JLG 24RS 24RSJ Service & Maintenance Manual (3121287) – PDF DOWNLOAD

Description

JLG 24RS 24RSJ Service & Maintenance Manual (3121287) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 24RS 24RSJ Service & Maintenance Manual (3121287) – PDF DOWNLOAD

Section 1. Specifications.................................................. 15
	1.1 Operating Specifications........................................... 15
		Operating Specifications........................................... 15
		Dimensional Data................................................... 15
		Capacities......................................................... 15
		Tires.............................................................. 16
		Engine Data........................................................ 16
		Hydraulic Oil...................................................... 16
		Major Component Weights............................................ 17
	1.2 Function Speeds.................................................... 17
	1.3 Operator Maintenance............................................... 22
Section 2. General......................................................... 31
	2.1 Machine Preparation, Inspection, and Maintenance................... 31
		General............................................................ 31
		Preparation, Inspection, and Maintenance........................... 31
		Pre-Start Inspection............................................... 31
		Pre-Delivery Inspection and Frequent Inspection.................... 31
		Annual Machine Inspection.......................................... 31
		Preventative Maintenance........................................... 31
	2.2 Service and Guidelines............................................. 32
		General............................................................ 32
		Safety and Workmanship............................................. 32
		Cleanliness........................................................ 32
		Components Removal and Installation................................ 32
		Component Disassembly and Reassembly............................... 33
		Pressure-Fit Parts................................................. 33
		Bearings........................................................... 33
		Gaskets............................................................ 33
		Bolt Usage and Torque Application.................................. 33
		Hydraulic Lines and Electrical Wiring.............................. 33
		Hydraulic System................................................... 33
		Lubrication........................................................ 34
		Battery............................................................ 34
		Lubrication and Servicing.......................................... 34
	2.3 Lubrication and Information........................................ 34
		Hydraulic System................................................... 34
		Hydraulic Oil...................................................... 34
		Changing Hydraulic Oil............................................. 34
		Lubrication Specifications......................................... 34
	2.4 Cylinder Drift Test................................................ 35
		Theory............................................................. 35
		Cylinder Leakage Test.............................................. 35
		Cylinder Thermal Drift............................................. 35
	2.5 Pins and Composite Bearing Repair Guidelines....................... 36
	2.6 Welding on JLG Equipment........................................... 36
		Do the Following When Welding on JLG Equipment..................... 36
		Do NOT Do the Following When Welding on JLG Equipment.............. 36
Section 3. Chassis & Turntable............................................. 41
	3.1 Tires and Wheels................................................... 41
		Tire Replacement................................................... 41
		Wheel and Tire Replacement......................................... 41
		Wheel Installation................................................. 41
	3.2 Drive Orientation System........................................... 42
	3.3 Drive System....................................................... 42
	3.4 Steer Cylinder..................................................... 43
		Removal............................................................ 43
		Installation....................................................... 43
	3.5 Drive Hub.......................................................... 44
		Removal............................................................ 44
		Installation....................................................... 48
	3.6 Drive Motor........................................................ 48
		Removal............................................................ 48
		Disassembly........................................................ 48
		End Cover Disassembly.............................................. 50
		Cleaning........................................................... 50
		Measuring And Replacement.......................................... 50
		Lubrication........................................................ 50
		Assembly........................................................... 50
		Assembly of End Cover.............................................. 51
		Installation....................................................... 52
	3.7 Swing Drive Hub.................................................... 53
		Disassembly........................................................ 53
		Tightening and Torquing Bolts...................................... 59
		Assembly........................................................... 59
		Brake Test......................................................... 68
		Roll and Leak Test................................................. 70
	3.8 Procedure for Setting Swing Gear backlash.......................... 76
	3.9 Swing Bearing...................................................... 78
		Wear Tolerance..................................................... 78
		Turntable/Swing Bearing Removal.................................... 84
		Installation....................................................... 88
		Swing Bearing Torque Values........................................ 90
	3.10 Chassis Tilt Indicator System..................................... 91
	3.11 Engine Installation............................................... 92
	3.12 Cold Start System................................................. 93
	3.13 Engine Operating States........................................... 93
	3.14 Engine Start Conditions........................................... 94
	3.15 Engine RPM Levels................................................. 94
		Engine Stop RPM.................................................... 94
		Idle RPM........................................................... 94
		Cold Idle RPM...................................................... 94
		Mid Engine RPM..................................................... 95
		High Engine RPM.................................................... 95
		Generator RPM...................................................... 95
	3.16 Engine Controls................................................... 95
		Alternator Excitation.............................................. 95
		Glow Plugs......................................................... 96
		Ambient Air Temperature Sensor..................................... 96
	3.17 Deutz EMR 2....................................................... 97
