JLG 40H 40H+6 Service & Maintenance Manual (3120240) – PDF Download

Description

JLG 40H 40H+6 Service & Maintenance Manual (3120240) – PDF Download

TABLE OF CONTENTS:

JLG 40H 40H+6 Service & Maintenance Manual (3120240) – PDF Download

SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A A General a
A B Hydraulic System Safety a
A C Maintenance a
EFFECTIVITY CHANGES b
TABLE OF CONTENTS I
LIST OF ILLUSTRATIONS II
LIST OF TABLES III
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
1 3 Performance Data 1-3
1 4 Torque Requirements 1-3
1 5 Lubrication 1-3
1 6 Pressure Settings 1-8
1 7 Cylinder Specifications 1-9
1 8 Boom Tape 1-9
1 9 Major Components Weights 1-10
1 10 Critical Stability Weights 1-10
1 11 Serial Number Location (See Figure 1-4 ) 1-10
SECTION 2 – PROCEDURES
2 1 General 2-1
2 2 Servicing And Maintenance Guidelines 2-1
2 3 Lubrication Information 2-2
2 4 Cylinders – Theory Of Operation 2-3
2 5 Valves – Theory Of Operation 2-3
2 6 Boom Chains (See Figure 2-1) 2-4
2 7 Wear Pads 2-6
2 8 Cylinder Checking Procedure 2-7
2 9 Cylinder Repair 2-9
2 10 Cylinder Removal And Installation 2-12
2 11 Boom Maintenance 2-14
2 12 Tilt Alarm Switch 2-19
2 13 Horizontal High Speed Cutout Switch Adjustment Procedure 2-19
2 14 Governor Checks And Addco Adjustment, Ford 2-20
2 15 Throttle Checks And Precision Governor Adjustments, Addco (See Figure 2-6 ) 2-21
2 16 Electric Governor And Adjustments – Ford Engines 2-22
2 17 Throttle Checks And Adjustments – Deutz F2l511 Engine (See Figure 2-8 ) 2-29
2 18 Throttle Checks And Adjustments Wisconsin Engine (See Figure 2-9 ) 2-33
2 19 Throttle Checks And Adjustments – Deutz F3l912 Engine (See Figure 2-10 ) 2-35
2 20 Throttle Checks And Adjustments – Deutz Engine F3l1011 (See Figure 2-11 ) 2-35
2 21 Pressure Setting Procedures 2-38
2 22 Racine Proportional Air Gap Adjustment 2-58
2 23 Swing Bearing 2-59
2 24 Torque Hub, 2w/d (See Figure 2-36 ) 2-63
2 25 Torque Hub 4wd (See Figure 2-37 ) 2-66
2 26 Swing Drive Brake, Mico (Machines Built Prior To May 1992) (See Figure 2-39 ) 2-71
2 27 Drive Brake, Mico (Machines Built Prior To May 1992)(See Figure 2-40 ) 2-72
2 28 Swing Drive Brake, Ausco (Machines Built Prior To May 1992) (See Figure 2-41 ) 2-75
2 29 Drive Brake, Ausco (Machines Built Prior To May 1992) (See Figure 2-43 ) 2-77
2 30 Drive Brake, Mico (Machines Built From May 1992 To S/n 33476) (See Figure 2-44 ) 2-79
2 31 Swing Brake, Mico (Machines Built From May 1992 To S/n 33476) (See Figure 2-45 ) 2-81
ii – JLG Lift – 3120240
TABLE OF CONTENTS (Continued)
2 32 Drive Brake, Mico (Machines Built From S/n 33476 To Present) (See Figure 2-46 ) 2-83
2 33 Swing Brake, Mico (Machines Built From S/n 33476 To Present) (See Figure 2-46 ) 2-85
2 34 Controllers 2-87
2 35 Oscillating Axle Bleeding Procedure 2-87
2 36 Oscillating Axle Lockout Test 2-88
2 37 Basket Rotator Brake (See Figure 2-48 ) 2-89
2 38 Free Wheeling Option 2-89
