Jlg 500RTS Service Manual Bedienungsanleitung

Service & Maintenance ManualModels400RTS500RTS3120829November 12, 2007

SECTION 1 - SPECIFICATIONS1-2 – JLG Sizzor – 3120829NOTE: Wheel lugs should be torqued to 109 Nm (80 ft lb) at50 hour intervals.When maintenance becom

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SPECIFICATIONS3120829 – JLG Sizzor – 1-3NOTE: Aside from JLG recommendations, it is not advisableto mix oils of different brands or types,

SECTION 1 - SPECIFICATIONS1-4 – JLG Sizzor – 3120829Figure 1-1. Lubrication Diagram

SECTION 1 - SPECIFICATIONS3120829 – JLG Sizzor – 1-5Table 1-3. Lubrication ChartINDEX NOCOMPONENT NUMBER/TYPE LUBE POINTS LUBE METHODINTERVAL HOURS1 O

SECTION 1 - SPECIFICATIONS1-6 – JLG Sizzor – 31208291.8 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the mach

SECTION 1 - SPECIFICATIONS3120829 – JLG Sizzor – 1-71.10 MAJOR COMPONENT WEIGHTS 1.11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STA

SECTION 1 - SPECIFICATIONS1-8 – JLG Sizzor – 3120829SAE GRADE 5SAE GRADE 8Note: These torque values do not apply to cadium plated fasteners.VALUES

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-1SECTION 2. PROCEDURES2.1 GENERALThis section provides information necessary to performmaintenance on

SECTION 2 - PROCEDURES2-2 – JLG Sizzor – 31208294. Lubricate new or used serviceable bearings beforeinstallation. When pressing a bearing into a retai

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-3NOTE: Start-up of hydraulic system with oil temperaturesbelow -26 ° C (-15 ° F). is not recommended. I

SECTION 2 - PROCEDURES2-4 – JLG Sizzor – 3120829between the pump outlet (pressure line) and the cylinderof the circuit, generally as an integral part

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-5WHEN WORKING ON THE LIFT CYLINDER, RAISE THE PLAT-FORM COMPLETELY AND SUPPORT THE PLATFORM USING ASUIT

SECTION 2 - PROCEDURES2-6 – JLG Sizzor – 3120829CYLINDERS WITH DOUBLE HOLDING VALVES. BEFORE REMOV-ING HOLDING VALVES CRACK BLEEDER TO RELEASE PRES-SU

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-717. If applicable, inspect piston rings for cracks or otherdamage. Replace as necessary.AssemblyNOTE:

SECTION 2 - PROCEDURES2-8 – JLG Sizzor – 312082911. Position the cylinder barrel in a suitable holding fix-ture. EXTREME CARE SHOULD BE TAKEN WHEN INS

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-97. Bottom out Rear Steer Right and Steer Left functionsand adjust each Steer Crossover Relief to 103 b

SECTION 2 - PROCEDURES2-10 – JLG Sizzor – 3120829PRESSURE PORTADJUST DECK EXT TO83 BAR (1200PSI)ADJUST MAIN RELIEF TO 156 BAR(2250 PSI) ON 400RTS AND

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-112.16 THROTTLE CHECKS AND ADJUSTMENTS - FORD ENGINEThrottle Checks1. Check that anti-dieseling solenoi

SECTION 2 - PROCEDURES2-12 – JLG Sizzor – 3120829Figure 2-3. Throttle Checks and Adjustments - Ford VSG 413STARTER LOCKOUT SPEED ADJUSTMAIN SPEED ADJ

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-13Figure 2-5. Throttle Adjustments, Deutz F3L1011

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3120829 – JLG Sizzor – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section

SECTION 2 - PROCEDURES2-14 – JLG Sizzor – 31208292.18 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoi

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-15Once charge pressure has been established, increasespeed to normal operating RPM. Charge pressure sho

SECTION 2 - PROCEDURES2-16 – JLG Sizzor – 31208292.19 OSCILLATING AXLE LOCKOUT CYLINDER BLEEDING PROCEDURE - (IF EQUIPPED)NOTE: Ensure platform is ful

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-17Figure 2-6. Piston Drive Motor

SECTION 2 - PROCEDURES2-18 – JLG Sizzor – 3120829DISASSEMBLE THE PISTON BLOCK AS FOLLOWS:NOTE: The following parts will be needed to disassemblethe pi

