JLG 80HX 80HX+6 80HXER Service & Maintenance Manual (3120271) – PDF Download (Eng)

Description

JLG 80HX 80HX+6 80HXER Service & Maintenance Manual (3120271) – PDF Download

TABLE OF CONTENTS:

JLG 80HX 80HX+6 80HXER Service & Maintenance Manual (3120271) – PDF Download

TABLE OF CONTENTS
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
Engine – Ford LSG423 1-1
Engine – Deutz F4L912 1-1
Engine – Wisconsin V465D 1-1
Engine – Cummins 4B 3 9C 1-1
Engine – Ford LRG-423 1-2
Engine – Ford LRG-425 1-2
Drive System 1-2
Drive Motor Displacement Machines Built Prior to Jan 1992 1-2
Drive Motor Displacement Machines Built from Jan 1992 to Present 1-2
Drive Hub Ratios 1-2
Steer System 1-2
Swing System 1-2
Hydraulic Pump 1-2
Auxiliary Power Pump 1-3
Hydraulic Filter – Tank 1-3
Hydraulic Filter – Inline (Racine Valve Only) 1-3
1 3 Performance Data 1-3
Travel Speed 1-3
Gradeability 1-3
Turning Radius (Outside) 1-3
Boom Speed (Telescope) 1-3
Boom Speed (Lift) 1-3
Swing Speed 360° 1-3
Boom Elevation 1-3
Machine Weight 1-3
Machine Stowed Height 1-3
Machine Stowed Length 1-3
Machine Width 1-3
Maximum Tire Load 1-3
Wheelbase 1-3
1 4 Torque Requirements 1-4
1 5 Lubrication 1-4
Ford Engines 1-9
Deutz F4L912 Engine 1-9
Wisconsin V465D Engine 1-9
Cummins 4B 3 9C 1-9
Lubrication Specifications 1-10
1 6 Pressure Settings 1-10
Prior to Mid 1987 1-10
80 HX 1-11
80HX w/Hydraulic Controls 1-11
80HX w/Oscillating Axle 1-11
1 7 Major Components Weights 1-12
1 8 Cylinder Specifications 1-12
ii – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
1 9 Boom Tape 1-12
American Standard 1-12
Canadian Standard 1-12
1 10 Critical Stability Weights 1-13
1 11 Serial Number Location 1-13
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-2
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-4
Hydraulic System 2-4
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-5
Platform Drift 2-5
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
2 6 Welding on JLG Equipment 2-6
Do the Following When Welding on JLG Equipment 2-6
Do NOT Do the Following When Welding on JLG Equipment 2-6
2 7 Applying Silicone Dielectric Compound to Electrical Connections 2-6
2 8 Preventive Maintenance and Inspection Schedule 2-7
SECTION 3 – CHASSIS & TURNTABLE
3 1 Torque Hub 3-1
Disassembly 3-1
Cleaning and Inspection 3-1
Repair 3-3
Input Shaft Assembly 3-4
Assembly 3-4
3120271 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
3 2 Drive Brake, Ausco – Machines Built Prior to October 1987 3-8
Disassembly 3-8
Cleaning and Inspection 3-9
Assembly 3-9
3 3 Drive Brake, Mico – Machines Built Prior to October 1987 3-10
Disassembly 3-10
Inspection 3-10
Assembly 3-10
Bleeding 3-11
3 4 Drive Brake, Ausco – Machines Built Prior to 1992 3-12
Disassembly 3-12
Cleaning and Inspection 3-12
Assembly 3-12
3 5 Drive Brake, Mico – Machines Built From 1992 to Present 3-14
Disassembly 3-14
Inspection 3-14
Assembly 3-14
3 6 Governor Checks and Adeco Adjustment, LRG423 & LRG425 3-17
Checks 3-17
Adjustments 3-17
3 7 Throttle Checks and Precision Governor Adjustments, LSG-423 & LRG-425 3-22
Checks 3-22
Carburetor and Governor Adjustment 3-22
3 8 E331 Precision Governor And Adjustments – Ford Engines 3-23
General 3-23
Quick-start Installations 3-23
Mounting-Actuator 3-24
Linkage 3-24
Mounting-Controller 3-25
Wiring 3-25
Power Distribution 3-25
Check-Out and Initial Start-Up Procedures 3-26
Troubleshooting 3-29
Automatic Choke Adjustment Procedure 3-31