	3.18 Auxiliary Pump....................................................109
		Removal............................................................109
		Installation.......................................................109
	3.19 Counterweight.....................................................116
Section 4. Boom & Platform.................................................117
	4.1 Platform Control Enable System.....................................117
	4.2 Function Speed Control System......................................117
	4.3 Transport Position Sensing System..................................117
	4.4 Boom Telescope Speed...............................................117
		Extend Function....................................................117
		Retract Function...................................................117
	4.5 Beyond Transport Position - Drive Speed Cutback System.............117
	4.6 Drive/Steer – Boom Function Cutout System (Optional)...............118
	4.7 Emergency Descent System...........................................118
	4.8 Platform Load Sensing System (Japan)...............................118
	4.9 Platform...........................................................119
		Platform Support Removal...........................................119
		Platform Support Installation......................................120
	4.10 Main Boom.........................................................122
		Dissassembly.......................................................122
		Assembly...........................................................123
	4.11 Lower Boom........................................................125
		Disassembly........................................................125
		Assembly...........................................................126
	4.12 Telescope Cylinder................................................132
		Removal............................................................132
		Installation.......................................................136
	4.13 Hose Adjustment Procedure.........................................137
	4.14 Skyguard..........................................................143
		Operation..........................................................143
		Functional Test....................................................143
		Diagnostic & Troubleshooting.......................................144
Section 5. Hydraulics......................................................145
	5.1 Lubricating O-Rings in the Hydraulic System........................145
		Cup and Brush......................................................145
		Dip Method.........................................................146
		Spray Method.......................................................146
		Brush-on Method....................................................146
	5.2 Hydraulic Cylinders................................................147
		Platform Slave Level Cylinder......................................147
		Master Cylinder....................................................149
		Steer Cylinder.....................................................152
		Lift Cylinder......................................................154
		Telescope Cylinder.................................................156
	5.3 Sauer Danfoss Pump.................................................174
		New Pump Startup Procedure.........................................174
		Troubleshooting....................................................175
		General Adjustment Practices.......................................178
		Charge Pressure Relief Valve Adjustment............................178
		Pressure Limiter Adjustments.......................................179
		Engaging the Bypass Function.......................................181
		Displacement Limiter Adjustment....................................181
		Control Neutral Adjustment.........................................182
		Mechanical Neutral Adjustment......................................183
		Standard Procedures, Removing the Pump.............................184
		Electric Control Module............................................185
		Control Solenoids..................................................186
		Shaft Seal, Roller Bearing and Shaft Replacement...................187
		Charge Pump........................................................188
		Charge Check / HPRV................................................189
		Charge Pressure Relief Valve.......................................190
		Pressure Limiter Valve Replacement.................................190
	5.4 Hydraulic Drive Pump Pre-fill Procedure............................194
	5.5 Pressure Setting Procedure.........................................194
Section 6. JLG Control System..............................................197
	6.1 JLG Control System Analyzer Kit Instructions.......................197
		Introduction.......................................................197
	6.2 Analyzer Menu Structure............................................198
	6.3 Using the Hand Held Analyzer.......................................199
		To Connect the JLG Control System Analyzer.........................199
		Using the Analyzer.................................................199
		Changing the Access Level of the Hand Held Analyzer................200
		Adjusting Parameters Using the Hand Held Analyzer..................201
		Machine Setup......................................................202
		Level Vehicle Description..........................................202
	6.4 System Fault Messages..............................................228
Section 7. Basic Electrical Information & Schematics.......................261
	7.1 General............................................................261
	7.2 Multimeter Basics..................................................261
		Grounding..........................................................261
		Backprobing........................................................261
		Min/Max............................................................261
		Polarity...........................................................261
		Scale..............................................................261
		Voltage Measurement................................................261
		Resistance Measurement.............................................262
		Continuity Measurement.............................................262
		Current Measurement................................................263
	7.3 Applying Silicone Dielectric Compound to Electrical Connections....263
		Installation of Dielectric Grease..................................264
		Deutsch HD, DT, DTM, DRC Series....................................264
		AMP Seal...........................................................264
		AMP Mate-N-Lok.....................................................265
		DIN Connectors.....................................................265
		Exclusions.........................................................266
		Brad Harrison / Phoenix Contact M12................................266
		AMP Junior Timer...................................................266
		Sealed Enclosures..................................................266
		MIL-C-5015 Spec Connectors.........................................267
		MOLEX CMC Series Connectors........................................267
	7.4 Electrical Schematics..............................................283

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