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-19Figure 2-7. Drive Torque Hub - (2WD/4WD rear)

SECTION 2 - PROCEDURES2-20 – JLG Sizzor – 3120829Disassembly1. Turn hub over on to its side. Remove coupling fromwide end of spindle.2. Mark location

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-21c. Remove retaining ring from around spindle inhub.Remove spacer from around spindle in hub.Set hub,

SECTION 2 - PROCEDURES2-22 – JLG Sizzor – 3120829SAFETY GLASSES MUST BE WORN DURING THE FOLLOWINGSTEP. BE AWARE THAT SPRING AND SPACERS, COMPRESSEDBY

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-23BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL-ING O-RING.18. Set cover assembly on table, interio

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Sizzor – 3120829REVISION LOGJune 1, 1993 - Original IssueMay 28, 1999 - RevisedFebruary 29, 2000

SECTION 2 - PROCEDURES2-24 – JLG Sizzor – 3120829Figure 2-9. Drive Torque Hub/Brake - 4WD Front

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-258. Remove thrust washer from carrier assembly.9. Remove thrust spacer from input shaft assembly.10. R

SECTION 2 - PROCEDURES2-26 – JLG Sizzor – 3120829NOTE: O-rings may be stretched to fit counterbore. If an o-ring has been stretched too much, simply s

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-27h. Place two remaining bolts into bolt holes in dis-connect cap and tighten.i. Using a torque wrench,

SECTION 2 - PROCEDURES2-28 – JLG Sizzor – 31208292.24 DRIVE BRAKE - 2WD/4WD REARDisassembly1. Remove end cover from housing by removingwasher head cap

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-29Figure 2-11. Drive Brake - (2WD/4WD Rear)

SECTION 2 - PROCEDURES2-30 – JLG Sizzor – 31208292.25 SPARK ARRESTOR MUFFLERThe multiple discs on these mufflers will require frequentcleaning if used

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-31To Engage Torque HubsEngage (reverse) disconnect cap on both drive torquehubs by removing two attachi

SECTION 2 - PROCEDURES2-32 – JLG Sizzor – 31208292.29 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks a

SECTION 2 - PROCEDURES3120829 – JLG Sizzor – 2-33*Inspection and Maintenance Code 10 to be performedannually.Table 2-4. Preventive Maintenance and Saf

3120829 – JLG Sizzor – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE

SECTION 2 - PROCEDURES2-34 – JLG Sizzor – 3120829NOTES:

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to beused

SECTION 3 - TROUBLESHOOTING3-2 – JLG Sizzor – 3120829Table 3-1. Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYNo response to control

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-3No electrical signal being sent to lift down control valve cartridgeRefer to electrical troublesh

SECTION 3 - TROUBLESHOOTING3-4 – JLG Sizzor – 3120829Table 3-2. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYDRIVE SYSTEMNo response to control

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-5Loose or damaged wire between platform and high speed solenoidEnsure proper connection of wire at

SECTION 3 - TROUBLESHOOTING3-6 – JLG Sizzor – 3120829Machine will not steer left or rightEnable switch not activated Activate enable switchFunction no

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-7Table 3-3. Chassis TroubleshootingTROUBLE PROBABLE CAUSE REMEDYENGINEEngine will not startStation

SECTION 3 - TROUBLESHOOTING3-8 – JLG Sizzor – 3120829Table 3-4. Hydraulic System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHydraulic pump noisyAir e

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-9Table 3-5. Electrical System TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHAND CONTROLLERRegardles

ii – JLG Sizzor – 3120829TABLE OF CONTENTS LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Lubrication Diagram . . . . . . . . .

SECTION 3 - TROUBLESHOOTING3-10 – JLG Sizzor – 3120829Defective Platform/Ground select switch Replace Platform/Ground select switchNo voltage e presen

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-11NOTES:

SECTION 3 - TROUBLESHOOTING3-12 – JLG Sizzor – 3120829Figure 3-1. Hydraulic Schematic (Sheet 1 of 6)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-13Figure 3-2. Hydraulic Schematic (Sheet 2 of 6)

SECTION 3 - TROUBLESHOOTING3-14 – JLG Sizzor – 3120829Figure 3-3. Hydraulic Schematic (Sheet 3 of 6)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-15Figure 3-4. Hydraulic Schematic (Sheet 4 of 6)

