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GRADALL 522
JLG GRADALL 522 Manuals
Manuals and User Guides for JLG GRADALL 522. We have
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JLG GRADALL 522 manual available for free PDF download: Owner's/Operator's Manual
JLG GRADALL 522 Owner's/Operator's Manual (289 pages)
Brand:
JLG
| Category:
Forklifts
| Size: 19.61 MB
Table of Contents
Important Safety Notice
6
Other Notices
6
Table of Contents
7
Introduction
8
Models Covered
8
Operator Qualifications
8
General
8
Nomenclature
9
Safety Highlights
10
Safety Precautions
10
Decals
11
Control and Instrument Identification
19
Operator's Cab
19
Level Indicator
20
Machine Level Lever
20
Ignition Switch
20
Accelerator Pedal
20
Checks and Services before Starting Engine
21
Before Entering the Operator's Cab
22
During Warm-Up Period
22
Engine Operation
22
Warm up & Operational Checks
22
Battery-Boosted Starting
23
Cold-Weather Starting Aids
23
Stopping the Engine
23
Normal Engine Operation
23
Brake System
24
Inching Travel
24
Parking Brakes
24
Service Brakes
24
Parking the Handler
25
Steering System
25
Traction Lock Switch
26
Drive Train
26
Four-Wheel Drive
26
Normal Travel
26
Boom
27
Checking & Adjusting Boom Cable
27
Frame-Leveling Controls
28
Leveling Handler Frame
28
Leveling the Handler
28
Two Ways to Level the Handler
28
Boom Control Joystick
29
Carriage Tilt Controls
29
Feathering
29
Hydraulic Controls
29
Load Center
30
Rated Capacity Charts
30
Boom Angle
30
Elevation
30
Approved Attachments
31
Attachments
31
Carriage/Fork Capacities
31
Non-Approved Attachments
31
Attachment Installation
32
Attachment Operation
32
Light Material Bucket
33
Capacity
33
Fork Positioner
33
Controls
33
Attachment Tilt Controls
34
Mast
34
Slope Pile Carriage
35
Swing Forks
35
Boom Head-Mounted Winch
36
Truss Boom & Truss Boom with Winch
37
Swing Mast
38
Personnel Work Platform
39
Lubrication & Routine Maintenance
40
Lubrication Advice
41
Recommended Lubricants & Capacities
42
Torque Chart
42
Moving Handler in Emergency
43
Moving Longer Distances
43
Moving Short Distances
43
Obtaining Hydraulic Oil Sample for Analysis
43
To Activate Tow Bypass
44
To Release Parking Brake
44
To Restore Parking Brake
44
Special Signals
45
Standard Signals
45
Instructions
45
Hand Signals
45
Hydraulic Schematic
47
Minor Repair and Replacement
50
Shaft Seal
50
Shaft Seal Installation Tool Dimensions
50
Variable Displacement Motor
50
Preparation for Disassembly
52
Disassembly of Pump
52
Parts Inspection
53
Break-In Procedure
54
Pump Reassembly
54
PERFORMANCE DATA (Typical)
58
System Schematic (Typical)
58
Brake Valve Actuated -- Power Steering in Neutral
59
Description and Operation of the Mico Open
59
Schematic of Brake Valve in Neutral
59
Hydraulic System Pressure Equal to Brake Line Pressure
60
Schematic of Brake Valve in Manual Operation
60
Installation Instructions
61
Primary Cup Design
62
Ring Seal Design
62
Sliding Piston Design
62
Three Open Center Hydraulic Power Brake Valve Designs
62
Specifications Chart
63
Open Center Hydraulic Brake Valve Primary Cup Design
64
Parts List
64
Bleeding
70
General Service Diagnosis
70
Pedal Goes to Floor
70
Spongy Pedal
70
Bleeding Schematic
71
Pressure Bleeding Procedure
71
Identification
74
Assembly of Power Wheel
74
Disassembly of Power Wheel
74
Carrier Assemblies
75
Lubrication Recommendations
75
Specifications
75
Towing Vehicle
75
Service Notes
78
Table of Contents
89
Description
91
Section 1: Introduction
91
Identification
91
Section 2: Removal and Disassembly
92
Remove Axle
92
Disassemble Ball and Ramp Brake
92
Disassemble Trumpet Assembly
93
Disassemble Planetary System and Axle Shaft
94
Disassemble Hydraulic Apply Wet Disc Brake
95
Disassemble Three Function Wet Disc Brake
95
Disassemble Main Housing
97
Disassemble Differential Case
98
Disassemble Pinion Bearing Cage
100
Section 3: Prepare Parts for Assembly
103
Clean Ground and Polished Parts
103
Clean Parts with Rough Finish
103
Clean Axle Assemblies
103
Dry Cleaned Parts
103
Prevent Corrosion
103
Inspect Parts
103
Inspect Tapered Roller Bearings
104
Inspect Hypoid Pinion and Ring Gear Sets
105
Inspect Main Differential Assembly
105
Inspect Axle Shafts
105
Inspect Main Housing
106
Inspect Yoke
106
Inspect Planetary System Parts
106
Inspect Brakes
106
Repair or Replace Parts
106
Repair Welding
106
Liquid Adhesive
107
Disassemble Locked Sets
107
Reassembly
107
Application
107
Apply Silicone Gasket Material
108
Duo-Cone Oil Seal: Mount and Install
108
Assemble Differential Case
113
Section 4: Assembly and Installation
113
Check Rotating Resistance of Differential Gears (Not Limited Slip)
116
Assemble Drive Pinion and Bearing Cage
