JLG 110HX Service Manual

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Page 1

Service and Maintenance Manual

Model

100HX

100HX+10

110HX

P/N - 3120636

March 11, 2010

Page 2

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INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

AGENERAL

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. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATO R.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

feed lines to system components can then be disconnected with minimal fluid loss.

CMAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure

3120636 – JLG Lift – A-1

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INTRODUCTION

REVISON LOG

March, 1989 - Original Issue October, 1994 - Revised August, 1997 - Revised January, 1999 - Revised October 8, 1999 - Revised May 20, 2002 - Revised April 6, 2009 - Revised March 11, 2010 - Revised

A-2 – JLG Lift – 3120636

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TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Engine - Ford LSG-423 & LRG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Ford LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Deutz F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Cummins 4B3.9C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Stowed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Stowed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maximum Tire Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Ford LSG423 & LRG423 & LRG425 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Deutz F4L912 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Cummins 4B3.9C Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Accessory Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Extend-A-Reach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.8 Boom Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

With 4620038 Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

With 4620044 or 4620078 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1.10 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

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3120636 – JLG Lift – i

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TABLE OF CONTENTS (Continued)

SECTION NO. TITLE PAGE NO.

SECTION 2 - PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Manual Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Proportional Control Valves - Vickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Adjusting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2.8 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cylinder w/o Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cylinders w/Single Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Cylinders w/Dual Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Master Level Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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ii – JLG Lift – 3120636

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TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

2.12 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.13 Tilt Alarm Switch Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.14 Limit Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Horizontal Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.15 Throttle Checks and Adjustments - Deutz F4l-912 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.16 Throttle Checks and Precision Governor Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . .2-32

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Automatic Choke Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Carburetor and Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.17 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Sequence Pressure (Prior to 1990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Sequence Pressure (1990 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Extend-A-Reach Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.18 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Bearing Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2.19 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

2.20 Swing Torque hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2.21 Swing Brake - Ausco - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

2.22 Swing Brake - Mico - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

2.23 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

2.24 Drive Brake - Ausco - Machines Built Prior To March 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

2.25 Drive Brake - Mico - Machines Built March 1992 TO S/N 33476 . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

 

3120636 – JLG Lift – iii

Page 8

TABLE OF CONTENTS (Continued)

SECTION NO. TITLE PAGE NO.

2.26 Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

2.27 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 2-74

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.28 OEM Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

THRESHOLD Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

HI RANGE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

IRS - RAMP RATE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

LO RANGE Adjustment (CREEP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.29 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2.30 Boom Length/angle Sensor Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

1st and 2nd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

3rd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

2.31 Load Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Platform Position Indication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Overmoment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

Overmoment Control Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

Load Management System Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

2.32 Load Management System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

2.33 Turntable Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

2.34 Pump Coupling Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Lovejoy Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Hayes Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

2.35 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-92

2.36 Platform Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

2.37 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

iv – JLG Lift – 3120636

Page 9

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

2-1. Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Boom Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Typical Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-4. Boom Positioning and Support - Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-5. Typical Hydraulic Cylinders - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-6. Typical Hydraulic Cylinders - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-6. Typical Hydraulic Cylinders - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-6. Typical Hydraulic Cylinders - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-6. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-7. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-8. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-9. Boom Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-10. Boom Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-11. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-12. Tilt Switch Adjustment - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-13. Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

2-15. Precision Governor Adjustment - Ford Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

2-14. Precision Governor Adjustment - Ford Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-16. Pressure Setting Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

2-17. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-18. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

2-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-20. Swing Bearing Bolt Torquing Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-21. Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2-22. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

2-23. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

2-24. Swing Brake - Ausco - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2-25. Swing Brake - Mico - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

2-26. Swing Brake - Machines Built 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-27. Drive Brake - Ausco (Prior to March 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

2-28. Drive Brake - Mico (March 1992 to S/N 33746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

2-29. Drive Brake - Mico (S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

2-30. Spring Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73

2-31. Boom Marking Tape Installation - 100HX+10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2-32. Boom Marking Tape Installation - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2-33. Load Radius Card Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

2-34. Boom Length/Angle Sensor Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

2-35. Load Radius Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

2-36. Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

2-37. Load Moment Limiting System Monitoring Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

             

3120636 – JLG Lift – v

Page 10

LIST OF FIGURES (Continued)

FIGURE NO. TITLE PAGE NO.

3-1. Wiring Diagram - Boom Indicator Pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-2. Wiring Diagram - Dual Fuel (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-3. Wiring Diagram - Generator (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-4. Wiring Diagram - Generator (Ford) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-5. Wiring Diagram - Platform (100HX & 110HX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Wiring Diagram - Platform (100HX+10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-9. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-10. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-11. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-12. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-14. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-15. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-16. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-17. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-18. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-19. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-20. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

vi – JLG Lift – 3120636

Page 11

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Maximum Tire Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-4 Mobil EAL Envirosyn H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-5 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-6 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-7 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-8 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

2-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-2 Cylinder Piston Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-4 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

2-5 Card Adjustment - 1st and 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

2-6 Card Adjustment - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

2-7 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

3-1 Platform Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 Turntable Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3120636 – JLG Lift – vii

Page 12

LIST OF TABLES (Continued)

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

viii – JLG Lift – 3120636

Page 13

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank - 28 gallons (98 liters).

Hydraulic Oil Tank - 55 gallons (208 liters).

Hydraulic System (Including Tank) - 65 gallons (246 liters).

Torque Hub, Drive - 90 oz. (2.7 liters).

Torque Hub, Swing - 17 oz. (0.5 liters).

NOTE: Torque Hubs should be one-half full of lubricant.

(EPGL-90)

Engine Crankcase

Ford LSG423 & LRG423 w/Filter - 5 quarts (4.7 liters) Ford LRG425 w/Filter - 4.5 quarts (4.25 liters) Deutz F4L912 w/Filter - 11 liters.

1.2 COMPONENT DATA

NOTE: Tolerance on all engine rpm settings is plus or minus

10%.

Engine - Ford LSG-423 & LRG-423

Fuel - Gasoline

Oil Capacity - 5 quarts (4.7 liters) w/Filter, 4 quarts (3.8 liters) w/o Filter

Cooling System - 16 quarts (15 liters)

Idle RPM - 850 no load

Low (Mid) RPM - 1800 no load

High RPM - 3000 no load

Alternator - 40 Amp

Battery - 1000 CCA, 210 minutes reserve capacity, 12VDC

Engine - Deutz F4L912

Fuel - Diesel

Oil Capacity - 12.7 quarts (12 liters)

Low (Mid) RPM - 1800

High RPM - 2400

Alternator -

Prior to Oct. 91 85 Amp

Oct 91 to Present 55 Amp

Battery - 1000 cold cranking Amps, 210 minutes reserve capacity, 12 VDC

Fuel Consumption

Low RPM - 2.4 gph (9.1 lph)

High RPM - 3.8 gph (14.2 lph)

Horsepower - 70 @ 2400 RPM, no load

Engine - Cummins 4B3.9C

Fuel - Diesel

Oil Capacity - 10 quarts (9.5 liters) w/o Filter

Cooling System Capacity - 21.4 quarts (20.2 liters)

Engine Capacity - 7.4 quarts (7 liters) Radiator capacity - 14 quarts (13.2 liters)

Low (Mid) RPM - 1800

High RPM - 2400.

