Oshkosh Corporation JLG M400AJPnarrow Manuals

Manuals and User Guides for Oshkosh Corporation JLG M400AJPnarrow. We have 3 Oshkosh Corporation JLG M400AJPnarrow manuals available for free PDF download: Service And Maintenance Manual

Oshkosh Corporation JLG M400AJPnarrow Service And Maintenance Manual (492 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 58 MB

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
20
Operating Specifications
20
Capacities
20
Tires
20
Dimensional Data
21
Lubrication Specifications
21
Hydraulic Oil
21
Critical Stability Weights
22
Torque Specifications
22
Major Component Weights
23
Serial Number Locations
23
Maintenance and Lubrication
25
General
34
Machine Preparation, Inspection, and Maintenance
34
Preparation, Inspection, and Maintenance
34
Pre-Start Inspection
34
Pre-Delivery Inspection and Frequent Inspection
34
Annual Machine Inspection
34
Preventative Maintenance
34
Service and Guidelines
35
General
35
Safety and Workmanship
35
Cleanliness
35
Components Removal and Installation
35
Component Disassembly and Reassembly
36
Pressure-Fit Parts
36
Bearings
36
Gaskets
36
Bolt Usage and Torque Application
36
Hydraulic Lines and Electrical Wiring
36
Hydraulic System
36
Lubrication
37
Battery
37
Lubrication and Servicing
37
Lubrication and Information
37
Hydraulic System
37
Hydraulic Oil
37
Changing Hydraulic Oil
37
Lubrication Specifications
37
Cylinder Drift
38
Theory
38
Cylinder Leakage Test
38
Cylinder Thermal Drift
38
Pins and Composite Bearing Repair Guidelines
39
Welding on JLG Equipment
39
Do the Following When Welding on JLG Equipment
39
Do NOT Do the Following When Welding on JLG Equipment
39
Chassis & Turntable
45
Tires & Wheels
45
Tire Inflation
45
Tire Damage
45
Tire Replacement
45
Wheel Replacement
45
Wheel Installation
45
Spindle
46
Setting Wheel Bearing End Play
46
Specifications
46
Checking
46
Greasing Requirements
46
Tilt Module
49
Speed Sensor
51
Drive Hub
57
Roll and Leak Testing
57
Tightening and Torquing Bolts
57
Main Disassembly
58
Output Carrier Disassembly
60
Input Carrier Disassembly
62
Hub-Spindle Disassembly
63
Cover Disassembly
64
Input Carrier Assembly
65
Output Planet Gear Assembly
65
Output Carrier Assembly
66
Hub-Spindle Assembly
66
Cover Assembly
67
Main Assembly
67
Drive Motor
70
Removal
70
Disassembly
70
Inspection
70
Assembly
71
Installation
71
Swing Bearing
73
Turntable Bearing Mounting Bolt Condition Check
73
Wear Tolerance
74
Replacement of Swing Bearing
75
Swing Bearing Torque Value
79
Checking Worm Gear End Play
79
Adjusting End Play
79
Swing Motor
81
Preparation before Disassembly
84
Disassembly and Inspection
84
Assembly
91
One Piece Stator Construction
97
Two Piece Stator Construction
98
Final Checks
98
Battery Maintenance and Charging
99
Battery Maintenance, Quarterly
99
Optional on Board Generator
99
Battery Charging (on Board Charger)
99
Battery Charger
101
Operating Instructions
101
Maintenance Instructions
102
Battery Charger Fault Codes
102
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
106
Checking/Changing the Battery Charger Algorithm
106
Generator
107
Engine
107
Alternator
107
Dynamo and Dynamo Voltage Regulator
107
Dynamo Output Fuse
107
Control Fuse
107
Start Battery
109
Engine Starter
109
Start Control Relay
109
Fuel Control Relay
110
Glow Plug Control Relay
110
Glow Plug
110
Fuel Pump
111
Fuel Solenoid
111
Engine Low Oil Pressure Switch
111
Engine Oil Temperature Sensor
111
Alternator Output Current Sensor
112
Engine Speed Sensor
112
RBS Engine/Generator Controller
112
Warnings and Safety Precautions
113
System Controls
113
System Status and Performance Monitoring
113
System Settings
113
RBS Start
114
RBS Shutdown
114
RBS Alarms and Flash Codes
115
Resetting the RBS Controller
115
Maintenance Schedule
115
Troubleshooting
116
APU Engine Start Battery Boosting
117
Supplementary Fuse for APU
118
Tools and Material
118
Procedure
118
Boom & Platform
121
Platform
121
Support Removal
121
Support Installation
122
Rotator and Slave Cylinder Removal
124
Removal
124
Installation
124
Main Boom Powertrack
125
Removal
125
Installation
125
Boom Maintenance
126
Removal
126
Disassembly
127
Inspection
127
Assembly
127
Installation
128
Wear Pads
129
Boom Limit Switches
129
Boom Cleanliness Guidelines
129
Articulating Jib Boom
132
Removal
132
Disassembly
132
Inspection
132
Assembly
132
Boom Synchronizing Procedure
133
Footswitch Adjustment
133
Rotary Actuator
