JLG 110Hx 100Hx+10 Service & Maintenance Manual (3120864) – PDF DOWNLOAD En

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JLG 110Hx 100Hx+10 Service & Maintenance Manual (3120864) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 110Hx 100Hx+10 Service & Maintenance Manual (3120864) – PDF DOWNLOAD

Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS......................  3
	A General.................................................................  3
	B Hydraulic System Safety.................................................  3
	C Maintenance.............................................................  3
Section 1. SPECIFICATIONS..................................................... 13
	1.1 Capacities............................................................ 13
	1.2 Component Data........................................................ 13
		Engine - Diesel....................................................... 13
		Drive System.......................................................... 13
		Steer System.......................................................... 13
		Swing System.......................................................... 13
		Hydraulic Pump........................................................ 13
		Auxiliary Power Pump.................................................. 13
		Hydraulic Filter - Tank............................................... 13
		Hydraulic Filter - Inline............................................. 13
	1.3 Performance Data...................................................... 13
		Travel Speed.......................................................... 13
		Gradeability.......................................................... 13
		Turning Radius........................................................ 14
		Boom Speed............................................................ 14
		Swing Speed........................................................... 14
		Boom Elevation........................................................ 14
		Machine Weight........................................................ 14
		Machine Stowed Height................................................. 14
		Machine Stowed Length................................................. 14
		Machine Width......................................................... 14
		Wheelbase............................................................. 14
		Maximum Tire Loads.................................................... 14
	1.4 Torque Requirements................................................... 14
	1.5 Lubrication........................................................... 15
		Deutz F4L912 Engine................................................... 15
		Lubrication Specifications............................................ 16
	1.6 Pressure Settings..................................................... 17
	1.7 Cylinder Specifications............................................... 17
	1.8 Boom Tape............................................................. 21
	1.9 Major Component Weights............................................... 21
	1.10 Serial Number Locations.............................................. 21
	1.11 Critical Stability Weights........................................... 21
	1.12 Boom Limit Switches.................................................. 22
Section 2. PROCEDURES......................................................... 25
	2.1 General............................................................... 25
	2.2 Servicing and Maintenance Guidelines.................................. 25
		General............................................................... 25
		Safety and Workmanship................................................ 25
		Cleanliness........................................................... 25
		Components Removal and Installation................................... 25
		Component Disassembly and Reassembly.................................. 25
		Pressure-Fit Parts.................................................... 25
		Bearings.............................................................. 26
		Gaskets............................................................... 26
		Bolt Usage and Torque Application..................................... 26
		Hydraulic Lines and Electrical Wiring................................. 26
		Hydraulic System...................................................... 26
		Lubrication........................................................... 26
		Battery............................................................... 26
		Lubrication and Servicing............................................. 26
	2.3 Lubrication Information............................................... 26
		Hydraulic System...................................................... 26
		Hydraulic Oil......................................................... 27
		Changing Hydraulic Oil................................................ 27
		Lubrication Specifications............................................ 27
	2.4 Cylinders - Theory of Operation....................................... 27
	2.5 VALVES - THEORY OF OPERATION.......................................... 27
		Solenoid Control Valves (Bang-Bang)................................... 27
		Manual Hydraulic Control Valves....................................... 28
		Proportional Control Valves - Vickers................................. 28
		Relief Valves......................................................... 28
		Crossover Relief Valves............................................... 28
	2.6 Boom Chains........................................................... 28
		Adjusting Procedures.................................................. 28
		Inspection Procedure.................................................. 32
		Auxiliary Boom Chains................................................. 34
	2.7 Wear Pads............................................................. 34
	2.8 Drift Test............................................................ 34
		Telescope Cylinder.................................................... 34
		Lift Cylinder......................................................... 35
	2.9 Cylinder Checking Procedures.......................................... 35
		Cylinder w/o Counterbalance Valves.................................... 35
		Cylinders w/Single Counterbalance Valves.............................. 36
		Cylinders w/Dual Counterbalance Valve................................. 37
	2.10 Cylinder Removal and Installation.................................... 37
		Telescope Cylinder Removal............................................ 37
		Telescope Cylinder Installation....................................... 42
		Lift Cylinder Removal................................................. 43
		Lift Cylinder Installation............................................ 43
		Master Level Cylinder Removal......................................... 43
		Master Level Cylinder Installation.................................... 44
	2.11 Cylinder Repair...................................................... 44
		Disassembly........................................................... 44