Alternator - 60 Amp.

Battery - 1000 CCA, 210 minutes reserve capacity, 

12 VDC.

Horsepower - 76 @ 2400 RPM, no load.

Fuel Consumption

LSG-423 - 4.6gph (17.4 lph) LRG-423 - 4.3gph (16.2 lph)

Horsepower

LSG-423 - 54 @ 3000 RPM, no load LRG-425 - 66 @ 3000 RPM, no load

Engine - Ford LRG-425

Fuel - Gasoline

No. of Cylinders - 4

BHP at Max. RPM - 70

RPM Setting (No Load) - Mid - 1500

3120636 – JLG Lift – 1-1

Page 14

SECTION 1 - SPECIFICATIONS

Drive System

Tires.

Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam

filled.

After March, 1993 - 385/65R22.5, 18 ply rating, foam

filled.

Drive Motor - 2.5 in3 (6.4 cm3) /rev. displacement.

Drive Hub - 93.7:1 ratio.

Drive Brake - Automatic spring applied, hydraulically released.

Steer System

Tires.

Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam

filled.

After March, 1993 - 385/65R22.5, 18 ply rating, foam

filled.

Toe-In - Adjust for 1/4in. (6.4 mm) overall.

Swing System

Swing Motor - 10.3 in3 (26.2 cm3)/rev. displacement.

Swing Hub - 69.5:1 ratio.

Swing Brake - Automatic spring applied, hydraulically released.

Hydraulic Pump

Hydraulic Filter - Tank

Return - Bypass Type

10 Microns Nominal

Hydraulic Filter - Inline

Return - Non-Bypass Type

10 Microns Nominal

1.3 PERFORMANCE DATA

Travel Speed

2.8 mph (4.5 kmh)

Gradeability

25% or 14° slope, hard surface.

Turn ing Ra d ius

Outside - 22ft. 10 1/4 in. (7.1 m) w/axles extended.

Boom Speed

Extend - 128-156 Seconds.

Retract - 93-113 Seconds.

Lift Up - 65-80 Seconds

Lift Down - 52-64 Seconds.

Swing Speed

360° - 260-350 Seconds

1st Section - 15.0 gpm (56.8 lpm)

2nd Section - 9.0 gpm (34.1 lpm)

3rd Section - 9.0 gpm (34.1 lpm)

Auxiliary Power Pump

18.0 lpm

12 Volts DC motor

Clockwise rotation

         

Boom Elevation

Models 100HX/110HX

+75° (above horizontal) to -21° (below horizontal)

Model 100HX+10

Main Boom - +75° (above horizontal) to -21° (below

horizontal)

Extend-a-Reach - +15° (above horizontal) to -80°

(below horizontal)

          

1-2 – JLG Lift – 3120636

Page 15

SECTION 1 - SPECIFICATIONS

Table 1-1.Maximum Tire Loads

Max. Load

Max Bearing Pressure

Description Lbs. Kg PSI

kg/cm

100HX 19900 9027 145 10

100HX+10 23740 10769 172 11.8

110 HX 21540 9771 156 10.7

Table 1-2.Torque Requirements

Description

Torque Value

Interval

Hours

Ft. Lbs. Nm

Bearing to Chassis 220 298 50/600*

Bearing to Turntable 220 298 50/600*

Wheel Lugs 300 407 100

Turntable Springs 75 102 200

Boom Chains 59 80 500

Platform Rotator Bolt 140 190 500

* Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter.

Machine Weight

100HX - 36,400 lbs. (16,511 kg)

110HX - 40,410 lbs. (18,330 kg)

100HX+10 - 39,685 lbs. (18,001 kg)

Machine Stowed Height

9 ft. 10 in. (3.0 m)

Machine Stowed Length

100HX - 36 ft. in. (11.0 m)

110HX - 38 ft. 7 in. (11.8 m)

100HX+10 - 44 ft. 2 in. (13.5 m)

Machine Width

With axles retracted - 8 ft. 6 in. (2.6 m)

With axles extended - 10 ft. 10 in. (3.3 m)

Wheelbase

11 ft. (3.4 m)

Maximum Tire Loads



1.4 TORQUE REQUIREMENTS

NOTE: See Procedure Section for tightening sequence of

turntable bearing bolts.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to determine proper torque value.

1.5 LUBRICATION

   

3120636 – JLG Lift – 1-3

Ford LSG423 & LRG423 & LRG425 Engines

Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD)

When Outside Temp is Consistently

-10° to +60° F (-24° to +16° C) *10W

+10° to +90° F (-12° C to +32° C) 20W-20

Above +32° F (0° C) 30

Above +50° F (+10° C) 40

Multi-Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

Below +10° F(-12° C) *5W-20

Below +60° F(+16° C) 5W-30

-10° to +90° F(-24° to +32° C) 10W-30

Above -10° F(-24° C) 10W-40 or 10W-50

Above +20° F( -7° C) 20W-40 or 20W-50

* This viscosity can be used at colder temperatures only with engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

Page 16

SECTION 1 - SPECIFICATIONS

Deutz F4L912 Engine

Single Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

-20° to +25° F (-29° to -4° C) *10W

+15° to +50° F (-10° C to +10° C) 20W-20

+40° to +85° F (+4° to +30° C) 30

Above 75° F (+24° C) 40

Multi-Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

-40° to +75° F(-40° to +24° C) *5W-20

-5° to +70° F(-21° to +21° C) 10W-30

-5° to +85° F(-21° to +30° C) 10W-40

+15° to +75° F(-10° to +24° C) 15W-30

Above +15° F(-10° C) 15W-40

* This viscosity can be used at colder temperatures only with engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

Table 1-3.Hydraulic Oil

Hydraulic System Operating

Temperature Range

0° to +23° F(-18° to -5° C) 10W

0° to +210° F(-18° to +100° C) 10W-20, 10W-30

+50° to +210° F(+10° to +99° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152 .

NOTE: When temperatures remain consistently below 20

degrees F (-7 degrees C.), JLG Industries recommends the use of Mobil DTE11.

NOTE: Aside from JLG recommendations, it is not advisable

to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

SAE Viscosity

Grade

Cummins 4B3.9C Engine

Single Viscosity Oils

When Outside Temp is Consistently

-22° to +23° F (-30° to -5° C) 10W

+14° to +50° F (-10° C to +10° C) 20W-20

+41° to +86° F (+5° to +30° C) 30

Above 77° F (+25° C) 40

Multi-Viscosity Oils (MS, SD, SE).