134
Theory of Operation
134
Tools Required for Assembly/Disassembly
134
Disassembly
137
Inspection
140
Assembly
141
Installing Counterbalance Valve
145
Greasing Thrust Washers
146
Testing the Actuator
146
Installation and Bleeding
147
Troubleshooting
148
Powertrack Maintenance
149
Removing a Link
149
Installing a New Link
152
Replacing Fixed End Brackets
157
Replacing Moving End Brackets
159
Skyguard
161
Operation
161
Function Test
161
Diagnostics & Troubleshooting
162
Basic Hydraulic Information & Schematics
164
Lubricating O-Rings in the Hydraulic System
164
Cup and Brush
164
Dip Method
165
Spray Method
165
Brush-On Method
165
Hydraulic Connection Assembly and Torque Specification
166
Tapered Thread Types
166
Straight Thread Types, Tube and Hose Connections
166
Straight Thread Types, Port Connections
167
Flange Connection Types
167
Tightening Methods
167
Assembly and Torque Specifications
168
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
169
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
170
Assembly Instructions for 37° (JIC) Flare Fittings
171
Assembly Instructions for 45° SAE Flare Fittings
175
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
177
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
179
Assembly Instructions for Bulkhead (BH) Fittings
181
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
193
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
201
Assembly Instructions for Adjustable Port End (BSPP) Fittings
203
Assembly Instructions for Flange Connections: (FL61 and FL62)
211
Double Wrench Method
214
FFWR and TFFT Methods
215
Adjustable Stud End Assembly
215
O-Ring Installation (Replacement)
216
Hydraulic Cylinders
217
Slave Cylinder (E400AN Only)
217
Slave Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
222
Jib Lift Cylinder
227
Lower Lift Cylinder (E400AN Only)
232
Lower Lift Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
239
MID Lift Cylinder(E400AN Only)
246
MID Lift Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
253
Upper Lift Cylinder
260
Master Cylinder (E400AN Only)
268
Master Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
273
Steer Cylinder
278
Telescope Cylinder (E400AN Only)
283
Telescope Cylinder (E400AJP/M400AJP/E400AJPN/M400AJPN Only)
288
Cylinder Removal and Installation
296
Main Boom Lift Cylinder Removal
296
Main Boom Lift Cylinder Installation
296
MID Boom Lift Cylinder Removal
297
MID Boom Lift Cylinder Installation
297
Lower Boom Lift Cylinder Removal
298
Lower Boom Lift Cylinder Installation
298
Main Boom Telescope Cylinder Removal
299
Main Boom Telescope Cylinder Installation
299
Pressure Setting Procedures
300
Main Relief
300
Main Lift down Relief
300
Lower Lift down Relief
300
Telescope Relief
300
Platform Level up Relief
301
Platform Level down Relief
301
Steer Relief
302
Jib Lift (up and Down) Relief
302
Releveling Valve Relief
302
Jlg Control System
329
Introduction
329
To Connect the JLG Control System Analyzer
330
Using the Analyzer
330
Changing the Access Level of the Hand Held Analyzer
331
Adjusting Parameters Using the Hand Held Analyzer
332
Machine Setup
332
Level Vehicle Description
333
Machine Personality Settings
341
Test Notes
351
Function Speed
351
Help Descriptions and Fault Flash Codes
362
Analyzer Diagnostics Menu Structure
369
System Self Test
375
Calibrating Steer
380
Calibrating Tilt Sensor
382
Calibrating Load Sensing
383
LSS System
386
Diagnostic Menu
387
Calibration Procedure
388
Testing & Evaluation
393
Troubleshooting
394
Resetting the MSSO System
395
Basic Electrical Information & Schematics
415
General
415
Multimeter Basics
415
Grounding
415
Backprobing
415
Min/Max
415
Polarity
415
Scale
415
Voltage Measurement
415
Resistance Measurement
416
Continuity Measurement
416
Current Measurement
417
Checking Switches
417
Basic Check
417
Limit Switches
417
Automatic Switches
418
Switch Wiring - Low Side, High Side
418
Installation of Dielectric Grease
419
Deutsch HD, DT, DTM, DRC Series
419
AWP Seal
419
AMP Mate-N-Lok
420
DIN Connectors
420
Exclusions
420
AMP Connector
422
Applying Silicone Dielectric Compound to AMP Connectors
422
Assembly
422
Disassembly
424
Wedge Lock
424
Service - Voltage Reading
424
DEUTSCH Connectors
426
DT/DTP Series Assembly
426
DT/DTP Series Disassembly
426
HD30/HDP20 Series Assembly
427
HD30/HDP20 Series Disassembly
427
Wiring Harness Connector Labels
428
Connector Labels
428
Component Labels
428

