JLG T350 PVC 2007 Service and Maintenance Manual (31217421) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG T350 PVC 2007 Service and Maintenance Manual (31217421) – PDF DOWNLOAD
31217421_A_T350_JLG Service English...................................................... 1 Section A. Introduction - Maintenance Safety Precautions............................. 3 A General........................................................................ 3 B Hydraulic System Safety........................................................ 3 C Maintenance.................................................................... 3 Table of Content..................................................................... 5 List of Figures...................................................................... 11 List of Tables....................................................................... 14 Section 1. Specifications............................................................ 15 1.1 Operating Specifications..................................................... 15 Machine Specifications....................................................... 15 1.2 Dimensional Data............................................................. 15 Machine Dimensional Data..................................................... 15 1.3 Capacities................................................................... 15 1.4 Electric Power Unit.......................................................... 16 1.5 Tires........................................................................ 16 1.6 Engine....................................................................... 16 1.7 Battery...................................................................... 16 1.8 Batteries (Electric Machines)................................................ 16 1.9 Lubrication.................................................................. 17 Hydraulic Oil................................................................ 17 1.10 Component Weights........................................................... 17 1.11 Pressure Settings........................................................... 17 1.12 Maintenance & Lubrication................................................... 19 1.13 ThreadLocking Compound...................................................... 22 1.14 Torque Charts............................................................... 23 SAE Fastener Torque Chart.................................................... 23 SAE Fastener Torque Chart (Continued)........................................ 24 SAE Fastener Torque Chart (Continued)........................................ 25 SAE Fastener Torque Chart (Continued)........................................ 26 SAE Fastener Torque Chart (Continued)........................................ 27 SAE Fastener Torque Chart (Continued)........................................ 28 Metric Fastener Torque Chart................................................. 29 Metric Fastener Torque Chart (Continued)..................................... 30 Metric Fastener Torque Chart (Continued)..................................... 31 Metric Fastener Torque Chart (Continued)..................................... 32 Section 2. General................................................................... 33 2.1 Machine Preparation, Inspection, and Maintenance............................. 33 General...................................................................... 33 Preparation, Inspection, and Maintenance..................................... 33 Pre-Start Inspection......................................................... 33 Pre-Delivery Inspection and Frequent Inspection.............................. 33 Annual Machine Inspection.................................................... 33 Preventative Maintenance..................................................... 33 2.2 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.................................................................. 36 Battery...................................................................... 36 Lubrication and Servicing.................................................... 36 2.3 Lubrication and Information.................................................. 36 Hydraulic System............................................................. 36 Hydraulic Oil................................................................ 36 Changing Hydraulic Oil....................................................... 36 Lubrication Specifications................................................... 36 2.4 Cylinder Drift............................................................... 37 Theory....................................................................... 37 Platform Drift............................................................... 37 Cylinder Leakage Test........................................................ 37 Cylinder Thermal Drift....................................................... 37 2.5 Pins and Composite Bearing Repair Guidelines................................. 38 2.6 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 Section 3. Chassis & Turntable....................................................... 41 3.1 Breaking-in a New Trailer.................................................... 41 Retighten Lug Nuts at First 10, 25 & 50 Miles................................ 41 Adjust Brake Shoes at First 200 Miles........................................ 41 Synchronizing the Brake Systems.............................................. 41 3.2 Trailer inspection and Service Instructions.................................. 41 Fasteners and Frame Members.................................................. 41 Brake Shoes and Drums........................................................ 41 Manually Adjusting Brake Shoes............................................... 42 3.3 Electric Brakes.............................................................. 42 Brake Controller............................................................. 43 Brake Cleaning and Inspection................................................ 43 Shoes and Linings............................................................ 43 3.4 Hydraulic (Surge) Brakes..................................................... 43 Self Adjusting Mechanism..................................................... 44 Parking Brake................................................................ 44 General Maintenance.......................................................... 44 3.5 Mechanical Brake............................................................. 45 Brake Maintenance............................................................ 45 Adjustment and Readjustment of the Overrun Braking System.................... 48 Troubleshooting.............................................................. 50 3.6 Hubs, Drums, Wheel Bearings.................................................. 55 Hub Removal.................................................................. 55 Brake Drum Inspection........................................................ 55 Bearing Inspection........................................................... 55 Bearing Lubrication.......................................................... 56 Seal Inspection and Replacement.............................................. 56 Bearing Adjustment........................................................... 56 3.7 Tires & Wheels............................................................... 58 Tire Inflation............................................................... 58 Tire Wear.................................................................... 58 Tire Replacement............................................................. 59 Wheel Replacement............................................................ 59 Wheel Installation........................................................... 