JLG T500J PVC 2007 Service and Maintenance Manual (31217422) – PDF DOWNLOAD

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JLG T500J PVC 2007 Service and Maintenance Manual (31217422) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG T500J PVC 2007 Service and Maintenance Manual (31217422) – PDF DOWNLOAD

31217422_A_T500J_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
		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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