Oshkosh Corporation JLG M400AJPnarrow Service And Maintenance Manual (261 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 20 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
16
Operating Specifications
16
Capacities
16
Battery Charger
16
Drive System
16
Hydraulic Pump/Electric Motor Assembly
16
Generator
16
Tires
16
Dimensional Data
17
Function Speeds
17
Machine Orientation When Doing Function Tests
18
Torque Specifications
18
Cylinder Specifications
19
Major Component Weights
19
Critical Stability Weights
20
Pressure Settings
20
Serial Number Locations
21
Lubrication
21
Lubrication Specifications
21
Operator Maintenance & Lubrication
23
Section 2 - General
34
Machine Preparation, Inspection, and Maintenance
34
General
34
Preparation, Inspection, and Maintenance
34
Pre-Start Inspection
34
Pre-Delivery Inspection and Frequent Inspection
34
Annual Machine Inspection
34
Preventive Maintenance
34
Service and Guidelines
35
General
35
Safety and Workmanship
35
Cleanliness
35
Components Removal and Installation
35
Component Disassembly and Reassembly
36
Pressure-Fit Parts
36
Bearings
36
Gaskets
36
Bolt Usage and Torque Application
36
Hydraulic Lines and Electrical Wiring
36
Hydraulic System
36
Lubrication
36
Battery
36
Lubrication and Servicing
36
Hydraulic Oil
37
Changing Hydraulic Oil
37
Lubrication Specifications
37
Cylinder Drift Test
37
Platform Drift
37
Cylinder Drift
37
Pins and Composite Bearing Repair Guidelines
38
Welding on JLG Equipment
38
Do the Following When Welding on JLG Equipment
38
Do NOT Do the Following When Welding on JLG Equipment
38
Engine Operating Temperature Specifications - Kubota
42
Section 3 - Chassis & Turntable
44
Tires & Wheels
44
Tire Inflation
44
Tire Damage
44
Tire Replacement
44
Wheel Replacement
44
Wheel Installation
44
Spindle
45
Setting Wheel Bearing End Play
45
Specifications
45
Checking
45
Greasing Requirements
45
Drive Hub (Part No. 2780236)
47
Dissembling
47
Disassembly
48
Disassembly of the First Stage Planetary Assembly (7)
48
Disassembly of Second Stage Planet Gears (1)
48
Assembly of First Stage Planetary Assembly (7)
48
Assembly of End Cover Unit (8)
48
Final Assembly
49
Initial Start-Up and after Repairs
49
Maintenance
49
Oil Change Interval-Gear Drive
49
Setting of Tapered Roller Bearings
49
Securing of the Shaft Nut
49
Drive Hub- Cutaway
49
Drive Brake - Mico
51
Disassembly
51
Assembly
51
Bleeding
51
Drive Brake
51
Speed Sensor Adjustment
54
Adjustment Procedure
54
Speed Sensor Orientation
55
Speed Sensor Installation Verification
59
Verification W/ Analyzer Procedure
59
Positrac/Tilt Module
62
Swing Motor - S/N 0300135649 to Present
64
Swing Motor - Cutaway
64
Swing Motor - Exploded View
66
Preparation before Disassembly
67
Disassembly and Inspection
67
Assembly
73
One Piece Stator Construction
80
Two Piece Stator Construction
81
Final Checks
81
Swing Bearing
82
Turntable Bearing Mounting Bolt Condition Check
82
Swing Bearing Feeler Gauge Check
82
Wear Tolerance
83
Swing Bearing Tolerance Boom Placement
83
Replacement of Swing Bearing
84
Swing Bearing Tolerance Measuring Point
84
Swing Bearing Torquing Sequence
85
Swing Bearing Torque Value
86
Checking Worm Gear End Play
86
Adjusting End Play
86
Battery Maintenance and Charging
88
Battery Maintenance, Quarterly
88
Charging Sequence of Remote LED Card
88
Remote LED Card
88
Battery Cable Connections
89
Battery Charging (on Board Charger)
90
Optional on Board Generator
90
Batteries and Battery Charger (Prior to S/N 0300059350)
90
On Board Generator
90
Battery Charger (S/N 0300059350 to Present)
92
Battery Charger ((S/N 0300059350 to Present)
92
Operating Instructions
92
Maintenance Instructions
92
Battery Charger Fault Codes
92
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
95
Checking/Changing the Battery Charger Algorithm
96
Generator (Prior to S/N 88539)
97
Alternator
97
Dynamo and Dynamo Voltage Regulator
97
Dynamo Output Fuse
97
Control Fuse
97
Start Battery
97
Engine Starter
97
Start Control Relay
97
Fuel Control Relay
97
Fuel Solenoid
97
