Service and Maintenance Manual Model(s) 15BD 19BD P/N - 3121154 June 14, 2012 ANSI
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FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine. REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
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INTRODUCTION - OPERATION/SAFETY PRECAUTIONS INTRODUCTION - OPERATION/SAFETY PRECAUTIONS All procedures herein are based on the use of the machine under proper operating conditions, with no deviations from original design intent ... as per OSHA regulations. 5. Load limits specified by the manufacturer shall not be exceeded. 6. Instruction and warning placards must be legible. 7.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General Maintenance Safety This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.
EFFECTIVITY PAGE EFFECTIVITY CHANGES February 5, 2009 - Original Issue of Manual June 14, 2012 - Manual Revised 3121154 – JLG Lift – c
EFFECTIVITY PAGE NOTES: d – JLG Lift – 3121154
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Safety . .
TABLE OF CONTENTS Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.5 MACHINE BOLT DOWN SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.6 AC JUNCTION BOX COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2.7 HYDRAULIC LIFT PUMP - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. TITLE PAGE NO.
TABLE OF CONTENTS NOTES: iv – JLG Lift – 3121154
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES 1.3 PERFORMANCE DATA Hydraulic Oil Capacity Machine Specifications System Capacity – 5 qts. U.S. (4.7 ltr.) SPECIFICATION Reservoir Size – 148 cu. in. (2.56 qts. U.S.) (2.42 Liter) minimum usable 15BD Maximum Occupants: (Persons) 19BD 1 Maximum Work Load (Platform Capacity): 350 lb. (160 kg) 1.2 COMPONENT DATA Machine Stowed Height: Hydraulic Pump/Electric Motor Assembly Machine Stowed Width: 77.22 in. (1.96 m) 77.81 in.
SECTION 1 - SPECIFICATIONS 1.5 HYDRAULIC PRESSURE ADJUSTMENT 1.7 SERIAL NUMBER LOCATIONS (See Figure 1-1.) Set hydraulic pressure to 1700 PSI as a starting point. Adjust system pressure so that platform will raise to full height with maximum rated capacity in platform. Turning adjustment screw clockwise, increases system pressure, turning screw counterclockwise, decreases system pressure. Do not adjust system pressure higher than required to raise the load.
SECTION 1 - SPECIFICATIONS 2 1 Figure 1-2. Lubrication Locations (See Table below). Table 1-4. Lubrication Intervals for Various Components INTERVAL HOURS (b) ITEM COMPONENT NO/TYPE (a) LUBE POINTS HO-Check Hyd. Oil Level 1 HO-Change Hyd. Oil Chain Lube - Brush 2 Mast Chains or Spray Key to Lubricants: MPG - Multipurpose Grease (See Table 1-3) HO - Hydraulic Oil Hydraulic Oil (c) Fill To Line on Reservoir 5 Qt. (4.
SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITE TM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 27 8 1.25 36.60 22.
SECTION 2 - SERVICE PROCEDURES SECTION 2. SERVICE PROCEDURES 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
SECTION 2 - SERVICE PROCEDURES Table 2-1. Inspection and Maintenance TYPE FREQUENCY PRIMARY RESPONSIBILITY SERVICE QUALIFICATION REFERENCE Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - SERVICE PROCEDURES Table 2-2. BD Model - Preventive Maintenance & Inspection Schedule. INTERVAL (a) AREA ON MACHINE PRE-START (b) INSPECTION 3 MONTH PREV. MAINT. 5 Hm. Hrs. PRE-DELIVERY (c) OR FREQUENT (d) INSPECTION ANNUAL (e) INSPECTION 20 Hm. Hrs.
SECTION 2 - SERVICE PROCEDURES Table 2-2. BD Model - Preventive Maintenance & Inspection Schedule. INTERVAL (a) AREA ON MACHINE 3 MONTH PREV. MAINT. 5 Hm. Hrs. PRE-START (b) INSPECTION PRE-DELIVERY (c) OR FREQUENT (d) INSPECTION ANNUAL (e) INSPECTION 20 Hm. Hrs.
SECTION 2 - SERVICE PROCEDURES 2.3 SERVICING AND MAINTENANCE GUIDELINES Components Removal and Installation General The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter. WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.
SECTION 2 - SERVICE PROCEDURES Bolt Usage and Torque Application Mast Chain Inspection Procedure Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.
SECTION 2 - SERVICE PROCEDURES EXAMPLE OF MEASURING A (.50") PITCH CHAIN 24 pitches = 12 inches on a NEW chain Maximum allowable stretch across 24 pitches (12 inches) = 12.24 inches Table 2-3. Chain Stretch Tolerance Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated. Chain Size Pin to Pin Measurement Allowable Stretch .50" pitch 12" or 24 pitches .24 in./12 in. span .625 pitch 15" or 24 pitches .30 in./15 in.
