Service Manual Owner's manual

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Service and Maintenance Manual

Model

150HAX

P/N - 3120817

February 15, 2012

Summary of content (156 pages)

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Service and Maintenance Manual Model 150HAX P/N - 3120817 February 15, 2012
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
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INTRODUCTION REVISON LOG Original Issue Revised Revised A-2 - June 1, 1992 - February 4, 2010 - February 15, 2012 – JLG Lift – 3120817
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 2.4 2.5 2.6 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 3.10 3.11 3.12 3.13 3.14 3.15 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Assembly . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) 5.2 5.3 5.4 5.5 5.6 5.7 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 2-1. 3-1. 3-2. 3-3. 3-4. 3-19. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-26. 3-27. 3-28. 4-1. 4-2. 4-3. 4-4. 5-1. 5-2. 5-3. 5-4. 5-5. 6-1. 6-2. 6-3. 6-4. 3120817 TITLE PAGE NO. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 2-1 2-2 2-3 3-1 4-1 5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 vi TITLE PAGE NO. Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Engine Datas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Drive Steer System . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 1.4 CAPACITIES PERFORMANCE DATA Table 1-1. Capacities Table 1-4. Performance Data Fuel Tank 68 gallons (257 liters) Maximum Drive Speed Hydraulic Oil Tank Approx. 124 gallons (469 liters) 2.7 mph (4.3 kph) @ Max RPM Hydraulic System Approx. 150 gallons (568 liters) Maximum Travel Grade (Grade- 31% ability) Drive - 90 ounces (2.7 liters) Drive - 90 ounces (2.7 liters) Turning Radius (Outside) Swing - 60 ounces (1.
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SECTION 1 - SPECIFICATIONS 1.6 LUBRICATION . Table 1-8. Mobil EAL 224 H Specs Table 1-6.Hydraulic Oil Hydraulic System Operating Temperature Range SAE Viscosity Grade 0° to +23° F(-18° to -5° C) 10W 0° to +210° F(-18° to +100° C) 10W-20, 10W-30 +50° to +210° F(+10° to +99° C) 20W-20 NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service.
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SECTION 1 - SPECIFICATIONS 1.7 TORQUE REQUIREMENTS 1.8 Table 1-11. Torque Requirements Torque Value (Dry) Interval Hours Bearing To Chassis 545 ft. lbs. (740 Nm) 50/600* Bearing To Turntable 545 ft. lbs. (740 Nm) 50/600* Wheel Lugs 300 ft. lbs. (407 Nm) 150 Drive Torque Hub to Spindle 260 ft. lbs. (353 Nm) 200 Main Boom Chains 50 ft. lbs. (68 Nm) 200 Swing Motor to Swing Brake 110 ft. lbs. (149 Nm) 500 Torque Hub to Turntable Mounting Plate 340 ft. lbs.
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SECTION 1 - SPECIFICATIONS 1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS Table 1-14. Critical Stability Weights Table 1-13. Major Component Weights LB. KG. LB. KG. 36 x 96 Platform 420 191 Counterweight 3285 1490 Platform Level Cylinder 80 36 Tire & Wheel Assembly 1020 494 Main Boom 6350 2880 Engine 680 308 Main Lift Cylinder 830 377 8 ft.
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SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance & Lubrication Diagram 1.12 OPERATOR MAINTENANCE NOTE: Table 1-15. Lubrication Specifications The following numbers correspond to those in Figure 1-1., Operator Maintenance & Lubrication Diagram. NOTE: The lubrication intervals in Figure 1-1.
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SECTION 1 - SPECIFICATIONS 1. Torque Hubs 3. Tie Rod Center Pivot Links Lube Point(s) - 1 Fill Plug per hub Capacity Lube - EPGL Interval - Check oil level at side plug on hub weekly. Change after first 3 months or 150 hours then every 2 years or 1200 hours of operation. Comments - Place Fill port at 12 o’clock position and pour lubricant into fill port until it just starts to flow out of check port when it’s at the 3 o’clock position.
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SECTION 1 - SPECIFICATIONS 6. Extending Axles Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turntable 9. Tower Boom Lift Cylinder Barrel End Lube Point(s) - N/A Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Apply by brush Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turntable 7. Swing Bearing Gear 10.
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SECTION 1 - SPECIFICATIONS 12. Platform Hinges 15. Platform Level Links Lube Point(s) - 3 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 16. Level Cylinder Rod End Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 13.
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SECTION 1 - SPECIFICATIONS 19. Engine Oil Filter 24. Main Boom Pivot Pin Lube Point(s) - N/A Lube - EO Comments - Refer to Engine Manual for Change interval. 20. Main Boom Chains Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 25. Tower Boom Pivot Pin Lube Point(s) - N/A Capacity - N/A Lube - Chain Lube Interval - Every 2 years or 1200 hours of operation. 21.
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SECTION 1 - SPECIFICATIONS 27. Upper Master Cylinder Rod End 31. Hydraulic Filter Interval - Replace filter after first 50 hours of operation, then every 6 months or 300 hours thereafter. 32. Air Filter Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments 28.
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SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
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SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
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SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
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SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
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SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
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SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3120817
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
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SECTION 2 - GENERAL fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles. Changing Hydraulic Oil 1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual.
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SECTION 2 - GENERAL Cylinder Drift b. Flaking, pealing, scoring, or scratches on the pin surface. c. Rusting of the pin in the bearing area. Table 2-2. Cylinder Drift Cylinder Bore Diameter 4. Re-assembly of pinned joints using filament wound bearings. Max. Acceptable Drift in 10 Minutes inches mm inches mm 3 76.2 0.026 0.66 3.5 89 0.019 0.48 4 101.6 0.015 0.38 5 127 0.009 0.22 6 152.4 0.006 0.15 7 177.8 0.005 0.13 8 203.2 0.0038 0.10 9 228.6 0.0030 0.08 a.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL AMBIENT AIR TEMPERATURE 120° F(49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F(43° C) 100° F(38° C) 90° F(32° C) 80° F(27° C) SUMMER GRADE FUEL SAE 15W-40 SAE 10W-30 ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
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SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3120817
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS ment tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.