To Connect the JLG Control System Analyzer to the Generator
100
Alarms and Fault Flash Codes
100
Output Current and Voltage Settings
102
Priming the Fuel Line
103
Generator (S/N 88539 to Present)
104
Engine
104
Alternator
104
Dynamo and Dynamo Voltage Regulator
104
Dynamo Output Fuse
104
Control Fuse
104
Start Battery
106
Engine Starter
106
Start Control Relay
106
Fuel Control Relay
107
Glow Plug Control Relay
107
Glow Plug
107
Fuel Pump
108
Fuel Solenoid
108
Engine Low Oil Pressure Switch
108
Engine Oil Temperature Sensor
108
Alternator Output Current Sensor
109
Engine Speed Sensor
109
RBS Engine/Generator Controller
109
Warnings and Safety Precautions
110
System Controls
110
System Status and Performance Monitoring
110
System Settings
110
RBS Start
111
RBS Shutdown
111
RBS Alarms and Flash Codes
112
Resetting the RBS Controller
112
Maintenance Schedule
112
Troubleshooting
113
APU Engine Start Battery Boosting
114
Supplementary Fuse for Apu
115
Tools and Material
115
Procedure
115
Section 4 - Boom & Platform
118
Boom Maintenance
118
Removal
118
Disassembly
118
Inspection
119
Assembly
119
Installation
120
Upper (Main) Boom Lift Cylinder
121
Removal
121
Installation
121
MID Boom Lift Cylinder
121
MID Boom Lift Cylinder Removal
121
Installation
122
Lower Boom Lift Cylinder
122
Removal
122
Lower Boom Lift Cylinder Removal
122
Upper Boom Telescope Cylinder
123
Removal
123
Installation
123
MID and Lower Lift Cylinder Bleeding Procedure
124
Wear Pads
124
Boom Synchronizing Procedure
125
Articulating Jib Boom
125
Removal
125
Disassembly
125
Inspection
125
Assembly
127
Footswitch Adjustment
127
Boom Limit Switches
127
Helac Rotary Actuator
129
Theory of Operation
129
Tools Required for Assembly/Disassembly
132
Disassembly
132
Inspection
136
Assembly
136
Installing Counterbalance Valve
140
Testing the Actuator
140
Installation and Bleeding
142
Troubleshooting
143
Powertrack Maintenance
144
Removing a Link
144
Installing a New Link
147
Replacing Fixed End Brackets
152
Replacing Moving End Brackets
154
Section 5 - Hydraulics
157
Lubricating O-Rings in the Hydraulic System
157
Cup and Brush
157
Dip Method
158
Spray Method
158
Brush-On Method
158
Cylinders - Theory of Operation
159
Double Acting Cylinder
159
Cylinder Checking Procedures
159
Cylinder Without Counterbalance Valves
159
Cylinders with Single Counterbalance Valve
159
Cylinders with Dual Counterbalance Valve
170
Cylinder Repair
170
Disassembly
170
Cleaning and Inspection
171
Assembly
172
Pressure Setting Procedures
176
Main Relief
176
Upper Lift down Relief
176
Lower Lift down Relief
176
Telescope Relief
176
Platform Level up Relief
176
Platform Level down Relief
177
Steer Relief
177
Jib Lift (up and Down) Relief
177
Jib Swing Relief
177
Releveling Valve Relief
177
Section 6 - Jlg Control System
184
JLG Control System Analyzer Kit Instructions
184
Introduction
184
To Connect the JLG Control System Analyzer
185
Using the Analyzer
186
Changing the Access Level of the Hand Held Analyzer
187
Adjusting Parameters Using the Hand Held Analyzer
188
Machine Setup
188
Machine Personality Settings
189
Machine Configuration Programming Information
193
Level Vehicle Description
194
Help Descriptions and Fault Flash Codes
194
Analyzer Diagnostics Menu Structure
204
System Self Test
205
Section 7 - Basic Troubleshooting, Electrical Information, & Schematics
218
General
218
Troubleshooting
218
Multimeter Basics
236
Grounding
236
Backprobing
236
Min/Max
236
Polarity
236
Scale
236
Voltage Measurement
236
Resistance Measurement
237
Continuity Measurement
237
Current Measurement
238
Checking Switches
238
Basic Check
238
Limit Switches
238
Automatic Switches
239
Switch Wiring - Low Side, High Side
239
Applying Silicone Dielectric Compound to Electrical Connections
239
AMP Connector
240
Applying Silicone Dielectric Compound to AMP Connectors
240
Assembly
240
Disassembly
242
Wedge Lock
242
Service - Voltage Reading
242
Deutsch Connectors
244
DT/DTP Series Assembly
244
DT/DTP Series Disassembly
244
HD30/HDP20 Series Assembly
245
HD30/HDP20 Series Disassembly
245

