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My Toughest Hydraulic Job Ever. DIY Advanced Hydraulics. JLG 80 HX Boom Lift
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- Опубліковано 18 сер 2024
- This hydraulic compartment has always loomed over me, like a mysterious monster that could rear its ugly head at any moment. In this video, I finally work through the system and figure out how to troubleshoot, test, and repair complicated hydraulics!
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00:00 Intro and New Test Kit
0:53 Telescope cylinder details
3:37 Attempt at testing pressure
6:57 BougeRV integration
9:19 Testing pressure
13:33 Adjusting pressure, first try.
15:04 Figuring out the whole system.
20:31 Adjusting valve block relief valve, 1st try.
27:47 Adjusting pressure, second try.
30:34 Swap relief valves
36:26 Adjust pressure, third try.
39:10 Adjust pressure, FOURTH try!
41:12 Success, sort of.
42:29 The final fix.
53:21 Outro
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Have an awesome weekend everybody!
I might have just thrown some aluminum foil in instead of shim to test my theory and then maybe make a custom shim later. But then again I don't need sweet sweet lathe footage for my yt channel. Great video i learned a lot.
enjoy your karma
Just keep the ads on a 10 sec interval so they're easier to skip! No offense fc do what you gotta do to keep bringing us content
@@justinthomas2458 I don’t know how ppl tolerate the ads. Get YT Premium. It’s the best $12/mo you’ll ever spend. Give up Hulu or something if you need to but YT w/o ads is a whole different experience
Glad to see another Guinness man there.
I've worked with hydraulics a lot, Construction machinery, recycling and 24 years as a Mechanic in the British Army working on Tanks & "shimming" is acceptable AS LONG as the pressure achieved is within the specified parameters.
You achieved this by use the pressure gauges and good old fashioned engineering maths.
Kudos and respect to you.
Yep, there is nothing wrong with "shimming" in this specific case.
it put the system back to the correct pressure. Springs are hard to come by and so this is a good work around. They shim engine valve springs all the time to bring them into tolerance and that is all that he is doing.
@@cameronnerdin4910 The point Jim was making that some people shim BUT don't check what the pressure is , this DANGEROUS
How the repair was done here is a text book example of "HOW TO"
I used to work with this type of machines about 10 years ago. A very common issue we had with both JLG and Genie were valves that got stuck either by a broken o-ring that got stuck in the valve or Loctite getting warm and melt and re-harden in the valve.
@@andreasdahlgren7714 i never thought about loctite getting in to a valve. Good to know.
As a European, thank you for putting the measures and weights in the metric system, it makes it easier to understand the explanations. I think that now all you have to do is do all the work with this boom lift. Hello from Belgium
Yeah, I’m never gonna tell him to ‘use metric’ that not fair, but it’s definitely appreciated when he gives both 😊
Adding metric for no reason is just annoyance
Nobody can prove how many kilometers away the moon is. Why? The only people who have ever been there measure in miles.
@@mwilliamshs For no reason? There is an obvious reason. For people like me (that don't measure things in body parts like thumbs and toes and what have you) to get a perspective. I really appreciate his effort to include it and it makes viewing his videos even more of a pleasure
@@mwilliamshs And the only people that did. Have done it using the metric system.
The main computer on the apollo spacecraft calculated with the metric system because it requires less correction factors. Conversions to the imperial system were only done, for the convenience of the pilots. (gauges and such)
Metric is the system that all units have a relationship to one and other. To say that it is an annoyance pointless. I just googled "distance to the moon, the answer was 384,400" nasa use the metric system
I am still amazed at the things that you are willing to tackle. Reminds me of me when I was a lot younger. Never afraid to take almost anything apart. Keep it up!
You are the perfect UA-camr. Your videos are well made, your process is well thought out, and you have the humility to admit when you're out of your depth. I feel like you have the mental processes of an engineer. I'd be interested to know what your background is. I never miss one of your videos, even though in most cases they aren't applicable to anything I am doing or will ever do. I just enjoy watching you apply your considerable problem-solving skills to whatever life throws your way.
I think he was a mechanical engineer in an earlier life, perhaps a professor. His step-by-step explanations make things easy to follow.
