Jlg 150HAX Service Manual User Manual

Service and Maintenance ManualModel150HAXP/N - 3120817February 15, 2012

vi – JLG Lift – 3120817LIST OF TABLES LIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Capacities . . . . . . . . . . .

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31208176. Remove two bolts and lockwashers securing eachof two trunnion blocks to base end of mid boom sec-tion

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-5Main Telescope Cylinder Removal1. Place machine on a flat and level surface, with mainboom fully retract

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 3120817Main Lift Cylinder Removal1. With tower boom at horizontal, depress plunger onlimit switch in main lift

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-7Lower Master Level Cylinder Installation1. With tower boom partly raised and properly sup-ported, align

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31208175.5 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-914. Inspect travel limiting collar or spacer for burrs andsharp edges. If necessary, dress inside diamet

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 312081710. Place new o-rings and seals in the applicable out-side diameter grooves of both the piston and the

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-115.6 PRESSURE SETTING PROCEDURESCold temperatures have a significant impact on pressurereadings. JLG Ind

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31208175 Stack Directional Control Valve (External Relief Adjustment Screws)NOTE: Make all pressure adjustment

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-13c. Adjust pressure to 3000 psi (207 bar). d. Bottom out Main Lift Down function. e. Adjust pressure to

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 ENGINE DATA1.3 DRIVE/STEER SYSTEM1.4 PERFORMANCE DATA1.5

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3120817Figure 5-2. Valve Locations - Turntable Mounted Valves

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-15Figure 5-3. Valve Locations - Frame Mounted Valves

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3120817c. Bottom out Tower Lift Down function. d. Adjust pressure to 3000 psi (207 bar). 6. Swing Relief. a. L

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-17to increase pressure, counterclockwise to decreasepressure. Tighten locknut. 6. Bottom out Rear Steer R

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3120817to increase pressure, counterclockwise to decreasepressure. Tighten locknut. 6. Bottom out Rear Axle Ex

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-195.7 HYDRAULIC GEAR PUMPDisassemblyDO NOT GRIP ON OR NEAR ANY MACHINED SURFACES DURINGASSEMBLY OR DISASS

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3120817Figure 5-4. Recommended Tool List

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-21Figure 5-5. Main Gear Pump Assembly1. Lip Seal2. Mounting End3. Not Used4. Plug5. Dowel Pin6. Thrust P

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31208175. Carefully remove the drive and driven gears. Avoidtapping the gear teeth together or against otherha

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-239. Lift or pry off the first section gear housing. Be care-ful not to damage machined surfaces. Examine

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31208171.6 LUBRICATION.NOTE: Hydraulic oils must have anti-wear qualities at leastto API Service Classifica

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 312081713. Grip the shaft end cover in a vise with the mountingface down. Remove the double lip seal by insert

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-254. New plugs should be screwed in tightly. Stake plugwith a prick punch at both ends of screwdriver slo

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 31208178. See that dowel pins are in place in any new cast-ings. Examine all dowels. Before inserting makesure

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-2712. Grease the new gasket seals and insert them intothe grooves in both sides of all gear housings. Pos

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 312081716. Slip the thrust plate with seal over gear journals andinto the housing bore. The flat side of the s

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-2920. Check the plug or plugs in the port end cover to besure they are tight. Follow the procedure outlin

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 3120817DRIVE SHAFTSReplace if there is any wear detectable by touch in theseal area or at the drive coupling.

