JLG Model 150Hax Service & Maintenance Manual (3120679)- PDF DOWNLOAD En

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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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• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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