I've been watching your videos for a few weeks or months and all I can say is: you have my respect! When you did the service on the cylinder I thought to myself: Oh man, this is the kind of job someone should not do alone. At the same time I thought, well this the type of job I would do just to see if I could do it without any help. So, congratulations, you got another subscriber from the other side of the pond! Also thanks a lot for taking the time to convert the math to the metric system.
You've basically made a video archive on how to get these lifts working perfectly. I imagine all the things you've showed would translate over to other models and maybe even other brands of lift, not to mention hydraulics in general, Pretty awesome! Also, you're the reason I never get anything done for an hour on saturday or sunday mornings lol. I'm always watching your videos. It's easier to watch someone work than to go work myself haha.
I’m envious of you having a hydraulic shop that doesn’t screw you over. Just bought 4 hoses here in LA and it was 720$, and that’s after I beat them up on price! I think it’s time to buy a crimp machine.
Well, your first problem is that you live in California
@@hannable3871 I agree. A lot is messed up here, but you can’t beat the weather and it is where my career is. We will probably leave once I retire, but until then I have to keep paying the California tax!
Makers Acres
what kind of hoses? length? thickness? the amount you paid and how reasonable it is depends on what you actually got which was left out of your comment.
@@hannable3871
if companies raise prices that will cause all other companies to raise prices (affects up and down the supply chain line). it's not a state issue, it's a business being greedy issue. everyone is racing towards the most profit but they do not seem to understand the impact those actions have on a grand scale.
@@hannable3871 Thank goodness, a political comment. I was starting to worry...
As an engineer, albeit of the computer science variant, I can tell you that with computers there are engineer friendly versions and the cost optimized versions. I would absolutely love the old IBM laptops... they had an entire chart of screwsizes at the bottom and every screwhole had both it's purpose (i.e. disk, memory, etc.) and screwsize labelled next to it.
Some people just ascribe to the Klingon school of technical design, "Comments are for the weak, code is supposed to be difficult to understand".
@@Mishn0 to be fair to those who are doing the coding. Your employer doesn't care about you at all. So obfuscating your code is a good way to make it hard for them to find someone cheaper to replace you with.
Wouldn't be an issue if companies stopped getting rid of the good (but "expensive") software devs.
@@harmonic5107 That only really works if the employer is also technically adept. Once the entrepreneur has sailed off into the tropics on his new yacht after selling his brain-child to an investor, they think everybody is replaceable. Been there too long so your salary has risen too high? Fired, replaced with a kid right out of college who has a lie packed resume. Let's see him unravel obfuscated code!
@@Mishn0I Agree with you both. I worked for IBM for 10 years as a top seller then get Leukemia proposing to my fiancé in Thailand. IBM got rid of me as soon as they had the chance. Even had the balls to call me and tell me oh btw we fired you as of a month ago. You need to find new health care too bud. Good luck with your Leukemia. Shittiest company ever. U would have also thought they had awesome healthcare having over half a million employees but nope. Cheers guys!
@@Mishn0 In my experience, that always comes back to bite you in the ass, just like not labeling hardware on equipment does. You _think_ you remember what does what, but in the end you always end up rereading your code or retracing lines in your machines to make sure, or just to figure it out again. You can never comment or label too much, especially if you're sure you'll be the next guy working on it.
Very impressive determination of root cause of the problem, verifying instruments, and developing and implementing corrective action. Nice to watch.
I reckon they adjusted that valve down to stop the engine stalling out. When you got it the engine was down on power. Great job.
Very good point. I had forgotten about that issue with the down-power engine and its occasional difficulties.
I thought I was kind of a tech savvy guy. This is an amazing piece of hydraulic troubleshooting. I project managed aerospace components. I knew my limitations for sure and highly respected and left alone folks who knew there $hit. In particular folks who could talk and communicate in layman terms.
Man do I admire the tenacity, determination and communication.
Jon, I love your sense of humor. I always enjoy every video you make. Keep doing what you are doing! You deserve many more subscribers!
yep
I had the pleasure of troubleshooting the hydraulics on the CNC-Lathe I work (CTX 2000 Gamma). Took me a day to identify the problem, another to wait for the replacement parts, and then two more to take out all the guts and put them back in... It turns out that due to a lack of preventive maintenance, two sets of valves had busted seals (those damn cute seals!)...