SECTION 2 - SERVICE PROCEDURES 2.4 LUBRICATION INFORMATION Hydraulic Oil Hydraulic System The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply.
SECTION 2 - SERVICE PROCEDURES 2.5 MACHINE BOLT DOWN SPECIFICATION 33.000 in. (83.82 cm) 2 1 2 18.000 in. (46 cm) 1 3 4 1. Base Weldment 2. Factory drilled .750" (19mm) diameter holes in base weldment (4 places) (a) 3. Mounting Fasteners 4. Solid, firm and level floor surface. Notes: (a) Use .500" (13mm) diameter - grade 5 hardware (minimum) with large steel flatwashers. Torque fastener per rating on torque chart in Section-1 of this service manual. Figure 2-1.
SECTION 2 - SERVICE PROCEDURES 2.6 AC JUNCTION BOX COMPONENTS HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELECTRIC POWER TO THE JUNCTION BOX BEFORE ATTEMPTING TO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPONENTS. WHEN TESTING CIRCUITS WITH ELECTRICAL POWER ON, USE ONLY INSTRUMENTS WITH INSULATED TEST LEADS KEEPING YOUR HANDS OUTSIDE THE BOX. 1 2 3 10 9 4 5 6 7 8 11 1. AC Box with Lid 4. AC/DC -Transformer 7. Plug 10. Harness Capacitor 2. 12VDC Starter Relay 5. Interlock Relay 8.
SECTION 2 - SERVICE PROCEDURES 2.7 HYDRAULIC LIFT PUMP - SERVICING Remove hydraulic pump from machine. MONARCH BRAND PUMP - Brush Replacement Motor Assembly - Remove/Install - Reference Marks 4 Pump Motor - Removal/Installation - Reference Marks • For reference when reassembling, mark motor cover, housing and valve body position before disassembling. 2 1. Motor Top Cover 2. Cover/Housing Reference Mark 3. Motor Housing 4. Housing/Motor Valve Body Reference Mark 5.
SECTION 2 - SERVICE PROCEDURES Brush Carrier Assembly - Remove/Install 4 2 3 1 Brush Carrier Assembly - Remove/Install 1. Stator/Brush Carrier Screws (Pump Rear) 2. Stator/Brush Carrier Screws (Pump Front) (a) 3. Mark Brush Carrier Position on Motor Housing 4. Brush Carrier Assembly NOTE: (a) Removed previously with motor cover disassembly (shown for reference only). Brush Assembly - Remove/Install 2 1 3 4 5 3 Brush Assembly - Remove/Install 1. Brush Assembly (a) 2. Brush Carrier Socket 3.
SECTION 2 - SERVICE PROCEDURES TANK AND PUMP REMOVAL - (All Pumps) Tank Installation Pump Installation 4 4 3 2 3 2 2 1 1 2 Pump Installation 1. Pump Assembly 2. Pump Assembly Screws Tank Installation 1. Tank Assembly 2. Tank Screws (4) 3. Pump Shaft Seal 4. Pump End Head 3. O-Ring Seal 4. Use Screwdriver to pry tank away from pump head. Filter Screen Installation 2 1 Filter Screen Installation 1. Filter Screen 2. Pump Pick-Up Tube Pump O-Ring Installation 1.
SECTION 2 - SERVICE PROCEDURES Pressure Adjust Valve Installation Pressure Check Valve Installation 7 5 6 6 4 3 4 2 3 1 2 5 1 Pressure Adjust Valve Installation 1. Adjust Valve Cap 2. Adjustment Screw 3. Valve Spring Pressure Check Valve Installation 4. Valve Ball 5. Adjust Valve Port 6. Extend (Pressure) Port (Shown Plugged) 1. 2. 3. 4. Note: Adjust pressure per specification shown in Section-1 of this Service Manual. 2-14 Check Valve Assembly O-Ring Seal O-Ring Seal Backing Ring 5.
SECTION 2 - SERVICE PROCEDURES 2.8 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD 4. Loosen the bottom fasteners of the mast side support rails, then remove the top fasteners attaching the supports to mast support bracket which is attached midway up the back of the mast. Rotate the side support brackets down out of the way. HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE.
SECTION 2 - SERVICE PROCEDURES Cylinder Removal From Mast 1. At the base end, remove and cap the extend and return hydraulic lines. 5. Push mast sections-3, 4 and 5 back towards the base assembly allowing the top of mast section-2 to be completely exposed. 2. Remove the mini covers from the tops of the mast sections. 1 2 3.