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SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. b. Remove spacer (26) from planet shaft, then, using a suitable drift, drive planet shaft from carrier, shearing off roll pin. Tap remaining roll pin from carrier using a suitable punch. Table 3-1. Wheel Torque Chart c. Remove cluster gear (27) from carrier and remove bearing cones (29) from cluster gear.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
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SECTION 3 - CHASSIS & TURNTABLE Cleaning and Inspection b. Turn hub over, small diameter up. Install two pipe plugs (37) into hub. 1. Thoroughly clean all parts in an approved cleaning solvent. 2. Inspect geared or splined components in primary and secondary planet carriers, input and output sun gears, ring gear, coupling and input shaft for chipped or broken teeth, and excessive or uneven wear patterns. Replace components as necessary. c. Press bearing cup (33) into small diameter end of hub.
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SECTION 3 - CHASSIS & TURNTABLE f. Lower hub onto spindle (30) with large open end up. g. Place bearing cone (32) over end of spindle and into bearing cup. h. Place bearing shim (34) over end of spindle and against bearing cone. i. Secure retaining ring (35) completely into spindle groove and against bearing shim. Ensure retaining ring is entirely in groove. j. Install retaining ring keeper ring (40) in location around retaining ring and on bearing shim. k.
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SECTION 3 - CHASSIS & TURNTABLE l. Place spring (43) into spindle counterbore. 2. Position hub/spindle assembly (36 and 30) with large open end up. m. Set second spacer washer (42) on top of spring. 3. Lower internal gear (21) onto spindle. 4. Place one thrust bearing (16) between two thrust washers (15) and place them onto spindle pilot. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. n.
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SECTION 3 - CHASSIS & TURNTABLE 5. Install retaining ring (19) in groove of input shaft (20). 6. Place input shaft into spindle counterbore of hub/ spindle assembly. The action of the disengaged spring should be checked at this time. 8. Place o-ring (14) into counterbore of hub/spindle assembly. Use grease or petroleum jelly to hold oring in place. 9. Assemble carrier assembly (22) as follows: a. Press bearing cups (28) into both ends of cluster gear (27) with large inside diameter facing out.
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SECTION 3 - CHASSIS & TURNTABLE c. Place cluster gear over planet shaft and onto bearing cone, with large gear on top. f. Bearings in cluster gear must be seated by applying 25-50 lbs. (11-23 kg) against them and rotating cluster gear at the same time. This can be done by sliding a second spacer (26) over planet shaft and pushing downward while rotating the gear. d. Place another bearing cone (29) over planet shaft and into cluster gear. This is a slip fit. g.
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SECTION 3 - CHASSIS & TURNTABLE l. While holding planet shaft in position, slide correct spacer onto planet shaft. i. Place bearing cones (29) into cluster gear. j. Place cluster gear into carrier with large gear up. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. m. Place carrier on table with something under planet shaft to hold it in correct position and install retaining ring (25). k. Slide planet shaft through carrier and cluster gear from bottom side.
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SECTION 3 - CHASSIS & TURNTABLE o. Repeat steps (a) through (n) for remaining two cluster gears. 10. Time carrier gears as follows: 12. While holding ring gear in mesh with carrier assembly, lower into internal gear (21). Small diameter cluster gear will mesh with internal gear. Slight rotation of ring gear may be necessary. a. Place carrier assembly on a flat surface, positioning two top gears at ten o’clock and two o’clock, and one bottom gear at six o’clock as shown in Figure 3-2.
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SECTION 3 - CHASSIS & TURNTABLE 15. Place one thrust bearing (16) between two thrust washers (15) and place into carrier counterbore. 16. Assemble cover assembly as follows: c. Install o-ring (10) into bore of cover cap 7. Disconnect rod (9) may be used to push o-ring down to groove in cover cap bore. d. Push disconnect rod into bore of cover cap. a. Screw pipe plugs (5 and 6) into cover 4. e. Locate large clearance hole in cover cap over pipe plug in cover and install cover cap in cover.
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SECTION 3 - CHASSIS & TURNTABLE f. Install disconnect cap (11) to cover cap with two remaining bolts (12) torqued to 70 to 80 in.lbs. (81-92 kgcm). 18. Secure cover assembly and ring gear to hub with four shoulder bolts (2) and lockwashers 3. Shoulder bolts fit into four counterbored holes in hub. It may be necessary to start bolts into hub by tapping lightly on bolts with a hammer. BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING. 19.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-2.
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SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476 Cleaning and Inspection 1. Clean all parts thoroughly. 2. Closely inspect all parts for excessive wear, cracks, and chips. Replace parts as necessary. Disassembly 1. Separate end cover (2) from housing (21) by removing capscrews (1). END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LBS.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-3.
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SECTION 3 - CHASSIS & TURNTABLE 6. Position new large diameter return plate (14) in housing with tabs guided by dowel pins (20) until disc rests on springs (15 & 16). 3.4 DRIVE BRAKE - MICO - MACHINES BUILT S/N 33476 TO PRESENT Disassembly DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES. 7. Place a new friction disc (12) on shaft (10) until it contacts return plate (14). 8.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 5. Remove separators (10) from housing (7). 6. Remove stack assembly, consisting of discs (23), return plate (8) and friction discs (22) from housing (7). NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. 7. Remove dowel pins (17), springs (5 & 6) from housing (7). 1. Press new rotary seal (1) into housing (7). Note the direction of seal. 8. Remove retaining ring (3) from housing (7). 2. Install new bearing (2) on shaft (4). 9.