3 9 Automatic Choke Adjustment – Ford Engine 3-31
3 10 Cold Weather Starting Difficulty 3-32
Checking the Carburetor 3-32
Checking the Ignition 3-33
Checking the Fuel 3-33
3 11 Throttle Checks and Adjustments – Deutz Engine 3-34
3 12 Swing Bearing 3-34
Turntable Bearing Mounting Bolt Condition Check 3-34
Wear Tolerance 3-35
Replacement and Devcon Application Procedures on Machines Built Prior to Mid 1991 3-35
Swing Bearing Torque Values 3-39
3 13 Oscillating Axle Bleeding Procedure 3-40
Lockout Cylinder Bleeding (Without Holding Valves) 3-40
Lockout Cylinder Bleeding (With Holding Valves) 3-40
3 14 Oscillating Axle Lockout Test 3-41
3 15 Free Wheeling Option 3-41
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc 3-41
To Engage Drive Motors and Brakes (Normal Operation) 3-41
3 16 Spark Arrestor Mufflers 3-42
3 17 Footswitch Adjustment 3-42
iv – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
3 18 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication 3-42
3 19 Dual Fuel System 3-42
Changing from gasoline to LP-Gas 3-42
Changing from LP Gas to Gasoline 3-42
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-4
Assembly 4-5
Installation 4-6
4 2 Boom Chains 4-7
Adjusting Procedures 4-7
Inspection Procedures 4-8
4 3 Wear Pads 4-10
4 4 Telescope Cylinder Eccentric Bushing 4-10
4 5 Horizontal High Speed Cutout Switch Adjustment Procedure 4-10
4 6 Controllers 4-10
PQ 4-10
OEM 4-10
VICKERS (All Hydraulic) 4-10
4 7 Capacity Indicator 4-10
Capacity Indicator Cable Adjustment 4-10
Capacity Indicator Boom Tape Replacement 4-11
Installation Procedure 4-11
Capacity Indicator Dial Decal Replacement 4-11
Indicator Decal Installation 4-11
4 8 Basket Rotator Brake 4-11
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory Of Operation 5-1
Double Acting Cylinders 5-1
5 2 Valves – Theory Of Operation 5-1
Holding Valves 5-1
Solenoid Control Valves (Bang-Bang) 5-1
Proportional Control Valve – Vickers 5-1
Main Relief Valves 5-1
Relief Valves 5-1
5 3 Cylinder Checking Procedure 5-3
Cylinders Without Counterbalance Valves 5-3
Cylinders With Single Counterbalance Valve 5-3
Cylinders With Dual Counterbalance Valves 5-4
5 4 Cylinder Repair 5-4
Disassembly 5-4
Cleaning and Inspection 5-11
Assembly 5-12
5 5 Cylinder Removal and Installation 5-14
Telescope Cylinder Removal 5-14
Telescope Cylinder Installation 5-14
Boom Lift Cylinder Removal 5-15
Boom Lift Cylinder Installation 5-15
3120271 – JLG Lift – v
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
5 6 Telescope Cylinder Eccentric Bushing 5-15
5 7 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication 5-15
5 8 Racine Proportional Air Gap Adjustment 5-16
5 9 Pressure Setting Procedures 5-16
SECTION 6 – TROUBLESHOOTING & SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting Information 6-1
6 3 Hydraulic Circuit Checks 6-1
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Diagram 1-5
1-2 Serial Number Locations 1-13
1-3 Torque Chart – (In/Lb – Ft/Lb) (For ASTM Fasteners) 1-14
1-4 Torque Chart (Metric Conversion) – (For ASTM Fasteners) 1-15
1-5 Torque Chart – (N, m) – (For Metric Class Fasteners) 1-16
3-1 Torque Hub Assembly 3-2
3-2 Drive Brake, Ausco – Machines Built Prior to October 1987 3-9
3-3 Drive Brake, Mico – Machines Built Prior to October 1987 3-11
3-4 Drive Brake, Ausco – Machines Built Prior to 1992 3-13
3-5 Drive Brake, Mico – Machines Built from 1992 to Present 3-15