SECTION 2 - SERVICE PROCEDURES 7. Remove the cylinder rod pin from the cylinder/chain anchor block. 2. At the bottom of mast section 2, slide the lift cylinder assembly out and place on a suitable work surface. 1 1 2 3 Cylinder Installation Cylinder Rod Pin Installation 1. Cylinder Rod Pin 2. Cylinder Rod 1. Lift Cylinder Assembly up and out of Cylinder Mount. 3. Cyl.
SECTION 2 - SERVICE PROCEDURES Cylinder Disassembly may be required to remove the head from the cylinder tube. 1. Before disassembling the cylinder, clean away all dirt and foreign substances from openings, particularly the head area. 5. Place the head/rod/piston assembly on a surface that will not damage the chrome. 6. Remove the piston locknut and separate the piston from the rod. NOTE: Always protect the chrome surface of the cylinder rod during assembly and disassembly.
SECTION 2 - SERVICE PROCEDURES Lift Cylinder Component Inspection Cylinder Assembly Cylinder Rod (See Figure 2-3.) 1. Rinse the inside of the tube with hydraulic fluid and allow to drain. A high-pressure rinse followed by a wipe with a lint-free rag is preferable. Clean all internal components of any foreign material. There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable.
SECTION 2 - SERVICE PROCEDURES Cylinder Installation To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this section, however perform the following additional steps during re-assembly. 1. Apply Loctite #222 (purple) and torque to 85 ft. lbs. the cylinder mount shoulder screws securing the lift cylinder mount halves together at the bottom of the mast. 2.
SECTION 2 - SERVICE PROCEDURES OPEN RAIL (REFERS TO OPEN RAIL FRONT OF MAST SECTION) TOP (REFERS TO TOP END OF MAST SECTION WHERE COVER AND SHEAVE WHEELS ARE ATTACHED) BOTTOM CLOSED RAIL (REFERS TO BOTTOM END OF MAST SECTION WHICH SETS IN MACHINE’S BASE FRAME) (REFERS TO CLOSED RAIL BACK OF MAST SECTION) Figure 2-4. Mast Section - Assembly Reference. NOTE: When sliding mast sections apart, be careful not to scratch or score the anodized surface in the slide pad channels. 10.
SECTION 2 - SERVICE PROCEDURES MAST SECTION-2 - REMOVAL 12. Slide mast section-2 out TOP of mast section-1 far enough to allow access to the chain assembly anchor block/sheave wheel assembly. 13. Remove countersunk-flathead screws securing chain anchor block/sheave wheel assembly attach bars on both side rails at TOP of mast section-2. 14.
SECTION 2 - SERVICE PROCEDURES DETAIL A SEE DETAIL A SEE DETAIL B DETAIL B SEE DETAIL A SEE DETAIL C DETAIL C DETAIL D SEE DETAIL D SEE DETAIL D CYLINDER INSTALLATION FOR S/N 0130005748 ONLY Figure 2-5. 15BD - Mast Assembly.
SECTION 2 - SERVICE PROCEDURES Figure 2-6.
SECTION 2 - SERVICE PROCEDURES 15BD - Mast Assembly MAST SECTION 2 - ASSEMBLY (See Figure 2-2.) NOTE: When sliding mast sections together, be careful not to scratch or score the anodized finish in the slide pad channels. MAST SECTION 1 - ASSEMBLY 1. Place mast section-1, rail (open) side up (See Figure 2-1.) on a clean, flat surface (preferably a table or work bench capable of supporting the weight of the entire mast assembly).
SECTION 2 - SERVICE PROCEDURES between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side. d. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel. Mast sections should be snug in channels but still be able to slide in channel by hand. LIFT CYLINDER INSTALLATION - EXCEPT FOR S/N- 0130005748 11.
SECTION 2 - SERVICE PROCEDURES thickness on each side to center the mount in the closed rail portion if necessary. NOTE: If hydraulic cylinder needs to be extended, the protective caps on the extend and return ports will need to be temporarily removed. Be careful not to nick or scour rod surface when extending, also catch any oil draining out of cylinder to avoid spillage onto work area. 18. Slide mast section-2 out of mast section-1 approximately one foot. 19.
SECTION 2 - SERVICE PROCEDURES CONTINUE MAST SECTION-2 ASSEMBLY HERE - ALL MACHINES e. Slide the whole anchor block/cylinder assembly with sheave pin, wheels and pin support bars into top of mast section-2. 21. Assemble one of the narrow chains sets (#444) to the small chain equalizer anchor plate using the pins, washers and cotter keys. Set aside. f.
