Jlg 18RS Service Manual manuals

Jlg 18RS Service Manual User Manual (230 pages)

Brand: Jlg | Category: Special machinery | Size: 32.86 MB |

English

Table of contents

P/N - 3121284

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

6

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

13

Hydraulic Oil

14

Major Component Weights

14

1.2 FUNCTION SPEEDS

14

SECTION 1 - SPECIFICATIONS

15

1.3 OPERATOR MAINTENANCE

17

SOCKET HEAD CAP SCREWS

23

Magni Coating (Ref 4150701)*

27

SECTION 2. GENERAL

29

2.2 SERVICE AND GUIDELINES

30

Safety and Workmanship

30

Cleanliness

30

SECTION 2 - GENERAL

31

Changing Hydraulic Oil

32

Lubrication Specifications

32

2.4 CYLINDER DRIFT TEST

32

Platform Drift

32

3.1 TIRES AND WHEELS

39

Tire Replacement

39

Wheel and Tire Replacement

39

Wheel Installation

39

3.2 DRIVE ORIENTATION SYSTEM

40

3.3 DRIVE SYSTEM

40

3.4 STEER CYLINDER

41

Installation

41

3-4 – JLG Lift – 3121284

42

3.5 DRIVE HUB

43

3-6 – JLG Lift – 3121284

44

3121284 – JLG Lift – 3-7

45

3.6 DRIVE MOTOR

46

Disassembly

46

3121284 – JLG Lift – 3-9

47

End Cover Disassembly

48

Cleaning

48

Measuring And Replacement

48

Lubrication

48

Assembly

48

Assembly of End Cover

49

3.7 SWING MOTOR

50

3121284 – JLG Lift – 3-13

51

3-14 – JLG Lift – 3121284

52

3121284 – JLG Lift – 3-15

53

Disassembly and Inspection

54

3121284 – JLG Lift – 3-17

55

3-18 – JLG Lift – 3121284

56

3121284 – JLG Lift – 3-19

57

3-20 – JLG Lift – 3121284

58

3121284 – JLG Lift – 3-21

59

3-22 – JLG Lift – 3121284

60

3-24 – JLG Lift – 3121284

62

3121284 – JLG Lift – 3-25

63

3-26 – JLG Lift – 3121284

64

3121284 – JLG Lift – 3-27

65

3-28 – JLG Lift – 3121284

66

One Piece Stator Construction

67

Two Piece Stator Construction

68

Final Checks

69

3.8 SWING BEARING

70

Description

70

3121284 – JLG Lift – 3-33

71

3121284 – JLG Lift – 3-35

73

Swing Bearing Torque Values

74

3.10 COLD START SYSTEM

75

3.11 ENGINE OPERATING STATES

75

3-38 – JLG Lift – 3121284

76

3.12 ENGINE START CONDITIONS

77

3.13 ENGINE RPM LEVELS

77

Engine Stop RPM

77

Idle RPM

77

Cold Idle RPM

77

Mid Engine RPM

78

High Engine RPM

78

Generator RPM

78

3.14 ENGINE CONTROLS

78

Alternator Excitation

78

Glow Plugs

79

3.15 COUNTERWEIGHT

79

3-42 – JLG Lift – 3121284

80

3121284 – JLG Lift – 4-1

81

4.8 LOWER BOOM

83

4-4 – JLG Lift – 3121284

84

3121284 – JLG Lift – 4-5

85

4.9 HOSE ADJUSTMENT PROCEDURE

86

3121284 – JLG Lift – 4-7

87

4-8 – JLG Lift – 3121284

88

3121284 – JLG Lift – 4-9

89

4-10 – JLG Lift – 3121284

90

SECTION 5. HYDRAULICS

91

Dip Method

92

Spray Method

92

Brush-on Method

92

5.2 HYDRAULIC CYLINDERS

93

Platform Slave Level Cylinder

93

Master Cylinder

95

Steer Cylinder

97

Lift Cylinder

99

5-10 – JLG Lift – 3121284

100

Main Boom Telescope Cylinder

101

SECTION 5 - HYDRAULICS

102

5.3 SAUER DANFOSS PUMP

121

New Pump Startup Procedure

121

Troubleshooting

122