3-6 Spring Loading 3-16
3-7 Governor Adjustment, LRG-423 & LRG-425 with Adeco 3-17
3-8 Adeco Adjustment, LRG-423 & LRG-425 3-18
3-9 Precision Governor Adjustment – LRG-423 & LRG-425 (Sheet 1 of 2) 3-19
3-10 Precision Governor Adjustment – LRG-423 & LRG-425 (Sheet 2 of 2) 3-20
3-11 Adeco Actuator Adjustments – F4L912 3-21
3-12 Swing Bearing Bolt Feeler Gauge Check 3-34
3-13 Swing Bearing Tolerance Measuring Point 3-35
3-14 Swing Bearing Tolerance Boom Placement 3-37
3-15 Swing Bearing Torquing Sequence 3-38
4-1 Boom Assembly (Sheet 1 of 2) 4-2
4-2 Boom Assembly (Sheet 2 of 2) 4-3
4-3 Typical Boom Assembly 4-7
4-4 Telescope Cylinder Eccentric Bushing 4-10
4-5 Boom Tape Replacement 4-11
4-6 Capacity Indicator Dial 4-11
4-7 Belleville Washers 4-11
5-1 Proportional Control Valve 5-2
5-2 Boom Positioning and Support – Cylinder Repair 5-5
5-3 Typical Hydraulic Cylinders (Sheet 1 of 4) 5-6
5-4 Typical Hydraulic Cylinders (Sheet 2 of 4) 5-7
5-5 Typical Hydraulic Cylinders (Sheet 3 of 4) 5-8
5-6 Typical Hydraulic Cylinders (Sheet 4 of 4) 5-9
5-7 Cylinder Barrel Support 5-10
5-8 Cylinder Rod Support 5-10
5-9 Poly-Pak Seal Installation 5-12
5-10 Telescope Cylinder Eccentric Bushing 5-15
5-11 Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987 5-16
5-12 Racine Proportional Valve Pressure Setting – Prior to Mid 1987 (Sheet 1 of 2) 5-17
5-13 Racine Proportional Valve Pressure Setting – Prior to Mid 1987 (Sheet 2 of 2) 5-18
vi – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
LIST OF FIGURES (continued)
FIGURE NO TITLE PAGE NO
5-14 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 1 of 4) 5-19
5-15 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 2 of 4) 5-20
5-16 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 3 of 4) 5-21
5-17 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 4 of 4) 5-22
5-18 Solenoid Valve Pressure Settings – Prior to Mid 1992 with Steering Wheel 5-23
5-19 Pressure and Flow Settings – Machines Prior to Mid 1992 with Steering Wheel 5-24
5-20 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 1 of 4) 5-25
5-21 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 2 of 4) 5-26
5-22 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 3 of 4) 5-27
5-23 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 4 of 4) 5-28
5-24 Pressure Setting – All Hydraulic Machines (Sheet 1 of 4) 5-29
5-25 Pressure Setting – All Hydraulic Machines (Sheet 2 of 4) 5-30
5-26 Pressure Setting – All Hydraulic Machines (Sheet 3 of 4) 5-31
5-27 Pressure Setting – All Hydraulic Machines (Sheet 4 of 4) 5-32
5-28 Solenoid Valve Pressure Settings – Machines Built to Present 5-33
5-29 Solenoid Valve Pressure Settings – 4 Wheel Steer 5-34
5-30 Extend-A-Reach Valve Pressure and Speed Settings 5-35
6-1 Wiring Schematic Dual Fuel 6-21
6-2 Wiring Diagram – Generator (Deutz Engines) 6-22
6-3 Wiring Diagram – Generator (Ford Engine) 6-23
6-4 Wiring Diagram – Platform Console Standard Controls (Sheet 1 of 2) 6-24
6-5 Wiring Diagram – Platform Console Standard Controls (Sheet 2 of 2) 6-25
6-6 Wiring Diagram – Platform Console Hydraulic Controls 6-27
6-7 Wiring Diagram – Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 of 2) 6-28
6-8 Wiring Diagram – Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 6-29
6-9 Wiring Diagram – Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-30
6-10 Wiring Diagram – Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 6-31
