JLG Model 150Hax Service & Maintenance Manual (3120679)- PDF DOWNLOAD
TABLE OF CONTENTS:
JLG Model 150Hax Service & Maintenance Manual (3120679)- PDF DOWNLOAD
Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS.................................................................................................................................................... 3 A General............................................................................................................................................................................................... 3 B Hydraulic System Safety............................................................................................................................................................................... 3 C Maintenance........................................................................................................................................................................................... 3 Section 1. Specifications................................................................................................................................................................................... 11 1.1 Capacities.......................................................................................................................................................................................... 11 1.2 Engine Data......................................................................................................................................................................................... 11 1.3 Drive/Steer System.................................................................................................................................................................................. 11 1.4 Performance Data.................................................................................................................................................................................... 11 1.5 Function Speeds..................................................................................................................................................................................... 11 1.6 Lubrication......................................................................................................................................................................................... 12 1.7 Torque Requirements................................................................................................................................................................................. 13 1.8 Pressure Settings - PSI (Bar)....................................................................................................................................................................... 13 1.9 Major Component Weights............................................................................................................................................................................. 14 1.10 Critical Stability weights......................................................................................................................................................................... 14 1.11 Serial Number Locations............................................................................................................................................................................ 14 1.12 Operator Maintenance............................................................................................................................................................................... 15 Section 2. General.......................................................................................................................................................................................... 29 2.1 Machine Preparation, Inspection, and Maintenance.................................................................................................................................................... 29 General............................................................................................................................................................................................. 29 Preparation, Inspection, and Maintenance............................................................................................................................................................ 29 Pre-Start Inspection................................................................................................................................................................................ 29 Pre-Delivery Inspection and Frequent Inspection..................................................................................................................................................... 29 Annual Machine Inspection........................................................................................................................................................................... 29 Preventative Maintenance............................................................................................................................................................................ 29 2.2 Service and Guidelines.............................................................................................................................................................................. 30 General............................................................................................................................................................................................. 30 Safety and Workmanship.............................................................................................................................................................................. 30 Cleanliness......................................................................................................................................................................................... 30 Components Removal and Installation................................................................................................................................................................. 30 Component Disassembly and Reassembly................................................................................................................................................................ 31 Pressure-Fit Parts.................................................................................................................................................................................. 31 Bearings............................................................................................................................................................................................ 31 Gaskets............................................................................................................................................................................................. 31 Bolt Usage and Torque Application................................................................................................................................................................... 31 Hydraulic Lines and Electrical Wiring............................................................................................................................................................... 31 Hydraulic System.................................................................................................................................................................................... 31 Lubrication......................................................................................................................................................................................... 31 Battery............................................................................................................................................................................................. 31 Lubrication and Servicing........................................................................................................................................................................... 31 2.3 Lubrication and Information......................................................................................................................................................................... 31 Hydraulic System.................................................................................................................................................................................... 31 Hydraulic Oil....................................................................................................................................................................................... 32 Changing Hydraulic Oil.............................................................................................................................................................................. 32 Lubrication Specifications.......................................................................................................................................................................... 32 2.4 Cylinder Drift Test................................................................................................................................................................................. 32 Platform Drift...................................................................................................................................................................................... 32 Cylinder Drift...................................................................................................................................................................................... 33 2.5 Pins and Composite Bearing Repair Guidelines........................................................................................................................................................ 33 2.6 Welding on JLG Equipment............................................................................................................................................................................ 33 Do the Following When Welding on JLG Equipment...................................................................................................................................................... 33 Do NOT Do the Following When Welding on JLG Equipment............................................................................................................................................... 33 SECTION 3. Chassis & Turntable.............................................................................................................................................................................. 39 3.1 Tires & Wheels...................................................................................................................................................................................... 39 Tire Inflation...................................................................................................................................................................................... 39 Tire Damage......................................................................................................................................................................................... 39 Tire Replacement.................................................................................................................................................................................... 39 Wheel Replacement................................................................................................................................................................................... 39 Wheel Installation.................................................................................................................................................................................. 39 3.2 Drive Torque Hub.................................................................................................................................................................................... 40 Disassembly......................................................................................................................................................................................... 40 Cleaning and Inspection............................................................................................................................................................................. 42 Assembly............................................................................................................................................................................................ 42 3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476......................................................................................................................................... 52 Disassembly......................................................................................................................................................................................... 52 Cleaning and Inspection............................................................................................................................................................................. 52 Assembly............................................................................................................................................................................................ 52 3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present............................................................................................................................................ 54 Disassembly......................................................................................................................................................................................... 54 Inspection.......................................................................................................................................................................................... 55 Assembly............................................................................................................................................................................................ 55 3.5 Free Wheeling Option................................................................................................................................................................................ 57 To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc................................................................................................................................... 57 To Engage Drive Motors and Brakes (Normal Operation)................................................................................................................................................ 57 3.6 Swing Bearing....................................................................................................................................................................................... 57 Turntable Bearing Mounting Bolt Condition Check..................................................................................................................................................... 57 Wear Tolerance...................................................................................................................................................................................... 59 Replacement and Devcon Application Procedures....................................................................................................................................................... 59 Swing Bearing Torque Values......................................................................................................................................................................... 62 3.7 Swing Torque Hub.................................................................................................................................................................................... 62 Disassembly......................................................................................................................................................................................... 62 Cleaning and Inspection............................................................................................................................................................................. 64 Assembly............................................................................................................................................................................................ 65 3.8 Swing Brake - Ausco - Machines Built To 1992........................................................................................................................................................ 