JLG GRADALL 522D Manuals

Manuals and User Guides for JLG GRADALL 522D. We have 1 JLG GRADALL 522D manual available for free PDF download: Owner's/Operator's Manual

JLG GRADALL 522D Owner's/Operator's Manual (289 pages)

Brand: JLG | Category: Forklifts | Size: 19.61 MB

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
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
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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JLG GRADALL 522D Manuals

JLG GRADALL 522D Owner's/Operator's Manual (289 pages)

Table of Contents

Section 1: Introduction

Section 2: Removal and Disassembly

Section 3: Prepare Parts for Assembly

Section 4: Assembly and Installation

Section 5: Adjustments

Section 6: Specifications

Appendix A: Cycle Times for Functions

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