6-11 Wiring Diagram – Standard (Deutz Engine/Hydraulic Controls)(Sheet 1 of 2) 6-32
6-12 Wiring Diagram – Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 of 2) 6-33
6-13 Wiring Diagram – Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 1 of 2) 6-34
6-14 Wiring Diagram – Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 6-35
6-15 Wiring Diagram – Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-36
6-16 Wiring Diagram – Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 6-37
6-17 Wiring Diagram – Standard (Ford Engine/Hydraulic Controls)(Sheet 1 of 2) 6-38
6-18 Wiring Diagram – Standard (Ford Engine/Hydraulic Controls)(Sheet 2 of 2) 6-39
6-19 Hydraulic Schematic (Sheet 1 of 6) 6-40
6-20 Hydraulic Schematic (Sheet 2 of 6) 6-41
6-21 Hydraulic Schematic (Sheet 3 of 6) 6-42
6-22 Hydraulic Schematic (Sheet 4 of 6) 6-43
6-23 Hydraulic Schematic (Sheet 5 of 6) 6-44
6-24 Hydraulic Schematic (Sheet 6 of 6) 6-45
3120271 – JLG Lift – vii
TABLE OF CONTENTS
LIST OF TABLES
TABLE NO TITLE PAGE NO
1-1 Torque Requirements 1-4
1-2 Lubrication Chart 1-6TABLE OF CONTENTS
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
Engine – Ford LSG423 1-1
Engine – Deutz F4L912 1-1
Engine – Wisconsin V465D 1-1
Engine – Cummins 4B 3 9C 1-1
Engine – Ford LRG-423 1-2
Engine – Ford LRG-425 1-2
Drive System 1-2
Drive Motor Displacement Machines Built Prior to Jan 1992 1-2
Drive Motor Displacement Machines Built from Jan 1992 to Present 1-2
Drive Hub Ratios 1-2
Steer System 1-2
Swing System 1-2
Hydraulic Pump 1-2
Auxiliary Power Pump 1-3
Hydraulic Filter – Tank 1-3
Hydraulic Filter – Inline (Racine Valve Only) 1-3
1 3 Performance Data 1-3
Travel Speed 1-3
Gradeability 1-3
Turning Radius (Outside) 1-3
Boom Speed (Telescope) 1-3
Boom Speed (Lift) 1-3
Swing Speed 360° 1-3
Boom Elevation 1-3
Machine Weight 1-3
Machine Stowed Height 1-3
Machine Stowed Length 1-3
Machine Width 1-3
Maximum Tire Load 1-3
Wheelbase 1-3
1 4 Torque Requirements 1-4
1 5 Lubrication 1-4
Ford Engines 1-9
Deutz F4L912 Engine 1-9
Wisconsin V465D Engine 1-9
Cummins 4B 3 9C 1-9
Lubrication Specifications 1-10
1 6 Pressure Settings 1-10
Prior to Mid 1987 1-10
80 HX 1-11
80HX w/Hydraulic Controls 1-11
80HX w/Oscillating Axle 1-11
1 7 Major Components Weights 1-12
1 8 Cylinder Specifications 1-12
ii – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
1 9 Boom Tape 1-12
American Standard 1-12
Canadian Standard 1-12
1 10 Critical Stability Weights 1-13
1 11 Serial Number Location 1-13
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-2
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-4
Hydraulic System 2-4
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-5
Platform Drift 2-5
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
2 6 Welding on JLG Equipment 2-6
Do the Following When Welding on JLG Equipment 2-6
Do NOT Do the Following When Welding on JLG Equipment 2-6
2 7 Applying Silicone Dielectric Compound to Electrical Connections 2-6
2 8 Preventive Maintenance and Inspection Schedule 2-7
SECTION 3 – CHASSIS & TURNTABLE
3 1 Torque Hub 3-1
Disassembly 3-1
Cleaning and Inspection 3-1
Repair 3-3
Input Shaft Assembly 3-4
Assembly 3-4
3120271 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
3 2 Drive Brake, Ausco – Machines Built Prior to October 1987 3-8
Disassembly 3-8
Cleaning and Inspection 3-9
Assembly 3-9
3 3 Drive Brake, Mico – Machines Built Prior to October 1987 3-10
Disassembly 3-10
