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

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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

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