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SECTION 3 - CHASSIS & TURNTABLE 29 28 1 15 54 2 3 56 52 53 17 58 22 23 22 23 51 20 21 57 18 19 11 14 13 25 55 28 29 1. 2. 3. 4. 5. 6. 7. 8. 9. Capscrew End Cover Bleeder Screw Case Seal O-ring Back-Up Ring Piston O-ring Backup Ring 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Disc Friction Disc Separators Return Plate Spring Spring Spring Guide Retaining Ring 19. 20. 21. 22. 23. 24. 25. 26. Bearing Dowel Pin Housing Retaining Ring Rotary Oil Seal O-ring Gasket Pin Figure 3-4.
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SECTION 3 - CHASSIS & TURNTABLE 3.5 FREE WHEELING OPTION 3.6 SWING BEARING To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. Turntable Bearing Mounting Bolt Condition Check 1. Chock wheels securely if not on a flat level surface. 2. Disconnect all drive hubs by inverting disconnect caps in center of hubs. To Engage Drive Motors and Brakes (Normal Operation) 1. Connect all drive hubs by inverting disconnect cap in center of hub. 2. Remove chocks from wheels as required.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-19.
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SECTION 3 - CHASSIS & TURNTABLE Check the turntable to bearing attach bolts as follows: c. Noise. d. Rough rotation. 1. Elevate the fully retracted boom to 70 degrees (full elevation). 2. At the positions indicated on Figure 3-18., Swing Bearing Bolt Feeler Gauge Check, try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position. 3. Lower the boom to horizontal and fully extend the boom. 4. At the position indicated on Figure 3-18.
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SECTION 3 - CHASSIS & TURNTABLE 9. Using a suitable tool, scribe a line on outer race of swing bearing and frame. This line will aid in aligning bearing upon installation. Remove bolts and washers which attach outer race of bearing to frame. Discard bolts. Use suitable lifting equipment to remove bearing from frame; move bearing to a clean suitably supported work area. underside of bearing mounting area of turntable base plate. b.
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SECTION 3 - CHASSIS & TURNTABLE k. Use suitable lifting equipment to carefully position turntable assembly above machine frame. l. Carefully lower turntable onto swing bearing, ensuring that turntable and bearing align as noted in step (i) above. IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE. m.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Swing Bearing Torquing Sequence Swing Bearing Torque Values 3.7 SWING TORQUE HUB 1. Outer Race - 545 ft. lb. (740 Nm) JLG Threadlocker. Disassembly 2. Inner Race - 545 ft. lb. (740 Nm) JLG Threadlocker. 1. Set unit on its shaft (1). Remove pipe plug (11) from bottom of hub near shaft, and drain oil from unit into a suitable container. 3. Swing Bearing Torquing Sequence, see Figure 2-9. 2. Remove the three pipe plugs (32) from cover (28).
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Output Shield Outer Bearing Cup Outer Bearing Cone Inner Bearing Cup Inner Bearing Cone Lockwasher Flatwasher 8. 9. 10. 11. 12. 13. 14. Bearing Nut Housing Lip Seal Pipe Plug Pipe Plug Needle Bearing Planet Shaft 15. 16. 17. 18. 19. 20. Thrust Washer Carrier Thrust Spacer Roll Pin Cluster Gear Internal Gear 21. 22. 23. 24. 25. 26. Ring Gear Thrust Washer O-ring Lockwasher Sun Gear Adapter Coupling 27. 28. 29. 30. 31. 32.
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SECTION 3 - CHASSIS & TURNTABLE 7. Remove o-ring (6) from counterbore around rim of cover. Discard o-ring. e. Remove tanged washer (7) from around shaft. f. Set hub on something wide enough to allow shaft to fall out of hub, and hammer or press shaft down out of hub. 8. Remove thrust washer (27) from “ledge” halfway down in counterbore in center of cover. Thrust washer may be on top of coupling (26). Remove washer and set it aside. g. Bearing cone (3) should be lying loose in hub.
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SECTION 3 - CHASSIS & TURNTABLE Assembly 1. Assemble hub/shaft assembly as follows: a. Set hub (9) on work surface, wide end up. Using a suitable press, press bearing cup (2) into counterbore in tall end of hub. b. Set hub on work surface, wide end down. Using the press, install bearing cup (4) into counterbore in small end of hub. c. Using the press, press bearing cone (5) onto smaller end of shaft (1). d. Slowly lower hub, small end down, onto shaft. Check initial torque.
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SECTION 3 - CHASSIS & TURNTABLE c. Apply a light coating of petroleum or multi-purpose grease to inside of small end of cluster and line inside of small end of cluster gear with nineteen needle rollers (13). 6. Place carrier assembly on work surface so one planet shaft hole faces you and other two planet shaft holes are opposite you. Line up punch marks on gear teeth of carrier assembly to the 12 o’clock position as shown in Figure 3-2. Place ring gear (21) onto carrier to keep punch marks in position.
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SECTION 3 - CHASSIS & TURNTABLE 16. Place twenty lockwashers (24) over bolt holes in cover. 8. Remove springs (6) and spring retainer (5) from housing. 17. Place twenty bolts (31) into bolt holes in cover and tighten. 9. Remove piston (13) from power plate by introducing low pressure air (15 psi [10 bar]) into the hydraulic inlet. Direct piston away from operator. 18. Torque bolts to 35-45 ft. lb. (47-61 Nm). 19.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-22.
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SECTION 3 - CHASSIS & TURNTABLE 5. Before installing seal (4), lubricate lip of seal with system hydraulic fluid or other suitable lubricant. Face lip of seal toward outside of brake in order to keep gear box oil or other external contaminants out of brake. Using a shop press, install seal (4) by pressing evenly around OD of seal. Use care to avoid cocking seal. 4. Remove piston (40) from end cover by inserting two 1/4-20 UNC bolts into threaded holes in piston.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-23.
