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PS3200 Guide
User manual for PS3200
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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 Dimensional Data
1.3 Capacities
1.4 Tires
1.5 Engine Data
1.6 Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes
1.7 Torque Requirements
1.8 Hydraulic Oil
1.9 Major Component Weights
1.10 Operator Maintenance
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
Pneumatic Tires
Polyurethane Foam Filled Tires
Tire Replacement
Wheel Replacement
Wheel Installation
3.2 Torque Hub
Oil Information
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Spindle-Brake Disassembly
Cover Disassembly
Cover Assembly
Input Carrier Assembly
Spindle - Brake Assembly
Hub-Spindle Assembly
Output Planet Gear Assembly
Main Assembly
Integral Brake Check
3.3 Free Wheeling Option
Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel)
Engage Drive Motors & Brakes (Normal Operation)
3.4 Drive Motor
Description
Shaft Seal Replacement
Removal
inspection
installation
Loop Flushing Valve
Removal
inspection
installation
Troubleshooting
Disassembly
Inspection
Piston
Slippers
Cylinder Block
Ball Guide and Slipper Retainer
Valve Plate
Swashplate and Journal Bearings
Shaft Bearings
Shaft
Servo Piston and Minimum Angle Stop
Loop Flushing Spool
Assembly
Initial Start-up Procedures
3.5 Oscillating Axle Bleed Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test
3.6 Steer Adjustments
3.7 Swing Drive
Gear Backlash
Swing Drive Lubrication
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Subassembly
Carrier Subassembly
Main Assembly
Motor and Brake Assembly
Motor Control Valve Assembly
3.8 Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Removal
Installation
Swing Bearing Torque Values
3.9 Rotary Coupling
3.10 Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
inspecting brush position
inspecting brushes
CLEANING SLIP RINGS
3.11 Deutz D2.9 L4 Engine
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters
3.12 Deutz D2011 Engine
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replace Fuel Filter
Clean Fuel Strainer
3.13 Spark Arrester Cleaning Instructions
3.14 Glow Plugs
3.15 Deutz EMR 2
3.16 Bio Fuel in Deutz Engines
General
Bio Fuel
Permitted bio-diesel fuels
approved engines
Basic conditions to be observed
Plant oil
Biological Contamination In Fuels
Symptoms
Cause
Preventive measures
Fuel additives
3.17 GM Engine General Maintenance
Drive Belt Maintenance
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing Engine Oil
Coolant Fill Procedure - Dual Fuel Engine
3.18 GM Engine Dual Fuel System
Fuel Filter
Direct Electronic Pressure Regulator (DEPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Electric Lock Off
Engine Control Module (ECM)
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.19 GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
Check/Drain Oil Build-Up In 2-Stage Vaporizer
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
Exhaust System And Catalytic Converter Inspection And Maintenance
Temperature Manifold Absolute Pressure (TMAP) Sensor
REMOVAL
INSTALLATION
Throttle Body (ETC) Replacement
REMOVAL
INSTALLATION
Mixer Replacement
INSTALLATION
Electronic Pressure Regulator (EPR) Replacement
Removal
Installation
Regulator Replacement
REMOVAL
Installation
Coolant Hose Replacement
REMOVAL
INSTALLATION
Vapor Hose Replacement
REMOVAL
INSTALLATION
Engine Control Module Replacement
REMOVAL
INSTALLATION
Heated Exhaust Gas Oxygen Sensor Replacement
3.20 GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids
Section 4. Boom & Platform
4.1 Boom Systems
Removal
4.2 Wear Pads
4.3 Boom Disassembly/Assembly & Cable Replacement
Boom Section Disassembly
4.4 Wire Rope
Inspection
Three Month Inspection
Eight Year Inspection
Replacement Criteria
4.5 Wire Rope Tensioning Adjustment
Wire Rope Tensioning Procedure
Inspection
Assembly
Installation
4.6 Articulating Jib Boom
Removal
Disassembly
Inspection
Assembly
4.7 Limit Switches and Cam Valve Adjustment
4.8 Boom Cleanliness Guidelines
4.9 Rotary Actuator
Theory of Operation
Required Tools
Disassembly
Inspection
Assembly
Installing Counterbalance Valve
Testing Actuator
Testing Actuator for Internal LeakS
Installation and Bleeding
Troubleshooting
4.10 Foot Switch Adjustment
4.11 Platform
Platform Support Torque Settings
Replace Platform Sections
4.12 Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets
Section 5. Hydraulics
5.1 O-Ring Lubrication
Cup and Brush
Dip
Spray
Brush-On
5.2 Cylinders - Theory of Operation
Systems With Double Acting Cylinders
Systems With Holding Valves
5.3 Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves
5.4 Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
5.5 Cylinder Repair
Disassembly
Cylinder Locations
Main Lift Cylinder
Disassembly
Cleaning and Inspection
Assembly
Master Cylinder
Disassembly
Cleaning and Inspection
Assembly
Telescope Cylinder
Disassembly
Cleaning and Inspection
Assembly
Platform Level (Slave) Cylinder
Disassembly
Cleaning and Inspection
Assembly
Jib Lift Cylinder (SJ Only)
Disassembly
Cleaning and Inspection
Assembly
Steer Cylinder
Disassembly
Cleaning and Inspection
Assembly
Axle Lockout Cylinder
Disassembly
Assembly
5.6 Hydraulic Pump (Gear)
Disassembly
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Assembly
Placing Pump Back Into Service
5.7 Variable Pump
Ports and Pressure Gauges
NFPE Control
Remove and Install FNR and NFPE Modules
Remove and Install FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
Charge Pump
5.8 Hydraulic Component Start-Up
5.9 Pressure Setting Procedures
Main Relief, Steer, Swing, and Lift Down
Platform Level
Articulating Jib Boom (If Equipped)
4 Wheel Steer (If Equipped)
Section 6. JLG Control System
6.1 Introduction
Connect JLG Control System Analyzer
Using Analyzer
Changing Access Level
Adjust Parameters
Machine Setup
Level Vehicle Description
6.2 Machine Personality Settings
6.3 Machine Orientation When Setting Function Speeds
Test Notes
6.4 CANbus Communications
Section 7. Basic Electrical Information & Schematics
7.1 General
7.2 Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement
7.3 Applying Silicone Dielectric Compound to Electrical Connections
Dielectric Grease Application
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions
Brad Harrison/Phoenix Contact M12
AMP Junior Timer
7.4 AMP Connector
Contact Assembly
Connector Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
7.5 Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
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