Learned a lot, hated it at times, but was happy in the end, that I could fix it on my own, plus my boss owes me a cast of beer now bc he got to avoid paying for the technician from DMG to come in :D
Also took a few pages from your playbook; your videos helped me better understand hydraulics!
/cheers, and I'm gonna enjoy the video now!
I like how you are honest about your mistakes. I enjoy your videos
I guess fully extended those two telescoping components of the boom have a lot of leverage on the opposing wear pads, so that gives a lot of pressure and thus friction on the pads. At 2900 PSI and 2.5 sq in, you're using over 7000 lbs of force to retract that boom. Think about the amount of wear that is causing. I'd probably be inclined to avoid horizontal retraction from full extension unless really necessary.
Man, this is possibly the last installment of the boom lift. He totally disassembled this machine in the boom area for us. The wear pads are the least of it. If you watched all the episodes of this wretched machine you'd understand the context (but yes it's a big time investment). Considering the starting issues, the slow hydraulic travel motors, the getting stuck at heights the list is endless.
This horizontal extension is the *very last piece* since it was the least importance. Now the machine is done hence the sitting on the deck fishing at the end.
I'd consider greasing the pads, tbh. Machine might get uglier from grease streaks but it will run smoother. Maybe use a dry lube like a graphite product?
yeah but shouldn't you make the same argument about extension? it's twice the force of retraction and hence never got stuck, the lift was engineered to cope with that, otherwise they would have locked out those movements in the first place
@@AL_O0 The extend could also have 300lbs of gorilla weight in it too when extending vertically, coming down is a different story :-)
Completely agree, the more vertical the main boom is, the easier it retracts
Makes me happy every time I hear that engine start up the first time every time.
Jon, it sure must have felt good to figure out the hydraulic system and the functions of the valves so you could finally achieve the correct pressures. Now you boom operates nicely. Good for you. Blessings to you.
Man, i have no idea why, but I just love learning about your lift and how it works, and how you troubleshoot it.
I was a prop tech on C-130's in my Air Force days. Glorified part swappers really.
Thanks for your videos.
16:00 but that means the customer can work on it without buying expensive service manuals or going to a shop… they can’t be having self sufficiency! Plus little tags cost money and when your penny pinching it’s an easy item to save in costs.
Lol 'Keep fixing it till its broken' A bit like trimmimg a bit off and its still too short. Great vide John. I love your determination to understand and repair / adjust your equipment. I guess the lack of labels keeps hydraulic engineers in a job. 😃😃
I can't be the only on sitting here watching, and smiling like a loon when it goes right for you, love this channel, got to be one of the best I watch on here,👏 well done mate.
I’m a mechanical engineer and it’s awesome watching you learn and explain things I went to school to learn!
coworker was in a JLG manlift once about 20 years back, I'm assuming one of the hydraulic solenoids stuck as he was driving it in an energized substation (we are mechanics and linemen) control just got stuck and kept on going right out of our work area and into an energized quarter million Volt line. after wrestling with everything and no response from the lift, he ducked in the basket and slapped the E-stop only a few feet away from being turned into burned toast. he refused to ever get inside anything made by JLG ever again.
As an engine driver these troubleshooting videos are just a bliss.
When I worked at JCB, working on hydraulics was something I fell in love with.
It still gives me great chances today doing maintenance on US Army vehicles over here in Belgium.
Your explanation of hydraulics is astounding. You make it so understandable. I have learned so much from these recent videos.
Excellent job! I deal with this type of problem solving in my work every day….I absolutely LOVE IT! Thanks for including all your trials and failures along with the success 👍
Glad you mentioned Jesse Muller. You and he are two of my favs on UA-cam!
a shim is often used to raise pressure by pre-tensioning the spring, Just be careful of spring bind. Ive blown a few pumps/hoses etc. over the years because the pump could not release pressure, it happens. Paul Munroe Hydraulics service tech retired.
I did 41 yrs tech trbl shooting in the power realm and, boy, this sure brought back many similar head-scratching situations. Thanks for the smiles.
Fantastic content. Thank you.
I am a former aircraft engineer apprentice and fitter. This content is ‘right up my alley’.