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SECTION 3 - CHASSIS & TURNTABLE Assembly NOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly. 1. Insert new o-ring (55), dowel pins (53) and springs (51, 52) in housing (56). 2. Install new bearing (54) in housing and press until bearing bottoms on shoulder in housing. 3. Position new large diameter disc (50) in housing with tabs guided by dowel pins (53) until disc rests on springs (51, 52). DISCS (46,50) AND FRICTION DISCS (48) SHOULD REMAIN DRY DURING INSTALLATION.
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SECTION 3 - CHASSIS & TURNTABLE 25 24 23 22 21 17 19 18 16 20 15 14 26 13 12 11 12 3 9 11 8 10 7 6 5 4 2 1 24 25 1. 2. 3. 4. 5. 6. 7. 8. 9. Capscrew End Cover Bleeder Screw Case Seal O-ring Back-Up Ring Piston O-ring Backup Ring 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Disc Friction Disc Separators Return Plate Spring Spring Spring Retainer Retaining Ring 19. 20. 21. 22. 23. 24. 25. 26. Bearing Dowel Pin Housing Retaining Ring Rotary Oil Seal O-ring Gasket Pin Figure 3-24.
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SECTION 3 - CHASSIS & TURNTABLE 5. Remove separators (13) from housing (21). 5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21). 6. Remove stack assembly, consisting of discs (11), return plate (14) and friction discs (12) from housing (21). NOTE: Not all models use the same number of springs or spring pattern. Record this information for assembly purposes. Spring retainer (17) was not used in earlier models. 7.
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SECTION 3 - CHASSIS & TURNTABLE 3.11 SWING MOTOR Assembly NOTE: Prior to motor assembly, lightly oil all seals, rollers and threaded bolt ends. Disassembly NOTE: Prior to any motor disassembly, plug open ports and clean all dirt from outside of motor. 1. Install new back-up ring (2) first, pushing it sealing surface toward outside of motor. Back-up can be seated with a dull object. 1. Mount motor in a vise or other holding device with shaft facing down. 2.
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SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Dust Seal Backup Ring Quad Ring Seal Rotary Valve Check Valve Ball IGR Assembly Snap Ring 8. 9. 10. 11. 12. 13. Ring Seal Vent Plug (Includes O-ring) Bolt Spline Shaft Body/Bearing Assembly Cover/Bearing Assembly Figure 3-25.
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SECTION 3 - CHASSIS & TURNTABLE 3.12 PQ CONTROLLERS 14. Using all applicable safety precautions, start machine and allow hydraulic oil to reach a temperature of 100 to 140 degrees (38 to 60 degrees C). TRIM Adjustment 1. Disconnect ORANGE/RED (dump) wire from applicable terminal strip in platform console. 15. Depress footswitch and operate controller until trailing edge of slide lock is even with housing lock notch. Hold control handle in that position. 2.
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SECTION 3 - CHASSIS & TURNTABLE e. Release footswitch and stop machine. f. Seal ramp pot adjustment screw with a drop of enamel paint to prevent maladjustment due to vibration. g. Install controller and secure machine. 2. Swing Controller. a. Using all applicable safety precautions, start machine and ensure that adequate space is available to maneuver machine. 3.
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SECTION 3 - CHASSIS & TURNTABLE Hayes Coupling PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH. Manual Adjustment 1. Park the machine on a flat, level surface. Ensure machine is level. NOTE: Ensure switch mounting bracket is level and securely attached. 1. 2. 3. 4. 5. 6. 2. Level the base of the indicator by tightening the three flange nuts. Tighten each nut through approximately one half of it’s spring’s travel.
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SECTION 3 - CHASSIS & TURNTABLE Voltmeter Adjustment 1800 RPM. Shut down engine. Reattach actuator cable to throttle lever, making sure that low (mid) engine setting remains the same. If necessary, adjust slide pin to contact low (mid) engine limit switch at 1800 RPM. Shut down engine. 8. Park machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure. 9. If engine is not running, turn ignition switch to ON. b.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-28.
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE Main Boom Removal 1. Shut down machine systems. Boom Mounted Limit Switches and Valves NOTE: The numbers on the following descriptions correspond with the numbers in Figure 4-1., Boom Mounted Limit Switches and Valves Installation. 1. Located inside of turntable at the main boom pivot pin on the left side - Controls speed of main boom lift and lower at fully stowed and fully elevated positions. 2.
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SECTION 4 - BOOM & PLATFORM Figure 4-1.
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SECTION 4 - BOOM & PLATFORM Tower Boom Removal 12. Shut down machine systems. 1. Remove main boom as outlined in Main Boom Removal. 2. Shut down machine systems. 13. Tag and disconnect all wiring to ground control box. 14. Remove the bolts and lockwashers securing the lower master cylinder rod end to the tower boom. NOTE: Tower Boom Assembly weighs approximately 14,700 lb. (6,668 kg). 15. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from tower boom.
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SECTION 4 - BOOM & PLATFORM Figure 4-2.
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SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Base Boom Mid Boom Fly Boom Telescope Cylinder Extend Sheave Fly Extend Chain Fly Retract Chain Chain Adjustment Assembly Chain Adjustment Assembly Retract Sheave Upper Rear Wear Pads Figure 4-3.
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SECTION 4 - BOOM & PLATFORM 6. Using a suitable brass drift, carefully drive telescope cylinder pin from base section. 19. Remove two bolts, washers, and lockwashers securing each trunnion pin cover to mid section. 7. Remove three locknuts and flatwashers from studs on top of aft end of base section. 20. Using a suitable tool, scribe a line on the outer end of each trunnion pin and boom structure as an aid to pin alignment during boom assembly. 8.