SECTION 3 - TROUBLESHOOTING3-16 – JLG Sizzor – 3120829Figure 3-5. Hydraulic Schematic (Sheet 5 of 6)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-17Figure 3-6. Hydraulic Schematic (Sheet 6 of 6)

SECTION 3 - TROUBLESHOOTING3-18 – JLG Sizzor – 3120829Figure 3-7. Electrical Schematic - 400 RTS - Ford LRG (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-19Figure 3-8. Electrical Schematic - 400 RTS - Ford LRG (Sheet 2 of 4)

3120829 – JLG Sizzor – iii TABLE OF CONTENTSLIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Hydraulic Oil . . . . . . . . . . . . . . . . . .

SECTION 3 - TROUBLESHOOTING3-20 – JLG Sizzor – 3120829Figure 3-9. Electrical Schematic - 400 RTS - Ford LRG (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-21Figure 3-10. Electrical Schematic - 400 RTS - Ford LRG (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-22 – JLG Sizzor – 3120829Figure 3-11. Electrical Schematic - 400RTS - Ford LRG (Sheet 1 of 3)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-231283067 DFigure 3-12. Electrical Schematic - 400RTS - Ford LRG (Sheet 2 of 3)

SECTION 3 - TROUBLESHOOTING3-24 – JLG Sizzor – 31208291283067 DFigure 3-13. Electrical Schematic - 400RTS - Ford LRG (Sheet 3 of 3)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-25NOTES:

SECTION 3 - TROUBLESHOOTING3-26 – JLG Sizzor – 3120829Figure 3-14. Electrical Schematic - 400 RTS - Ford VSG (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-27Figure 3-15. Electrical Schematic - 400 RTS - Ford VSG (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-28 – JLG Sizzor – 3120829Figure 3-16. Electrical Schematic - 400 RTS - Ford VSG (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-29Figure 3-17. Electrical Schematic - 400 RTS - Ford VSG (Sheet 4 of 4)

iv – JLG Sizzor – 3120829TABLE OF CONTENTS This page intentionally left blank.

SECTION 3 - TROUBLESHOOTING3-30 – JLG Sizzor – 3120829Figure 3-18. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-31Figure 3-19. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-32 – JLG Sizzor – 3120829Figure 3-20. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-33Figure 3-21. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-34 – JLG Sizzor – 3120829Figure 3-22. Electrical Schematic - 400RTS - Deutz (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-351283066 CFigure 3-23. Electrical Schematic - 400RTS - Deutz (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-36 – JLG Sizzor – 3120829Figure 3-24. Electrical Schematic - 400RTS - Deutz (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-371283066 CFigure 3-25. Electrical Schematic - 400RTS - Deutz (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-38 – JLG Sizzor – 3120829Figure 3-26. Electrical Schematic - 500 RTS Ford LRG (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-39Figure 3-27. Electrical Schematic - 500 RTS Ford LRG (Sheet 2 of 2)

SECTION 1 - SPECIFICATIONS3120829 – JLG Sizzor – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES Hydraulic Oil Tank Approximately 138.17 liters (36.5 U.S.

SECTION 3 - TROUBLESHOOTING3-40 – JLG Sizzor – 3120829Figure 3-28. Electrical Schematic - 500 RTS Ford LSG (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-411282341 CFigure 3-29. Electrical Schematic - 500 RTS Ford LSG (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-42 – JLG Sizzor – 3120829Figure 3-30. Electrical Schematic - 500 RTS Ford VSG (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-43Figure 3-31. Electrical Schematic - 500 RTS Ford VSG (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-44 – JLG Sizzor – 3120829Figure 3-32. Electrical Schematic - 500RTS Deutz (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-45Figure 3-33. Electrical Schematic - 500RTS Deutz (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-46 – JLG Sizzor – 3120829Figure 3-34. Electrical Schematic - 500RTS Duetz (Sheet 1 of 2)

SECTION 3 - TROUBLESHOOTING3120829 – JLG Sizzor – 3-471283064 FFigure 3-35. Electrical Schematic - 500RTS Duetz (Sheet 2 of 2)

SECTION 3 - TROUBLESHOOTING3-48 – JLG Sizzor – 3120829NOTES:

CALIFORNIAN PROPOSITION 65BATTERY WARNINGBattery posts,terminals and relatedaccessories containlead and lead compounds,chemical known to theState of C