Although, at around 36 minute mark I would have been in tears with frustration.
I've really enjoyed watching you work on this lift. great series.
I would love to have a lift like that on my farm, but after seeing how much of a full time job the maintenance is, I’ll probably just rent one! Cool video though!
@35:59 "I mean sometimes you just need to trade positions" 🤣🤣🤣
Love your channel. By the time you finish working on this lift you’ll be ready to open a lift repair business.
Good job, Jon! I admire your patience and perseverance for continuing right through to the end result.
Your troubleshooting is admiring. Knowledge and practice in one.
Lousy cameraman can always improve 😉
Enjoyed your troubleshooting on the JLG80. I Volunteer with the California State Railroad Museum shop. We have a JLG70. The biggest problem we've had was after the head gasket blew and figuring out that it was out of 87 Ford Ranger. Now it starts and runs perfectly. But watching your rebuild of the hydraulic cylinder and adjusting the pressures on the hydraulics was awesome.
I was foreman over a hydraulic planner mill in an oil field machine shop. That mill got to where it would surge about 10 inches, only when it was cutting, very dangerious. Maintenance found a roach the size of your thumb, stuck in a hydraulic line. :O)
I've worked with many industrial mechanics, some of whom couldn't troubleshoot a super soaker. Jon is indeed a hydraulics mechanic.
Hey I‘ve worked as an Aircraft Mechanic in Germany and even we do „shim“ the Hydraulics as a temporary Fix as long as its within limits and regulations.
So it should be More than Safe for your Lift.
You sir, are a bad ass. I went through vocational school with a young fellow that said he is a relative of yours. His initials are JT. His father used to be a piano tuner. They used to live in South Carolina but now live in Navarre Florida. His mother is an executive in the medical industry.
My father-in-law is a guy like you. He can fix anything. I'm a fan of anybody like you or him. Great channel , I'm so impressed with your talents. What is your educational background. Are you a trained engineer?
You probably already noticed, but at 53 mins or so, on retraction, there were two spots on the chain where the chains lifted up - more lube required? Great video, as ever, always look forward to the next one. Thank you.
Thats just the cable carrier, you could lube it but that will also catch dirt and lead to excessive wear on the cables/hydraulic hoses inside de cable carrier
if you wonder if there was someone screaming at the screen for like mostly the whole video to tell you you were working the wrong screw... you are correct. there was someone. and that someone was me. and that someone also learned this the hard way. i dont remember if i mentioned it in a early video but i suspected a pressure relief valve issue when i first saw this issue.
I can't tell you enough how fun that was to watch. I knew you'd get it fixed eventually! :)
I would say getting abrasive in the system is the second worst thing to do.. setting the whole thing on fire is still number one! 🤣😉
Ok, I have to agree!
When you checked the out pressure and it came up at 2800 i immediately said oh he should just swap them, and you did, that was freaking genius. This whole video was an amazing example of in field genius.
I think that programmes like your have done wonders in the de-mistification of engineering as well as lots of other subjects as well. it too many cases the old salts would not allow you to gain this kind of knowledge for fear of them becoming less important to the company. I found lots of instances where RTFM or test and prove have all worked well for me good stuff keep it coming
This boom lift project, wow did you have to dig deep to finish - as far as you are. But anyone with that energy deserves a cool Guinness as a treat. Well done, mate.
Job well done. You ought to be a teacher.
Your persistence and patience is admirable.
You apply logic correctly.
I really enjoyed this video John ! You did a great job figuring this all out , I admire you for you perseverance !
Jon, love your UA-cam vides, keep up the good work.
Manufactures don’t label for primarily because they want you to call “their factory trained people”. They need their field service people employed to do their warranty work. So they need keep everyone they’ll need - employed, they need to keep them employed doing as much as possible (warranty work is not enough)… hence, this is the biggest reason they NON’T label their parts. But, their shop service manuals will guide them to the parts layout to fix all problems. Another reason they don’t want to even post an equipment location or schematic sticker(s) where others can do this cross referencing information (these stickers cost money as well) and for DIY people to fix. Too, if they should label and label wrong, this could lead to liability problems.
I’m with you about Jesse Muller’s channel. Good stuff.