When Outside Temp is Consistently

-40° to +77° F(-40° to +25° C) 5W-20

-4° to +68° F(-20° to +20° C) 10W-30

-4° to +86° F(-20° to +30° C) 10W-40

+14° to +77° F(-10° to +25° C) 15W-30

Above +14° F(-10° C) 15W-40

NOTE: Crankcase oil should meet one of the following API

classification grades: SE/CC, SE/CD, SF/CC, SF/ CD.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

1-4 – JLG Lift – 3120636

Page 17

SECTION 1 - SPECIFICATIONS



Table 1-4. Mobil EAL Envirosyn H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point, Max

Flash Point, Min.

Weight

Viscosity

at 104° F (40° C) 45 cSt

at 212° F (100° C) 8.0 cSt

Viscosity Index 153

Table 1-5. Mobil EAL 224 H Specs

Type Biodegradable Vegetable Oil

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max

Flash Point, Min.

Weight

Viscosity

at 104° F (40° C) 37 cSt

at 212° F (100° C) 8.4 cSt

Viscosity Index 213

Operating Temp 0-180° F (-17 - -162°C)

Note: Must be stored above 32° F (14° C)

-44°F (-44°C)

500°F (260°C)

7.64 lb. per gal. (0.9 kg per liter)

-25°F (-32°C)

428°F (220°C)

7.64 lb. per gal. (0.9 kg per liter)

Table 1-6. Mobil DTE 13M Specs

Ty pe Petroleum Base

ISO Viscosity Grade 32

Specific Gravity .877

Pour Point, Max

Flash Point, Min.

Viscosity

at 104° F (40° C) 33 cSt

at 212° F (100° C) 6.5 cSt

Viscosity Index 140

-40°F (-40°C)

330°F (166°C)

Lubrication Specifications

Table 1-7.Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 35 0

degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meetin g API Service Classi-

fication GL-5 or Mil-Spec Mil-L- 2105.

HO Hydraulic Oil. API Service Classification GL-3, SAE 10W-20,

Viscosity Index 152.

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

Refer to Lubrication Chart for specific lubrication proce-



dures.

3120636 – JLG Lift – 1-5

Page 18

SECTION 1 - SPECIFICATIONS

1011

6, 7

1, 5, 16

23, 24

26, 27, 28

18, 20

Note

The lubrication intervals in this

chart are equivalent to the following:

150 hours = 3 months 300 hours = 6 months

600 hours = 1 year

1200 hours = 2 years

Figure 1-1. Lubrication Diagram

1-6 – JLG Lift – 3120636

Page 19

Table 1-8. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Components

Master Cylinder - Barrel End

Master Cylinder - Rod End

Boom Pivot Bushings

Lift Cylinder - Rod End

Lift Cylinder - Barrel End

Slave Cylinder - Rod End

Slave Cylinder - Shaft End

Extend-A-Reach Cylinder - Rod End

Extend-A-Reach Cylinder - Attach Pin

Platform Door Hinges

Platform Door Latch

Rotary Platform Control Stand

Platform Attach Pin and Rotary Worm

Gear

Drive Hubs

Swing Bearing Gear

Swing Bearing

Steer Spindles

Steer Cylinder - Rod End

Steer Cylinder - Barrel End

Tie Rod Ends

Extending Axle Beams

Wheel Bearings

Engine Crankcase

Engine Oil Filter

Door and Access Panel Hinges

Hydraulic Fluid

Hyd. Filter Element (Tank)

Hyd. Filter Element (Inline)

Telescope Cylinder Sheave

Extend Chain Sheave

Retract Chain Sheave

Number/Type

Lube Points

Lube & Method

Interval

Hours

Comments

1 Grease Fitting MPG - Pressure Gun 150 Remote Access

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150 Remote Access

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG- Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

N/A SAE10 - Oil Can 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting Each MPG - Pressure Gun 150

Fill Plug EPGL - SAE90 150/1200 Check every 150 hrs. /Change every 1200 hrs.

N/A M PG - Brush 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

N/A M PG - Brush 150

N/A MPG - Repack 1200

Fill Cap EO-SAE30 10/300 Check daily /Change every 300 hrs.

N/A Replaceable Cartridge 300

N/A SAE10 - Oil Can 150

Fill Cap HO 10/1200 Che ck daily/Change every 1200 hrs.

N/A N/A 50/300 Rep lace filter after first 50 hrs. of operation,

then every 300 hrs. thereafter

N/A N/A 50/300 Rep lace filter after first 50 hrs. of operation,

then every 300 hrs. thereafter

1 Grease Fitting MPG - Pressure Gun 150

3120636 – JLG Lift – 1-7

Page 20

SECTION 1 - SPECIFICATIONS

Table 1-9.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Lift 9.0

(22.9)

43.375 (120.3)

4.0

(10.2)

Maser Level (100HX, 110HX)

2.5

(6.4)

14.5

(36.8)

1.25 (3.2)

Master Level (100HX+10)

2.5

(6.4)

15.1

(38.4)

1.25 (3.2)

Slave Level (100HX, 110HX)

2.5

(6.4)

13.875 (35.2)

1.25 (3.2)

Slave Level (100HX+10)

3.5

(8.9)

6.94

(17.6)

1.75 (4.4)

Steer 3

(7.6)

10.31 (26.2)

1.5

(3.8)

Telescope (100HX, 100HX+10

(12.7)

247.81

(629.4)

3.5

(8.9)

Telescope (110HX)

(12.7)

266

(675.6)

3.5

(8.9)

Axle Extension 2.5

(6.4)

28.19 (71.6)

1.25 (3.2)

Extend-a-Reach (100HX+10)

3.5

(8.9

18.31 (46.5)

2.5

(6.4)

Table 1-8. Lubrication Chart

Components

Boom Chains

Turntable Pivot Pin

Extend-A-Reach Link Attach Pin

Extend-A-Reach Pivot Pin

NOTES:

1.6 PRESSURE SETTINGS

Proportional Valve

Drive - 3500 psi (241 bar)

Lift Up - 3000 psi (207 bar)

Lift Down - 1200 psi (83 bar)

Telescope In - 2500 psi (172 bar)

Number/Type

Lube Points

N/A Chain Lube/Hot Oil Dip 1200 Includes extend and retract chains

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

Lube & Method

Interval

Hours

Key to Lubricants:

EO EPGL HO MPG t

Comments

Engine Oil Extreme Pressure Gear Lube Hydraulic Fluid (Mobil #424 or equivalent) Multi-Purpose Grease

1.7 CYLINDER SPECIFICATIONS

NOTE: All cylinder dimensions are given in inches (in), with

the metric equivalent, centimeters (cm) in parentheses.

Telescope Out - 1500 psi (103 bar)

Swing - 1200 psi (83 bar)

Accessory Valve

Main Relief - 3500 psi (241 bar)

Sequence Cartridge - 450 psi (31 bar)

Pressure Reducing Cartridge - 550 psi (38 bar)

Solenoid Valve

Main Relief - 2500 psi (172 bar)

Rotate - 2500 psi (172 bar)

Level - 2500 psi (172 bar)

Steer - 2000 psi (138 bar)

Extend-A-Reach Valve

Extend (Up) - 2500 psi (172 bar)

Retract (Down) - 700 psi (48 bar)

NOTE: Refer to Section 2 for pressure setting procedures.

