JLG Model 150Hax Service & Maintenance Manual (3120817) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG Model 150Hax Service & Maintenance Manual (3120817) – 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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JLG Model 150Hax Service & Maintenance Manual (3120817) – PDF DOWNLOADJLG Model 150Hax Service & Maintenance Manual (3120817) – PDF DOWNLOADJLG Model 150Hax Service & MainJLG Model 150Hax Service & Maintenance Manual (3120817) – PDF DOWNLOADtenance Manual (3120817) – PDF DOWNLOAD
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