Oshkosh Corporation JLG M400AJPnarrow Service And Maintenance Manual (258 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 16 MB

Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications

15
- Operating Specifications
  15
- Capacities
  15
- Battery Charger
  15
- Drive System
  15
- Hydraulic Pump/Electric Motor Assembly
  15
- Generator
  15
- Tires
  15
- Dimensional Data
  16
- Function Speeds
  16
  - Machine Orientation When Doing Function Tests
    17
- Torque Specifications
  17
- Cylinder Specifications
  18
- Major Component Weights
  18
- Critical Stability Weights
  19
- Pressure Settings
  19
- Serial Number Locations
  20
- Lubrication
  20
  - Lubrication Specifications
    20
- Operator Maintenance & Lubrication
  22
Section 2 - General

33
- Machine Preparation, Inspection, and Maintenance
  33
- Service and Guidelines
  34
  - General
    34
  - Safety and Workmanship
    34
  - Cleanliness
    34
  - Components Removal and Installation
    34
  - Component Disassembly and Reassembly
    35
  - Pressure-Fit Parts
    35
  - Bearings
    35
  - Gaskets
    35
  - Bolt Usage and Torque Application
    35
  - Hydraulic Lines and Electrical Wiring
    35
  - Hydraulic System
    35
  - Lubrication
    35
  - Battery
    35
  - Lubrication and Servicing
    35
  - Hydraulic Oil
    36
  - Changing Hydraulic Oil
    36
  - Lubrication Specifications
    36
- Cylinder Drift Test
  36
  - Platform Drift
    36
  - Cylinder Drift
    36
- Pins and Composite Bearing Repair Guidelines
  37
- Welding on JLG Equipment
  37
  - Do the Following When Welding on JLG Equipment
    37
  - Do NOT Do the Following When Welding on JLG Equipment
    37
- Engine Operating Temperature Specifications - Kubota
  41
Section 3 - Chassis & Turntable

