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JLG 40H User Manual

JLG 40H
152 pages
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Service and Maintenance Manual
ANSI
Model
40H
40H+6
3120240
October 11, 2001

Table of Contents

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JLG 40H Specifications

General IconGeneral
Platform Height40 ft
Weight12, 700 lb
Working Height46 ft
Fuel TypeDiesel
Gradeability45 %
Platform Capacity500 lbs
Machine Height8.2 ft
EngineDiesel
Stowed Height8.2 ft

Summary

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A GENERAL

Outlines general safety precautions for aerial platform maintenance.

A.B HYDRAULIC SYSTEM SAFETY

Details safety measures for high-pressure hydraulic systems.

A.C MAINTENANCE

Covers general safety procedures during maintenance tasks.

EFFECTIVITY CHANGES

REVISON LOG

Lists revisions made to the manual over time.

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Specifies fluid capacities for fuel, hydraulic oil, and engine systems.

1.2 COMPONENT DATA

Provides technical data for various engine models used.

1.3 PERFORMANCE DATA

Details operational performance metrics like travel speed and gradeability.

1.4 TORQUE REQUIREMENTS

Lists torque specifications for critical fasteners and components.

1.5 LUBRICATION

Specifies lubricants and intervals for machine components.

1.6 PRESSURE SETTINGS

Lists hydraulic system pressure settings for various valves.

1.7 CYLINDER SPECIFICATIONS

Details bore, stroke, and rod diameter for machine cylinders.

1.8 BOOM TAPE

Specifies lengths for boom tape sections.

1.9 MAJOR COMPONENTS WEIGHTS

Lists weights of major machine components for handling.

1.10 CRITICAL STABILITY WEIGHTS

Provides weight data crucial for machine stability.

1.11 SERIAL NUMBER LOCATION

Guides on how to locate the machine's serial number.

SECTION 2 - PROCEDURES

2.1 GENERAL

Provides an overview of maintenance procedures and safety.

2.2 SERVICING AND MAINTENANCE GUIDELINES

Outlines general principles for servicing and maintenance.

2.3 LUBRICATION INFORMATION

Details on hydraulic oil types, viscosity, and contamination.

2.4 CYLINDERS - THEORY OF OPERATION

Explains the function of double-acting hydraulic cylinders.

2.5 VALVES - THEORY OF OPERATION

Explains solenoid and bang-bang control valve operation.

2.6 BOOM CHAINS

Covers procedures for adjusting and inspecting boom chains.

2.7 WEAR PADS

Provides guidelines for wear pad shimming and replacement.

2.8 CYLINDER CHECKING PROCEDURE

Details methods for checking hydraulic cylinder leakage.

2.9 CYLINDER REPAIR

Outlines general procedures for cylinder disassembly and repair.

2.10 CYLINDER REMOVAL AND INSTALLATION

Provides steps for removing and installing telescope cylinders.

2.11 BOOM MAINTENANCE

Covers boom assembly removal and disassembly procedures.

2.12 TILT ALARM SWITCH

Details manual and voltmeter methods for adjusting the tilt alarm switch.

2.13 HORIZONTAL HIGH SPEED CUTOUT SWITCH ADJUSTMENT PROCEDURE

Procedure for adjusting the horizontal high speed cutout switch.

2.14 GOVERNOR CHECKS AND ADDCO ADJUSTMENT, FORD

Covers checks and adjustments for Ford engine governor systems.

2.15 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS, ADDCO

Details throttle checks and governor adjustments for Addco systems.

Choke Adjustments

Provides instructions for adjusting the automatic choke.

Carburetor and Governor Adjustment

Covers carburetor and governor adjustments for Ford engines.

2.16 ELECTRIC GOVERNOR AND ADJUSTMENTS - FORD ENGINES

Details installation and adjustment of electric governors on Ford engines.

Governor Adjustments (Mid Engine, Start Lockout, Over Speed, Factory)

Covers adjustments for governor settings like mid engine, start lockout, over speed, and factory.

Troubleshooting Governor Issues

Provides steps for diagnosing and fixing governor problems.

Automatic Choke Adjustment Procedure

Details the procedure for adjusting the automatic choke.

2.21 PRESSURE SETTING PROCEDURES

Lists procedures for setting hydraulic pressure for various valves.

2.22 RACINE PROPORTIONAL AIR GAP ADJUSTMENT

Procedure to adjust the air gap on Racine proportional valves.

2.23 SWING BEARING

Covers checking turntable bearing mounting bolt condition.

2.24 TORQUE HUB, 2W/D

Details disassembly and assembly of 2WD torque hubs.

2.25 TORQUE HUB 4WD

Details disassembly and assembly of 4WD torque hubs.

2.26 SWING DRIVE BRAKE, MICO

Covers disassembly and assembly of Mico swing drive brakes (prior to May 1992).

2.29 DRIVE BRAKE, AUSCO

Covers disassembly and assembly of Ausco drive brakes (prior to May 1992).

2.30 DRIVE BRAKE, MICO

Details disassembly and assembly of Mico drive brakes (May 1992 to S/N 33476).

2.31 SWING BRAKE, MICO

Details disassembly and assembly of Mico swing brakes (May 1992 to S/N 33476).

2.32 DRIVE BRAKE, MICO

Details disassembly and assembly of Mico drive brakes (S/N 33476 to present).

2.33 SWING BRAKE, MICO

Details disassembly and assembly of Mico swing brakes (S/N 33476 to present).

2.35 OSCILLATING AXLE BLEEDING PROCEDURE

Procedures for bleeding lockout cylinders with and without holding valves.

2.36 OSCILLATING AXLE LOCKOUT TEST

Test procedure to verify the oscillating axle lockout system function.

2.43 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Schedule for routine maintenance and inspections of machine components.

SECTION 3 - TROUBLESHOOTING

3.1 GENERAL

General information on using the troubleshooting section.

3.2 TROUBLESHOOTING INFORMATION

Overview of troubleshooting procedures and system divisions.

Platform Assembly Troubleshooting

Troubleshooting guide for platform leveling system issues.

Boom Assembly Troubleshooting

Troubleshooting guide for boom elevation and extension system issues.

Boom Extension and Retraction Troubleshooting

Troubleshooting for boom extension and retraction problems.

Boom Swing System Troubleshooting

Troubleshooting for boom swing system issues.

Turntable Assembly Troubleshooting

Troubleshooting guide for engine start and run issues.

Chassis Assembly Troubleshooting

Troubleshooting for control valves, fuel system, and front frame axle issues.

Rear Frame Axle and Drive System Troubleshooting

Troubleshooting for machine movement and drive system issues.

Steering System Troubleshooting

Troubleshooting for steering system response and erratic movement.

Hydraulic Assembly Troubleshooting

Troubleshooting for hydraulic pump noise, cavitation, and overheating.

Hydraulic System Performance Issues

Troubleshooting for sluggish operation, erratic system behavior, and auxiliary pump issues.

Platform Controls Troubleshooting

Troubleshooting for platform control power and switch issues.

Engine Starter System Troubleshooting

Troubleshooting for starter motor, relay, and ignition switch problems.

Instruments and Indicators Troubleshooting

Troubleshooting for hourmeter, tilt alarm, wheel motor speed, and high engine speed.

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