Inspection 3-10
Assembly 3-10
Bleeding 3-11
3 4 Drive Brake, Ausco – Machines Built Prior to 1992 3-12
Disassembly 3-12
Cleaning and Inspection 3-12
Assembly 3-12
3 5 Drive Brake, Mico – Machines Built From 1992 to Present 3-14
Disassembly 3-14
Inspection 3-14
Assembly 3-14
3 6 Governor Checks and Adeco Adjustment, LRG423 & LRG425 3-17
Checks 3-17
Adjustments 3-17
3 7 Throttle Checks and Precision Governor Adjustments, LSG-423 & LRG-425 3-22
Checks 3-22
Carburetor and Governor Adjustment 3-22
3 8 E331 Precision Governor And Adjustments – Ford Engines 3-23
General 3-23
Quick-start Installations 3-23
Mounting-Actuator 3-24
Linkage 3-24
Mounting-Controller 3-25
Wiring 3-25
Power Distribution 3-25
Check-Out and Initial Start-Up Procedures 3-26
Troubleshooting 3-29
Automatic Choke Adjustment Procedure 3-31
3 9 Automatic Choke Adjustment – Ford Engine 3-31
3 10 Cold Weather Starting Difficulty 3-32
Checking the Carburetor 3-32
Checking the Ignition 3-33
Checking the Fuel 3-33
3 11 Throttle Checks and Adjustments – Deutz Engine 3-34
3 12 Swing Bearing 3-34
Turntable Bearing Mounting Bolt Condition Check 3-34
Wear Tolerance 3-35
Replacement and Devcon Application Procedures on Machines Built Prior to Mid 1991 3-35
Swing Bearing Torque Values 3-39
3 13 Oscillating Axle Bleeding Procedure 3-40
Lockout Cylinder Bleeding (Without Holding Valves) 3-40
Lockout Cylinder Bleeding (With Holding Valves) 3-40
3 14 Oscillating Axle Lockout Test 3-41
3 15 Free Wheeling Option 3-41
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc 3-41
To Engage Drive Motors and Brakes (Normal Operation) 3-41
3 16 Spark Arrestor Mufflers 3-42
3 17 Footswitch Adjustment 3-42
iv – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
3 18 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication 3-42
3 19 Dual Fuel System 3-42
Changing from gasoline to LP-Gas 3-42
Changing from LP Gas to Gasoline 3-42
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-4
Assembly 4-5
Installation 4-6
4 2 Boom Chains 4-7
Adjusting Procedures 4-7
Inspection Procedures 4-8
4 3 Wear Pads 4-10
4 4 Telescope Cylinder Eccentric Bushing 4-10
4 5 Horizontal High Speed Cutout Switch Adjustment Procedure 4-10
4 6 Controllers 4-10
PQ 4-10
OEM 4-10
VICKERS (All Hydraulic) 4-10
4 7 Capacity Indicator 4-10
Capacity Indicator Cable Adjustment 4-10
Capacity Indicator Boom Tape Replacement 4-11
Installation Procedure 4-11
Capacity Indicator Dial Decal Replacement 4-11
Indicator Decal Installation 4-11
4 8 Basket Rotator Brake 4-11
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory Of Operation 5-1
Double Acting Cylinders 5-1
5 2 Valves – Theory Of Operation 5-1
Holding Valves 5-1
Solenoid Control Valves (Bang-Bang) 5-1
Proportional Control Valve – Vickers 5-1
Main Relief Valves 5-1
Relief Valves 5-1
5 3 Cylinder Checking Procedure 5-3
Cylinders Without Counterbalance Valves 5-3
Cylinders With Single Counterbalance Valve 5-3
Cylinders With Dual Counterbalance Valves 5-4
5 4 Cylinder Repair 5-4
Disassembly 5-4
Cleaning and Inspection 5-11
Assembly 5-12
5 5 Cylinder Removal and Installation 5-14
Telescope Cylinder Removal 5-14
Telescope Cylinder Installation 5-14
Boom Lift Cylinder Removal 5-15
Boom Lift Cylinder Installation 5-15
3120271 – JLG Lift – v
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
5 6 Telescope Cylinder Eccentric Bushing 5-15
5 7 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication 5-15