SECTION 2 - SERVICE PROCEDURES MAST SECTION 3 - ASSEMBLY 3 NOTE: When sliding mast sections together, be careful not to scratch or score the anodized finish in the slide pad channels. 29. Carefully slide mast section-3 into section-2 until ends are even. 30. Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing inward towards section3. (Same as Figure 2-8.
SECTION 2 - SERVICE PROCEDURES pin keeper. Allow to hang out the top of mast section-3 for later assembly. e. Attach to top of mast section-3 using two (2) 3/ 8"-16UNC x 1/2" long socket head-countersunkflathead cap screws, each side. Coat threads with Loctite #171 and tighten. 41. Insert the threaded the ends of chain assembly (attached to top of mast section-1), into the opening between mast section-2 and mast section-3.
SECTION 2 - SERVICE PROCEDURES MAST SECTION 4 - ASSEMBLY g. When mast slide pads are shimmed properly, there should be no side to side movement of slide pad in rail channel. Mast sections should be very snug in channels but still be able to slide in channel by hand. 44. Locate the remaining mast section-4 (platform mounting - mast section). Lay mast section on flat stable surface. 45. Attach the remaining chain bottom anchor plate (one with threaded holes aligned at the outside of bracket).
SECTION 2 - SERVICE PROCEDURES 4 2 5 4 3 5 3 5 1 Mast Section 4 - Bottom End Components (Chain Anchor Bracket and Slide Pad Installation) 1. Chain Anchor Bracket 2. Anchor Bracket Bolts/Washers (a) 3. Slide Pad 4. Long Slide Pad 5. Slide Pad Bolts/Washers (a) Notes: (a) Apply Loctite #242 to threads.
SECTION 2 - SERVICE PROCEDURES Mast To Base Frame Installation 1. Using an overhead crane or suitable lifting device capable of supporting the weight of mast assembly, attach a sling strap around the mast assembly at the AC Junction Box/Ground Control Station support bracket. NOTE: Do not completely tighten the mast side support bracket bolts until mast is checked for vertical alignment (plumb). 5.
SECTION 2 - SERVICE PROCEDURES Mast Chains Adjustment - 15BD The intention of this procedure is to assure equal load distribution between the individual chains of a mast section chain set. Also to step each front mast section up approximately 1/4 in. (6.5mm) from the section behind it to allow clearance for the individual mast section covers. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.
SECTION 2 - SERVICE PROCEDURES MAST SIDE PROFILE MAST CHAIN ADJUSTERS STEP APPROXIMATELY 1/4 in. (6.5mm) SEQUENCE CABLE ADJUST NUT SECTION-1 FIXED TO BASE SECTION-2 EXTENDED BY CYLINDER SECTION-3 EXTENDED BY CHAIN SECTION-4 (PLATFORM HEADER SECTION) EXTENDED BY CHAIN CHAIN ANCHOR PLATE ADJUST NUT Note: When chain adjustment is complete, before tightening the jamnut against the adjust nut, apply Loctite #242 to the threads under the jamnut. JAMNUT THREADED CHAIN END Figure 2-9.
SECTION 2 - SERVICE PROCEDURES 2.10 19BD - MAST ASSEMBLY AND DISASSEMBLY PROCEDURE 5. Carefully slide short mast section-5 out BOTTOM of mast section-4 rails. Disassemble slide pads, shims and cable anchor plate from mast section-5, if necessary. (See Figure 2-10., Figure 2-11. and Figure 2-12.) MAST SECTION - 4 - REMOVAL 19BD - Mast Disassembly Procedure 6. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-4.
SECTION 2 - SERVICE PROCEDURES MAST SECTION - 3 - REMOVAL 11. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-3. Push threaded ends of chain through anchor plate. 12. At top of mast section-3, pull chains out and allow to hang loose. 13. Slide mast section-3 out TOP of mast section-2 far enough to allow access to the chain sheave wheel assembly. 14.
SECTION 2 - SERVICE PROCEDURES Apply Krytox Lubricant to the INSIDE front and rear slide pad wear surfaces on ALL mast sections before assembly. MAST SECTION-1 MAST SECTION-2 MAST SECTION-3 MAST SECTION-4 MAST SECTION-5 LIFT CYLINDER ORIGINAL DESIGN LIFT CYLINDER AND MOUNT NEW DESIGN LIFT CYLINDER AND MOUNT Figure 2-11. 19BD Mast Assembly Components.
SECTION 2 - SERVICE PROCEDURES Figure 2-12. 19BD Mast Chain Routing Diagram.