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SECTION 4 - BOOM & PLATFORM 29. Remove bolts and lockwashers which attach bottom wear pads at front of outer mid section and remove pads and any shims. 30. Remove bolts and lockwashers which attach side wear pads at front of mid section and remove pads and any shims. 3. Remove bolts and lockwashers securing telescope cylinder mounting plate to telescope cylinder. NOTE: Note and record the number and thickness of any wear pad shims during wear pad removal. 4.
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SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. 6. Base Boom Mid Boom Fly Boom Telescope Cylinder Upper Rear Wear Pads Cylinder Mounting Plate Figure 4-4.
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SECTION 4 - BOOM & PLATFORM 13. Using suitable lifting equipment, carefully slide telescope cylinder out of fly and mid sections and lower to ground or suitably supported work area. Inspection 1. Inspect all sheaves (extend chains, retract chains and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as necessary. NOTE: Note and record number and thickness of any wear pad shims during wear pad removal. 2.
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SECTION 4 - BOOM & PLATFORM Main Boom Assembly NOTE: When installing fly section wear pads, install same number and thickness of shims as were removed during disassembly. 1. Install top and side aft fly section wear pads and shims, as required, using bolts and lockwashers. 2. Using suitable lifting equipment, carefully slide fly section into mid section. NOTE: When installing mid section wear pads, install same number and thickness of shims as were removed during disassembly. 3.
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SECTION 4 - BOOM & PLATFORM 24. Install trunnion pins, tapping pins into place with a soft headed mallet if necessary. Install cover plate over trunnion pins and secure to mid section with bolts, washers, and lockwashers. Tower Boom Assembly 1. If removed, align barrel end of upper master cylinder with mounting holes on end of tower boom fly section and install attach pin. Secure pin in place with a bolt and lockwasher. 25.
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SECTION 4 - BOOM & PLATFORM NOTE: When installing mid section wear pads, install same number and thickness of shims as were removed during disassembly. Tower Boom Installation 1. Using suitable lifting equipment, position assembled tower boom on turntable so that boom pivot holes in tower boom and turntable are aligned. 10. Install mid section top front wear pads and shims, as required, using bolts and lockwashers. 11.
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SECTION 4 - BOOM & PLATFORM Main Boom Installation 4.2 BOOM CHAINS 1. Using suitable lifting equipment, position assembled main boom on tower boom so that boom pivot holes in main boom and tower boom are aligned. Adjusting Procedures - Main Boom 2. Insert boom pivot pin, gently tapping pin into position with a soft headed mallet if necessary. Secure pin with bolts and lockwashers. ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE. 1.
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SECTION 4 - BOOM & PLATFORM Inspection Procedure BOOM CHAINS ARE TO BE INSPECTED AT TIME OF NEXT BOOM OVERHAUL AND WHEN DEEMED NECESSARY BY MACHINE OWNER. INSPECTION INTERVAL SHOULD NOT EXCEED 500 HOURS OF MACHINE OPERATION. Inspect boom chains for the following conditions: 1. Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the extend/retract sheaves, joints and plate edges very gradually wear.
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SECTION 4 - BOOM & PLATFORM 5. Tight Joints: All joints in the roller chain should flex freely. On roller chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting care fully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain.
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SECTION 4 - BOOM & PLATFORM 8. Chain Anchors, Sheaves, and Pins: An inspection of the chain must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution. Sheaves should be inspected for worn flanges, which would indicate misalignment, and wear on the outside diameter of the sheave.
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SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 VALVES - THEORY OF OPERATION Relief Valves Solenoid Control Valves (Bang-Bang) Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir.
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SECTION 5 - HYDRAULICS 5.3 CYLINDER CHECKING PROCEDURES NOTE: Cylinder checks must be performed any time a cylinder component is replaced or when improper system operation is suspected. Cylinders w/o Counterbalance Valves Front and Rear Steer Cylinders, Front and Rear Frame Lift Cylinders, Upper Master Cylinder, Lower Master Cylinder, Front and Rear Axle Extension Cylinders OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1.
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SECTION 5 - HYDRAULICS Cylinders w/Dual Counterbalance Valve Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Level Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system. 2. If working on the main telescope cylinder, raise the tower boom and then raise the main boom above horizontal. Extend the main fly boom approximately 1 foot (30.5 cm).
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SECTION 5 - HYDRAULICS 6. Remove two bolts and lockwashers securing each of two trunnion blocks to base end of mid boom section. Remove trunnion blocks. Tower Lift Cylinder Removal 1. Place machine on a flat and level surface. Start engine and raise tower boom. Shut down engine and attach a suitable support device to boom. 7. Remove bolt, lockwasher and end cap from each end of fly attach pin. Using a suitable brass drift, carefully drive fly attach pin from fly section. 2.
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SECTION 5 - HYDRAULICS Main Telescope Cylinder Removal 1. Place machine on a flat and level surface, with main boom fully retracted and in the horizontal position. 2. Shut down engine. Support boom platform end with a prop or overhead lifting device. 18. Using another lifting device, support sheave wheel end of cylinder and remove cylinder from boom assembly. 19. Carefully lift cylinder clear of boom assembly and lower to ground or suitably supported work area. Main Telescope Cylinder Installation 3.
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SECTION 5 - HYDRAULICS Main Lift Cylinder Removal Lower Master Level Cylinder Removal 1. With tower boom at horizontal, depress plunger on limit switch in main lift circuit, located inside turntable. Keep plunger depressed with a c-clamp. Raise main boom above horizontal, just enough to be able to access main lift cylinder. Attach a suitable support device or devices to main boom. 1. With tower boom partly raised and properly supported, prepare to remove lower master level cylinder. 2.
