Related Manuals for JLG 430LRT
Summarization of Contents
Section A. Introduction - Maintenance Safety Precautions
A General
General safety precautions for Mobile Elevating Work Platform (MEWP) maintenance.
B Hydraulic System Safety
Safety precautions for high-pressure hydraulic systems during maintenance.
C Maintenance
General maintenance safety precautions and guidelines for safe operation.
Section 1 - Specifications
1.1 Specifications
Details on machine, generator, dimensional data, fluid capacities, drive, steering, tires, and weights.
1.2 Serial Number Location
Information on where to find the machine's serial number plate and stamped number.
1.3 Lubrication
Recommendations for hydraulic oils and lubrication specifications.
1.4 Hydraulic Pressure Settings
Specific pressure settings for the hydraulic system components.
1.5 Hydraulic Cylinder Specifications
Details on hydraulic cylinder dimensions like bore, stroke, and rod diameter.
1.6 Engine Specifications
Technical specifications for the Kubota Diesel and Dual Fuel engines.
1.7 Elevation/Tilt Limit Settings
Information on limit switches for elevation and tilt, and cutout settings.
1.8 ThreadLocking Compound
Table of JLG PN, Loctite®, and ND Industries equivalents for threadlocking.
1.9 Torque Charts
Reference tables for SAE and Metric fastener torque specifications.
Section 2 - General
2.1 Machine Preparation, Inspection, and Maintenance
Guidelines for preparing, inspecting, and maintaining the machine for safe operation.
2.2 Preventive Maintenance and Inspection Schedule
Schedule and codes for periodic preventive maintenance and inspections.
2.3 Service And Guidelines
General guidelines for servicing and maintenance procedures.
2.4 Lubrication And Information
Details on hydraulic system lubrication, oil specifications, and changing oil.
2.5 Service Maintenance Components
Procedures for setting scissor arm safety props and general maintenance tips.
2.6 Cylinder Drift Test
Methods for measuring acceptable platform and cylinder drift.
2.7 Pins and Composite Bearing Repair Guidelines
Guidelines for inspecting and repairing pins and composite bearings.
Section 3 - Chassis, Platform, & Scissor Arms
3.1 Operating Characteristics
Explanation of leveling jacks, generator, lift, and drive operations.
3.2 Tires, Wheels & Drive Assembly
Procedures for tire damage, replacement, and wheel installation.
3.3 Drive Hub
Instructions for roll and leak testing, tightening bolts, and oil information.
3.4 Drive Motor (Sauer)
Details on drive motor description, shaft seal replacement, and troubleshooting.
3.5 Axle Installation
Procedures for axle removal and assembly.
3.6 Steer Installation (All Markets Except for CE and JAPAN)
Instructions for steer cylinder and spindle removal and assembly.
3.7 Steer Installation (CE and Japan Markets)
Specific steer installation procedures for CE and Japan markets.
3.8 Leveling Jacks (If Equipped)
Procedures for removal and assembly of leveling jack cylinders.
3.9 Platform
Instructions for platform removal and installation.
3.10 Scissor Arms
Procedures for lift cylinder and scissor arm removal and assembly.
3.11 Side Compartment Covers
Steps for removing and installing side compartment covers.
3.12 Ground Control Station
Procedures for removal and installation of the ground control station.
3.13 Battery
Instructions for battery removal and installation.
3.14 Fuel Tank
Procedures for fuel tank removal and installation.
3.15 Hydraulic Tank
Steps for hydraulic tank removal and installation.
3.16 Kubota Engine
Instructions for engine tray swing out, and engine removal.
Dual Fuel/LPG System
Procedures for switching between gasoline and LP gas fuels, and using LP gas.
Generator (If Equipped)
Instructions for generator removal and installation.
Exhaust System
Procedures for removing and installing the exhaust system for Gas/LPG and Diesel engines.
Air Cleaner System
Procedures for removing and installing the air cleaner assembly.
Radiator
Procedures for radiator removal and installation.
Engine Electrical Component Locations
Diagrams showing locations of electrical components in the engine compartment.
Hydraulic Pump Installation
Procedures for removing and installing hydraulic pumps.
Pump Coupling Assembly
Procedures for removing and installing the pump coupling assembly.
Engine Speed Sensor (Kubota Diesel Engine)
Instructions for installing the engine speed sensor.
Throttle Actuator Adjustment
Procedure for adjusting the throttle actuator and its air gap setting.
Diagnosis of Actuator
Common failure modes and troubleshooting steps for the throttle actuator.
Adjustment of The Actuator
Procedure for adjusting the throttle actuator linkage and clevis connections.
Adjustment Verification of Actuator
Steps to measure plunger travel and verify actuator operation.
Section 4 - Basic Hydraulic Information & Schematics
4.1 Cylinders - Theory of Operation
Explanation of double acting and single acting cylinder operations.
4.2 Valves - Theory of Operation
Theory of operation for solenoid control valves and relief valves.
4.3 Cylinder Checking Procedure
Procedure for checking cylinders without counterbalance valves and with single counterbalance valves.
4.4 Oscillating Axle - Lockout Cylinder Test (If Equipped)
Test procedure for the oscillating axle lockout cylinder system.
4.5 Drive Pump Pre-fill Procedure
Methods for pre-filling drive pump housing with and without HOC.
4.6 Drive Pump Start-up Procedure
Procedure for starting up a new pump or restarting after removal.
4.7 Hydraulic Component Start-Up Procedures & Recommendations
Start-up procedures and recommendations for hydrostatic systems.
4.8 Hydraulic Valves
Identification and specifications for main hydraulic valves.
Main Hydraulic Valve
Diagram showing port identification for the main hydraulic valve.
