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Pro-SOLO MkII Guide
User manual for Pro-SOLO MkII
Here is the user manual for Pro-SOLO MkII. You can read and download this user guide for free. User's manual, provided by the manufacturer, allows you to use properly your home appliances and electronics.
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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 Capacities
Fuel Tank
Hydraulic Oil Tank
Hydraulic System (Including Tank)
Torque Hub, Drive
Engine Crankcase
1.2 Component Data
Engine - Diesel (Liquid-Cooled)
Drive System
Steer System
Swing System
Hydraulic Gear Pump (at 1800 RPM)
Auxiliary Power Pump
Hydraulic Filter - In-line
1.3 Performance Data
Turning Radius (Outside)
Turning Radius (Inside)
Boom Elevation
Machine Weight approximately
Machine Height (Stowed)
Machine Length (Stowed)
Machine Width
Wheel base
1.4 Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes
1.5 Torque Requirements
1.6 Lubrication
Ford LRG425 Engine
Deutz F3M1011F Engine
Hydraulic Oil
Lubrication Specifications
1.7 Pressure Settings
Rexroth Valve
1.8 Cylinder Specifications
1.9 Major Component Weights
1.10 Critical Stability Weights
1.11 Serial Number Locations
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
Preventative 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
2.7 Applying Silicone Dielectric Compound to Electrical Connections
2.8 AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
Section 3. Chassis & Turntable
3.1 Torque Hub, Drive
Disassembly
Cleaning and Inspection
Repair
Assembly
3.2 Torque Hub, Drive (Auburn Gear)
Disassembly
Assembly
3.3 Drive Brake - Ausco
Disassembly
Inspection
Assembly
3.4 Drive Brake - Mico
Disassembly
Assembly
Bleeding
3.5 Drive Motor (Prior to S/N 85132)
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup
3.6 Drive Motor Adjustment Procedure (PRior to S/N 85132)
3.7 Drive Motor (S/N 85132 to Present)
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures
3.8 Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
To Engage Drive Motors and Brakes (Normal Operation)
3.9 Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test
3.10 Steer Adjustments
3.11 Swing Hub
Adjustment Procedures
3.12 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Value
3.13 Swing Brake - Ausco
Disassembly
Inspection
Assembly
3.14 Swing Motor
Disassembly
Reassembly
Motor Timing
3.15 Tilt Alarm Switch (Machines with External Tilt Sensor)
Manual Adjustment
3.16 Spark Arrester Cleaning Instructions
3.17 Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline
3.18 Electric Governor Installation and Adjustments - Ford Engine
General
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Check-Out and Initial Start-Up Procedures
Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout)
Single-Turn Adjustment (Gain, Factory Adjust)
Troubleshooting
3.19 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306)
General
Procedure
Controller Status
Failure Modes
3.20 Automatic Choke Adjustment - Ford Engine
3.21 Cold Weather Starting Difficulty
Checking the Carburetor
Checking the Ignition
3.22 Checking the Fuel
3.23 Ford EFI Engine (machines after S/N 58209)
Performing Diagnostics
EFI Diagnostics (S/N 58209 to S/N 60188)
Engine Module and Sensors
Fuel System
Section 4. Boom & Platform
4.1 Boom Maintenance
Removal
Disassembly Boom Sections
Inspection
Assembly
Installation
4.2 Boom Rope Torquing Procedures
Torque Procedures
4.3 Wear Pads
Main Boom
4.4 Wire Rope
Inspection
Three Month Inspection
Eight Year Inspection
Replacement Criteria
4.5 Limit Switches and Cam Valve Adjustment
Limit Switch Functional Check
4.6 Rotator - Helac
Disassembly
Inspection
Assembly
4.7 Drive Card Setup Procedures
Lift, Swing, and Drive Cards
Flow Control Card
4.8 Foot Switch Adjustment
Section 5. Hydraulics
5.1 Cylinders - Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves
5.2 Valves - Theory of Operation
Solenoid Control Valve - Rexroth
Relief Valves
5.3 Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Dual Counterbalance Valves
5.4 Cylinder Repair
Disassembly
Cleaning and Inspection
Assembly
5.5 Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Boom Lift Cylinder Removal
Boom Lift Cylinder Installation
5.6 Variable Displacement pump (M46 series)
Troubleshooting
Inspections and Adjustments
Minor Repair and Replacement
5.7 Pressure Setting Procedures
Main Relief, Steer, Swing and Lift Down
Platform Level
4 Wheel Steer (If Equipped)
5.8 Directional Control Valve
5.9 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
5.10 Hydraulic Component Start-Up Procedures and Recommendations
Section 6. JLG CONTROL SYSTEM (ADE)
6.1 Introduction
6.2 To Connect the JLG Control System Analyzer
6.3 Using the Analyzer
6.4 Changing the Access Level of the Hand Held Analyzer
6.5 Adjusting Parameters Using the Hand Held Analyzer
6.6 Machine Setup
6.7 Level Vehicle Description
6.8 Machine Personality Settings
6.9 Analyzer Diagnostics Menu Structure
Section 7. schematics
7.1 General
7.2 Troubleshooting
7.3 Hydraulic Circuit Checks
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