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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