43
- Tires & Wheels
  43
  - Tire Inflation
    43
  - Tire Damage
    43
  - Tire Replacement
    43
  - Wheel Replacement
    43
  - Wheel Installation
    43
- Spindle
  44
  - Setting Wheel Bearing End Play
    44
  - Specifications
    44
  - Checking
    44
  - Greasing Requirements
    44
- Drive Hub (Part No. 2780236)
  46
- Drive Hub- Cutaway
  48
  - Drive Brake - Mico
    50
    
    Disassembly
    50
    
    Assembly
    50
    
    Bleeding
    50
- Drive Brake
  50
  - Speed Sensor Adjustment
    53
    
    Adjustment Procedure
    53
- Speed Sensor Orientation
  54
- Swing Motor - Cutaway
  63
- Swing Motor - Exploded View
  65
  - Preparation before Disassembly
    66
  - Disassembly and Inspection
    66
  - Assembly
    72
  - One Piece Stator Construction
    79
  - Two Piece Stator Construction
    80
  - Final Checks
    80
  - Swing Bearing
    81
    
    Turntable Bearing Mounting Bolt Condition Check
    81
- Swing Bearing Feeler Gauge Check
  81
  - Wear Tolerance
    82
- Swing Bearing Tolerance Boom Placement
  82
  - Replacement of Swing Bearing
    83
- Swing Bearing Tolerance Measuring Point
  83
- Swing Bearing Torquing Sequence
  84
- Remote LED Card
  87
- Battery Cable Connections
  88
  - Battery Charging (on Board Charger)
    89
  - Optional on Board Generator
    89
- Batteries and Battery Charger (Prior to S/N 0300059350)
  89
- On Board Generator
  89
  - Battery Charger (S/N 0300059350 to Present)
    91
- Battery Charger ((S/N 0300059350 to Present)
  91
  - Operating Instructions
    91
  - Maintenance Instructions
    91
  - Battery Charger Fault Codes
    91
  - Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
    94
  - Checking/Changing the Battery Charger Algorithm
    95
  - Generator (Prior to S/N 88539)
    96
    
    Alternator
    96
    
    Dynamo and Dynamo Voltage Regulator
    96
    
    Dynamo Output Fuse
    96
    
    Control Fuse
    96
    
    Start Battery
    96
    
    Engine Starter
    96
    
    Start Control Relay
    96
    
    Fuel Control Relay
    96
    
    Fuel Solenoid
    96
    
    To Connect the JLG Control System Analyzer to the Generator
    99
    
    Alarms and Fault Flash Codes
    99
    
    Output Current and Voltage Settings
    101
    
    Priming the Fuel Line
    102
  - Generator (S/N 88539 to Present)
    103
    
    Engine
    103
    
    Alternator
    103
    
    Dynamo and Dynamo Voltage Regulator
    103
    
    Dynamo Output Fuse
    103
    
    Control Fuse
    103
    
    Start Battery
    105
    
    Engine Starter
    105
    
    Start Control Relay
    105
    
    Fuel Control Relay
    106
    
    Glow Plug Control Relay
    106
    
    Glow Plug
    106
    
    Fuel Pump
    107
    
    Fuel Solenoid
    107
    
    Engine Low Oil Pressure Switch
    107
    
    Engine Oil Temperature Sensor
    107
    
    Alternator Output Current Sensor
    108
    
    Engine Speed Sensor
    108
    
    RBS Engine/Generator Controller
    108
    
    Warnings and Safety Precautions
    109
    
    System Controls
    109
    
    System Status and Performance Monitoring
    109
    
    System Settings
    109
    
    RBS Start
    110
    
    RBS Shutdown
    110
    
    RBS Alarms and Flash Codes
    111
    
    Resetting the RBS Controller
    111
    
    Maintenance Schedule
    111
    
    Troubleshooting
    112
    
    APU Engine Start Battery Boosting
    113
  - Supplementary Fuse for Apu
    114
    
    Tools and Material
    114
    
    Procedure
    114
Section 4 - Boom & Platform

117
- Boom Maintenance
  117
  - Removal
    117
  - Disassembly
    117
  - Inspection
    118
  - Assembly
    118
  - Installation
    119
- Upper (Main) Boom Lift Cylinder
  120
  - Removal
    120
  - Installation
    120
- MID Boom Lift Cylinder
  120
- MID Boom Lift Cylinder Removal
  120
  - Installation
    121
  - Lower Boom Lift Cylinder
    121
    