SECTION 2 - SERVICE PROCEDURES 19BD - Mast Assembly NOTE: Always use the an even amount of shim material behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the mast section. (See Figure 2-11. and Figure 2-12.) MAST SECTION - 1 - ASSEMBLY a. Start with a .036" thick shim and a .075" thick shim per side at each slide pad.
SECTION 2 - SERVICE PROCEDURES side clearance to prevent any strain on the sides of the mast when the bolts are tightened. 13. New Design Cylinder Mount: Install the cylinder mounting plates at the bottom of the mast section-1. Mount plates two each side, using the the (2) two long pass through bolts and nuts, apply Loctite #242 to the bolt threads before tightening nuts. 14. Original Design Cylinder: Clamp the cylinder in the mounting journal of the cylinder mount.
SECTION 2 - SERVICE PROCEDURES flathead cap screws, each side. Coat threads with Loctite #171 and tighten. NOTE: When sliding mast sections together, be careful not to scratch or score the anodized finish in the slide pad channels. 28. Carefully slide mast section-3 into section-2 until ends are even. Check to make sure chain assembly (wide chains) are seating properly in chain anchor block chain sheave wheels attached to mast section-2. 29.
SECTION 2 - SERVICE PROCEDURES 42. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes in outside rail on top of mast section-3 and into the slide pad inserts. Thread in enough to hold pad in place. b. Start with a total thickness of approximately .035" and .075" thick shim stock. c.
SECTION 2 - SERVICE PROCEDURES chains. Check that chains are seated in their sheave wheels at top of mast assembly. 10. Carefully set machine in an upright position on its base frame wheels. 54. Assemble the mini covers to the top of each mast section and the sequencing cables and hardware to the side of the mast assembly. 11. Locate the mast support bracket.
SECTION 2 - SERVICE PROCEDURES MAST SIDE PROFILE MAST CHAIN ADJUSTERS STEP APPROXIMATELY 1/4 in.
SECTION 2 - SERVICE PROCEDURES 7. Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2-9. 8. Repeat steps (1) through (7) for remaining mast sections. 2.11 SEQUENCING CABLE ADJUSTMENT (See Figure 2-9. or Figure 2-13.) 1. Retract mast completely, and check each sequencing cable on the outside of masts for excessive slack. Adjust only to remove slack from cable. 9.
SECTION 2 - SERVICE PROCEDURES 2.12 SEQUENCE CABLE REPLACEMENT KIT A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables. This kit consists of a replacement sequence cable with the threaded (top) end attached same as the top end of the factory cable. Also included is a clamp (drum/socket type) to secure the bottom end of the cable. Use the following procedure to install the replacement cable and clamp kit. Remove Old Cable 1.
SECTION 2 - SERVICE PROCEDURES 3. Use a suitable tool and cut the cable as shown in the illustration following. For 1/8 in. cable the recommended length is 5/8 in. past the end of the sleeve. 4. Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the cable. When done properly the outer strands will form a symmetrical basket.
SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL 3.3 HYDRAULIC CIRCUIT CHECKS This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 3.
SECTION 3 - TROUBLESHOOTING Min/Max Procedure Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down. Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.
SECTION 3 - TROUBLESHOOTING Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
SECTION 3 - TROUBLESHOOTING Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4.
SECTION 3 - TROUBLESHOOTING 3.5 ELECTRICAL SWITCH TESTING 1. Remove prox switch from its mount. 2. Reconnect harness if it was disconnected for step 1, and turn on machine. Basic Check 3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See vehicle or control system documentation on how to do this. The following check determines if the switch is functioning properly, not the circuit in which the switch is placed.
SECTION 3 - TROUBLESHOOTING Table 3-1. BD Model - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform does not rise. Red emergency stop button is engaged (PUSHED IN) on either ground control station or on platform. Disengage (TURN CLOCKWISE) red emergency button until it pops out. Control relay not functioning. Replace control relay. Motor start relay not functioning. Replace motor start relay. Unit wiring not properly grounded. Check all ground connections in the wiring.
SECTION 3 - TROUBLESHOOTING 2792491_A Figure 3-5. Hydraulic Schematic.
SECTION 3 - TROUBLESHOOTING Figure 3-6. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING VAC JUNCTION BOX 1001111740 A Figure 3-2. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 1001133268_B Figure 3-7. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 1001133268_B Figure 3-2. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 1001144701_A Figure 3-8. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING 1001144701_A Figure 3-2. Electrical Diagram.
SECTION 3 - TROUBLESHOOTING NOTES: 3-14 – JLG Lift – 3120752
CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm.
3121154 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.