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SECTION 5 - HYDRAULICS Lower Master Level Cylinder Installation 1. With tower boom partly raised and properly supported, align level cylinder barrel end bushing with pin attach blocks in turntable and install barrel attach pin using appropriate brass drift. Secure pin with bolt and lockwasher. 7. Remove bolt and lockwasher securing level cylinder barrel attach pin to lower boom. Using an appropriate brass drift, drive out level cylinder barrel attach pin and remove cylinder from lower boom.
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SECTION 5 - HYDRAULICS 5.5 CYLINDER REPAIR 10. Remove the piston rings. NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting. 11. Remove and discard the piston o-rings, seal rings, and backup rings. 12.
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SECTION 5 - HYDRAULICS 14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent. 6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible. 15. If applicable, inspect port block fittings and holding valve. Replace as necessary. 7. Push the piston onto the rod until it abuts the spacer end and install the attaching nut. 16.
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SECTION 5 - HYDRAULICS 10. Place new o-rings and seals in the applicable outside diameter grooves of both the piston and the cylinder head. 11. Position the cylinder barrel in a suitable holding fixture. NOTE: Steps (17) through (20) apply to the telescope cylinder. 17. Elevate the barrel end of the cylinder to a work bench or other suitable device. 18. Plug the retract port and supply hydraulic power to the extend port. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON.
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SECTION 5 - HYDRAULICS 5.6 PRESSURE SETTING PROCEDURES 1. Test the hydraulic pressures: Cold temperatures have a significant impact on pressure readings. JLG Industries, Inc. recommends operating the machine until hydraulic system has warmed to normal operating temperatures prior to checking pressures. It is also recommended that a calibrated gauge is used. Pressure readings are acceptable if within ±5% of specified pressures. a. Start the engine and stall each function. Record the pressures. b.
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SECTION 5 - HYDRAULICS 5 Stack Directional Control Valve (External Relief Adjustment Screws) d. Turn off the engine and apply a vacuum to the hydraulic tank. e. Remove the main relief cap. f. Remove the springs and relief cartridge. g. Install a new relief cartridge and springs and install the main relief cap. h. Remove the vacuum from the hydraulic tank and retest the main pressure reading. 2. Main Telescope Relief. a. Bottom out Main Telescope Out function. b. Adjust pressure to 3000 psi (207 bar).
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SECTION 5 - HYDRAULICS c. Adjust pressure to 3000 psi (207 bar). d. Adjust pressure to 2600 psi (179 bar). d. Bottom out Main Lift Down function. 5. Tower Lift Relief. e. Adjust pressure to 1850 psi (128 bar). a. Bottom out Tower Lift Up function. b. Adjust pressure to 3700 psi (255 bar). 4. Tower Telescope Relief. a. Bottom out Tower Telescope Out function. b. Adjust pressure to 3000 psi (207 bar). c. Bottom out Tower Telescope In function.
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SECTION 5 - HYDRAULICS Figure 5-2.
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SECTION 5 - HYDRAULICS Figure 5-3.
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SECTION 5 - HYDRAULICS c. Bottom out Tower Lift Down function. screw clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locknut. d. Adjust pressure to 3000 psi (207 bar). 6. Bottom out Rotate Left function. 7. Loosen locknut and turn adjusting screw on opposite side of valve section to 2500 psi (172 bar). Turn adjusting screw clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locknut. 8. Bottom out Level Up function. 9.
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SECTION 5 - HYDRAULICS to increase pressure, counterclockwise to decrease pressure. Tighten locknut. to increase pressure, counterclockwise to decrease pressure. Tighten locknut. 6. Bottom out Rear Steer Right function. 7. Loosen locknut on rear steer valve section and turn adjusting screw to adjust valve section to 2000 psi (138 bar). Turn adjusting screw clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locknut. Four Stack Directional Control Valve 1.
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SECTION 5 - HYDRAULICS to increase pressure, counterclockwise to decrease pressure. Tighten locknut. to increase pressure, counterclockwise to decrease pressure. Tighten locknut. 6. Bottom out Rear Axle Extend function. 7. Loosen locknut on applicable valve section and turn adjusting screw to adjust valve section to 2000 psi (138 bar). Turn adjusting screw clockwise to increase pressure, counterclockwise to decrease pressure. Tighten locknut. 10.
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SECTION 5 - HYDRAULICS 5.7 HYDRAULIC GEAR PUMP 3. Lift off the port end cover. If prying is necessary, be careful not to damage the machined surfaces. Dowel pins will remain in either port end cover or gear housing. Do not remove the dowel pins. Disassembly DO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURING ASSEMBLY OR DISASSEMBLY. 1. Place the pump in a vise with the drive shaft pointing down. Match mark all sections. Be sure to align these marks when reassembling. 4. Remove the thrust plate.
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SECTION 5 - HYDRAULICS Figure 5-4.
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SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Lip Seal Mounting End Not Used Plug Dowel Pin Thrust Plate Channel Seal Drive Gear Set Square Seal Gear Housing Bearing Carrier Connector Shaft Gear Set Gear Housing Piggyback Housing Nut Flatwasher Stud Connector Shaft Thrust Plate Channel Seal Gear Set Square Seal Gear Housing Dowel Pin End Cover Bolt Thrustwasher Figure 5-5.
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SECTION 5 - HYDRAULICS 5. Carefully remove the drive and driven gears. Avoid tapping the gear teeth together or against other hardened surfaces. Keep these gears together because they are a matched set. Examine and replace if necessary. Remove the thrust plate from the bearing carrier. Examine and replace if necessary. 6. Lift the gear housing from the bearing carrier. If prying is necessary, take care not to damage machined surfaces. Examine and replace if necessary. 5-22 – JLG Lift – 7.