    Removal
    121
- Lower Boom Lift Cylinder Removal
  121
  - Upper Boom Telescope Cylinder
    122
    
    Removal
    122
    
    Installation
    122
- Upper Telescope Cylinder Removal
  122
  - MID and Lower Lift Cylinder Bleeding Procedure
    123
  - Wear Pads
    123
  - Boom Synchronizing Procedure
    124
  - Articulating Jib Boom
    124
    
    Removal
    124
    
    Disassembly
    124
    
    Inspection
    124
    
    Assembly
    126
  - Footswitch Adjustment
    126
  - Boom Limit Switches
    126
  - Helac Rotary Actuator
    128
    
    Theory of Operation
    128
    
    Tools Required for Assembly/Disassembly
    131
    
    Disassembly
    131
    
    Inspection
    135
    
    Assembly
    135
    
    Installing Counterbalance Valve
    139
    
    Testing the Actuator
    139
    
    Installation and Bleeding
    141
    
    Troubleshooting
    142
  - Powertrack Maintenance
    143
    
    Removing a Link
    143
    
    Installing a New Link
    146
    
    Replacing Fixed End Brackets
    151
    
    Replacing Moving End Brackets
    153
Section 5 - Hydraulics

155
- Lubricating O-Rings in the Hydraulic System
  155
  - Cup and Brush
    155
  - Dip Method
    156
  - Spray Method
    156
  - Brush-On Method
    156
- Cylinders - Theory of Operation
  157
  - Double Acting Cylinder
    157
- Cylinder Checking Procedures
  157
- Cylinder Repair
  168
  - Disassembly
    168
  - Cleaning and Inspection
    169
  - Assembly
    170
- Pressure Setting Procedures
  174
  - Main Relief
    174
  - Upper Lift down Relief
    174
  - Lower Lift down Relief
    174
  - Telescope Relief
    174
  - Platform Level up Relief
    174
  - Platform Level down Relief
    175
  - Steer Relief
    175
  - Jib Lift (up and Down) Relief
    175
  - Jib Swing Relief
    175
  - Releveling Valve Relief
    175
Section 6 - Jlg Control System

181
- JLG Control System Analyzer Kit Instructions
  181
  - Introduction
    181
  - To Connect the JLG Control System Analyzer
    182
  - Using the Analyzer
    183
  - Changing the Access Level of the Hand Held Analyzer
    184
  - Adjusting Parameters Using the Hand Held Analyzer
    185
  - Machine Setup
    185
  - Machine Personality Settings
    186
  - Machine Configuration Programming Information
    190
  - Level Vehicle Description
    191
  - Help Descriptions and Fault Flash Codes
    191
  - Analyzer Diagnostics Menu Structure
    201
  - System Self Test
    202
Section 7 - Basic Troubleshooting, Electrical Information, & Schematics

215
- General
  215
- Troubleshooting
  215
- Multimeter Basics
  233
  - Grounding
    233
  - Backprobing
    233
  - Min/Max
    233
  - Polarity
    233
  - Scale
    233
  - Voltage Measurement
    233
  - Resistance Measurement
    234
  - Continuity Measurement
    234
  - Current Measurement
    235
- Checking Switches
  235
  - Basic Check
    235
  - Limit Switches
    235
  - Automatic Switches
    236
  - Switch Wiring - Low Side, High Side
    236
- Applying Silicone Dielectric Compound to Electrical Connections
  236
- AMP Connector
  237
  - Applying Silicone Dielectric Compound to AMP Connectors
    237
  - Assembly
    237
  - Disassembly
    239
  - Wedge Lock
    239
  - Service - Voltage Reading
    239
- Deutsch Connectors
  241
  - DT/DTP Series Assembly
    241
  - DT/DTP Series Disassembly
    241
  - HD30/HDP20 Series Assembly
    242
  - HD30/HDP20 Series Disassembly
    242

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Section 1 - Specifications

Section 2 - General

Section 3 - Chassis & Turntable

Section 4 - Boom & Platform

Section 5 - Hydraulics

Section 6 - Jlg Control System

Section 7 - Basic Troubleshooting, Electrical Information, & Schematics

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