1-8 – JLG Lift – 3120636

Page 21

SECTION 1 - SPECIFICATIONS

Table 1-10.Major Component Weights

Component Lbs. KG.

Platform (36x48) w/o Control Box 150 68

Platform (36x60) w/o Control Box 165 75

Platform (36x72) w/o Control Box 180 82

Platform (36x96) w/o Control Box 220 100

Boom - 100HX (Incl. Lift Cylinder) 9920 4.500

Boom - 110HX (Incl. Lift Cylinder) 10960 4,971

Boom - 100HX+10 (Incl. Lift Cylinder) 10680 4,844

Turntable (w/Ford Engine, Less Cwt.) 10300 4,672

Turntable (w/Deutz Engine, Less Cwt.) 10620 4,817

Turntable (w/Cummins Engine, Less Cwt.) 10455 4,742

Frame Complete (incl. Wheels and Tires) 13620 6,178

Complete Machine - 100HX 37000 16,783

Complete Machine - 110HX 40500 18,371

Complete Machine - 100HX+10 38500 17,464

1.8 BOOM TAPE

With 4620038 Turntable

110HX Single Capacity

Blue - Not used

Yellow - Not used

Red - 119.5 in. (303.5 cm)

White - 154.5 in. (392.4 cm)

110HX Dual Capacity

Blue - Not used

Yellow - 82.5 in. (209.6 cm)

Red - 119.5 in. (303.5 cm)

White - 154.5 in. (392.4 cm)

100HX+10

Blue - 50 in. (127 cm)

Yellow - Not used

Red - 84 in. (213.4 cm)

White - 135.5 in. (344.2 cm)

100HX+10.

Blue - 53 in. (134.6 cm)

Yellow - Not used

Red - 87 in. (221.0 cm)

White - 138.5 in. (351.8 cm)

1.9 MAJOR COMPONENT WEIGHTS

With 4620044 or 4620078 Turntable

100HX Dual Capacity

Blue - Not used

Yellow - 62 in. (157.5 cm)

Red - 90 in. (228.6 cm)

White- 118 in. (299.7 cm)

110HX Single Capacity

Blue - Not used

Yellow - Not used

Red - 122.5 in. (311.2 cm)

White - 157.5 in. (400.1 cm)

110HX Dual Capacity

Blue - Not used

Yellow - 85.5 in. (217.2 cm)

Red - 122.5 in. (311.2 cm)

White - 160.5 in. (400.1 cm)

    

3120636 – JLG Lift – 1-9

1.10 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the left side of the frame, below the battery compartment. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame between the front and rear wheels, below the turntable bearing and on the right side of the turntable in the bottom of the valve compartment. In addition, the last five digits of the serial number are stamped on top of the fly end of the base boom section.

          

Page 22

SECTION 1 - SPECIFICATIONS

Serial Number - Stamped

(Frame)

Serial Number Plate

(Frame)

Serial Number - Stamped

(Boom Sections)

Serial Number - Stamped

(Turntable - Far Side)

Figure 1-2. Serial Number Locations

Table 1-11.Critical Stability Weights

Component 100HX 110HX 100HX+10

Counterweight (1.5:1)

6150 lbs. (2790 kg)

10,350 lbs.

(4695 kg)

9,850 lbs. (4468 kg)

Counterweight (2:1)

N/A 10,350 lbs.

(4695 kg)

9,850 lbs. (4468 kg)

Foam-Filled Tires (each)

700 lbs.

(318 kg)

700 lbs.

(318 kg)

700 lbs. (318 kg)

Ford Engine 525 lbs.

(238 kg)

525 lbs. (238 kg)

Deutz Engine 837 lbs.

(380 kg)

837 lbs. (380 kg)

Cummins Engine 680 lbs.

(308 kg)

680 lbs. (308 kg)

36x48 Platform N/A N/A 150 lbs.

(68 kg)

36x60 Platform N/A N/A 165 lbs.

(75 kg)

36x72 Platform N/A N/A 180 lb.

(82 kg)

36x96 Platform (100 kg) (100 kg) (1 00 kg)

1.11 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS THE COUNTERWEIGHT OR FOAM-FILLED TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.



1-10 – JLG Lift – 3120636

Page 23

SIZE

1-1/2

3.8100

3.4925

4.0132

39781

2983

2224

3118

4827

4712

4068

3559

2983

2712

2136

1898

1492

3200

2766

2413

2034

1844

1464

4284

3688

3227

2712

2468

1953

1736

1356

983

895

631

570

359

326

258

224

183

1003

922

678

624

434

380

244

231

176

149

895

814

570

515

326

298

231

204

163

149

142200

57380

53570

47174

43818

38554

34927

31162

27080

23360

20775

18870

15241

13653

10433

9231

8278

7539

6532

5783

4854

4332

3583

3175

2821

2141

1488

1297

817

717

599

572

417

372

272

245

1708

2373

1247

1762

895

1254

719

997

475

705

298

448

176

258

1980

2746

1492

2068

1139

1593

814

1139

651

915

434

644

271

387

149

224

122

183

136

109

163

115

2278

2630

1980

1519

1681

1193

949

1085

868

583

353

637

407

231

163

204

149

122

102

33113

35381

29076

24404

19187

17509

13336

9662

6532

5262

4105

3085

3425

2540

1678

2241

1515

1052

583

426

277

191

916

508

408

263

172

27035

21546

19142

14697

10796

7394

5874

4854

3.3401

3.5687

2.9337

2.4613

1.9380

1.5392

1.1735

0.8484

0.5740

0.4623

0.3604

0.2700

0.1969

0.1331

0.0925

0.0508

0.0808

0.0445

0.0356

0.0232

0.0153

0.0374

0.0258

0.0168

2.7254

2.1742

1.6840

1.2929

0.9474

0.6502

0.5156

0.4061

0.3015

0.2230

0.1473

3.1750

2.8575

2.5400

2.2225

1.9050

1.5875

1.4288

1.2700

1.1112

0.9525

0.7938

0.6350

0.4826

0.4166

0.3505

0.2845

1-1/4

1-1/8

7/8

3/4

5/8

9/16

1/2

7/16

5/16

3/8

1/4

THD

SAE GRADE 5 BOLTS & GRADE 2 NUTS

SAE GRADE 5

SAE GRADE 8

SAE GRADE 8 BOLTS & GRADE 8 NUTS

UNBRAKO 1960 SERIES

SOCKET HEAD CAP SCREW

WITH LOC-WEL PATCH

BOLT

DIA.