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-31Run the pump at least two minutes at no load and moder-ate speed (not over 1500 rpm). if the pump becom

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3120817NOTES:

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-1SECTION 6. SCHEMATICS6.1 GENERALThis section contains troubleshooting information to beused for locatin

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-31.7 TORQUE REQUIREMENTS 1.8 PRESSURE SETTINGS - PSI (BAR)Table 1-11. Torque RequirementsDescriptionT

SECTION 6 - SCHEMATICS6-2 – JLG Lift – 3120817Table 6-1.Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM LEVELING SYSTEMSPlatf

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-3CONTROL VALVESValve spool sticking.Dirt in oil causing excessive temperature build-up.Flush system and c

SECTION 6 - SCHEMATICS6-4 – JLG Lift – 3120817.Table 6-2.Boom Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYBOOM ELEVATION SYSTEM.No response

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-5Boom raises and lowers erratically.Hydraulic system oil low. Replenish oil as required. Restricted or b

SECTION 6 - SCHEMATICS6-6 – JLG Lift – 3120817Boom will not extend.Damaged wiring on control switch, solenoid valve or proportional valve. Repair or r

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-7.BOOM SWING SYSTEMNo response to swing control. Hydraulic system oil low. Replenish oil as necessary. S

SECTION 6 - SCHEMATICS6-8 – JLG Lift – 3120817Table 6-3.Turntable - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPOWER PLANTEngine will not start. Stat

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-9Valve Spool Sticking. Dirt in oil causing excessive temperature build-up. Change oil using recommended

SECTION 6 - SCHEMATICS6-10 – JLG Lift – 3120817.Table 6-4.Chassis - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYFRONT AXLE AREAOne or both front wheel

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-11Difficulty encountered when moving machine.Load capacity exceeded. Reduce load. Apply loads only in acc

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31208171.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS1.11 SERIAL NUMBER LOCATIONSFor machine i

SECTION 6 - SCHEMATICS6-12 – JLG Lift – 3120817Machine will not travel in forward.Hydraulic system oil low. Replenish oil as necessary.Restricted or b

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-13 Poor response, function shuts off slowly when command is removed.Low spool spring preload. Check for

SECTION 6 - SCHEMATICS6-14 – JLG Lift – 3120817Machine hard to steer or steering is erratic. Hydraulic system oil low. Replenish oil as necessary. Res

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-15Machine wanders; steering not firm.Crossover relief valve set too low or not function-ing properly. Res

SECTION 6 - SCHEMATICS6-16 – JLG Lift – 3120817.Table 6-5.Hydraulic System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHYDRAULIC SYSTEM - GENERALHyd

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-17System(s) operate erratically.Sticking or binding valve spools, pistons, rods, etc.Clean, repair, or re

SECTION 6 - SCHEMATICS6-18 – JLG Lift – 3120817.Table 6-6.Electrical System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM CONTROLSNo power to

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-19Travel warning horn inoperative.Damaged wiring in horn circuit. Repair or replace wiring. Damaged horn

SECTION 6 - SCHEMATICS6-20 – JLG Lift – 3120817Function occurs very rapidly when handle is moved in one direction and very slowly when moved in the op

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-21Speed not proportional. “High” and “Low” pots not adjusted properly. Adjust pots to factory specificat

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-51.12 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-1., Operator M

SECTION 6 - SCHEMATICS6-22 – JLG Lift – 3120817Figure 6-1. Electrical Schematic - Sheet 1 of 2

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-23Figure 6-2. Electrical Schematic - Sheet 2 of 21870232 B

SECTION 6 - SCHEMATICS6-24 – JLG Lift – 3120817Figure 6-3. Hydraulic Schematic - Sheet 1 of 2

SECTION 6 - SCHEMATICS3120817 – JLG Lift – 6-251001110253 BFigure 6-4. Hydraulic Schematic - Sheet 2 of 2

SECTION 6 - SCHEMATICS6-26 – JLG Lift – 3120817NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31208171. To r q u e H ub sLube Point(s) - 1 Fill Plug per hubCapacity - Lube - EPGLInterval - Check oil l

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-76. Extending AxlesLube Point(s) - N/ACapacity - A/RLube - MPGInterval - Every 3 months or 150 hrs of

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 312081712. Platform HingesLube Point(s) - 2 Grease FittingsCapacity - A/RLube - MPGInterval - Every 3 month