I really enjoy your methodology and thought process as you work through problems. I feel like this is being lost with the new generation.
Your worried about hydraulic mechanic yelling "Don't do it!" Meanwhile I've been muttering to myself half the video "Just shim the d*mn thing" 😂. Keep up the good videos man! And yeah farmers are kinda known for questionable repairs but a day without a machine working can be a big impact on their income and they can always fix it right tomorrow.....but if that bailing wire has held this long....
I'm so glad your doing this, your diagnostic skills are amazing. Learning alot. Thanks.
I once heard the John L, Grove, inventor of the JLG, had the unit designed after his sons rigging accident that took his life. If this is true, imagine how many accidents were avoided by it's invention? I have worked hundreds of hours in these baskets welding pipe and they are a life saver. 120 footers are a bit twitchy in the wind though, but better than climbing and hanging on cold steel. Thank you Mr. Grove, and my family thanks you also.
Was working on a much much much smaller hydraulic issue myself yesterday. The third function kit I added to my Kubota recently was dumping fluid on the ground. Took it all apart, found a vitron o-ring that was chowdered up (at the factory?!), replaced it and reassembled, and it seems all better.
Great video, learned several useful things. ...including how to trim down a washer, which I will use shortly to fix a PTO shaft.
As a long-time maintenance mechanic, it was painfully obvious what was going on before you pulled the relief valves. But you did fine. I've seen actual maintenance mechanics struggle much further before realizing that one.
I have zero crafting experience but I find your videos really nice to follow. I like your explanations.
It amazed me that the hydraulic world has practically zero standard. It is super maddening. I have the feeling a lot more could be done if they would simply introduce more standards.
Glad to see you using sealant instead of Teflon! Loctite 545 is my go-to for all hydraulics. A buddy of mine found a tiny piece of Teflon in his $10k hydraulic pump. AFTER the stealership sold him a new pump! I quit using Teflon on anything except my household plumbing quite a few years ago. I have never had a Loctite 545 sealed fitting leak ever.
It’s an open loop hydraulic system. Hydrostatic systems would be an example of closed loop hydraulic systems. Love your videos. Very educational and entertaining.
There are no roadblocks in your world, just dare and double-dares. The playlists on this channel play like seasons. Re-watching reveals something I missed. Really appreciate the sheer time you put into each video. 👍
You are the only channel that an hour long video isn't nearly long enough
You did a good job. 40 years USAF Hydraulics and 10 years Industrial. Point, two types of seals, static and dynamic. The O-ring you replaced needed a static i.e. a gasket not to be used on moving parts. They have a stiffer rubber and made to fill imperfection while the dynamic are made to conform to changing surface areas. I will say I have used dynamic seals for a gasket but not at the pressure of 3000 psi. Still as long as it doesn't leak . Also lifts like you have use pilot operated check valves. You need pressure on the other side of the cylinder to open the check valve to return. This locks the cylinder unless you have the pressure to operate it safely. As for shimming, I've done it as a temporary measure but the amount you will use it, I believe I'd leave the shim in. I wouldn't have minded working with you back when I turned wrenches. A lot of the people I worked with removed and replaced until the problem was solved. Trouble shooting your way is the Right way . Thanks for a good time.
You're the only one I don't fast fwd through your sponsor clips. You make them interesting instead of a commercial. Thanks for that. I love Jesse Muller's channel. Good stuff. 37:20 😂🤣 Great video about hydraulics. Nice ending. You really crack me up smart guy. Love your channel. 😆😂👍
Craftsman screwdrivers you can slide a closed in wrench over handle. Great for those tight jamb nuts adjustments.
Within the first minute I saw a Tim Allen reference to a new tool. I’m 40 minutes into the video, and you have figured out the telescopic pressure.
Even though, I don’t own a lift, or work on hydraulics. I genuinely watched out of curiosity. Lol, I am bow a new subscriber
Just a tip when you have cooler next to like that after taking a drink set the can back in cooler.
Thanks for making such great content I am a retired Fitter and Turner from Australia and I am constantly amazed at the jobs you tackle and your cool nature when things don't go as expected. Take care and thanks again for sharing with us.😊
Your experience of "just a simple valve adjustment" is about the same as every DIY'er. Wrong tools, distance away from tool box... the usual. Rarely anything is easy, or at least it seems that way. Thanks for the video. I look forward to your technical descriptions of how you figure the inner workings out. A vital component to be a DIY'er.