(CM)

CLAMP

LOAD

(KG)

CLAMP

LOAD

(KG)

CLAMP LOAD

(KG)

TORQUE

(DRY OR

LOC. 263)

(DRY OR

LOC. 263)

(LOCTITE

262)

(LOCTITE

262)

(LOCTITE

)

242 OR 271

(LOCTITE

)

242 OR 271

TORQUE

(as received)

(LUB.)

Note: These torque values do not apply to cadium plated fasteners.

THREAD

STRESS

AREA

(SQ. CM)

1220

109

3607

1302

122

163

5322

1342

122

VALUES FOR ZINC PLATED BOLTS ONLY

UNPLATED

CAP SCREWS

108

133

148

183

207

325

363

523

576

785

858

968

1087

1368

1516

1792

2042

2379

2676

102

149

156

210

224

285

298

495

542

793

861

1173

1241

1681

1871

2373

2549

3145

3308

4122

4433

71669

63731

59648

52391

48671

43954

38828

34610

30074

27488

23088

20956

16919

15150

11612

10251

9208

8256

7253

6437

5384

4822

3983

3493

2631

2377

1651

1442

1079

931

724

658

456

408

277

244

209

188

146

130

1396

1566

1970

2183

2586

2935

3430

3856

Figure 1-3. Torque Chart

SECTION 1 - SPECIFICATIONS

3120636 – JLG Lift – 1-11

Page 24

SECTION 1 - SPECIFICATIONS

This page left blank intentionally

1-12 – JLG Lift – 3120636

Page 25

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

NOTE: The JLG Models 100HX, 110HX and 100HX+10

have been built with two different turntable configurations. Turntable number 4620044 is used on machines with serial numbers 11511, 12249, 12598, 12836, 12838 and higher through March, 1992. Turntable number 4620078 is used on machines since March, 1992. Where differences between specifications on maintenance procedures exist, the turntable number will be specified. Refer to the JLG Illustrated Parts Manual for turntable illustrations.

This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

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.

The maintenance procedures included consist of servicing and component removal and installation, disassembly and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc.,have been removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or molybdenum disulfide base compound to lubricate the mating surface.

3120636 – JLG Lift – 2-1

Page 26

SECTION 2 - PROCEDURES

Bearings

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1. 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.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. See the Torque Chart in Section 1 - Specifications.

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable

cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti-corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

2.3 LUBRICATION INFORMATION

Hydraulic System

1. 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 (suction) lines.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in Section 1. Always examine filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

2-2 – JLG Lift – 3120636

Page 27

SECTION 2 - PROCEDURES

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

1. Refer to Table 1-1 for recommendations for viscosity ranges.

2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).

3. The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent. This will allow start up at temperatures down to -20 degrees F (-29 degrees C). However, use of this oil will give poor performance at temperatures above 120 degrees F (49 degrees C). Systems using DTE 11 oil should not be operated at temperatures above 200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Table 1-2 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4 CYLINDERS - THEORY OF OPERATION

1. Cylinders are of the double acting type. Systems incorporating double acting cylinders are as follows: Lift, Telescope, Steer, Master Level, Slave Level, Axle Extend, Frame Lift (if equipped) and Extend-AReach (if equipped). A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

2. Holding valves are used in the Lift, Slave Level, Telescope, and Extend-A-Reach circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

2.5 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

3120636 – JLG Lift – 2-3

Page 28

SECTION 2 - PROCEDURES

A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Manual Hydraulic Control Valves

The manual hydraulic control valves consist of four-way, multi-position valve sections, each section incorporating a sliding spool, spring-loaded to neutral or off. Each spool is attached to a control lever which provides for proportional control of the selected system function. This proportional control enables metering of oil flow in accordance with spool position, affording variable and smooth speed control capability. Spool movement causes work ports within the valve to align in a predetermined way, permitting flow to the selected function, with the opposing work ports positioned to allow return flow to the hydraulic reservoir.

Proportional Control Valves - Vickers

The Vickers proportional valves provide a power output matching that required by the load. A small line connected to a load sensing port feeds load pressure back to a sequence valve. The sequence valve senses the difference between the load and pump outlet pressure, and varies the pump displacement to keep the difference constant. This differential pressure is applied across the valve’s meter-in spool, with the effect that pump flow is determined by the degree of spool opening, independent of load pressure. Return lines are connected together, simplifying routing of return flow and to help reduce cavitation.

Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve. Integral actuator port relief valves, anti-cavitation check valves, and load check valves are standard.

Relief Valves

Main relief valves are installed at various points with the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than

the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral reliefs are provided for each side of the circuit.

2.6 BOOM CHAINS

Adjusting Procedures

ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE.

1. Position boom fully retracted at +5 degrees horizontal, no load in platform.

2. Torque outer mid section extend chain adjuster to 59 ft. lb. (80 Nm).

3. Torque outer mid section retract chain adjuster to 59 ft. lb. (80 Nm).

4. Torque fly section extend chain adjuster to 59 ft. lb. (80 Nm).

5. Torque fly section retract chain adjuster to 59 ft. lb. (80 Nm).

6. Cycle boom (extend at least 6 feet [2 meters], then retract fully).

7. Recheck outer mid section extend chain.

8. Recheck outer mid section retract chain.

9. Recheck fly section extend chain.

10. Recheck fly section retract chain.

11. Repeat steps (2) thru (10) if necessary.

12. Check for proper operation of boom.

JLG Industries, Inc. requires a complete boom disassembly, per instructions outlined in Boom Maintenance in this section, every two years. All boom chains and related components (i.e., sheaves, pins, sprockets, wear pads, etc.) must also be inspected and replaced (as necessary) during this disassembly.

2-4 – JLG Lift – 3120636

Page 29

SECTION 2 - PROCEDURES

Meter-Out Poppet

Adjustable Relief

Actuator Port "A"

Actuator Port "B"

Load Drop Check

Pilot Relief

"A" Solenoid

Pilot Supply Passages

Gasket

Valve Inlet Port

Meter-In Chambers

Load Sensing Check Valves

Electro-Hydraulic Reducing Valve Spool

Meter-In Spool

"B" Solenoid

Vent

Return Port

Figure 2-1. Proportional Control Valve

3120636 – JLG Lift – 2-5

Page 30

SECTION 2 - PROCEDURES

FLY EXTEND

FLY RETRACT

OUTER MID RETRACT

OUTER MID EXTEND

Figure 2-2. Boom Chain Adjustments

2-6 – JLG Lift – 3120636

Page 31

SECTION 2 - PROCEDURES

Figure 2-3. Typical Boom Assembly

3120636 – JLG Lift – 2-7

Page 32

SECTION 2 - PROCEDURES

H for a 1" chain Maximum wear Minimum plate depth

= 0.950" = 5% of 0.950" = 0.047" = 0.950" - 0.047" = 0.903"

An immediate disassembly of the boom assembly and inspection of the boom chains and related components is required if any of the following conditions occur:

1. After the machine is exposed to hostile environments or conditions (i.e. extreme cold, dust, sand, blasting grit, salt, chemicals, etc.), which could adversely affect boom operation.