67 Disassembly......................................................................................................................................................................................... 67 Cleaning and Inspection............................................................................................................................................................................. 67 Assembly............................................................................................................................................................................................ 67 3.9 Swing Brake - Mico - Machines Built To 1992......................................................................................................................................................... 69 Disassembly......................................................................................................................................................................................... 69 Cleaning and Inspection............................................................................................................................................................................. 69 Assembly............................................................................................................................................................................................ 71 3.10 Swing Brake - Machines Built 1992 To Present....................................................................................................................................................... 71 Disassembly......................................................................................................................................................................................... 71 Cleaning and Inspection............................................................................................................................................................................. 73 Assembly............................................................................................................................................................................................ 73 3.11 Swing Motor........................................................................................................................................................................................ 74 Disassembly......................................................................................................................................................................................... 74 Assembly............................................................................................................................................................................................ 74 3.12 PQ Controllers..................................................................................................................................................................................... 76 TRIM Adjustment..................................................................................................................................................................................... 76 RAMP Adjustment..................................................................................................................................................................................... 76 3.13 Pump Coupling Conversion Procedures................................................................................................................................................................ 77 Lovejoy Coupling.................................................................................................................................................................................... 77 Hayes Coupling...................................................................................................................................................................................... 78 3.14 Tilt Alarm Switch.................................................................................................................................................................................. 78 Manual Adjustment................................................................................................................................................................................... 78 Voltmeter Adjustment................................................................................................................................................................................ 79 3.15 Throttle Checks and Adjustments.................................................................................................................................................................... 79 SECTION 4. Boom & Platform.................................................................................................................................................................................. 81 4.1 Boom Maintenance.................................................................................................................................................................................... 81 Boom Mounted Limit Switches and Valves.............................................................................................................................................................. 81 Main Boom Removal................................................................................................................................................................................... 81 Tower Boom Removal.................................................................................................................................................................................. 83 Main Boom Disassembly............................................................................................................................................................................... 83 Tower Boom Disassembly.............................................................................................................................................................................. 87 Inspection.......................................................................................................................................................................................... 89 Main Boom Assembly.................................................................................................................................................................................. 90 Tower Boom Assembly................................................................................................................................................................................. 91 Tower Boom Installation............................................................................................................................................................................. 92 Main Boom Installation.............................................................................................................................................................................. 93 4.2 Boom Chains......................................................................................................................................................................................... 93 Adjusting Procedures - Main Boom.................................................................................................................................................................... 93 Inspection Procedure................................................................................................................................................................................ 94 4.3 Wear Pads........................................................................................................................................................................................... 96 4.4 Platform Rotator Brake.............................................................................................................................................................................. 96 SECTION 5. Hydraulics....................................................................................................................................................................................... 97 5.1 Valves - Theory of Operation........................................................................................................................................................................ 97 Solenoid Control Valves (Bang-Bang)................................................................................................................................................................. 97 Proportional Control Valves - Vickers............................................................................................................................................................... 97 Relief Valves....................................................................................................................................................................................... 97 Crossover Relief Valves............................................................................................................................................................................. 97 5.2 Cylinders - Theory of Operation..................................................................................................................................................................... 97 5.3 Cylinder Checking Procedures........................................................................................................................................................................ 98 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.... 98 Cylinders w/Single Counterbalance Valves - Main Lift Cylinder, Tower Telescope Cylinder............................................................................................................. 98 Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Level Cylinder................................................................................. 99 5.4 Cylinder Removal and Installation................................................................................................................................................................... 99 Tower Telescope Cylinder Removal.................................................................................................................................................................... 99 Tower Telescope Cylinder Installation...............................................................................................................................................................100 Tower Lift Cylinder Removal.........................................................................................................................................................................100 Tower Lift Cylinder Installation....................................................................................................................................................................100 Main Telescope Cylinder Removal.....................................................................................................................................................................101 Main Telescope Cylinder Installation................................................................................................................................................................101 Main Lift Cylinder Removal..........................................................................................................................................................................102 Main Lift Cylinder Installation.....................................................................................................................................................................102 Lower Master Level Cylinder Removal.................................................................................................................................................................102 Lower Master Level Cylinder Installation............................................................................................................................................................103 Upper Master Level Cylinder Removal.................................................................................................................................................................103 Upper Master Level Cylinder Installation............................................................................................................................................................103 5.5 Cylinder Repair.....................................................................................................................................................................................104 Disassembly.........................................................................................................................................................................................104 Cleaning and Inspection.............................................................................................................................................................................104 Assembly............................................................................................................................................................................................105 5.6 Pressure Setting Procedures.........................................................................................................................................................................107 Low Drive System....................................................................................................................................................................................107 5 Stack Directional Control Valve (Internal Relief Adjustment)......................................................................................................................................107 5 Stack Directional Control Valve (External Relief Adjustment Screws)...............................................................................................................................108 Two Stack Directional Control Valve.................................................................................................................................................................112 Three Stack Directional Control Valve...............................................................................................................................................................112 Four Stack Directional Control Valve................................................................................................................................................................113 5.7 Hydraulic Gear Pump.................................................................................................................................................................................115 Disassembly.........................................................................................................................................................................................115 Assembly............................................................................................................................................................................................120 Wear Guide for Replacement..........................................................................................................................................................................125 Recommended Start-up Procedure for New or Rebuilt Pump..............................................................................................................................................126 Recommended Test Procedure..........................................................................................................................................................................126 SECTION 6. Schematics.......................................................................................................................................................................................129 6.1 General.............................................................................................................................................................................................129 6.2 Troubleshooting.....................................................................................................................................................................................129 6.3 Hydraulic Circuit Checks............................................................................................................................................................................129
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