5 8 Racine Proportional Air Gap Adjustment 5-16
5 9 Pressure Setting Procedures 5-16
SECTION 6 – TROUBLESHOOTING & SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting Information 6-1
6 3 Hydraulic Circuit Checks 6-1
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Diagram 1-5
1-2 Serial Number Locations 1-13
1-3 Torque Chart – (In/Lb – Ft/Lb) (For ASTM Fasteners) 1-14
1-4 Torque Chart (Metric Conversion) – (For ASTM Fasteners) 1-15
1-5 Torque Chart – (N, m) – (For Metric Class Fasteners) 1-16
3-1 Torque Hub Assembly 3-2
3-2 Drive Brake, Ausco – Machines Built Prior to October 1987 3-9
3-3 Drive Brake, Mico – Machines Built Prior to October 1987 3-11
3-4 Drive Brake, Ausco – Machines Built Prior to 1992 3-13
3-5 Drive Brake, Mico – Machines Built from 1992 to Present 3-15
3-6 Spring Loading 3-16
3-7 Governor Adjustment, LRG-423 & LRG-425 with Adeco 3-17
3-8 Adeco Adjustment, LRG-423 & LRG-425 3-18
3-9 Precision Governor Adjustment – LRG-423 & LRG-425 (Sheet 1 of 2) 3-19
3-10 Precision Governor Adjustment – LRG-423 & LRG-425 (Sheet 2 of 2) 3-20
3-11 Adeco Actuator Adjustments – F4L912 3-21
3-12 Swing Bearing Bolt Feeler Gauge Check 3-34
3-13 Swing Bearing Tolerance Measuring Point 3-35
3-14 Swing Bearing Tolerance Boom Placement 3-37
3-15 Swing Bearing Torquing Sequence 3-38
4-1 Boom Assembly (Sheet 1 of 2) 4-2
4-2 Boom Assembly (Sheet 2 of 2) 4-3
4-3 Typical Boom Assembly 4-7
4-4 Telescope Cylinder Eccentric Bushing 4-10
4-5 Boom Tape Replacement 4-11
4-6 Capacity Indicator Dial 4-11
4-7 Belleville Washers 4-11
5-1 Proportional Control Valve 5-2
5-2 Boom Positioning and Support – Cylinder Repair 5-5
5-3 Typical Hydraulic Cylinders (Sheet 1 of 4) 5-6
5-4 Typical Hydraulic Cylinders (Sheet 2 of 4) 5-7
5-5 Typical Hydraulic Cylinders (Sheet 3 of 4) 5-8
5-6 Typical Hydraulic Cylinders (Sheet 4 of 4) 5-9
5-7 Cylinder Barrel Support 5-10
5-8 Cylinder Rod Support 5-10
5-9 Poly-Pak Seal Installation 5-12
5-10 Telescope Cylinder Eccentric Bushing 5-15
5-11 Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987 5-16
5-12 Racine Proportional Valve Pressure Setting – Prior to Mid 1987 (Sheet 1 of 2) 5-17
5-13 Racine Proportional Valve Pressure Setting – Prior to Mid 1987 (Sheet 2 of 2) 5-18
vi – JLG Lift – 3120271
TABLE OF CONTENTS (Continued)
LIST OF FIGURES (continued)
FIGURE NO TITLE PAGE NO
5-14 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 1 of 4) 5-19
5-15 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 2 of 4) 5-20
5-16 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 3 of 4) 5-21
5-17 Vickers Proportional Valve Pressure Setting – Prior to 1989 with Accessory Valve (Sheet 4 of 4) 5-22
5-18 Solenoid Valve Pressure Settings – Prior to Mid 1992 with Steering Wheel 5-23
5-19 Pressure and Flow Settings – Machines Prior to Mid 1992 with Steering Wheel 5-24
5-20 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 1 of 4) 5-25
5-21 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 2 of 4) 5-26
5-22 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 3 of 4) 5-27
5-23 Vickers Proportional Valve Pressure Setting – Mid 1992 to Present (Sheet 4 of 4) 5-28
5-24 Pressure Setting – All Hydraulic Machines (Sheet 1 of 4) 5-29
5-25 Pressure Setting – All Hydraulic Machines (Sheet 2 of 4) 5-30
5-26 Pressure Setting – All Hydraulic Machines (Sheet 3 of 4) 5-31
5-27 Pressure Setting – All Hydraulic Machines (Sheet 4 of 4) 5-32