2 39 Spark Arrestor Mufflers 2-89
2 40 Footswitch Adjustment 2-89
2 41 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication 2-89
2 42 Dual Fuel System 2-89
2 43 Preventive Maintenance And Inspection Schedule 2-90
2 44 Capacity Indicator 2-92
SECTION 3 – TROUBLESHOOTING
3 1 General 3-1
3 2 Troubleshooting Information 3-1
3 3 Hydraulic Circuit Checks 3-1
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Torque Chart 1-5
1-2 Lubrication Chart (Sheet 1 of 2) 1-6
1-2 Lubrication Chart (Sheet 2 of 2) 1-7
1-3 Serial Number Locations 1-11
2-1 Typical Three Section Boom Assembly 2-5
2-2 Boom Positioning and Support, Cylinder Repair 2-8
2-3 Poly-Pak Seal Installation 2-11
2-4 Governor Adjustment, Ford with Addco 2-20
2-5 Addco Adjustment, Ford 2-21
2-6 Precision Governor Adjustment, Ford (Sheet 1 of 2) 2-30
2-7 Precision governor Adjustment, Ford (Sheet 2 of 2) 2-31
2-8 Addco Actuator Adjustments, F2L511 2-32
2-9 Addco Actuator Adjustments, VG4D 2-34
2-10 Addco Actuator Adjustments, F3L912 2-36
2-11 Addco Actuator Adjustments, F3L1011 2-37
2-12 Racine Proportional Valve Pressure Setting (Machines Built Prior To Mid 1987) (Sheet 1 of 2) 2-39
2-13 Racine Proportional Valve Setting (Machines Built Prior To Mid 1967) (Sheet 2 of 2) 2-40
2-14 Vickers Proportional Valve Pressure Setting, Machines Built To Present (Sheet 1 of 4) 2-41
2-15 Vickers Proportional Valve Pressure Setting, Machines Built To Present (Sheet2 of 4) 2-42
2-16 Vickers Proportional Valve Pressure Setting, Machines Built To Present (Sheet 3 Of 4) 2-43
2-17 Vickers Proportional Valve Pressure Setting, Machines Built To Present (Sheet 4 of 4) 2-44
2-18 Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve (Sheet 1 of 4) 2-45
2-19 Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve (Sheet 2 of 4) 2-46
2-20 Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessory Valve (Sheet 3 Of 4) 2-47
2-21 Vickers Proportional Valve Pressure Setting,
Machines Built Prior To 1989 With Accessary Valve (Sheet 4 Of 4) 2-48
2-22 Solenoid Valve Pressure Settings (Machines Built Prior To 1992 With Steering Wheel) 2-49
2-23 Pressure And Flow Settings (Machines Built Prior To May 1992 With Steering Wheel) 2-50
2-24 Vickers All Hydraulic Machines Pressure Settings (Sheet 1 of 4) 2-51
3120240 – JLG Lift – iii
TABLE OF CONTENTS
2-25 Vickers All Hydraulic Machines Pressure Settings (Sheet 2 of 4) 2-52
2-26 Vickers All Hydraulic Machines Pressure Settings (Sheet 3 of 4) 2-53
2-27 Vickers All Hydraulic Machines Pressure Settings (Sheet 4 of 4) 2-54
2-28 Solenoid Valve Pressure Settings, Machines Built Before 1995 (Sheet 1 of 2) 2-55
2-29 Solenoid Valve Pressure Settings, Machines Built from 1995 To Present (Sheet 2 of 2) 2-56
2-30 Extend-A-Reach Valve Pressure and Speed Settings Model 40+6 2-57
2-31 Racine Proportional Air Gap Adjustment, Machines Built Prior To Mid 1987 2-58