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-919. Engine Oil FilterLube Point(s) - N/ALube - EOComments - Refer to Engine Manual for Changeinterva

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312081727. Upper Master Cylinder Rod EndLube Point(s) - 1 Grease FittingCapacity - A/RLube - MPGInterval -

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-11Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120817Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-13Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3120817Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-15Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3120817Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3120817 – JLG Lift – 1-17Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3120817NOTES:

SECTION 2 - GENERAL3120817 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

INTRODUCTION3120817 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - GENERAL2-2 – JLG Lift – 31208172.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3120817 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 3120817fied intervals required in the Lubrication Chart inSection 1. Always examine filters for evidence ofmetal p

SECTION 2 - GENERAL3120817 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 2 - GENERAL2-6 – JLG Lift – 3120817Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3120817 – JLG Lift – 2-7Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 2 - GENERAL2-8 – JLG Lift – 3120817Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL3120817 – JLG Lift – 2-9(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL

SECTION 2 - GENERAL2-10 – JLG Lift – 3120817NOTES:

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

INTRODUCTIONA-2 – JLG Lift – 3120817REVISON LOGOriginal Issue - June 1, 1992Revised - February 4, 2010Revised - February 15, 2012

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31208173. The tightening of the nuts should be done in stages.Following the recommended sequence,

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-31. Bolt2. Bolt3. Lockwasher4. Cover5. Pipe Plug6. Pipe Plug7. Cover Cap8. O-ring9. Disconne

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3120817Cleaning and Inspection1. Thoroughly clean all parts in an approved cleaningsolvent.2. Insp

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-5f. Lower hub onto spindle (30) with large open endup.g. Place bearing cone (32) over end of

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3120817l. Place spring (43) into spindle counterbore.m. Set second spacer washer (42) on top of sp

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-75. Install retaining ring (19) in groove of input shaft(20).6. Place input shaft into spind

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3120817c. Place cluster gear over planet shaft and ontobearing cone, with large gear on top.d. Pla

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-9i. Place bearing cones (29) into cluster gear.j. Place cluster gear into carrier with large

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3120817o. Repeat steps (a) through (n) for remaining twocluster gears.10. Time carrier gears as f

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-1115. Place one thrust bearing (16) between two thrustwashers (15) and place into carrier co

3120817 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3120817f. Install disconnect cap (11) to cover cap with tworemaining bolts (12) torqued to 70 to

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-13Figure 3-2. Torque Hub Carrier Timing

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31208173.3 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476Disassembly1. Separate end

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-15Figure 3-3. Drive Brake - Mico (March 1992 to S/N 33746)

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 31208176. Position new large diameter return plate (14) inhousing with tabs guided by dowel pins

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-175. Remove separators (10) from housing (7).6. Remove stack assembly, consisting of discs (

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 31208171. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-r

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-193.5 FREE WHEELING OPTIONTo Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3120817Figure 3-19. Swing Bearing Tolerance Boom Placement

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-21Check the turntable to bearing attach bolts as follows:1. Elevate the fully retracted boom

ii – JLG Lift – 3120817TABLE OF CONTENTS (Continued) 2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31208179. Using a suitable tool, scribe a line on outer race ofswing bearing and frame. This line

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-23k. Use suitable lifting equipment to carefully posi-tion turntable assembly above machine

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3120817Swing Bearing Torque Values1. Outer Race - 545 ft. lb. (740 Nm) JLG Threadlocker. 2. Inner

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-251. Output Shield2. Outer Bearing Cup3. Outer Bearing Cone4. Inner Bearing Cup5. Inner Bear

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31208177. Remove o-ring (6) from counterbore around rim ofcover. Discard o-ring. 8. Remove thrust

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-27Assembly1. Assemble hub/shaft assembly as follows: a. Set hub (9) on work surface, wide en

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3120817c. Apply a light coating of petroleum or multi-pur-pose grease to inside of small end of c

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-2916. Place twenty lockwashers (24) over bolt holes incover. 17. Place twenty bolts (31) int

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3120817Figure 3-22. Swing Brake - Ausco - Machines Built to 1992

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-315. Before installing seal (4), lubricate lip of seal withsystem hydraulic fluid or other s

3120817 – JLG Lift – iii TABLE OF CONTENTS3.10 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3120817Figure 3-23. Swing Brake - Mico - Machines Built to 1992

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-33AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1.

