JLG 18RS 18RSJ Service & Maintenance Manual (3121284)-PDF Download (Eng)

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JLG 18RS 18RSJ Service & Maintenance Manual (3121284)-PDF Download

TABLE OF CONTENTS:

JLG 18RS 18RSJ Service & Maintenance Manual (3121284)-PDF Download

Section 1. Specifications.................................................. 13
	1.1 Operating Specifications........................................... 13
		Operating Specifications........................................... 13
		Dimensional Data................................................... 13
		Capacities......................................................... 13
		Tires.............................................................. 13
		Engine Data........................................................ 13
		Hydraulic Oil...................................................... 14
		Major Component Weights............................................ 14
	1.2 Function Speeds.................................................... 14
	1.3 Operator Maintenance............................................... 18
Section 2. General......................................................... 27
	2.1 Machine Preparation, Inspection, and Maintenance................... 27
		General............................................................ 27
		Preparation, Inspection, and Maintenance........................... 27
		Pre-Start Inspection............................................... 27
		Pre-Delivery Inspection and Frequent Inspection.................... 27
		Annual Machine Inspection.......................................... 27
		Preventative Maintenance........................................... 27
	2.2 Service and Guidelines............................................. 28
		General............................................................ 28
		Safety and Workmanship............................................. 28
		Cleanliness........................................................ 28
		Components Removal and Installation................................ 28
		Component Disassembly and Reassembly............................... 29
		Pressure-Fit Parts................................................. 29
		Bearings........................................................... 29
		Gaskets............................................................ 29
		Bolt Usage and Torque Application.................................. 29
		Hydraulic Lines and Electrical Wiring.............................. 29
		Hydraulic System................................................... 29
		Lubrication........................................................ 30
		Battery............................................................ 30
		Lubrication and Servicing.......................................... 30
	2.3 Lubrication and Information........................................ 30
		Hydraulic System................................................... 30
		Hydraulic Oil...................................................... 30
		Changing Hydraulic Oil............................................. 30
		Lubrication Specifications......................................... 30
	2.4 Cylinder Drift Test................................................ 31
		Theory............................................................. 31
		Cylinder Leakage Test.............................................. 31
		Cylinder Thermal Drift............................................. 31
	2.5 Pins and Composite Bearing Repair Guidelines....................... 32
	2.6 Welding on JLG Equipment........................................... 32
		Do the Following When Welding on JLG Equipment..................... 32
		Do NOT Do the Following When Welding on JLG Equipment.............. 32
Section 3. Chassis & Turntable............................................. 37
	3.1 Tires and Wheels................................................... 37
		Tire Replacement................................................... 37
		Wheel and Tire Replacement......................................... 37
		Wheel Installation................................................. 37
	3.2 Drive Orientation System........................................... 38
	3.3 Drive System....................................................... 38
	3.4 Steer Cylinder..................................................... 39
		Removal............................................................ 39
		Installation....................................................... 39
	3.5 Drive Hub.......................................................... 41
		Removal............................................................ 41
		Installation....................................................... 44
	3.6 Drive Motor........................................................ 44
		Removal............................................................ 44
		Disassembly........................................................ 44
		End Cover Disassembly.............................................. 46
		Cleaning........................................................... 46
		Measuring And Replacement.......................................... 46
		Lubrication........................................................ 46
		Assembly........................................................... 46
		Assembly of End Cover.............................................. 47
		Installation....................................................... 48
	3.7 Swing Motor........................................................ 48
		Removal............................................................ 51
		Preparation Before Disassembly..................................... 51
		Disassembly and Inspection......................................... 52
		Assembly........................................................... 59
		One Piece Stator Construction...................................... 65
		Two Piece Stator Construction...................................... 66
		Final Checks....................................................... 67
		Installation....................................................... 67
	3.8 Swing Bearing...................................................... 68
		Description........................................................ 68
		Turntable/Swing Bearing Removal.................................... 68
		Installation....................................................... 68
		Disassembly........................................................ 70
		Assembly........................................................... 70
		Swing Bearing Torque Values........................................ 72
	3.9 Chassis Tilt Indicator System...................................... 75
	3.10 Cold Start System................................................. 75
	3.11 Engine Installation............................................... 76
	3.12 Engine Operating States........................................... 77
	3.13 Engine Start Conditions........................................... 78
	3.14 Engine RPM Levels................................................. 78
		Engine Stop RPM.................................................... 78
		Idle RPM........................................................... 78
		Cold Idle RPM...................................................... 78
		Mid Engine RPM..................................................... 79
		High Engine RPM.................................................... 79
