JLG 500RTS Scissor Lift Service & Maintenance Manual (ANSI)

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This service manual PDF download for the 500RTS JLG Scissor Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

TABLE OF CONTENTS :

Section 1. specifications
1.1 Capacities
1.2 Component Data
1.3 Performance Data
1.4 Lubrication
1.5 Lubrication Specifications
1.6 Pressure Settings
1.7 Limit Switches
1.8 Cylinder Specifications
1.9 Serial Number Locations
1.10 Major Component Weights
1.11 Critical Stability Weights

Section 2. Procedures
2.1 General
2.2 Servicing and Maintenance Guidelines
2.3 Lubrication Information
2.4 Cylinders – Theory of Operation
2.5 Valves – Theory of Operation
2.6 Component Functional Description
2.7 Sliding Wear Pads
2.8 Pump Coupling Lubrication
2.9 Cylinder Checking Procedures
2.10 Cylinder Removal and Installation
2.11 Cylinder Repair
2.12 Tilt Alarm Switch
2.13 Pressure Setting Procedures
2.14 Drive Pump Start-up Procedure
2.15 Throttle Checks and Adjustments – Ford Engine
2.16 Throttle Checks and Adjustments – Deutz F3L1011
2.17 Hydraulic Component Start-Up Procedures and Recommendations
2.18 Oscillating Axle Lockout Cylinder Bleeding Procedure – (If Equipped)
2.19 Lockout Cylinder Check
2.20 Piston Drive Motor – 2WD & 4WD
2.21 Drive Torque Hub – 2WD/4WD Rear
2.22 Drive Torque Hub/Brake – 4WD Front
2.23 Drive Brake – 2WD/4WD Rear
2.24 Spark Arrestor Muffler
2.25 Dual Fuel/LPG System
2.26 Freewheeling Feature
2.27 Limit Switch Adjustment Procedure
2.28 Preventive Maintenance and Inspection Schedule

Section 3. Troubleshooting
3.1 General
3.2 Troubleshooting Information
3.3 Hydraulic Circuit Checks

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121103
Total Pages : 80

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Service & Maintenance Manual
Section A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A.A General
A.B Hydraulic System Safety
A.C Maintenance
Section 1. specifications
1.1 Capacities
Hydraulic Oil Tank
Hydraulic System (Including Tank)
Fuel Tank
Engine Crankcase
1.2 Component Data
Gasoline Engine
Diesel Engine
Oil Capacity
Drive/Steer System
1.3 Performance Data
Travel Speed
Gradeability
Turning Radius (Outside)
Lift Speed – 500RTS
Platform Capacity – Fixed Platform
Platform Capacity – Traversing Platform Extension (If Equipped)
Machine Weight
Machine Height (Platform Lowered)
Machine Length
Machine Width
1.4 Lubrication
1.5 Lubrication Specifications
1.6 Pressure Settings
500RTS
1.7 Limit Switches
High Drive Speed Cut-Out
Lift Cut-Out (If Equipped)
Drive Cut-Out (If Equipped)
1.8 Cylinder Specifications
500RTS – Tilt Alarm
1.9 Serial Number Locations
1.10 Major Component Weights
1.11 Critical Stability Weights
Section 2. Procedures
2.1 General
2.2 Servicing and Maintenance Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Batteries
Lubrication and Servicing
2.3 Lubrication Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinders – Theory of Operation
2.5 Valves – Theory of Operation
Solenoid Control Valves(Bang Bang)
Relief Valves
Crossover Relief Valves
2.6 Component Functional Description
Piston Hydraulic Pump
Gear Hydraulic Pump
Manual Descent Valve (If Equipped)
2.7 Sliding Wear Pads
2.8 Pump Coupling Lubrication
2.9 Cylinder Checking Procedures
Cylinder w/o Counterbalance Valves – Steer Cylinder, Platform Ext. Cylinder, Axle Lockout Cylinder (If Equipped)
Cylinders w/Single Counterbalance Valves – Lift Cylinder, Leveling Jacks (If Equipped)
2.10 Cylinder Removal and Installation
Lift Cylinder Removal
Lift Cylinder Installation
2.11 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
2.12 Tilt Alarm Switch
Manual Adjustment
2.13 Pressure Setting Procedures
Rexroth/Hydraforce Valve
2.14 Drive Pump Start-up Procedure
2.15 Throttle Checks and Adjustments – Ford Engine
Throttle Checks
Throttle Adjustments – In Sequence
2.16 Throttle Checks and Adjustments – Deutz F3L1011
2.17 Hydraulic Component Start-Up Procedures and Recommendations
2.18 Oscillating Axle Lockout Cylinder Bleeding Procedure – (If Equipped)
2.19 Lockout Cylinder Check
2.20 Piston Drive Motor – 2WD & 4WD
Disassembly
Inspection
Assembly
2.21 Drive Torque Hub – 2WD/4WD Rear
Roll Test
Leak Test
Assembly
2.22 Drive Torque Hub/Brake – 4WD Front
Disassembly
Roll Test
Leak Test
Assembly
2.23 Drive Brake – 2WD/4WD Rear
Disassembly
Assembly
2.24 Spark Arrestor Muffler
2.25 Dual Fuel/LPG System
Changing From Gasoline to LP Gas
Changing From LP Gas to Gasoline
Using Liquid Petroleum (LP) Gas
2.26 Freewheeling Feature
To Disengage Torque Hubs (Freewheel)
To Engage Torque Hubs
2.27 Limit Switch Adjustment Procedure
Drive Cut-Out Switch
Drive Speed Cutout
2.28 Preventive Maintenance and Inspection Schedule
Section 3. Troubleshooting
3.1 General
3.2 Troubleshooting Information
3.3 Hydraulic Circuit Checks

 

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JLG 500RTS Scissor Lift Service & Maintenance Manual (ANSI).pdf

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