JLG T500J PVC 2001 Service and Maintenance Manual (31215071) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG T500J PVC 2001 Service and Maintenance Manual (31215071) – PDF DOWNLOAD
31215071_A_T500J_JLG_Service_English..................................................... 1 Section A. Introduction - Maintenance Safety Precautions............................. 3 A General........................................................................ 3 B Hydraulic System Safety........................................................ 3 C Maintenance.................................................................... 3 Revision Log......................................................................... 4 Table of Contents.................................................................... 5 Section 1. Specifications............................................................ 15 1.1 Operating Specifications..................................................... 15 1.2 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.................................................. 56 Hub Removal.................................................................. 56 Brake Drum Inspection........................................................ 56 Bearing Inspection........................................................... 56 Bearing Lubrication.......................................................... 56 Seal Inspection and Replacement.............................................. 57 Bearing Adjustment........................................................... 57 3.7 Tires & Wheels............................................................... 59 Tire Inflation............................................................... 59 Tire Wear.................................................................... 59 Tire Replacement............................................................. 60 Wheel Replacement............................................................ 60 Wheel Installation........................................................... 60 Lug Nuts (Bolts)............................................................. 60 3.8 Coupler Assembly............................................................. 62 Engaging Manual Lockout Lever................................................ 62 Servicing the Breakaway Assembly............................................. 62 Actuator Maintenance......................................................... 64 Coupler Maintenance.......................................................... 64 3.9 Hitch Coupler & Axle (CE Only)............................................... 65 Ball Coupler................................................................. 65 Coupling Head Maintenance.................................................... 67 Damper Maintenance........................................................... 68 3.10 Trailer Jack................................................................ 70 Installation................................................................. 70 Operation.................................................................... 70 Maintenance.................................................................. 70 Assembly..................................................................... 71 3.11 Swing Motor................................................................. 72 Removal...................................................................... 72 Disassembly and Inspection................................................... 72 Assembly..................................................................... 79 One Piece Stator Construction................................................ 86 Installation................................................................. 87 3.12 Swing Bearing............................................................... 88 Turntable Bearing Mounting Bolt Condition Check.............................. 88 Wear Tolerance............................................................... 90 Swing Bearing Removal........................................................ 90 Swing Bearing Installation................................................... 91 Swing Bearing Torque Values.................................................. 92 Swing Drive Checks........................................................... 92 3.13 Engine...................................................................... 95 Throttle & Choke Adjustment.................................................. 95 Fuel Valve Lever............................................................. 95 Checking RPM Level........................................................... 95 Choke Actuator............................................................... 95 Checking Oil Level........................................................... 96 3.14 Outrigger cylinder and Stabilizer........................................... 98 Removal...................................................................... 98 Installation................................................................. 99 3.15 Outrigger Limit Switches....................................................101 Adjustment...................................................................101 3.16 Automatic Leveling Sensing System...........................................101 3.17 Procedure For Retracting Outriggers Using Service Harness (Optional)........101 3.18 Drive & Set.................................................................102 Drive & Set Interlocks.......................................................104 3.19 Wheel Drive.................................................................108 Removal......................................................................108 Installation.................................................................108 3.20 Drive Motor.................................................................110 Disassembly and inspection...................................................110 Assembly.....................................................................117 One Piece Stator Construction................................................124 3.21 Drive Engage Cylinder.......................................................126 Removal......................................................................126 Installation.................................................................126 3.22 Batteries (Electric Machines)...............................................127 Quarterly Battery Maintenance................................................127 3.23 Battery Charger.............................................................131 Operating Instructions.......................................................131 Maintenance Instructions.....................................................131 Battery Charger Fault Codes..................................................131 Section 4. Boom & Platform...........................................................133 4.1 Platform and Rotator.........................................................133 Removal......................................................................133 Installation.................................................................134 4.2 Main Boom Powertrack.........................................................135 Removal......................................................................135 Installation.................................................................135 4.3 Boom and Cylinder Assembly...................................................136 Removal......................................................................136 Installation.................................................................136 4.4 Main Boom Assembly...........................................................137 Removal......................................................................137 Disassembly..................................................................138 Assembly.....................................................................140 Installation.................................................................142 4.5 Main Lift Cylinder...........................................................143 Removal......................................................................143 Installation.................................................................143 4.6 Master Cylinder..............................................................144 Removal......................................................................144 Installation.................................................................144 