		Cleaning and Inspection............................................... 45
		Assembly.............................................................. 46
	2.12 Boom Maintenance..................................................... 47
		Removal............................................................... 47
		Disassembly........................................................... 47
		Inspection............................................................ 49
		Assembly.............................................................. 49
		Installation.......................................................... 53
	2.13 Tilt Alarm Switch Leveling........................................... 53
		Manual Adjustment..................................................... 53
		Voltmeter Adjustment.................................................. 54
	2.14 Limit Switch Adjustments............................................. 55
		Boom Limit Switch..................................................... 55
		Horizontal Cut-Out Switch............................................. 55
	2.15 Throttle Checks and Adjustments - Deutz F4l-912 Engine............... 55
	2.16 Throttle Checks and Precision Governor Adjustments - Ford Engine..... 57
		Checks................................................................ 57
		Choke Adjustments..................................................... 57
		Carburetor and Governor Adjustments................................... 57
	2.17 Pressure Setting Procedures.......................................... 60
		Sequence Pressure (Prior to 1990)..................................... 60
		Sequence Pressure (1990 to Present)................................... 60
		Pilot Pressure........................................................ 60
		Proportional Valve.................................................... 60
		Solenoid Valve........................................................ 61
		Extend-A-Reach Valve (If Equipped).................................... 61
	2.18 Swing Bearing........................................................ 65
		Turntable Bearing Mounting Bolt Condition Check....................... 65
		Bearing Wear Tolerance................................................ 65
		Bearing Replacement................................................... 67
		Swing Bearing Torque Values........................................... 68
	2.19 Drive Torque Hub..................................................... 69
		Disassembly........................................................... 69
		Cleaning and Inspection............................................... 69
		Assembly.............................................................. 71
	2.20 Swing Torque hub..................................................... 80
		Disassembly........................................................... 80
		Cleaning and Inspection............................................... 82
		Assembly.............................................................. 82
	2.21 Swing Brake - Ausco - Machines Built To 1992......................... 83
		Disassembly........................................................... 83
		Cleaning and Inspection............................................... 85
		Assembly.............................................................. 85
	2.22 Swing Brake - Mico - Machines Built To 1992.......................... 85
		Cleaning and Inspection............................................... 85
		Assembly.............................................................. 87
	2.23 Swing Brake - Machines Built 1992 To Present......................... 87
		Cleaning and Inspection............................................... 89
		Assembly.............................................................. 89
	2.24 Drive Brake - Ausco - Machines Built Prior To March 1992............. 89
		Disassembly........................................................... 89
		Inspection............................................................ 91
		Assembly.............................................................. 91
	2.25 Drive Brake - Mico - Machines Built March 1992 TO S/N 33476.......... 91
		Disassembly........................................................... 91
		Cleaning and Inspection............................................... 93
		Assembly.............................................................. 93
	2.26 Drive Brake - Mico - Machines Built S/N 33476 To Present............. 93
		Disassembly........................................................... 93
		Inspection............................................................ 95
		Assembly.............................................................. 95
	2.27 Free Wheeling Option................................................. 96
		To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc..... 96
		To Engage Drive Motors and Brakes (Normal Operation).................. 96
	2.28 OEM Controllers...................................................... 96
		THRESHOLD Adjustment.................................................. 97
		HI RANGE Adjustment................................................... 97
		IRS - RAMP RATE Adjustment............................................ 97
		LO RANGE Adjustment (CREEP)........................................... 97
	2.29 Boom Marking Tape Installation....................................... 97
	2.30 Boom Length/angle Sensor Adjustment Procedures....................... 97
		1st, and 2nd Generation Radius Cards.................................. 97
		3rd Generation Radius Cards...........................................105
	2.31 Load Management System...............................................107
		Platform Position Indication System...................................107
		Overmoment Control System.............................................108
		Overmoment Control Monitoring System..................................109
		Load Management System Daily Check....................................109
	2.32 Load Management System Adjustment....................................111
		Turntable 4620038.....................................................111
		Turntables 4620044 and 4620078........................................111
	2.33 Turntable Springs....................................................111
		Turntable 4620038.....................................................111
		Turntables 4620044 and 4620078........................................112
	2.34 Pump Coupling Conversion Procedures..................................112
		Lovejoy Coupling......................................................112
		Hayes Coupling........................................................112
	2.35 Platform Rotator Brake...............................................112
	2.36 Preventive Maintenance and Inspection Schedule.......................112
Section 3. TROUBLESHOOTING....................................................117
	3.1 General...............................................................117
	3.2 Troubleshooting.......................................................117
	3.3 Hydraulic Circuit Checks..............................................117

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