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 31208171. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-r

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-355. Remove separators (13) from housing (21).6. Remove stack assembly, consisting of discs

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31208173.11 SWING MOTORDisassemblyNOTE: Prior to any motor disassembly, plug open ports andclean

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-371. Dust Seal2. Backup Ring3. Quad Ring Seal4. Rotary Valve5. Check Valve Ball6. IGR Assemb

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31208173.12 PQ CONTROLLERSTRIM Adjustment1. Disconnect ORANGE/RED (dump) wire from appli-cable te

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-39e. Release footswitch and stop machine. f. Seal ramp pot adjustment screw with a drop ofen

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3120817Hayes Coupling1. Install pump coupling on flywheel and secure withbolts and lockwashers. T

SECTION 3 - CHASSIS & TURNTABLE3120817 – JLG Lift – 3-41Voltmeter Adjustment8. Park machine on a flat, level surface. Ensuremachine is level and t

iv – JLG Lift – 3120817TABLE OF CONTENTS (Continued) 5.2 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3120817Figure 3-28. Throttle Checks and Adjustments - Deutz Engine

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCEBoom Mounted Limit Switches and ValvesNOTE:

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3120817Figure 4-1. Boom Mounted Limit Switches and Valves Installation

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-3Tower Boom Removal1. Remove main boom as outlined in Main BoomRemoval. 2. Shut down machine sys

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3120817Figure 4-2. Main Boom Assembly - Sheet 1 of 2

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-5Figure 4-3. Main Boom Assembly - Sheet 2 of 21. Base Boom2. Mid Boom3. Fly Boom4. Telescope Cy

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31208176. Using a suitable brass drift, carefully drive telescopecylinder pin from base section. 7. Re

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-729. Remove bolts and lockwashers which attach bottomwear pads at front of outer mid section and

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3120817Figure 4-4. Tower Boom1. Base Boom2. Mid Boom3. Fly Boom4. Telescope Cylinder5. Upper Rear Wea

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-913. Using suitable lifting equipment, carefully slide tele-scope cylinder out of fly and mid se

3120817 – JLG Lift – v LIST OF FIGURESLIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Operator Maintenance & Lubrication Diagram . . .

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3120817 Main Boom AssemblyNOTE: When installing fly section wear pads, install samenumber and thickne

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-1124. Install trunnion pins, tapping pins into place with asoft headed mallet if necessary. Inst

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3120817NOTE: When installing mid section wear pads, install samenumber and thickness of shims as were

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-13Main Boom Installation1. Using suitable lifting equipment, position assembledmain boom on towe

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3120817Inspection ProcedureBOOM CHAINS ARE TO BE INSPECTED AT TIME OF NEXT BOOMOVERHAUL AND WHEN DEEM

SECTION 4 - BOOM & PLATFORM3120817 – JLG Lift – 4-155. Tight Joints: All joints in the roller chain should flexfreely. On roller chain, tight join

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31208178. Chain Anchors, Sheaves, and Pins: An inspectionof the chain must include a close examinatio

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 VALVES - THEORY OF OPERATIONSolenoid Control Valves (Bang-Bang)Control valves

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 31208175.3 CYLINDER CHECKING PROCEDURESNOTE: Cylinder checks must be performed any time a cylin-der component i

SECTION 5 - HYDRAULICS3120817 – JLG Lift – 5-3Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Lev