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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