Jlg 40H Service Manual User Manual Page 32
- Page / 152
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 2 - PROCEDURES
2-12 – JLG Lift – 3120240
21. An alternative to steps (18) through (20) is to posi-
tion the barrel horizontally in a suitable holding
device, attach a hydraulic power source to both
extend and retract ports, while supporting the cylin-
der rod, cycle the cylinder a minimum of 5 times with
the bleeder port unplugged venting all trapped air to
atmosphere. A suitable hose may be attached to the
bleeder port with the end in a container suitable to
contain the hydraulic fluid. After all air is vented
remove all attached hoses, and install the bleeder
port plug. Also plug the extend and retract ports until
cylinder is installed in boom.
NOTE: After torquing piston nut spot drill cylinder rod for set-
screws.
2.10 CYLINDER REMOVAL AND
INSTALLATION.
Telescope Cylinder Removal.
1. Be sure boom is fully retracted and in a horizontal
position.
2. Shut down engine. Support boom basket end with a
prop. (See Figure 2-2.)
3. Remove boom end-cover.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
4. Tag and disconnect hydraulic lines to telescope cyl-
inder. Use suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
5. Remove the two setscrews that retain the telescope
cylinder pin to the base boom.
6. Using a suitable brass drift, carefully drive the tele-
scope cylinder pin from the base boom.
NOTE: Steps 7, 8 and 9 apply to 3 Section Boom Only.
7. Remove the telescope cylinder trunnion pin covers
from each side of the base boom.
8. Remove the cap screws securing the trunnion pins
from each side of the boom.
9. Using a suitable slide hammer, remove the trunnion
pins attaching the telescope cylinder to the mid
boom.
Table 2-2. Cylinder Piston Nut Torque Specification
Descr ipt io n Nut
Torque Value
(Wet)
Setscrew
Torque Value
(Dry)
Lift Cylinder 600 ft. lbs.
(814 Nm)
200 in. lbs.
(23 Nm)
Slave Cylinder 80 ft. lbs.
(109 Nm)
100 in. lbs.
(12 Nm)
Master Cylinder 80 ft. lbs.
(109 Nm)
100 in. lbs.
(12 Nm)
Steer Cylinder 80 ft. lbs.
(109 Nm)
100 in. lbs.
(12 Nm)
Lockout Cylinder 80 ft. lbs.
(109 Nm)
100 in. lbs.
(12 Nm)
Telescope Cylin-
der
600 ft. lbs.
(814 Nm)
200 in. lbs.
(23 Nm)
Extend-A-Reach
Lift Cylinder 200 ft. lbs.
(271 Nm)
100 in. lbs.
(12 Nm)
Slave Cylinder 200 ft. lbs.
(271 Nm)
100 in. lbs.
(12 Nm)
Table 2-3. Holding Valve Torque Specifications.
Description Torque Value
SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.
(41-48 NM)
SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.
(61-68 NM)
SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.
(204-217 NM)
RACINE - 1 1/8 HEX 1 1/16 - 12
THDS.
50-55 ft. lbs.
(68-75 NM)
RACINE - 1 3/8 HEX 1 3/16 - 12
THDS.
75-80 ft. lbs.
(102-109 NM)
RACINE - 1 7/8 HEX 1 5/8 - 12
THDS.
100-110 ft. lbs.
(136-149 NM)
- October 11, 2001 1
- PRECAUTIONS 3
- REVISON LOG 4
- TABLE OF CONTENTS 5
- (Continued) 6
- SECTION 3 - TROUBLESHOOTING 6
- LIST OF FIGURES 6
- FIGURE NO. TITLE PAGE NO 6
- (INTENTIONAL BLANK PAGE) 8
- SECTION 1. SPECIFICATIONS 9
- 1-2 – JLG Lift – 3120240 10
- 3120240 – JLG Lift – 1-3 11
- SECTION 1 - SPECIFICATIONS 12
- Deutz F3L912/F3L1011 Engine 12
- Wisconsin VG4D Engine 12
- 1-8 – JLG Lift – 3120240 16
- 3120240 – JLG Lift – 1-9 17
- SECTION 2. PROCEDURES 21
- 2-2 – JLG Lift – 3120240 22
- 3120240 – JLG Lift – 2-3 23
- 2-4 – JLG Lift – 3120240 24
- 3120240 – JLG Lift – 2-5 25
- 2-6 – JLG Lift – 3120240 26
- 3120240 – JLG Lift – 2-7 27
- 2.9 CYLINDER REPAIR 29
- Disassembly 29
- Cleaning and Inspection 30
- Assembly 30
- 2.10 CYLINDER REMOVAL AND 32
- INSTALLATION 32
- Telescope Cylinder Removal 32
- 2-14 – JLG Lift – 3120240 34
- Inspection 36
- 3120240 – JLG Lift – 2-19 39
- 2-20 – JLG Lift – 3120240 40
- 3120240 – JLG Lift – 2-21 41
- 2-22 – JLG Lift – 3120240 42
- Linkage 43
- Mounting-Controller 44
- Power Distribution 44
- Troubleshooting 48
- 2.17 THROTTLE CHECKS AND 49
- ADJUSTMENTS - DEUTZ F2L511 49
- ENGINE. (SEE FIGURE 2-8.) 49
- 3120240 – JLG Lift – 2-33 53
- 3120240 – JLG Lift – 2-35 55
- ADJUSTMENT 78
- 2.23 SWING BEARING 79
- Wear Tolerance 80
- Installation 81
- Swing Bearing Torque Values 82
- Repair 85
- 2.26 SWING DRIVE BRAKE, MICO 91
- (MACHINES BUILT PRIOR TO MAY 91
- 1992). (SEE FIGURE 2-39.) 91
- 2-72 – JLG Lift – 3120240 92
- Bleeding 94
- 3120240 – JLG Lift – 2-75 95
- 3120240 – JLG Lift – 2-77 97
- 3120240 – JLG Lift – 2-79 99
- SECTION 2 - PROCEDURES 100
- 3120240 – JLG Lift – 2-81 101
- 3120240 – JLG Lift – 2-83 103
- 3120240 – JLG Lift – 2-85 105
- 3120240 – JLG Lift – 2-87 107
- 3120240 – JLG Lift – 2-89 109
- INSPECTION SCHEDULE 110
- 2-92 – JLG Lift – 3120240 112
- SECTION 3. TROUBLESHOOTING 113
- SECTION 3 - TROUBLESHOOTING 114
- JLG Worldwide Locations 152
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