5-28 Solenoid Valve Pressure Settings – Machines Built to Present 5-33
5-29 Solenoid Valve Pressure Settings – 4 Wheel Steer 5-34
5-30 Extend-A-Reach Valve Pressure and Speed Settings 5-35
6-1 Wiring Schematic Dual Fuel 6-21
6-2 Wiring Diagram – Generator (Deutz Engines) 6-22
6-3 Wiring Diagram – Generator (Ford Engine) 6-23
6-4 Wiring Diagram – Platform Console Standard Controls (Sheet 1 of 2) 6-24
6-5 Wiring Diagram – Platform Console Standard Controls (Sheet 2 of 2) 6-25
6-6 Wiring Diagram – Platform Console Hydraulic Controls 6-27
6-7 Wiring Diagram – Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 of 2) 6-28
6-8 Wiring Diagram – Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 6-29
6-9 Wiring Diagram – Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-30
6-10 Wiring Diagram – Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 6-31
6-11 Wiring Diagram – Standard (Deutz Engine/Hydraulic Controls)(Sheet 1 of 2) 6-32
6-12 Wiring Diagram – Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 of 2) 6-33
6-13 Wiring Diagram – Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 1 of 2) 6-34
6-14 Wiring Diagram – Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2) 6-35
6-15 Wiring Diagram – Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 1 of 2) 6-36
6-16 Wiring Diagram – Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2) 6-37
6-17 Wiring Diagram – Standard (Ford Engine/Hydraulic Controls)(Sheet 1 of 2) 6-38
6-18 Wiring Diagram – Standard (Ford Engine/Hydraulic Controls)(Sheet 2 of 2) 6-39
6-19 Hydraulic Schematic (Sheet 1 of 6) 6-40
6-20 Hydraulic Schematic (Sheet 2 of 6) 6-41
6-21 Hydraulic Schematic (Sheet 3 of 6) 6-42
6-22 Hydraulic Schematic (Sheet 4 of 6) 6-43
6-23 Hydraulic Schematic (Sheet 5 of 6) 6-44
6-24 Hydraulic Schematic (Sheet 6 of 6) 6-45
3120271 – JLG Lift – vii
TABLE OF CONTENTS
LIST OF TABLES
TABLE NO TITLE PAGE NO
1-1 Torque Requirements 1-4
1-2 Lubrication Chart 1-6
1-4 Mobil EAL 224 H Specs 1-10
1-5 Mobil DTE 13M Specs 1-10
1-3 Hydraulic Oil 1-10
1-6 Lubrication Specifications 1-10
1-7 Major Component Weights 1-12
1-8 Cylinder Specifications 1-12
1-9 Critical Stability Weights 1-13
2-1 Inspection and Maintenance 2-2
2-2 Cylinder Drift 2-5
2-3 Preventive Maintenance and Inspection Schedule 2-8
4-1 Chain Stretch Tolerance 4-9
5-1 Cylinder Piston Nut Torque Specifications 5-13
5-2 Holding Valve Torque Specification 5-14
6-1 Platform Assembly – Troubleshooting 6-2
6-2 Boom Assembly – Troubleshooting 6-3
6-3 Turntable Assembly – Troubleshooting 6-8
6-4 Chassis Assembly – Troubleshooting 6-9
6-5 Hydraulic System – Troubleshooting 6-15
6-6 Electrical System – Troubleshooting 6-18
1-4 Mobil EAL 224 H Specs 1-10
1-5 Mobil DTE 13M Specs 1-10
1-3 Hydraulic Oil 1-10
1-6 Lubrication Specifications 1-10
1-7 Major Component Weights 1-12
1-8 Cylinder Specifications 1-12
1-9 Critical Stability Weights 1-13
2-1 Inspection and Maintenance 2-2
2-2 Cylinder Drift 2-5
2-3 Preventive Maintenance and Inspection Schedule 2-8
4-1 Chain Stretch Tolerance 4-9
5-1 Cylinder Piston Nut Torque Specifications 5-13
5-2 Holding Valve Torque Specification 5-14
6-1 Platform Assembly – Troubleshooting 6-2
6-2 Boom Assembly – Troubleshooting 6-3
6-3 Turntable Assembly – Troubleshooting 6-8
6-4 Chassis Assembly – Troubleshooting 6-9
6-5 Hydraulic System – Troubleshooting 6-15
6-6 Electrical System – Troubleshooting 6-18

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