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SECTION 5 - HYDRAULICS 9. Lift or pry off the first section gear housing. Be careful not to damage machined surfaces. Examine and replace if necessary. 10. Inspect all bushings for scoring or discoloration and replace if necessary. Use a bushing puller as shown in the tool list to remove bushings. 3120817 11. If the pump is equipped with an outboard bearing, place the shaft end cover in the vise with the mounting face up. Remove the snap ring with snap ring pliers.
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SECTION 5 - HYDRAULICS 13. Grip the shaft end cover in a vise with the mounting face down. Remove the double lip seal by inserting the special seal removal tool into the notch between the double lip seal and the shaft end cover. Tap the seal out and discard. Remove and discard all rubber and polymer seals. 2. If bushings have been removed, deburr the bushing bores with emery cloth. Rinse parts in solvent. Air blast all parts and wipe with a clean lint less cloth before starting assembly. 3.
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SECTION 5 - HYDRAULICS 4. New plugs should be screwed in tightly. Stake plug with a prick punch at both ends of screwdriver slot and around edges. Peen edge of hole 0.031 to 0.062 inches with a 1.5 inch diameter steel ball. 6. Bushings should be pressed into the bores, one at a time using the special installation tool and an arbor press. Be sure the grooves (or seams) are positioned as stated in step 5. Bushings must be pressed into the bores flush with the casting face.
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SECTION 5 - HYDRAULICS 8. See that dowel pins are in place in any new castings. Examine all dowels. Before inserting make sure the hole is clean and free from burrs. Gently start pin straight into hole and tap lightly with a soft hammer. 9. Before inserting a new lip seal in the shaft end cover, coat the outer edge of the lip seal and its recess with Permatex Aviation Form-A-Gasket No. 3 non hardening sealant or equivalent.
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SECTION 5 - HYDRAULICS 12. Grease the new gasket seals and insert them into the grooves in both sides of all gear housings. Position the first gear housing over the shaft end cover and dowels. Tap it with a soft hammer until it rests tightly against the shaft end cover. Be careful not to pinch the gasket seal. Also be sure the large rounded core is on the inlet side. 13.
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SECTION 5 - HYDRAULICS 16. Slip the thrust plate with seal over gear journals and into the housing bore. The flat side of the seal should face up with the relief groove facing the outlet side. 17. Position the bearing carrier over the gear housing so the bushings receive the journals of the drive and driven gears. Be sure to line up the dowel holes over the dowel pins. When the parts are parallel, squeeze them together or alternately tap over each dowel until the parts are together. 5-28 18.
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SECTION 5 - HYDRAULICS 20. Check the plug or plugs in the port end cover to be sure they are tight. Follow the procedure outlined in step 4 for new plugs. 21. Place the port end cover over the gear journals. Align the dowels with the holes in the mating casting. Being careful not to pinch the gasket seal, tap the port end cover lightly in the center between bearing bores to engage the dowels and to move parts together in the final seating. 22.
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SECTION 5 - HYDRAULICS DRIVE SHAFTS Replace if there is any wear detectable by touch in the seal area or at the drive coupling. 0.002 inches (0.05 mm) wear is the maximum allowable. Wear in the shaft seal area indicates oil contamination. Wear or damage to splines, keys, or keyways necessitates replacement. THRUST PLATES The thrust plates seal the gear section at the sides of the gears. Wear here will allow internal slippage, meaning oil will bypass the pump. A maximum of 0.002 inches (0.
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SECTION 5 - HYDRAULICS Run the pump at least two minutes at no load and moderate speed (not over 1500 rpm). if the pump becomes excessively hot, shut down immediately and locate the problem source. Gradually increase pressure on pump, in 500 psi increments until the desired test pressure has been reached. This should take about five minutes. Delivery should run close to rated performance figures which are averaged from testing several pumps.
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SECTION 5 - HYDRAULICS NOTES: 5-32 – JLG Lift – 3120817
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SECTION 6 - SCHEMATICS SECTION 6. SCHEMATICS 6.1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 6.
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SECTION 6 - SCHEMATICS Table 6-1.Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM LEVELING SYSTEMS Platform will not maintain level attitude. Hydraulic system oil low. Replenish oil as necessary. Dual pilot check valves dirty/ inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on slave cylinder or master leveling cylinder. Clean, repair, or replace line or fitting. Spit valve(s) leaking. Clean, repair, or replace spit valve(s).
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SECTION 6 - SCHEMATICS Table 6-1.Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature buildup. Flush system and change oil using recommended viscosity Moisture in oil. Flush system and change oil using recommended viscosity Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting. Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary.
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SECTION 6 - SCHEMATICS . Table 6-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM ELEVATION SYSTEM. No response to lift control switch. Lift control inoperative. Repair or replace control lever. Dump valve (bypass) not operating. Determine cause and repair or replace valve. Hydraulic system oil low. Replenish oil as necessary. Restricted or broken supply line on valve bank or hydraulic pump. Clean or replace line. Control valve not functioning properly.
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SECTION 6 - SCHEMATICS Table 6-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom raises and lowers erratically. Hydraulic system oil low. Replenish oil as required. Restricted or broken hydraulic line or fitting. Clean or replace line. Lack of lubricant on cylinder shafts and/or boom pivot. Lubricate as required. (Refer to Lubrication Chart) Counterbalance valve on lift cylinder improperly adjusted or not functioning properly. Replace valve.
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SECTION 6 - SCHEMATICS Table 6-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom will not extend. Damaged wiring on control switch, solenoid valve or proportional valve. Repair or replace wiring. Solenoid valve or proportional valve not functioning properly. Repair or replace valve. Control lever not functioning properly. Repair or replace lever. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting.
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SECTION 6 - SCHEMATICS Table 6-2.Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM SWING SYSTEM No response to swing control. Hydraulic system oil low. Replenish oil as necessary. Swing control lever not functioning. Repair or replace swing lever. Restricted or broken supply line on valve bank or hydraulic pump. Clean or replace line. Control valve not functioning properly. Repair or replace valve. Swing motor not functioning properly. Repair or replace motor.
