JLG 150HAX Articulating Boom Lift Service and Maintenance Manual (ANSI)

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This service manual PDF download for the 150HAX JLG Articulating Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


TABLE OF CONTENTS :

Section A. Introduction - Maintenance Safety Precautions
    A General
    B Hydraulic System Safety
    C Maintenance
    
Section 1. Specifications
    1.1 Capacities
    1.2 Engine Data
    1.3 Drive/Steer System
    1.4 Performance Data
    1.5 Function Speeds
    1.6 Lubrication
    1.7 Torque Requirements
    1.8 Pressure Settings - PSI (Bar)
    1.9 Major Component Weights
    1.10 Critical Stability weights
    1.11 Serial Number Locations
    1.12 Operator Maintenance
    
Section 2. General
    2.1 Machine Preparation, Inspection, and Maintenance
    2.2 Service and Guidelines
    2.3 Lubrication and Information
    2.4 Cylinder Drift Test
    2.5 Pins and Composite Bearing Repair Guidelines
    2.6 Welding on JLG Equipment
        
Section 3. Chassis & Turntable
    3.1 Tires & Wheels
    3.2 Drive Torque Hub
    3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476
    3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present
    3.5 Free Wheeling Option
    3.6 Swing Bearing
    3.7 Swing Torque Hub
    3.8 Swing Brake - Ausco - Machines Built To 1992
    3.9 Swing Brake - Mico - Machines Built To 1992
    3.10 Swing Brake - Machines Built 1992 To Present
    3.11 Swing Motor
    3.12 PQ Controllers
    3.13 Pump Coupling Conversion Procedures
    3.14 Tilt Alarm Switch
    3.15 Throttle Checks and Adjustments
    
Section 4. Boom & Platform
    4.1 Boom Maintenance
    4.2 Boom Chains
    4.3 Wear Pads
    4.4 Platform Rotator Brake
    
Section 5. Hydraulics
    5.1 Valves - Theory of Operation
    5.2 Cylinders - Theory of Operation
    5.3 Cylinder Checking Procedures
    5.4 Cylinder Removal and Installation
    5.5 Cylinder Repair
    5.6 Pressure Setting Procedures
    5.7 Hydraulic Gear Pump
        
Section 6. Schematics
    6.1 General
    6.2 Troubleshooting
    6.3 Hydraulic Circuit Checks
    
LIST OF FIGURES
LIST OF TABLES


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3120679
Total Pages : 160


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Section A. Introduction - Maintenance Safety Precautions
    A General
    B Hydraulic System Safety
    C Maintenance
    
Section 1. Specifications
    1.1 Capacities
    1.2 Engine Data
    1.3 Drive/Steer System
    1.4 Performance Data
    1.5 Function Speeds
    1.6 Lubrication
    1.7 Torque Requirements
    1.8 Pressure Settings - PSI (Bar)
    1.9 Major Component Weights
    1.10 Critical Stability weights
    1.11 Serial Number Locations
    1.12 Operator Maintenance
    
Section 2. General
    2.1 Machine Preparation, Inspection, and Maintenance
        General
        Preparation, Inspection, and Maintenance
        Pre-Start Inspection
        Pre-Delivery Inspection and Frequent Inspection
        Annual Machine Inspection
        Preventative Maintenance
    2.2 Service and Guidelines
        General
        Safety and Workmanship
        Cleanliness
        Components Removal and Installation
        Component Disassembly and Reassembly
        Pressure-Fit Parts
        Bearings
        Gaskets
        Bolt Usage and Torque Application
        Hydraulic Lines and Electrical Wiring
        Hydraulic System
        Lubrication
        Battery
        Lubrication and Servicing
    2.3 Lubrication and Information
        Hydraulic System
        Hydraulic Oil
        Changing Hydraulic Oil
        Lubrication Specifications
    2.4 Cylinder Drift Test
        Platform Drift
        Cylinder Drift
    2.5 Pins and Composite Bearing Repair Guidelines
    2.6 Welding on JLG Equipment
        Do the Following When Welding on JLG Equipment
        Do NOT Do the Following When Welding on JLG Equipment
        