Main Hydraulic Valve (CE Only)
Diagram showing port identification for the main hydraulic valve (CE version).
Flow Divider Valve
Diagram illustrating the flow divider valve.
Leveling Jack Directional Valve (If Equipped)
Diagram showing port identification for the leveling jack directional valve.
Leveling Jack Valves (If Equipped)
Diagram and torque specifications for leveling jack valves.
Leveling Jack Manifold Valve (If Equipped)
Diagram and torque specifications for the leveling jack manifold valve.
Pressure Relief Valve - Setting Procedures
Procedures for setting main, steer, and outrigger jack relief valves.
4.9 Gear Pump
Specifications for the tandem gear pump used in diesel applications.
4.10 Axial HI 45 Pump
Specifications and port identification for the Axial HI 45 Pump.
General Repair Instructions
General guidelines for pump removal, cleaning, and securing the unit.
Start-Up Procedure
Procedure for starting up a new pump or restarting after removal.
Removing the Pump
Procedure for removing the pump, including disassembly, inspection, and reassembly.
Electric Control Module
Procedures for removing, inspecting, and reassembling the electric control module.
Control Solenoids
Procedures for removing, inspecting, and reassembling control solenoids.
Shaft Seal, Roller Bearing & Shaft Replacement
Procedures for replacing shaft seal, roller bearing, and shaft.
Charge Pump
Procedure for removing the auxiliary pump and connecting shaft.
Charge Check/HPRV
Procedures for removing, inspecting, and installing High Pressure Relief Valves.
Charge Pressure Relief Valve
Procedure for replacing the charge pressure relief valve.
Pressure Limiter Valve Replacement
Procedure for replacing the pressure limiter valve.
4.11 Charge Pump Filter
Procedures for removing and installing the charge pump filter assembly.
4.12 Cylinder Repair
General procedures for cylinder disassembly, cleaning, inspection, and assembly.
4.13 Cylinder Assemblies
Exploded views and part identification for steer and lift cylinders.
4.14 Hydraulic Schematics
Procedure for bleeding the oscillating axle cylinder.
Section 5 - JLG Control System
5.1 Analyzer
Instructions for connecting the JLG Analyzer to the control system.
Using the Analyzer
Guide to navigating the Analyzer menu and understanding displays.
Changing the Access Level
Procedure to change Analyzer access level by entering a password.
Adjusting Parameters
How to adjust personality settings using UP/DOWN arrow keys.
Machine Setup
Procedure for adjusting machine setup parameters.
System Fault/DTC Indication
How DTC flash codes are indicated and where to find more information.
5.2 Analyzer Menu Flow Chart
Diagram illustrating the Analyzer's menu structure and navigation.
5.3 Diagnostic Troubleshooting Codes (DTC’s) and Flash Codes Description
List of DTC codes, flash codes, descriptions, and item check lists for troubleshooting.
5.4 Chassis Tilt Sensor Installation
Procedure for installing the chassis tilt sensor assembly.
5.5 Location of Additional Sensors
Diagram showing the location of elevation, arm stack tilt, and oscillating axle tilt sensors.
5.6 Calibration Procedures
Steps for calibrating chassis tilt, oscillating axle tilt, set stow elevation, load sensing, and joystick.
Set Stow Elevation
Procedure to set the stow elevation for the platform.
Load Sensing
Calibration procedure for the Load Sensing System.
Joystick
Procedure for calibrating the joystick.
5.7 Service Mode Procedures
Procedures for ECM override, elevation service, EEPROM reset, allow drive, and allow leveling jack retract.
5.8 Machine Configuration and Programming Settings
Table detailing machine configuration and personality settings.
Section 6 - LSS Setup/Calibration/Service
6.1 Connecting the JLG Control System Analyzer
Instructions for connecting the JLG Analyzer to the control system.
6.2 Help Menu & Fault Codes
Explanation of the Help Menu and documentation of LSS Fault Codes.
6.3 Diagnostic Menu
Details and descriptions of the Diagnostic Load Menu parameters.
6.4 Personalities
Explanation of parameters in the PERSONALITIES, LOAD menu for LSS performance adjustment.
6.5 Machine Setup Menu
Procedure to access and configure the LSS within the Machine Setup menu.
6.6 Calibration Menu
Steps to access the Calibration Load Menu for zeroing empty platform weight.
6.7 Service
Description of the Load Sensing System components and their connections.
6.8 Calibration
Procedure for calibrating the LSS module, including testing and evaluation.
6.9 Troubleshooting
Tables providing resolutions for common LSS difficulties (General, Calibration).
Section 7 - General Electrical Information & Schematics
7.1 General
General electrical information and schematics for troubleshooting.
7.2 Multimeter Basics
Instructions on using multimeters for measurements like voltage, resistance, and continuity.
Continuity Measurement Over Long Distances
Method for checking continuity of long harnesses or wires without long leads.
7.3 Applying Silicone Dielectric Compound to Electrical Connections
Procedure and reasons for applying silicone dielectric compound to connectors.
7.4 Dielectric Grease Application
General guidance for applying dielectric grease to connector systems.
7.5 AMP Connector
Procedure for assembling AMP connector contacts and housings.
Service - Voltage Reading
Guidelines for taking voltage readings without piercing wire insulation.
7.6 Working with Deutsch Connectors
Procedures for assembling and disassembling DT/DTP series Deutsch connectors.
HD30/HDP20 Series Connectors
Procedures for assembling and disassembling HD30/HDP20 series connectors.
7.7 Switches
Basic checks for mechanical and inductive limit switches.
7.8 Electrical Schematics
Index of electrical schematic sheets for the 330/430LRT.
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