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SECTION 6 - SCHEMATICS Table 6-3.Turntable - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY POWER PLANT Engine will not start. Station power selector switch not in required position. Actuate switch as required. Circuit breaker open. Determine and correct cause; reset circuit breaker. Defective starter motor. Replace starter motor. Fuel shutoff solenoid defective. Replace solenoid. Damaged wiring in ignition circuit (broken wire on starter). Repair or replace wiring.
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SECTION 6 - SCHEMATICS Table 6-3.Turntable - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Valve Spool Sticking. Dirt in oil causing excessive temperature buildup. Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting. Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary. Return spring weak or broken. Remove valve and repair or replace as necessary.
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SECTION 6 - SCHEMATICS . Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY FRONT AXLE AREA One or both front wheels will not steer. Steering link or tie rod broken or attaching hardware missing. Replace steering link, tie rod or hardware as necessary. One or both front wheels will not rotate or rotate erratically. Wheel hub or bearings damaged or not lubricated. Replace hub or bearings as necessary and repack bearings with approved grease. Hub attachment nut loose or missing.
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SECTION 6 - SCHEMATICS Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Difficulty encountered when moving machine. Load capacity exceeded. Reduce load. Apply loads only in accordance with load capacity indicator. Machine being moved up too steep a grade. Remove machine from grade and check that drive system operates correctly. Grade too steep. See Caution Placard on platform for specified grades and sideslopes. Drive wheel tire treads worn smooth.
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SECTION 6 - SCHEMATICS Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine will not travel in forward. Hydraulic system oil low. Replenish oil as necessary. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Control valve not functioning properly. Repair or replace valve. Drive motor(s) not functioning properly. Repair or replace motor(s). Circuit breaker open. Determine and correct cause; reset circuit breaker.
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SECTION 6 - SCHEMATICS Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Poor response, function shuts off slowly when command is removed. Low spool spring preload. Check for correct spring and shims in end caps. Restricted tank return line. Check for restrictions in tank return line. Sticking spool due to contamination. Remove end cap and check spool freedom. Ramp potentiometer adjustment improper. Re-adjust ramping time on controller. STEERING SYSTEM. No response to control.
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SECTION 6 - SCHEMATICS Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine hard to steer or steering is erratic. Hydraulic system oil low. Replenish oil as necessary. Restricted hydraulic line or fitting. Clean, repair or replace line or fitting. Lack of lubrication. Lubricate as required. (Refer to Lubrication Chart.) Restricted crossover relief valve. Clean or replace valve. Steer system pressure low. Adjust pressure. Bent linkage (tie rod(s) or steering hitch).
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SECTION 6 - SCHEMATICS Table 6-4.Chassis - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine wanders; steering not firm. 3120817 Crossover relief valve set too low or not functioning properly. Reset, repair or replace valve as required. Steer linkages loose. Tighten linkage. Steer wheel toe-in not set properly. Adjust toe-in for 1/4 inch overall. Spindle bushings badly worn. Replace bushings. Leaking rotary oil coupling. Repair or replace oil coupling.
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SECTION 6 - SCHEMATICS . Table 6-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEM - GENERAL Hydraulic pump noisy. Air entering system through broken line or fitting. (Suction Side.) Repair or replace line or fitting. Air bubbles in oil. (Reservoir oil too low.) Replenish oil as required. Oil filter(s) dirty. Clean and/or replace filter(s) as necessary. Pump cavitating. (Vacuum in pump due to oil starvation.) Restricted suction line.
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SECTION 6 - SCHEMATICS Table 6-5.Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY System(s) operate erratically. Sticking or binding valve spools, pistons, rods, etc. Clean, repair, or replace components as required. AUXILIARY HYDRAULIC SYSTEM. Auxiliary hydraulic pump inoperable. 3120817 Circuit breaker open. Determine and correct cause; reset circuit breaker. Battery requires charging or will not hold a charge. Charge or replace battery as required.
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SECTION 6 - SCHEMATICS . Table 6-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS No power to platform controls. 20 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary. Contact block in footswitch malfunctioning. Repair, replace or adjust contact block as required. Faulty power circuit wiring. Check wiring continuity.
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SECTION 6 - SCHEMATICS Table 6-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Travel warning horn inoperative. Damaged wiring in horn circuit. Repair or replace wiring. Damaged horn. Replace horn. Damaged wiring in hourmeter circuit. Repair or replace wiring. Defective vacuum switch. Replace vacuum switch. Inoperative hourmeter. Replace hourmeter. Damaged wiring in tilt alarm circuit. Repair or replace wiring. See proper wiring diagram. Tilt alarm inoperative.
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SECTION 6 - SCHEMATICS Table 6-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function occurs very rapidly when handle is moved in one direction and very slowly when moved in the opposite direction. Improper null of the handle. Check and re-adjust null. Potentiometer off center. Center potentiometer. Defective printed circuit board. Replace printed circuit board. Valve will not function when handle is moved in either direction. No electrical power to handle.
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SECTION 6 - SCHEMATICS Table 6-6.Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Speed not proportional. “High” and “Low” pots not adjusted properly. Adjust pots to factory specifications or refer to PQ Publication 3120304 for proper adjustment. Cylinder drifts or drive motor slowly rotates when controller is returned to neutral. (high null bias) 3120817 Controller failed resulting in a command at neutral position. Adjust or replace microswitch.
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SECTION 6 - SCHEMATICS Figure 6-1.
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SECTION 6 - SCHEMATICS 1870232 B Figure 6-2.
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SECTION 6 - SCHEMATICS Figure 6-3.
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SECTION 6 - SCHEMATICS 1001110253 B Figure 6-4.
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SECTION 6 - SCHEMATICS NOTES: 6-26 – JLG Lift – 3120817
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3120817 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.