The JLG 40F Boom Lift Dilemma

[willie59]

Simply click on my username at one of my posts. That will give you a link to my email.

 

[od1]

I just received your reply. I already sent them to you at work. I hope that's OK. It takes 12 minutes per page on dial-up. My server redirects my mail through another server. Sometimes this can make trouble on the other end. If you do not see the 4 emails check your deleted file or your spam file. Some anti-virus programs trash my emails.
The joystick diagram came from a dealer that I called last year. I don't remember his name. The other 3 came from Dewayne. He was a big help. He first faxed them to me. They were imposible to read. Then he emailed them to me in an unknown format. I printed them out and then scanned them as a JPEG and uploaded them to this site.

 

[willie59]

Yeah, that's cool. Having some clean schematics of a, what, 30 year old machine! I'll check my mail at work tomorrow.

 

[od1]

I'm glad the pictures made it. The 3 wiring pictures were from , your contact. They gave me great advice as well. I'll call them first if I need parts. Thanks for the contact.
If you can figure out what all of the words are on those diagrams I can then make type them out in Excel or Publisher and replace all of the corrupted stuff. Then I'll rescan it and save it in a format that everyone could use, and repost it here and maybe on another forum. It would be a great help to all. The color chart is also imposable to make out. I could make a number chart to go with it for those who have cable that is numbered (like I do). Let me know what you think.
Dewayne over at Best Line Equipment said it's hard to find parts for the bertea pump, and that if it F's up I'll probably have to change the whole pump. Bummer.
Big $$

 

[willie59]

LoL...Dewaye is probably right, the parts for the Bertea 40F are getting rare. These are old machines. I can't recall for sure, but I don't think the F is the first series of manlifts that John L. Grove produced, but I think I'm safe in saying the F is one of the early models of the JLG company. It's a challenge, but, maybe with a little effort, we can keep one more F alive...yours.

 

[OFF]

Hi, I just stumbled across this site, saw this thread, and registered.

JLG 40F and 60F were my specialty "back in the day". I kept all the factory diagrams & info.......and a lot of spare parts.....even though the compny I work got rid of the last "F" probably 15 years ago.
I can help.

Oh and ah.......:canada:

 

[willie59]

Welcome to the forum OFF. :usa

 

[od1]

Man that would be great.
Everything is on hold here until I can figure out the wiring diagram. I posted them, but all of the writing is impossible to read. I need to know the color chart as well. If you recognize anything written on the let me know. I’ll retype it all in Excel and redo the diagrams then repost them. That way when someone enlarges them they will still be able to read them.
Let me know what you think.
OD1

 

[willie59]

Man that would be great.
Everything is on hold here until I can figure out the wiring diagram. I posted them, but all of the writing is impossible to read. I need to know the color chart as well. If you recognize anything written on the let me know. I’ll retype it all in Excel and redo the diagrams then repost them. That way when someone enlarges them they will still be able to read them.
Let me know what you think.
OD1

Yes sir od1, wouldn't that be sweet if OFF had some clean drawings. I can see the lower control box fine, but the terminal connections for the 16/24 cable going from platform to lower master panel is unreadable. I know the first four terminals are black, white, red, and green, but I know that because that's the way JLG's have been for years. If we can get some clean drawings, maybe we can make some progress. JLG drawings can be tricky to read, if you have any questions be sure and ask, we'll walk you through it.

 

[od1]

Thanks Atcoequip
Everything is at a full stop for now. I don't want to start tearing it apart until this is worked out. I can't trust the wiring that is there do to the creative patching that was done over the years.
I wish JLG would step in here. They don't return phone calls. I've left voice messages, but they don't return my calls.
Maybe someone out there has some clout with them?

 

[OFF]

Morning guys

Yeah, I've got all the schematics on 17 x 22 paper. I could fax what you need, but it would have to be in 4 sections I guess.
We're talking a 40F with racine proportionals, racine bang-bangs, and PQ controllers, right?

 

[OFF]

I've got a section of JLG 16/30 cable too

 

[OFF]

Oops, the pictures in the thread didn't open for me till now. I see you've got Bertea valves. I don't have a specific schematic for Bertea.

I do have clear ground control & main control box diagrams, the wire colour codes and numbering should be the same.

On your hydraulic oil question, in the dark ages we used HVI22 hydraulic oil cut with 50% kerosene in the winter time on these machines. That was the only way they would operate at below -30. Even then they had to be run on ground control for an hour to warm up the oil enough for the valves to work.
Later on, we discovered Amsoil synthetic ATF and used it with great succses. These days they are making HVI15 hyd oil which is a lot better than 22 was. We use a lot of synthetic 0W30 in hydraulics now. Start & go at -40, no problems.