2-32 Swing Bearing Tolerance Boom Placement 2-59
2-33 Swing Bolt Feeler Gauge Check 2-59
2-34 Swing Bearing Tolerance Measuring Point 2-61
2-35 Swing Bearing Torquing Sequence 2-63
2-36 Torque Hub Assembly, 2/WD 2-64
2-37 Torque Hub 4/WD 2-68
2-38 Torque Hub Carrier Timing 2-70
2-39 Swing Brake Assembly – Mico (Machines Built Prior To May 1992) 2-71
2-40 Drive Brake Assembly – Mico (Machines Built Prior To May 1992) 2-73
2-41 Swing Brake Assembly – Ausco (Machines Built Prior to May 1992) 2-76
2-42 Drive Brake, (machines Built Prior to May 1992) 2-78
2-43 Drive Brake, Mico (Machines Built From May 1992 To Machine S/N 33476) 2-80
2-44 Swing Brake, Mico (Machines Built From May 1992 To Machine S/N 33476) 2-82
2-45 Drive Brake, Mico (Machines Built From S/N 33476 To Present) 2-84
2-46 Swing Brake, Mico (Machines Built From S/N 33476 to Present) 2-86
2-47 Basket Rotator Brake 2-88
2-48 Boom Tape Replacement Chart 2-92
2-49 Capacity Indicator Dial 2-92
3-1 Wiring Diagram – Dual Fuel (Ford Or Wisconsin) 3-20
3-2 Wiring Diagram – 110v Generator (Ford) 3-21
3-3 Wiring Diagram – 110v Generator (Deutz) 3-22
3-4 Wiring Diagram – Platform Console (W/all Hydraulic Controls) 3-23
3-5 Wiring Diagram – Platform Console Standard (Sheet 1 Of 2) 3-24
3-6 Wiring Diagram – Platform Console Standard (Sheet 2 Of 2) 3-25
3-7 Wiring Diagram – Standard (Deutz F2l511/f3l912 & Wisconsin
Engine W/ Standard Controls) (Sheet 1 Of 2) 3-26
3-8 Wiring Diagram – Standard (Deutz F2l4511/f3l912 & Wisconsin
Engine W/ Standard Controls) (Sheet 2 Of 2) 3-27
3-9 Wiring Diagram – Standard (Deutz F2l511/f3l912 &
Engine W/ Hydraulic Controls) (Sheet 1 Of 2) 3-28
3-10 Wiring Diagram – Standard (Deutz F2l511/f3l912 & Wisconsin
Engine W/ Hydraulic Controls) (Sheet 2 Of 2) 3-29
3-11 Wiring Diagram – Standard (Deutz F3l1011 Engine W/ Standard Controls) (Sheet 1 Of 2) 3-30
3-12 Wiring Diagram – Standard (Deutz F3l1011 Engine W/ Standard Controls) (Sheet 2 Of 2) 3-31
3-13 Wiring Diagram – Standard (Deutz F3l1011 Engine W/ Hydraulic Controls) (Sheet 1 Of 2) 3-32
3-14 Wiring Diagram – Standard (Deutz F3l1011 Engine W/ Hydraulic Controls) (Sheet 2 Of 2) 3-33
3-15 Wiring Diagram – Standard (Ford Lrg425 Dis Engine W/ Standard Controls) (Sheet 1 Of 2) 3-34
3-16 Wiring Diagram – Standard (Ford Lrg425 Dis Engine W/ Standard Controls) (Sheet 2 Of 2) 3-35
3-17 Wiring Diagram – Standard (Ford Dis Engine W/ Hydraulic Controls) (Sheet 1 Of 2) 3-36
3-18 Wiring Diagram – Standard (Ford Dis Engine W/ Hydraulic Controls) (Sheet 2 Of 2) 3-37
LIST OF TABLES
TABLE NO TITLE PAGE NO
2-1 Chain Stretch Tolerance 2-7
2-2 Cylinder Piston Nut Torque Specification 2-12
2-3 Holding Valve Torque Specifications 2-12
2-4 Preventive Maintenance and Inspection Schedule 2-91
3-1 Platform Assembly Troubleshooting 3-2
iv – JLG Lift – 3120240

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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