		Generator RPM...................................................... 79
	3.15 Engine controls................................................... 79
		Alternator Excitation.............................................. 79
		Glow Plugs......................................................... 80
		Ambient Air Temperature Sensor..................................... 80
	3.16 Deutz EMR 2....................................................... 81
	3.17 Counterweight..................................................... 93
Section 4. Boom & Platform................................................. 95
	4.1 Platform Control Enable System..................................... 95
	4.2 Function Speed Control System...................................... 95
	4.3 Transport Position Sensing System.................................. 95
	4.4 Beyond Transport Position - Drive Speed Cutback System............. 95
	4.5 Drive/Steer – Boom Function Cutout System (Optional)............... 95
	4.6 Emergency Descent System........................................... 95
	4.7 Boom Telescope Speed............................................... 96
	4.8 Platform Load Sensing System (Japan)............................... 96
	4.9 Platform........................................................... 97
		Platform Support Removal........................................... 97
		Platform Support Installation...................................... 98
	4.10 Main Boom.........................................................100
		Disassembly........................................................100
		Assembly...........................................................100
	4.11 Lower Boom........................................................101
		Disassembly........................................................101
		Assembly...........................................................101
	4.12 Hose Adjustment Procedure.........................................104
	4.13 Skyguard..........................................................108
		Operation..........................................................108
		Functional Test....................................................108
		Diagnostic & Troubleshooting.......................................109
Section 5. Hydraulics......................................................111
	5.1 Lubricating O-Rings in the Hydraulic System........................111
		Cup and Brush......................................................111
		Dip Method.........................................................112
		Spray Method.......................................................112
		Brush-on Method....................................................112
	5.2 Hydraulic Cylinders................................................113
		Platform Slave Level Cylinder......................................113
		Master Cylinder....................................................115
		Steer Cylinder.....................................................118
		Lift Cylinder......................................................120
		Main Boom Telescope Cylinder.......................................122
	5.3 Sauer Danfoss Pump.................................................140
		New Pump Startup Procedure.........................................140
		Troubleshooting....................................................141
		General Adjustment Practices.......................................144
		Charge Pressure Relief Valve Adjustment............................144
		Pressure Limiter Adjustments.......................................145
		Engaging the Bypass Function.......................................147
		Displacement Limiter Adjustment....................................147
		Control Neutral Adjustment.........................................148
		Mechanical Neutral Adjustment......................................149
		Standard Procedures, Removing the Pump.............................150
		Electric Control Module............................................151
		Control Solenoids..................................................152
		Shaft Seal, Roller Bearing and Shaft Replacement...................153
		Charge Pump........................................................154
		Charge Check / HPRV................................................155
		Charge Pressure Relief Valve.......................................156
		Pressure Limiter Valve Replacement.................................156
	5.4 Hydraulic Drive Pump Pre-fill Procedure............................160
	5.5 Pressure Setting Procedure.........................................160
Section 6. JLG Control System..............................................163
	6.1 JLG Control System Analyzer Kit Instructions.......................163
		Introduction.......................................................163
	6.2 Analyzer Menu Structure............................................164
	6.3 Using The Hand Held Analyzer.......................................165
		To Connect the JLG Control System Analyzer.........................165
		Using the Analyzer.................................................165
		Changing the Access Level of the Hand Held Analyzer................166
		Adjusting Parameters Using the Hand Held Analyzer..................167
		Machine Setup......................................................168
		Level Vehicle Description..........................................168
	6.4 System Fault Messages..............................................194
Section 7. Basic Electrical Information & Schematics.......................227
	7.1 General............................................................227
	7.2 Multimeter Basics..................................................227
		Grounding..........................................................227
		Backprobing........................................................227
		Min/Max............................................................227
		Polarity...........................................................227
		Scale..............................................................227
		Voltage Measurement................................................227
		Resistance Measurement.............................................228
		Continuity Measurement.............................................228
		Current Measurement................................................229
	7.3 Applying Silicone Dielectric Compound to Electrical Connections....229
		Installation of Dielectric Grease..................................230
		Deutsch HD, DT, DTM, DRC Series....................................230
		AMP Seal...........................................................230
		AMP Mate-N-Lok.....................................................231
		DIN Connectors.....................................................231
		Exclusions.........................................................232
		Brad Harrison / Phoenix Contact M12................................232
		AMP Junior Timer...................................................232
		Sealed Enclosures..................................................232
		MIL-C-5015 Spec Connectors.........................................233
		MOLEX CMC Series Connectors........................................233
	7.4 Electrical Schematics..............................................249

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• This is the SAME exact manual used by your dealers to fix your vehicle.
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