fuel System Description
    • Diagnostic Aids
• Section 4. Boom & Platform
  • 4.1 Main Boom Maintenance
    • Remove Rotator
    • Remove Platform Level (Slave) Cylinder
    • Remove Jib Lift Cylinder (600AJ Only)
    • Remove Main Boom Powertrack
    • Remove Main Boom
  • 4.2 Tower Boom
    • Remove Tower Upright
    • Remove Tower Boom
  • 4.3 Boom Cleanliness Guidelines
  • 4.4 Rotary Actuator
    • Theory of Operation
    • Required Tools
    • Disassembly
    • Inspection
    • Assembly
    • Installing Counterbalance Valve
    • Testing Actuator
    • Testing Actuator for Internal LeakS
    • Installation and Bleeding
    • Troubleshooting
  • 4.5 Foot Switch Adjustment
  • 4.6 Platform
    • Platform Support Torque Settings
    • Replace Platform Sections
  • 4.7 Powertrack Maintenance
    • Remove Link
    • Install New Link
    • Replace Fixed End Brackets
    • Replace Moving End Brackets
• Section 5. Hydraulics
  • 5.1 O-Ring Lubrication
    • Cup and Brush
    • Dip
    • Spray
    • Brush-On
  • 5.2 Cylinders - Theory of Operation
    • Systems With Double Acting Cylinders
    • Systems With Holding Valves
  • 5.3 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valves
  • 5.4 Cylinder Removal and Installation
    • Cylinder Locations
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
    • Upright Level Cylinder Removal
    • Upright Level Cylinder Installation
    • Tower Boom Lift Cylinder Removal
    • Tower Lift Cylinder Installation
    • Tower Telescope Cylinder Removal
    • Tower Telescope Cylinder Installation
  • 5.5 Hydraulic Cylinder repair
    • Tower Boom Lift Cylinder
    • Cleaning and Inspection
    • Assembly
    • Upright Level Cylinder
    • Cleaning and Inspection
    • Assembly
    • Master Cylinder
    • Cleaning and Inspection
    • Assembly
    • Main Boom Lift Cylinder
    • Cleaning and Inspection
    • Assembly
    • Main Boom Telescope Cylinder
    • Cleaning and Inspection
    • Assembly
    • Tower Boom Telescope Cylinder
    • Cleaning and Inspection
    • Assembly
    • Platform Level (Slave) Cylinder
    • Cleaning and Inspection
    • Assembly
    • Jib Lift Cylinder (AJ Only)
    • Cleaning and Inspection
    • Assembly
    • Steer Cylinder
    • Cleaning and Inspection
    • Assembly
    • Axle Lockout Cylinder
  • 5.6 Hydraulic Pump (Gear)
    • Disassembly
    • Inspect Parts For Wear
    • General Information
    • Reverse Shaft Rotation of Pump
    • Assembly
    • Placing Pump Back Into Service
  • 5.7 Variable Pump
    • Ports and Pressure Gauges
    • NFPE Control
    • Remove and Install FNR and NFPE Modules
    • Remove and Install FNR and NFPE Control Orifices
    • Charge Relief Valve
    • Shaft Seal and Shaft Replacement
    • Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
    • Charge Pump
  • 5.8 Hydraulic Component Start-Up
  • 5.9 Pressure Setting Procedures
    • Main Relief, Steer, Swing, and Lift Down
    • Platform Level
    • Articulating Jib Boom (If Equipped)
    • 4 Wheel Steer (If Equipped)
• Section 6. JLG Control System
  • 6.1 introduction
    • Connect JLG Control System Analyzer
    • Using Analyzer
    • Changing Access Level
    • Adjust Parameters
    • Machine Setup
    • Level Vehicle Description
  • 6.2 Machine Personality Settings
  • 6.3 Machine Orientation When Setting Function Speeds
    • Test Notes
  • 6.4 CANbus Communications
• 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 Applying Silicone Dielectric Compound to Electrical Connections
    • Dielectric Grease Application
    • Deutsch HD, DT, DTM, DRC Series
    • AMP Seal
    • AMP Mate-N-Lok
    • DIN Connectors
    • Exclusions
  • 7.4 AMP Connector
    • Contact Assembly
    • 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