59 Lug Nuts (Bolts)............................................................. 59 3.8 Hydraulic Brake Coupler...................................................... 61 Troubleshooting.............................................................. 61 Bleeding the Brake System.................................................... 62 Towing....................................................................... 62 Backing Up................................................................... 64 Maintenance.................................................................. 64 Extended Storage Instructions................................................ 64 Proper Towing Checklist...................................................... 64 3.9 COMBINATION COUPLER.......................................................... 65 Bleeding the Brake System.................................................... 65 General Maintenance.......................................................... 65 Servicing the Emergency Lever................................................ 65 3.10 Coupler Assembly............................................................ 66 Engaging Manual Lockout Lever................................................ 66 Servicing the Breakaway Assembly............................................. 66 Actuator Maintenance......................................................... 68 Coupler Maintenance.......................................................... 68 3.11 Hitch Coupler & Axle (CE Only).............................................. 69 Ball Coupler................................................................. 69 Coupling Head Maintenance.................................................... 71 Damper Maintenance........................................................... 72 3.12 Trailer Jack................................................................ 74 Installation................................................................. 74 Operation.................................................................... 74 Maintenance.................................................................. 74 Assembly..................................................................... 75 3.13 Swing Motor................................................................. 76 Removal...................................................................... 76 Disassembly And Inspection................................................... 76 Assembly..................................................................... 83 One Piece Stator Construction................................................ 90 Installation................................................................. 91 3.14 Swing Bearing............................................................... 92 Turntable Bearing Mounting Bolt Condition Check.............................. 92 Wear Tolerance............................................................... 94 Swing Bearing Removal........................................................ 94 Swing Bearing Installation................................................... 95 Swing Bearing Torque Values.................................................. 96 Swing Drive Checks........................................................... 96 3.15 Engine...................................................................... 99 Throttle & Choke Adjustment.................................................. 99 Fuel Valve Lever............................................................. 99 Checking RPM Level........................................................... 99 Choke Actuator............................................................... 99 Checking Oil Level...........................................................100 3.16 Outrigger Cylinder and Stabilizer...........................................102 Removal......................................................................102 Installation.................................................................103 3.17 Outrigger Limit Switches....................................................105 Adjustment...................................................................105 3.18 Automatic Leveling Sensing System...........................................105 3.19 Procedure for Retracting Outriggers Using Service Harness (Optional)........105 3.20 Drive & Set.................................................................106 Drive & Set Interlocks.......................................................108 3.21 Wheel Drive.................................................................112 Removal......................................................................112 Installation.................................................................112 3.22 Drive Motor.................................................................114 Disassembly and Inspection...................................................114 Assembly.....................................................................121 One Piece Stator Construction................................................128 3.23 Drive Engage Cylinder.......................................................130 Removal......................................................................130 Installation.................................................................130 3.24 Batteries (Electric Machines)...............................................131 Quarterly Battery Maintenance................................................131 3.25 Battery Charger.............................................................135 Operating Instructions.......................................................135 Maintenance Instructions.....................................................135 Battery Charger Fault Codes..................................................135 Section 4. Boom & Platform...........................................................137 4.1 Platform and Rotator.........................................................137 Removal......................................................................137 Installation.................................................................138 4.2 Main Boom Powertrack.........................................................139 Removal......................................................................139 Installation.................................................................139 4.3 Boom and Cylinder Assembly...................................................140 Removal......................................................................140 Installation.................................................................140 4.4 Main Boom Assembly...........................................................141 Removal......................................................................141 Disassembly..................................................................142 Assembly.....................................................................144 Installation.................................................................146 4.5 Main Lift Cylinder...........................................................147 Removal......................................................................147 Installation.................................................................147 4.6 Master Cylinder..............................................................148 Removal......................................................................148 Installation.................................................................148 4.7 Platform Level Cylinder......................................................149 Removal......................................................................149 Installation.................................................................149 4.8 Boom Sensors.................................................................151 Boom Elevation Limit