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361
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361 Guide
User manual for 361
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Table of contents
Document Outline
Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General
B Hydraulic System Safety
C Maintenance
Section 1. Specifications
1.1 Operating specifications
1.2 Capacities
1.3 Tires
1.4 Battery Charger
1.5 Dimensional Data
1.6 Drive System
1.7 Hydraulic Pump/Electric Motor Assembly
1.8 Generator
1.9 Function Speeds
1.10 Pressure Settings
1.11 Torque Specifications
1.12 Lubrication Specifications
Hydraulic Oil
1.13 Critical Stability Weights
1.14 Cylinder Specifications
1.15 Major Component Weights
1.16 Serial Number Locations
1.17 Operator Maintenance & Lubrication
Section 2. General
2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive Maintenance
2.2 Service and 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
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment
Section 3. Chassis & Turntable
3.1 Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Spindle
Setting Wheel Bearing End Play
Specifications
Checking
Greasing Requirements
3.3 Drive Hub Part No. 2780236
Disassembly
Disassembly of Cover
Disassembly of First Stage Planetary Assembly (7)
Disassembly of Second Stage Planet Gears (1)
Assembly of First Stage Planetary Assembly (7)
Assembly of End Cover Unit (8)
Final Assembly
Initial Start-up and After Repairs
Maintenance
Oil Change Interval-Gear Drive
Setting of Tapered Roller Bearings
Securing of the Shaft Nut
3.4 Drive Brake - Mico
Disassembly
Assembly
Bleeding
3.5 Speed Sensor Adjustment
Adjustment Procedure
Speed Sensor Installation Verification
Verification w/ Analyzer Procedure
3.6 Positrac/Tilt module
3.7 Swing Motor - S/N 0300135649 to Present
Preparation Before Disassembly
Disassembly and Inspection
Assembly
One Piece Stator Construction
Two Piece Stator Construction
Final Checks
3.8 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Checking Worm Gear End Play
Adjusting End Play
3.9 Battery Maintenance and Charging
Battery Maintenance, Quarterly
Optional On Board Generator
Battery Charging (On Board Charger)
3.10 Battery Charger (S/N 0300059350 to Present)
Operating Instructions
Maintenance Instructions
Battery Charger Fault Codes
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
Checking/Changing the Battery Charger Algorithm
3.11 Generator (Prior to S/N 88539)
Timing Sequences
To Connect the JLG Control System Analyzer to the Generator
Alarms and Fault Flash Codes
Output Current and Voltage Settings
Priming the Fuel Line
3.12 Generator (S/N 88539 to Present)
Engine
Alternator
Dynamo and Dynamo Voltage Regulator
Dynamo Output Fuse
Control Fuse
Start Battery
Engine Starter
Start Control Relay
Fuel Control Relay
Glow Plug Control Relay
Glow Plug
Fuel Pump
Fuel Solenoid
Engine Low Oil Pressure Switch
Engine Oil Temperature Sensor
Alternator Output Current Sensor
Engine Speed Sensor
RBS Engine/Generator Controller
Warnings and Safety Precautions
System Controls
System Status and Performance Monitoring
System Settings
RBS Start
RBS shutdown
RBS Alarms and Flash Codes
Resetting the RBS Controller
Maintenance Schedule
Troubleshooting
APU Engine Start Battery Boosting
3.13 Supplementary fuse for apu
Tools And Material
Procedure
Section 4. Boom & Platform
4.1 Boom Maintenance
Removal
Disassembly
Inspection
Assembly
Installation
4.2 Upper (Main) Boom Lift Cylinder
Removal
Installation
4.3 Mid Boom Lift Cylinder
Removal
Installation
4.4 Lower Boom Lift Cylinder
Removal
Installation
4.5 Upper Boom Telescope Cylinder
Removal
Installation
4.6 Mid and Lower Lift Cylinder Bleeding Procedure
4.7 Wear Pads
4.8 Boom Limit Switches
4.9 Articulating Jib Boom
Removal
Disassembly
Inspection
Assembly
4.10 load sensing system
Calibration
4.11 Boom Synchronizing Procedure
4.12 Footswitch Adjustment
4.13 Helac Rotary actuator
Theory Of Operation
Tools Required for Assembly/Disassembly
Disassembly
Inspection
Assembly
Installing Counterbalance Valve
Testing the Actuator
Installation and Bleeding
Troubleshooting
4.14 Powertrack Maintenance
Removing a Link
Installing a New Link
Replacing Fixed End Brackets
Replacing Moving End Brackets
Section 5. Hydraulics
5.1 Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method
5.2 Cylinders - Theory of Operation
Double Acting Cylinder
5.3 Cylinder Checking Procedures
Cylinder Without Counterbalance Valves
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valve
5.4 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
5.5 Pressure Setting Procedures
Main Relief
Upper Lift Down Relief
Lower Lift Down Relief
Telescope Relief
Platform Level Up Relief
Platform Level Down Relief
Steer Relief
Jib Lift (Up and Down) Relief
Releveling Valve Relief
Section 6. JLG Control System
6.1 JLG Control System Analyzer Kit Instructions
Introduction
To Connect the JLG Control System Analyzer
Using the Analyzer
Changing the Access Level of the Hand Held Analyzer
Adjusting Parameters Using the Hand Held Analyzer
Machine Setup
Machine Personality Settings
Machine Configuration Programming Information
Level Vehicle Description
Help Descriptions and Fault Flash Codes
Analyzer Diagnostics Menu Structure
System Self Test
Section 7. Basic troubleshooting, Electrical Information, & schematics
7.1 General
7.2 Troubleshooting
7.3 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.4 Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side
7.5 Applying Silicone Dielectric Compound to Electrical Connections
7.6 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
7.7 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
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