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JLG 40H+6 User Manual

JLG 40H+6
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+6 Specifications

General IconGeneral
Power SourceDiesel
Gradeability - 4WD45%
Lift Capacity500 lb
Ground Clearance12 in
Platform Dimensions30 in x 72 in

Summary

Service and Maintenance Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A.A GENERAL

General safety precautions for aerial platform maintenance.

A.B HYDRAULIC SYSTEM SAFETY

Safety precautions for high-pressure hydraulic systems.

A.C MAINTENANCE

General maintenance safety precautions and warnings.

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Details fluid and lubricant capacities for various machine components.

1.2 COMPONENT DATA

Provides technical data for different engine models and drive systems.

1.3 PERFORMANCE DATA

Lists travel speed, gradeability, turning radius, and boom speeds.

1.4 TORQUE REQUIREMENTS

Specifies torque values for various fasteners and components.

1.5 LUBRICATION

Details lubrication points, types, and intervals for machine components.

1.6 PRESSURE SETTINGS

Lists hydraulic system pressure settings for various valves and functions.

1.7 CYLINDER SPECIFICATIONS

Provides bore, stroke, and rod diameter for hydraulic cylinders.

1.8 BOOM TAPE

Lists boom tape lengths for different boom configurations.

1.9 MAJOR COMPONENTS WEIGHTS

Details weight specifications for major machine components.

1.10 CRITICAL STABILITY WEIGHTS

Lists critical weight data for stability calculations.

1.11 SERIAL NUMBER LOCATION

Explains how to find the machine's serial number.

SECTION 2. PROCEDURES

2.1 GENERAL

Provides an overview of maintenance procedures and safety guidelines.

2.2 SERVICING AND MAINTENANCE GUIDELINES

Offers general guidance on safety, workmanship, and cleanliness during maintenance.

2.3 LUBRICATION INFORMATION

Details hydraulic system lubrication, specifications, and recommendations.

2.4 CYLINDERS - THEORY OF OPERATION

Explains the operation of double-acting cylinders in hydraulic systems.

2.5 VALVES - THEORY OF OPERATION

Describes the function of solenoid control valves (Bang-Bang).

2.6 BOOM CHAINS

Details procedures for adjusting and inspecting boom chains.

2.8 CYLINDER CHECKING PROCEDURE

Outlines procedures for checking hydraulic cylinders for leaks.

2.9 CYLINDER REPAIR

Provides general procedures for disassembling, cleaning, inspecting, and assembling cylinders.

2.10 CYLINDER REMOVAL AND INSTALLATION

Details the removal and installation procedures for telescope cylinders.

2.11 BOOM MAINTENANCE

Covers the removal and disassembly of the boom assembly.

2.12 TILT ALARM SWITCH

Explains how to adjust the tilt alarm switch using manual or voltmeter methods.

2.13 HORIZONTAL HIGH SPEED CUTOUT SWITCH ADJUSTMENT PROCEDURE

Describes how to adjust the horizontal high speed cutout switch.

2.14 GOVERNOR CHECKS AND ADDCO ADJUSTMENT, FORD

Details checks and adjustments for Ford engines with Addco governor systems.

2.15 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS, ADDCO

Covers throttle checks and governor adjustments for Addco systems.

2.16 ELECTRIC GOVERNOR AND ADJUSTMENTS - FORD ENGINES

Provides instructions for installing and adjusting electric governors on Ford engines.

2.18 THROTTLE CHECKS AND ADJUSTMENTS WISCONSIN ENGINE

Covers throttle checks and adjustments for Wisconsin engines.

2.19 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ F3L912 ENGINE

Details throttle checks and adjustments for Deutz F3L912 engines.

2.20 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ ENGINE F3L1011

Details throttle checks and adjustments for Deutz F3L1011 engines.

2.21 PRESSURE SETTING PROCEDURES

Outlines procedures for setting hydraulic pressure for various valves.

2.22 RACINE PROPORTIONAL AIR GAP ADJUSTMENT

Procedure for adjusting the air gap on Racine proportional valves.

2.23 SWING BEARING

Procedures for checking the condition of the turntable bearing mounting bolts.

2.24 TORQUE HUB, 2W/D

Disassembly and cleaning/inspection procedures for 2WD torque hubs.

2.25 TORQUE HUB 4WD

Disassembly and cleaning/inspection procedures for 4WD torque hubs.

2.26 SWING DRIVE BRAKE, MICO (MACHINES BUILT PRIOR TO MAY 1992)

Disassembly, cleaning, inspection, and assembly of Mico swing drive brakes.

2.29 DRIVE BRAKE, AUSCO. (MACHINES BUILT PRIOR TO MAY 1992)

Disassembly, cleaning, inspection, and assembly of Ausco drive brakes.

2.30 DRIVE BRAKE, MICO. (MACHINES BUILT FROM MAY 1992 TO S/N 33476)

Disassembly, inspection, and assembly of Mico drive brakes for specific serial numbers.

2.31 SWING BRAKE, MICO. (MACHINES BUILT FROM MAY 1992 TO S/N 33476)

Disassembly, inspection, and assembly of Mico swing brakes for specific serial numbers.

2.32 DRIVE BRAKE, MICO. (MACHINES BUILT FROM S/N 33476 TO PRESENT)

Disassembly, inspection, and assembly of Mico drive brakes for later serial numbers.

2.33 SWING BRAKE, MICO.(MACHINES BUILT FROM S/N 33476 TO PRESENT)

Disassembly, inspection, and assembly of Mico swing brakes for later serial numbers.

2.35 OSCILLATING AXLE BLEEDING PROCEDURE

Procedures for bleeding lockout cylinders with and without holding valves.

2.36 OSCILLATING AXLE LOCKOUT TEST

Tests the function of the oscillating axle lockout system.

2.43 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Provides a schedule for preventive maintenance and inspections.

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

Introduction to troubleshooting information for aerial platform operating problems.

3.2 TROUBLESHOOTING INFORMATION

Lists troubleshooting procedures divided into major system groups.

3.3 HYDRAULIC CIRCUIT CHECKS

Guidelines for diagnosing hydraulic system issues starting with the power source.

Table 3-1. Platform Assembly Troubleshooting

Troubleshooting guide for platform leveling system issues.

Table 3-2. Boom Assembly Troubleshooting

Troubleshooting guide for boom elevation system problems.

Table 3-3. Turntable Assembly Troubleshooting

Troubleshooting guide for turntable power plant issues.

Table 3-4. Chassis Assembly Troubleshooting

Troubleshooting guide for chassis system issues.

Table 3-5. Hydraulic Assembly Troubleshooting

Troubleshooting guide for hydraulic system issues.

Table 3-6. Electrical Assembly Troubleshooting

Troubleshooting guide for electrical system issues.

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