Really impressive. Your determination to solve problems and getting them resolved is really great.
Thanks!
I’m just a tractor delivery driver out of Nashville and I understood everything
Thank you for the great explanation
I'm no hydraulic engineer just merely a youtube viewer, but as a youtube viewer i gotta say - you are doing a good job, sir!
Worked on these lifts a bunch . When you're scoped out horizontally like this there is a ton of friction to overcome coming back in . I use dry graphite spray on the boom sections where the wear pads rub and it helps make it move easier and smoother.
H Jon. Beautiful property. Beautiful mind. To quote my late Dad, "If a job's worth doing it's worth doing well". Well done and best wishes.
Only thing I'd add is: When you're pulling cartridges from a valve bank, go Key On Engine Off and cycle the functions to remove any pressure from the hoses. It will save a little on leaks depending on where you're opening the system.
You might want to work on your fishing reel, it sounds like it might need to either be used more or maybe cleaned and greased. 😁
Glad to see that you were successful in whipping the hydraulic back into shape.
As soon as you adjusted the valve and it didn’t change, I knew you were turning the wrong one. Adding a shim is fine as long as you don’t go over the pressure. I have the same pressure gage set, I work a few of those lifts only a little smaller. Persistence without getting pissed off, is the key for difficult situations.
By marking parts & not letting frustration kreap in. You gradually identified each process. Hyraulics can produce amazing processes that save time. Diagnostics & documentation eventually break down a process. Good you can revisit issue until solved. Hydraulics & pneumatics can save time & improve working conditions. Had huge companies & utilities to work for. Have a safe time .
I was sitting here laughing my ass off from the second all your adjustments had no effect.
Glad to see you've gotten this problem fixed and are ready to go into more advanced problems like this!
Thank you. You may not be an expert hydraulic mechanic but I am not an expert repairman, yet your channel haa given me the confidence to undertake many home and machine repairs.
Thank you for calling the Bouge a power station. You truly are a UA-cam legend!
No teacher is better than hands on do it yourself, figure it out for yourself. You now can build on that knowledge and apply it to other systems. Well done.
Hydraulic pump enginerd here. Well done working through the fluid power system. The spring probably just took a set after all these years and numerous pressure cycles. Shimming should be ok so long as the spring doesn’t reach solid height. I’ve also run into those farmers burying reliefs for more chooch factor and blame us for making junk.
Thanks Jon for hydraulics 101. Very informative and much appreciated 😊
i've got about 10 years working on hydraulic equipment. shimming a weak relief spring is totally fine. still worth getting the right one, but you're not hurting anything by taking up the "slop" in the spring that lost it's strength.
Thank you for being smart and not having your face infront of the hydraulic bank when you were testing.
Some of the best content on UA-cam in my opinion. Thank you for sharing
I think when the bucket is under load it would need that extra 200 psi.
Wow that was quite a stumper with the valves reversed from the obvious orientation. Good thinking outside the box John. Great video thumbs up.
Good explanations John. Going to be alot of people in the future thanking you for recording all you have done on your machine. Thanks eh
Guess what! Guinness should drop some money at Jon, also because he's drinking one of the finest stouts in the world.
Great tutorial on hydraulic valves and pressure adjusting. And the sarcasm is the cherry on top. Cheers!
When you find that spring you'll find every 10 mm socket you ever lost 😂
This boom lift repair is one of my favorite series on UA-cam to watch these days! 🎉
To show you how involved I get with your videos when you were looking for the missing piece that dropped and you videoed with your phone I shouted out at the screen ‘There it is John’ 🙄😉😊 I love watching you work .. I get so involved, like I was actually with you .. brilliant stuff 😊😊😊👍
Really good presentation. Subd. You are probably right about spool valve. I studied this decades ago as part of a control theory/practical course. Brought back the memory. Clunky equipment layout as you (politely) said. Wish more manufacturers would pay attention to ease of maintenance!
Didn't catch anything? I beg to differ!!! You caught some rays with a beer and a nap and THAT is a success to me!!!