2. Erratic boom operation or unusual noise exists. See the Troubleshooting section in this Service Manual.

3. Chain adjustment is required more often than specified in the Preventive Maintenance and Inspection Schedule or links need to be removed (chain shortened) to make the proper adjustment.

4. The machine is idle for an extended period (6 months or longer.)

5. The boom is overloaded or sustained a shock load.

FAILURE TO DISASSEMBLE THE BOOM ASSEMBLY AND PROPERLY INSPECT AND/OR REPLACE THE BOOM CHAINS AND RELATED COMPONENTS (I.E., SHEAVES, PINS, SPROCKETS, WEAR PADS, ETC.) COULD RESULT IN THE DAMAGE AND/OR BREAKAGE OF THE BOOM CHAINS AND/OR RELATED COMPONENTS. DAMAGE AND/OR BREAKAGE OF THESE ITEMS COULD RESULT IN UNCONTROLLED EXTENSION OR RETRACTION OF THE BOOM ASSEMBLY AND COULD CAUSE SERIOUS INJURY OR DEATH TO PERSONNEL OPERATING THE JLG BOOM LIFT.

                       

Inspection Procedure

Inspect boom chains for the following conditions:

1. Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the extend/retract sheaves, joints and plate edges very gradually wear. Chain “stretch” can be measured using a manufacturers wear scale or steel tape. When chains have elongated 3% they must be removed and replaced. Refer to Table 2-1, Chain Stretch Tolerance for proper chain specifications and allowable stretch tolerances. Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave, or unusually heavy loads. All of the above require replacement of the chain and correction of the cause. Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set.

2-8 – JLG Lift – 3120636

Page 33

Table 2-1.Chain Stretch Tolerance

TIGHT JOINTS

SECTION 2 - PROCEDURES

Chain Size

0.50 in. (1.27 cm) pitch 14 in. (36 cm) or 28 pitches 0.42 in. (1.07 cm)

0.625 in. (1.59 cm) pitch 15 in. (38 cm) or 24 pitches 0.45 in. (1.14 cm)

0.75 in. (1.91 cm) pitch 15 in. (38 cm) or 20 pitches 0.45 in. (1.14 cm)

1 in. (2.54 cm) pitch 14 in. (36 cm) or 14 pitches 0.42 in. (1.07 cm)

1.25 in. (3.18 cm) pitch 15 in. (38 cm) or 12 pitches 0.45 in. (1.14 cm)

2. Lubrication: One of the most important but often overlooked factors is adequate lubrication. In addition to reducing internal friction, maintaining a film of oil on all chain surfaces will inhibit rusting and corrosion. This is important as corrosion of highly stressed, hardened steel chain components can cause a major reduction in the load capacity of leaf chain and result in link plate cracking.

NOTE: The need for lubrication can be determined by the

presence of rust on the exposed portions of chain.

3. Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not steam clean or degrease chains. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times.



If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

4. Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of chain plate failures. Fatigue cracks are found through the link holes, perpendicular (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.

Pin to Pin

Measurement

Allowable Stretch

5. Tight Joints: All joints in the roller chain should flex freely. On roller chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting carefully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:



1. Bent pins or plates.

2. Rusty joints.

3. Peened plate edges.



Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated.

6. Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction between the pin and plates (pin and bushing on roller chain). In extreme cases, this frictional torque can actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

7. Stress Corrosion Cracking: The outside link plates, which are heavily press-fitted to the pins, are particularly susceptible to stress corrosion cracking. Like fatigue cracks, these initiate at the point of highest stress (aperture) but tend to extend in an arc-like path, often parallel to the rolling grain of the material.

3120636 – JLG Lift – 2-9

Page 34

SECTION 2 - PROCEDURES

ABNORMAL PROTRUSION OR

TURNED PINS

ARC-LIKE CRACKED PLATES

(STRESS CORROSION)



Also, more than one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere. Stress corrosion is an environmentally assisted failure. Two conditions must be present - corrosive agent and static stress.



In the chain, static stress is present at the aperture due to the press fit pin. No cycle motion is required and the plates can crack during idle periods. The reactions of many chemical agents (such as battery acid fumes) with hardened metals liberate hydrogen which attacks and weakens the metal grain structure.

2.7 WEAR PADS

9. Shim up wear pads to within 1/16 in. (0.8 mm) tolerance between wear pad and adjacent surface.

10. Replace wear pads when worn within 1/8 in. (3.2 mm) of threaded insert.

2.8 DRIFT TEST

NOTE: It is recommended that the machine be shut down in

the test mode for at least one hour prior to beginning the drift test. This will allow the oil temperature in the cylinder to stabilize with the ambient temperature. Thermal expansion or retraction of the hydraulic oil can greatly affect cylinder movement.

Telescope Cylinder

NOTE: Switches referenced in this procedure are located on

the Ground Control Panel.

1. Activate hydraulic system, properly set extendable axles and position boom in stowed position; adhere to all safety precautions.

8. Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.



Sheaves should be inspected for worn flanges, which would indicate misalignment, and wear on the outside diameter of the sheave. A worn sheave can mean several problems, as follows:



1. Chains too tight.

2. Sheave bearings/pin bad.

3. Bent/misaligned chains.

     

2-10 – JLG Lift – 3120636

Page 35

BEFORE RAISING AND EXTENDING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM AND AHEAD OF PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL.

2. Position LIFT control switch to UP and hold until boom reaches horizontal.

3. Position TELESCOPE control switch to OUT and hold until boom extends approximately four (4) feet (1.2 meter); measure from end of base section to end of mid section.

4. Position LIFT control switch to UP and hold until boom reaches maximum elevation. Shut down engine.

5. Tag and carefully disconnect the hydraulic lines to the telescope cylinder at control valve.

6. Observe oil flow from cylinder lines. Oil leaking from extend port hose indicates a leaking counterbalance valve. Oil leaking from retract port hose indicates leakage by cylinder piston.

7. Leave boom elevated in test position for approximately one hour.

BEFORE LOWERING BOOM, ENSURE THAT AREAS BELOW BOOM AND PLATFORM ARE CLEAR OF ALL PERSONNEL AND OBSTRUCTIONS.

SECTION 2 - PROCEDURES

2. Attach tape measure or cord to bottom of platform.

BEFORE RAISING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL.

3. With boom fully retracted, place LIFT control switch to UP and hold until platform is approximately 6 feet (2 meters) above ground level. Shut down engine.

4. Tag and carefully disconnect hydraulic lines to lift cylinder at control valve. Use a suitable container to retain any residual hydraulic fluid.

5. Observe oil flow from cylinder lines. Oil leaking from extend port hose indicates a leaking counterbalance valve. Oil leaking from retract port hose indicates leakage by cylinder piston.

6. Leave boom elevated in test position for approximately one (1) hour.

7. With tape measure or cord used for reference, check to see whether boom has lowered (crept) more than 3 inches (7.6 cm).