117
Adjust Pinion Bearing Preload (Without Press)
118
Adjust Thickness of Pinion Bearing Cage Shim Pack (Depth of Pinion)
119
Install Pinion Bearing Cage Assembly on Main Housing
121
Install Differential Housing Assembly into Main Housing (with Shims)
122
Install Differential Housing Assembly into Main Housing (with Adjusting Ring 2 Sides)
123
Assemble Axle Shaft
124
Assemble Trumpet Assembly
125
Assemble Hydraulic Apply Brake Housing Assembly
128
Hydraulic Apply Brake Housing Functional Test
128
Assemble Three Function Brake Housing Assembly
129
Assemble Ball and Ramp Brakes, Brake Discs, Reaction Plate and Pins
132
Assemble Three Function Brake, Brake Discs, Reaction Plate and Pins
133
Install Housing Assembly into Main Housing
133
Assemble Three Function Brake Release Bolts and Sleeves
134
Section 5: Adjustments
137
Check Ring Gear Runout Specification: 0.008 In. (0.20 MM)
137
Teeth Contact Patterns
138
Verification Procedure
138
Correct Contact Patterns
139
Incorrect Contact Patterns
139
High Contact Pattern
139
Deep Contact Pattern
140
Variations Along Length of Gear Teeth
140
Replace Lubricant
141
Section 6: Specifications
142
Oil Change Intervals and Specifications
142
Nut Lock Special Tool
143
Proa 352/382
144
Torque Chart - PROA 352/382
145
PRA 352 – Trumpet Variation No. 2
146
Proa 352 G2H, G2M
148
Torque Chart - PROA 352, G2H, G2M
149
Hydraulic Oil Reservoir
157
Park Brake
158
Hydraulic Filter Condition
160
Engine Speed
161
Charge Pressure
163
Charge Pressure Test Port
163
Hydrostatic Transmission
164
Rear Drive Motor Assemblies
164
Front Motor
165
Control Pressure
166
Floorplate Assembly
169
Inching Valve
169
Front Motor Begin Point
170
Front Motor Controls
171
Hydraulic Transmission Pressure
172
Machine Operation
174
Hydraulic System Pressures
175
Boom Maintenance
177
Orientation
180
Fastener and Fitting Torque
180
Preparing the Material Handler for Service
180
Additional Maintenance / Service Precautions
180
Special Note on Boom Cables
182
Safety
183
Boom Adjustment
189
Bearing Pad Package
189
Boom Wear Pad Adjustments
190
General Service Notes
190
Front Inside
192
Area 3 & 4
193
Rear Outside
193
Bearing Pad Bolt Quantities
193
Area 4
194
Bearing Pad Removal
197
Bearing Pad Installation
199
Separating Boom Sections
203
Removal of the Complete Boom Assembly from the Machine
203
Reinstalling the Complete Boom Assembly to the Machine
204
Assembling Boom
211
Retract Cable and Hose Sheaves
216
Crowd Cylinder
217
Crowd Cylinder & Push Beam Assembly
218
Extension Cable Sheave
219
Assembly
220
Boom Weldment
220
Bearing Pads & Hose Take-Up Assembly
221
Boom Assembly Rear, Crowd Cylinder and Mounting Bracket
223
Strong Back Installation
224
Hose Take-Up Assembly, Hydraulic Hoses & Clamps
224
Boom Cables
226
General Cable Information
226
Boom Cable Data
226
Cable Adjustments
227
Retraction Cable Removal
228
Extension Cable Reinstallation
236
Tilt and Auxiliary Circuit Hydraulic Hoses
239
Auxiliary Electric Cable
241
Electric Boom Cable
241
Electrical Wire Data
241
Electric Cable Removal
242
Electric Cable Installation
243
Crowd Cylinder Removal and Installation
244
Rear Boom Assembly Strong Back
245
Fastener Torque Chart
247
Lubricated English Bolts
247
Metric Fasteners
248
Hose Fitting Torque Chart
249
4-Bolt Split Flange Bolt Torque
249
SAE Fittings, Straight & Adjustable
249
Implement Circuit Performance Checks
253
Additional Maintenance/Service Precautions
256
Introduction
256
Preparing the Material Handler for Service
256
Hydraulic System Precautions
257
Required Tools for Testing/Adjusting
257
Safety
258
Note on Using the Manual
259
Hydraulic Oil Reservoir
260
Hydraulic Filter Condition
261
Engine Speed
262
Charge Pressure
263
Steering Circuit
264
Main Control Valve Pump Relief
265
Tilt Circuit Relief Valves
266
Crowd Circuit Extend Relief Valve
267
Auxiliary Circuit Relief Valves
268
Service Brake Valve
269
C-Series Cycle Times
270
D-Series Cycle Times
270
Appendix A: Cycle Times for Functions
270
User Fork Wear Standards
273
Important Rim and Wheel Safety Precautions
275
How to Prevent Rim Accidents During Tire Mounting
275
During Tire Demounting
275
During Vehicle Operation
275
Mounting
276
Demounting
276
Demountable Rims
279
Disc Wheels
279
Spoke Wheels
279
Proper Maintenance of ACCU-RIDE Rims and Wheels
280
Rim and Wheel Maintenance During Tire Inspections
280
Rim and Wheel Maintenance During Tire Changes
280
How to Insure Greater Safety
282
Troubleshooting
285
Steering Control Units, Char-Lynn
285
Cyclopac Service Procedures
287
Measure Restriction
287
Filter Servicing
287
Empty the Dust Cup
287
Air Filter Service Tips
288
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