Section 3. Chassis & Turntable
    3.1 Tires & Wheels
        Tire Inflation
        Tire Damage
        Tire Replacement
        Wheel Replacement
        Wheel Installation
    3.2 Drive Torque Hub
        Disassembly
        Cleaning and Inspection
        Assembly
    3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476
        Disassembly
        Cleaning and Inspection
        Assembly
    3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present
        Disassembly
        Inspection
        Assembly
    3.5 Free Wheeling Option
        To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
        To Engage Drive Motors and Brakes (Normal Operation)
    3.6 Swing Bearing
        Turntable Bearing Mounting Bolt Condition Check
        Wear Tolerance
        Replacement and Devcon Application Procedures
        Swing Bearing Torque Values
    3.7 Swing Torque Hub
        Disassembly
        Cleaning and Inspection
        Assembly
    3.8 Swing Brake - Ausco - Machines Built To 1992
        Disassembly
        Cleaning and Inspection
        Assembly
    3.9 Swing Brake - Mico - Machines Built To 1992
        Disassembly
        Cleaning and Inspection
        Assembly
    3.10 Swing Brake - Machines Built 1992 To Present
        Disassembly
        Cleaning and Inspection
        Assembly
    3.11 Swing Motor
        Disassembly
        Assembly
    3.12 PQ Controllers
        TRIM Adjustment
        RAMP Adjustment
    3.13 Pump Coupling Conversion Procedures
        Lovejoy Coupling
        Hayes Coupling
    3.14 Tilt Alarm Switch
        Manual Adjustment
        Voltmeter Adjustment
    3.15 Throttle Checks and Adjustments
    
Section 4. Boom & Platform
    4.1 Boom Maintenance
        Boom Mounted Limit Switches and Valves
        Main Boom Removal
        Tower Boom Removal
        Main Boom Disassembly
        Tower Boom Disassembly
        Inspection
        Main Boom Assembly
        Tower Boom Assembly
        Tower Boom Installation
        Main Boom Installation
    4.2 Boom Chains
        Adjusting Procedures - Main Boom
        Inspection Procedure
    4.3 Wear Pads
    4.4 Platform Rotator Brake
    
Section 5. Hydraulics
    5.1 Valves - Theory of Operation
        Solenoid Control Valves (Bang-Bang)
        Proportional Control Valves - Vickers
        Relief Valves
        Crossover Relief Valves
    5.2 Cylinders - Theory of Operation
    5.3 Cylinder Checking Procedures
        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
        Cylinders w/Single Counterbalance Valves - Main Lift Cylinder, Tower Telescope Cylinder
        Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Level Cylinder
    5.4 Cylinder Removal and Installation
        Tower Telescope Cylinder Removal
        Tower Telescope Cylinder Installation
        Tower Lift Cylinder Removal
        Tower Lift Cylinder Installation
        Main Telescope Cylinder Removal
        Main Telescope Cylinder Installation
        Main Lift Cylinder Removal
        Main Lift Cylinder Installation
        Lower Master Level Cylinder Removal
        Lower Master Level Cylinder Installation
        Upper Master Level Cylinder Removal
        Upper Master Level Cylinder Installation
    5.5 Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    5.6 Pressure Setting Procedures
        Low Drive System
        5 Stack Directional Control Valve (Internal Relief Adjustment)
        5 Stack Directional Control Valve (External Relief Adjustment Screws)
        Two Stack Directional Control Valve
        Three Stack Directional Control Valve
        Four Stack Directional Control Valve
    5.7 Hydraulic Gear Pump
        Disassembly
        Assembly
        Wear Guide for Replacement
        Recommended Start-up Procedure for New or Rebuilt Pump
        Recommended Test Procedure
        
Section 6. Schematics
    6.1 General
    6.2 Troubleshooting
    6.3 Hydraulic Circuit Checks
    
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