8. If boom has lowered and oil is leaking around rodend cap of cylinder, seals in cylinder are defective and require replacement. If boom has lowered and oil is leaking from the counterbalance valve, the valve is either improperly adjusted or defective and requires replacement.

8. Position LIFT control switch to DOWN and hold until boom reaches horizontal; check boom length against measurement. If boom has retracted more than 1 inch (2.5 cm) and oil is leaking around rodend of telescope cylinder (check with light and inspection mirror), seals are defective and require replacement, or cylinder rod is scored and cylinder requires overhaul or replacement. If boom has retracted and oil is leaking from counterbalance valve, the valve is either improperly adjusted, or defective and requires replacement.

9. Connect hydraulic lines to control valve.

Lift Cylinder

NOTE: Switches referenced in this procedure are located on

the Ground Control Panel.

1. Activate hydraulic system, properly set extendable axles and position boom in stowed position; adhere to all safety precautions.

NOTE: Tape measure or cord should be at least 7 feet (2.1

meters) long for use in this test.

ENSURE THAT HYDRAULIC LINES ARE CONNECTED AS MARKED PRIOR TO BEING DISCONNECTED.

9. Connect hydraulic lines to control valve.

2.9 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is replaced or when improper system operation is suspected.

Cylinder w/o Counterbalance Valves

Steer Cylinder, Master Level Cylinder, Axle Extension Cylinders

OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate engine and fully extend cylinder to be checked. Shut down engine.

3120636 – JLG Lift – 2-11

Page 36

SECTION 2 - PROCEDURES

Figure 2-4. Boom Positioning and Support - Cylinder Repair

2. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the retract port.

3. Activate engine and activate cylinder extend function. Check retract port for leakage.

4. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to retract port and retract cylinder.

5. With cylinder fully retracted, shut down engine and carefully disconnect hydraulic hose from cylinder extend port.

6. Activate engine and activate cylinder retract function. Check extend port for leakage.

7. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks.

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

WHEN WORKING ON THE LIFT CYLINDER, RAISE THE BOOM TO HORIZONTAL AND SUPPORT THE BOOM USING A SUITABLE BOOM PROP OR OVERHEAD LIFTING DEVICE.

2. If working on the lift cylinder, raise boom to horizontal and place a suitable boom prop approximately 1 inch (2.5 cm) below the boom. If working on the telescope cylinder, raise the boom above horizontal and extend the fly boom approximately 1 foot (30.5 cm).

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Turn ignition switch to ON, move control switch or lever for applicable cylinder in each direction, then turn ignition switch to OFF. This is done to relieve excess pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

Cylinders w/Single Counterbalance Valves

Lift Cylinder, Telescope Cylinder, Extend-A-Reach Cylinder (if equipped)

4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8

2-12 – JLG Lift – 3120636

Page 37

SECTION 2 - PROCEDURES

drops per minute or more, cylinder repairs must be made. If the retract port is leaking, the piston seals are defective and must be replaced. If the extend port is leaking, the counterbalance valve is defective and must be replaced.

5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

6. If used, remove boom prop or lifting device from boom, activate hydraulic system and run cylinder through one complete cycle to check for leaks.

Cylinders w/Dual Counterbalance Valve

Platform Slave Level Cylinder, Extend-A-Reach Slave Level Cylinder (if equipped), Axle Lift Cylinder (if equipped)

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

2. If working on the telescope cylinder, raise the boom above horizontal and extend the fly boom approximately 1 foot (30.5 cm). If working on the platform slave level cylinder, stroke platform level cylinder forward until platform sits at a 45° angle.

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Turn ignition switch to ON, move control switch or lever for applicable cylinder in each direction, then turn ignition switch to OFF. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

4. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced.

5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge, there should not be any further leakage from the ports. If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and must be replaced.

6. If no repairs are necessary or when repairs have been made, replace counterbalance valve and carefully reconnect hydraulic hoses to cylinder port block.

7. Activate hydraulic system and run cylinder through one complete cycle to check for leaks.

2.10 CYLINDER REMOVAL AND INSTALLATION

Telescope Cylinder Removal

1. Place machine on a flat and level surface, with axles extended and the boom fully retracted and in the horizontal position.

2. Shut down engine. Support boom platform end with a prop or suitable overhead lifting device.

3. Remove boom end cover.

4. Remove boom length/angle indicator from boom assembly.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.

5. Tag and disconnect hydraulic lines to telescope cylinder. Use suitable containers to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

6. Remove the two (2) cotter pins that retain the telescope rod attach pin to the base boom.

7. Using a suitable brass drift, carefully drive the telescope cylinder rod attach pin from the base boom.

8. Remove the telescope cylinder trunnion attach pin cover from each side of the base boom.

9. Remove the setscrews securing the telescope cylinder attach pin from each side of the telescope cylinder trunnion.

10. Using a suitable slide hammer, remove the half pins attaching the telescope cylinder to the inner mid boom section.

11. Attach a suitable sling to the telescope cylinder rod. Support with an overhead crane or other suitable lifting device.

12. Remove the rod support bracket at the aft end of the base boom.

13. Remove the two (2) extension chain adjusting nuts at the aft end of the base boom.

14. Remove the three (3) bolts, washers and lockwashers attaching the chain adjust bracket to the aft end of the base boom and remove bracket.

3120636 – JLG Lift – 2-13

Page 38

SECTION 2 - PROCEDURES

BARREL

PISTON

SPACER

HEAD

ROD SUPPORT

ROD

SETSCREW

PISTON SEALS

HEAD RETAINER

ROD

SUPPORT

BLOCK

HEAD SEALS

TELESCOPE

CYLINDER

BARREL

HEAD

RETAINER

HEAD SEALS

ROD

PISTON

SEALS

HOLDING

VALV E

SETSCREW

SPACER

AXLE LIFT CYLINDER

Figure 2-5. Typical Hydraulic Cylinders - Sheet 1 of 5

Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.

2-14 – JLG Lift – 3120636

Page 39

SECTION 2 - PROCEDURES

BARREL

HEAD

RETAINER

HEAD SEALS

ROD

PISTON

PISTON SEALS

HOLDING

VALV E

SETSCREW

SPACER

LIFT

CYLINDER

BARREL

HEAD

HEAD SEALS

ROD

SPACER

NUT

PISTON

SEALS

HOLDING

VALV E

HOLDING

VALV E

SETSCREW

SLAVE

CYLINDER

Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.

Figure 2-6. Typical Hydraulic Cylinders - Sheet 2 of 5

3120636 – JLG Lift – 2-15

Page 40

SECTION 2 - PROCEDURES

BARREL

PISTON

NUT

SPACER

HEAD

HEAD RETAINER

ROD

SETSCREW

PISTON SEALS

HEAD SEALS

MASTER

CYLINDER

BARREL

HEAD

HEAD SEALS

ROD

NUT

PISTON

SEALS

SETSCREWSETSCREW

SETSCREW

SPACER

STEER

CYLINDER

Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.