According to the factory "bill of material" sheets for the 40F Racine, they used
15ft of 16/3
6ft of 16/12
64ft of 16/24
64ft of 12/4
all of it SDN ITT type cable.

Hope that helps.

If you've got PQ controllers, I have 3 new cards and lots of assorted used parts for them.

 

[willie59]

Morning guys

Yeah, I've got all the schematics on 17 x 22 paper. I could fax what you need, but it would have to be in 4 sections I guess.
We're talking a 40F with racine proportionals, racine bang-bangs, and PQ controllers, right?

No, don't fax them. The resolution of fax machines make schematics look like the one's we have. It's better if you scan them and save them on your computer, then you can save it as a PDF file, and e-mail them. Makes much better schematics.

 

[OFF]

No, don't fax them. The resolution of fax machines make schematics look like the one's we have. It's better if you scan them and save them on your computer, then you can save it as a PDF file, and e-mail them. Makes much better schematics.

I'll give that a try in the morning :cool2

I'm with you, I really miss those old machines. Loved working on them.
I'll take 40F over a Z60/80 anyday.

 

[willie59]

I'll give that a try in the morning :cool2

I'm with you, I really miss those old machines. Loved working on them.
I'll take 40F over a Z60/80 anyday.

LoL OFF, the 40F with the Bertea valves were a quirky little cuss. Aside from that, they were built like an anvil. It's been years ago, but I can remember a Bertea acting goofy, like trying to drive when your not operating the joystick. It seems I remember you disassemble the pilot components of the valve, clean everything with a spray solvent, put it back together, and now it works perfect. Those valves were very sensitive to even the smallest grain of debris. Everything else on the machine was pretty simple and straightforward to work on. I've always liked the JLG machines myself. Been through the factory in McConnellsburg and went through their certification training. That factory is a cool operation. Right now I'm working on a 110HX in our shop. Now that's a cool machine. A 40,000 lb machine that will put you 110 feet in the air.

 

[od1]

Morning guys

Yeah, I've got all the schematics on 17 x 22 paper. I could fax what you need, but it would have to be in 4 sections I guess.
We're talking a 40F with racine proportionals, racine bang-bangs, and PQ controllers, right?

Wow that’s amazing news.
Is there anyway they could be copied at that size and mailed? I’ll be glad to pay for them, and something for your trouble as well. Faxes don’t seem to work well. Let me know what you think? The controls are the Bertea type (lower left in the diagram) .

 

[willie59]

Slow down there od1, OFF said he had schematics for the 40 with Racine valves. They are a little different. Although, I do agree with him, they both use the 16/24 cable and the terminal connections will probably be the same. I'm interested to look at them as well. I don't think it's necessary for him to mail them. If he has a good scanner, he can scan them and save them on his computer, then e-mail the copies. The e-mail copies are generally good if they came from a good scan. And if they are saved as a PDF, it's easy to rotate the copies for viewing as well as printing the copies.

 

[od1]

Oops, the pictures in the thread didn't open for me till now. I see you've got Bertea valves. I don't have a specific schematic for Bertea.

I do have clear ground control & main control box diagrams, the wire colour codes and numbering should be the same.

On your hydraulic oil question, in the dark ages we used HVI22 hydraulic oil cut with 50% kerosene in the winter time on these machines. That was the only way they would operate at below -30. Even then they had to be run on ground control for an hour to warm up the oil enough for the valves to work.
Later on, we discovered Amsoil synthetic ATF and used it with great succses. These days they are making HVI15 hyd oil which is a lot better than 22 was. We use a lot of synthetic 0W30 in hydraulics now. Start & go at -40, no problems.

According to the factory "bill of material" sheets for the 40F Racine, they used
15ft of 16/3
6ft of 16/12
64ft of 16/24
64ft of 12/4
all of it SDN ITT type cable.

Hope that helps.

If you've got PQ controllers, I have 3 new cards and lots of assorted used parts for them.

Man that was perfect except I was told the cable run could be either 65 feet or 80 feet depending what valves were on there. I ordered 80 feet to be safe. The oil tips were really needed. It takes 45 minutes for the controls on the Bertea side to function when the temp. drops below -10. At -20 it’s over an hour.

 

[od1]

I heard that the only difference was the cable lenth.
The Racine used a shorter lenth for the 16 awg X 24.