Switch..................................................151 4.9 Boom Cleanliness Guidelines..................................................152 4.10 Platform Control Enable System (Trigger)....................................152 4.11 Side Entry Platform.........................................................152 4.12 Hydraulic Manual Descent System.............................................152 4.13 Powertrack Maintenance......................................................153 Remove Link..................................................................153 Install New Link.............................................................156 Replace Fixed End Brackets...................................................159 Replace Moving End Brackets..................................................160 Section 5. Basic Hydraulic Information & Schematics..................................163 5.1 Lubricating O-Rings in the Hydraulic System..................................163 Cup and Brush................................................................163 Dip Method...................................................................164 Spray Method.................................................................164 Brush-on Method..............................................................164 5.2 Hydraulic Cylinders..........................................................165 Cylinder Locations...........................................................165 Disassembly..................................................................167 Assembly.....................................................................173 Outrigger Cylinder...........................................................174 Brake Release Cylinder.......................................................179 Drive Engage Cylinder........................................................183 5.3 Hydraulic Pump (Gear)........................................................188 Removal......................................................................188 Installation.................................................................188 5.4 Pressure Setting Procedure...................................................189 Main Relief..................................................................189 Telescope In.................................................................189 Telescope Out................................................................189 Platform Level Up............................................................189 Platform Level Down..........................................................189 Swing Right..................................................................189 Swing Left...................................................................189 Outrigger Up.................................................................189 5.5 Hydraulic Oil Fill at Startup................................................191 5.6 Hydraulic Hoses..............................................................191 5.7 Hydraulic Filter and Breather................................................191 5.8 Hydraulic Schematics.........................................................200 5.9 Hydraulic Diagram............................................................208 Section 6. JLG Control System........................................................221 6.1 Introduction.................................................................221 6.2 To Connect the JLG Control System Analyzer...................................222 Using the Analyzer...........................................................222 6.3 Changing Access Level........................................................223 6.4 Adjust Parameters............................................................224 6.5 Machine Setup................................................................225 Level Vehicle Description....................................................225 6.6 System Test..................................................................231 Platform Test................................................................231 Ground Test..................................................................233 6.7 Leveling, Tilt Sensor Calibration............................................235 When Machine Is on a Firm Level Surface......................................235 Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure:....236 6.8 User Fault Codes.............................................................237 6.9 Machine Orientation When Setting Speeds......................................246 Test Notes...................................................................246 Section 7. Basic Electrical Information & Schematics.................................259 7.1 General......................................................................259 7.2 Multimeter Basics............................................................259 Grounding....................................................................259 Backprobing..................................................................259 Min/Max......................................................................259 Polarity.....................................................................259 Scale........................................................................259 Voltage Measurement..........................................................259 Resistance Measurement.......................................................260 Continuity Measurement.......................................................260 Current Measurement..........................................................261 7.3 Checking Switches............................................................261 Basic Check..................................................................261 Limit Switches...............................................................262 Automatic Switches...........................................................262 Switch Wiring - Low Side, High Side..........................................262 7.4 Applying Silicone Dielectric Compound to Electrical Connections..............263 Installation of Dielectric Grease............................................263 Deutsch HD, DT, DTM, DRC Series..............................................264 AMP Seal.....................................................................264 AMP Mate-N-Lok...............................................................264 DIN Connectors...............................................................265 Exclusions...................................................................265 Brad Harrison/phoenix Contact M12............................................265 Engine Control Unit Connectors...............................................265 7.5 AMP Connector................................................................266 Applying Silicone Dielectric Compound to AMP Connectors......................266 Assembly.....................................................................266 Disassembly..................................................................268 Wedge Lock...................................................................268 Service - Voltage Reading....................................................268 7.6 Deutsch Connectors...........................................................270 DT/DTP Series Assembly.......................................................270 DT/DTP Series Disassembly....................................................270 HD30/HDP20 Series Assembly...................................................271 HD30/HDP20 Series Disassembly................................................271 7.7 Electrical Component.........................................................272 7.8 Electrical Schematics........................................................280
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