4.7 Platform Level Cylinder......................................................145 Removal......................................................................145 Installation.................................................................145 4.8 Jib Cylinder.................................................................146 Removal......................................................................146 Installation.................................................................146 4.9 Boom Sensors.................................................................148 Boom Elevation Limit Switch..................................................148 4.10 Boom Cleanliness Guidelines.................................................149 4.11 Platform Control Enable System (Trigger)....................................149 4.12 Side Entry Platform.........................................................149 4.13 Hydraulic Manual Descent System.............................................149 4.14 Powertrack Maintenance......................................................150 Remove Link..................................................................150 Install New Link.............................................................153 Replace Fixed End Brackets...................................................156 Replace Moving End Brackets..................................................157 Section 5. Basic Hydraulic Information & Schematics..................................159 5.1 Lubricating O-Rings in the Hydraulic System..................................159 Cup and Brush................................................................159 Dip Method...................................................................160 Spray Method.................................................................160 Brush-on Method..............................................................160 5.2 Hydraulic Cylinders..........................................................161 Cylinder Locations...........................................................161 Disassembly..................................................................163 Cleaning and Inspection......................................................169 Assembly.....................................................................170 Outrigger Cylinder...........................................................171 Brake Release Cylinder.......................................................176 Drive Engage Cylinder........................................................180 5.3 Hydraulic Pump (Gear)........................................................185 Removal......................................................................185 Installation.................................................................185 5.4 Pressure Setting Procedure...................................................186 Main Relief..................................................................186 Telescope In.................................................................186 Telescope Out................................................................186 Platform Level Up............................................................186 Platform Level Down..........................................................186 Swing Right..................................................................186 Swing Left...................................................................186 Outrigger Up.................................................................186 5.5 Hydraulic Oil Fill at Startup................................................188 5.6 Hydraulic Hoses..............................................................188 5.7 Hydraulic Filter and Breather................................................188 5.8 Hydraulic Schematics.........................................................198 5.9 Hydraulic Diagram............................................................206 Section 6. JLG Control System........................................................219 6.1 Introduction.................................................................219 6.2 To Connect the JLG Control System Analyzer...................................220 Using the Analyzer...........................................................220 6.3 Changing Access Level........................................................221 6.4 Adjust Parameters............................................................222 6.5 Machine Setup................................................................223 Level Vehicle Description....................................................223 6.6 System Test..................................................................229 Platform Test................................................................229 Ground Test..................................................................231 6.7 Leveling, Tilt Sensor Calibration............................................233 When Machine Is on a Firm Level Surface......................................233 Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure:....234 6.8 User Fault Codes.............................................................235 6.9 Machine Orientation When Setting Speeds......................................244 Test Notes...................................................................244 Section 7. Basic Electrical Information & Schematics.................................257 7.1 General......................................................................257 7.2 Multimeter Basics............................................................257 Grounding....................................................................257 Backprobing..................................................................257 Min/Max......................................................................257 Polarity.....................................................................257 Scale........................................................................257 Voltage Measurement..........................................................257 Resistance Measurement.......................................................258 Continuity Measurement.......................................................258 Current Measurement..........................................................259 7.3 Checking Switches............................................................259 Basic Check..................................................................259 Limit Switches...............................................................260 Automatic Switches...........................................................260 Switch Wiring - Low Side, High Side..........................................260 7.4 Applying Silicone Dielectric Compound to Electrical Connections..............261 Installation of Dielectric Grease............................................261 Deutsch HD, DT, DTM, DRC Series..............................................262 AMP Seal.....................................................................262 AMP Mate-N-Lok...............................................................262 DIN Connectors...............................................................263 Exclusions...................................................................263 Brad Harrison/phoenix Contact M12............................................263 Engine Control Unit Connectors...............................................263 7.5 AMP Connector................................................................264 Applying Silicone Dielectric Compound to AMP Connectors......................264 Assembly.....................................................................264 Disassembly..................................................................266 Wedge Lock...................................................................266 Service - Voltage Reading....................................................266 7.6 Deutsch Connectors...........................................................268 DT/DTP Series Assembly.......................................................268 DT/DTP Series Disassembly....................................................268 HD30/HDP20 Series Assembly...................................................269 HD30/HDP20 Series Disassembly................................................269 7.7 Electrical Component.........................................................270 7.8 Electrical Schematics........................................................278
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