General Adjustment Practices

125

Pressure Limiter Adjustments

126

Engaging the Bypass Function

128

Control Neutral Adjustment

129

Mechanical Neutral Adjustment

130

Electric Control Module

132

Control Solenoids

133

Charge Pump

135

Charge Check / HPRV

136

Charge Pressure Relief Valve

137

INSTRUCTIONS

143

Introduction

143

6.2 ANALYZER MENU STRUCTURE

144

Using the Analyzer

145

Analyzer

146

Machine Setup

148

Level Vehicle Description

148

3121284 – JLG Lift – 6-7

149

6-8 – JLG Lift – 3121284

150

ANALYZER

151

MACHINE

153

DIAGNOSTICS

154

6-14 – JLG Lift – 3121284

156

3121284 – JLG Lift – 6-15

157

6-16 – JLG Lift – 3121284

158

3121284 – JLG Lift – 6-17

159

6-18 – JLG Lift – 3121284

160

3121284 – JLG Lift – 6-19

161

6.4 SYSTEM FAULT MESSAGES

162

3121284 – JLG Lift – 6-21

163

6-22 – JLG Lift – 3121284

164

3121284 – JLG Lift – 6-23

165

6-24 – JLG Lift – 3121284

166

1001147652-B

166

3121284 – JLG Lift – 6-25

167

6-26 – JLG Lift – 3121284

168

3121284 – JLG Lift – 6-27

169

6-28 – JLG Lift – 3121284

170

3121284 – JLG Lift – 6-29

171

6-30 – JLG Lift – 3121284

172

3121284 – JLG Lift – 6-31

173

6-32 – JLG Lift – 3121284

174

3121284 – JLG Lift – 6-33

175

6-34 – JLG Lift – 3121284

176

3121284 – JLG Lift – 6-35

177

6-36 – JLG Lift – 3121284

178

3121284 – JLG Lift – 6-37

179

6-38 – JLG Lift – 3121284

180

3121284 – JLG Lift – 6-39

181

6-40 – JLG Lift – 3121284

182

3121284 – JLG Lift – 6-41

183

6-42 – JLG Lift – 3121284

184

3121284 – JLG Lift – 6-43

185

6-44 – JLG Lift – 3121284

186

3121284 – JLG Lift – 6-45

187

6-46 – JLG Lift – 3121284

188

3121284 – JLG Lift – 6-47

189

6-48 – JLG Lift – 3121284

190

3121284 – JLG Lift – 6-49

191

6-50 – JLG Lift – 3121284

192

3121284 – JLG Lift – 6-51

193

6-52 – JLG Lift – 3121284

194

3121284 – JLG Lift – 6-53

195

6-54 – JLG Lift – 3121284

196

3121284 – JLG Lift – 6-55

197

6-56 – JLG Lift – 3121284

198

3121284 – JLG Lift – 6-57

199

6-58 – JLG Lift – 3121284

200

3121284 – JLG Lift – 7-1

201

Resistance Measurement

202

Continuity Measurement

202

Current Measurement

203

TO ELECTRICAL CONNECTIONS

203

AMP Seal

204

AMP Mate-N-Lok

205

DIN Connectors

205

Exclusions

205

7-6 – JLG Lift – 3121284

206

AMP JUNIOR TIMER

206

SEALED ENCLOSURES

206

MIL-C-5015 SPEC CONNECTORS

206

3121284 – JLG Lift – 7-7

207

7-8 – JLG Lift – 3121284

208

3121284 – JLG Lift – 7-9

209

7-10 – JLG Lift – 3121284

210

3121284 – JLG Lift – 7-11

211

7-12 – JLG Lift – 3121284

212

3121284 – JLG Lift – 7-13

213

7-14 – JLG Lift – 3121284

214

ELECTRICAL SCHEMATIC

215

7-16 – JLG Lift – 3121284

216

1001129238-B

217

7-18 – JLG Lift – 3121284

218

7-20 – JLG Lift – 3121284

220

7-22 – JLG Lift – 3121284

222

7-24 – JLG Lift – 3121284

224

7-26 – JLG Lift – 3121284

226

1001131499-A

227

7-28 – JLG Lift – 3121284

228

JLG Worldwide Locations

230

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