Figure 2-6. Typical Hydraulic Cylinders - Sheet 3 of 5

2-16 – JLG Lift – 3120636

Page 41

SECTION 2 - PROCEDURES

BARREL

HEAD

HEAD SEALS

ROD

SPACER

PISTON

SEALS

HOLDING

VALV E

HOLDING

VALV E

SETSCREW

SLAVE

CYLINDER

(Extend-A-Reach)

BARREL

HEAD

RETAINER

HEAD SEALS

ROD

SPACER

PISTON

SEALS

SETSCREW

NUT

AXLE

CYLINDER

Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.

Figure 2-6. Typical Hydraulic Cylinders - Sheet 4 of 5

3120636 – JLG Lift – 2-17

Page 42

SECTION 2 - PROCEDURES

BARREL

HEAD

RETAINER

HEAD SEALS

ROD

SPACER

NUT

PISTON

SEALS

SETSCREW

HOLDING

VALV E

EXTEND-A-REACH

LIFT CYLINDER

Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine.

Typical Hydraulic Cylinders - Sheet 5 of 5

1. Pull boom sections apart several feet.

2. Using the lifting equipment, raise the cylinder to obtain sufficient clearance for removal of the cylinder.

3. Connect a suitable lifting device to the extension chain adjust rod on top of the telescope cylinder.

4. Using both lifting devices, carefully pull the cylinder

8. Using another lifting device, support the sheave wheel end of the cylinder and remove the cylinder from the boom assembly.

9. Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area.

Telescope Cylinder Installation

from the boom assembly.

NOTE: The extension rod will come out of the boom twice as

far as the telescope cylinder proportionally.

5. Continue sliding the cylinder and extension rod out of the boom until the rod can be separated from the extension chain by removing the chain clevis attach pin.

6. Using the lifting equipment, remove the extension chain bar.

7. Continue sliding the cylinder from the boom, laying the extension chain on top of the base boom as the cylinder is coming out.

1. Using suitable lifting equipment, carefully lower the cylinder to the boom assembly.

2. Using another lifting device, support the sheave wheel end of the cylinder and install the cylinder into the boom assembly.

3. Slide the extension cylinder into the boom, sliding the extension chain in place as the cylinder is moving in.

4. Using the lifting equipment, install the extension chain bar.

5. Continue sliding the cylinder and extension rod into the boom until the rod can be attached to the extension chain by installing the chain clevis attach pin.

2-18 – JLG Lift – 3120636

Page 43

SECTION 2 - PROCEDURES

6. Install the chain adjust bracket and install the three (3) bolts, washers and lockwashers which attach the bracket to the aft end of the base boom.

7. Install the two (2) extension chain adjusting nuts at the aft end of the base boom.

8. Install the rod support bracket at the aft end of the base boom.

9. Remove the sling attached to the telescope cylinder rod.

10. Pull boom sections back into the fully retracted position.

11. Using a suitable brass drift, if necessary, install the half pins attaching the telescope cylinder to the inner mid boom section.

12. Install setscrews that attach the telescope cylinder attach pins to each side of the telescope cylinder trunnions.

13. Install the telescope cylinder trunnion attach pin cover to each side of the base boom.

14. Carefully install the telescope cylinder rod attach pin into the base boom.

15. Install the two (2) cotter pins that retain the telescope rod attach pin to the base boom.

16. Remove applicable hydraulic line and port caps and correctly connect the hydraulic lines to the telescope cylinder. Ensure that all hoses are correctly routed.

17. Cycle telescope function several times to dissipate any air from cylinder and lines. Properly torque boom chains to 59 ft. lb. (80 Nm).

18. Install boom length/angle indicator on boom assembly.

NOTE: Boom length/angle indicator will need to be adjusted

as per the procedure listed in Section 2.30, Boom Length/angle Sensor Adjustment Procedures.

19. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary.

20. Install boom end cover.

21. Retract boom fully and place in stowed position.

Lift Cylinder Removal

1. Place the machine on a flat and level surface. Start the engine and place the boom in a horizontal position. Shut down the engine and attach a suitable support device to the boom. Using a suitable brass drift drive out the cylinder rod attach pin.

2. Using auxiliary power, retract the lift cylinder rod completely.

3. Remove the barrel end attach pin retaining plate and hardware. Using a suitable brass drift drive out the barrel end attach pin from the upright.

4. Remove the cylinder from the boom and place in a suitable work area.

Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings or supports, aligning attach pin mounting holes on the upright.

2. Using a suitable drift, drive the barrel end attach pin through the mounting holes in the lift cylinder and the upright. Secure in place with the pin retaining plate and hardware.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. Using auxiliary power, extend the cylinder rod until the attach pin hole aligns with those in the boom. Using a suitable drift, drive the cylinder rod attach pin through the aligned holes, taking care to align the grooved pin holes. Secure the pin in place with the bolt, lockwasher and nut.

5. Place boom in the stowed position and shut down engine. Check hydraulic fluid level and adjust accordingly.

Master Level Cylinder Removal

1. With the main boom positioned to horizontal and properly supported, prepare to remove the upright level cylinder.

2. Remove the bolt, lockwasher and nut securing the level cylinder rod attach pin to the tower boom. Using an appropriate brass drift, drive out the level cylinder rod attach pin.

3. Tag, disconnect and cap hydraulic lines to level cylinder.

NOTE: When disconnecting hydraulic lines, any residual

hydraulic fluid should be drained into a suitable container.

4. Make up two temporary hose assemblies (3/8 In. x 10 ft.) to carry power from the turntable swing motor supply hoses to the lift cylinder. Couple temporary hoses to swing motor supply hoses, using reducer fittings if necessary. Plug ports in swing motor.

5. After installing temporary hoses, activate swing function, using auxiliary power, to fully retract level cylinder rod.

3120636 – JLG Lift – 2-19

Page 44

SECTION 2 - PROCEDURES

ROD SUPPORT

SUPPORT

TABLE

ROD CLAMP

PROTECTED

BARREL CLAMP

Figure 2-6. Cylinder Barrel Support

6. Remove temporary hoses from level cylinder and cap them. Plug cylinder ports.

7. Using slings, restrain level cylinder.

8. Remove retaining plate and bolts from upright cylinder attach pin.

9. Using an appropriate brass drift, drive out the upright attach pin. Carefully remove restraining slings and remove level cylinder from boom

Master Level Cylinder Installation

1. With the boom positioned at horizontal and properly supported, place the master level cylinder in position on the boom and secure in place using slings.

2. Align barrel end bushing with pin attach blocks in turntable upright and install upright attach pin using appropriate brass drift. Secure pin with retaining plate and retaining plate bolts.

3. Remove caps from temporary hydraulic lines and attach to level cylinder ports. Using auxiliary power, activate swing function and extend cylinder rod until rod bushing aligns with boom lift cylinder rod end attach bushing.

4. Using an appropriate brass drift drive the rod attach pin through the aligned bushings of the cylinder rod and boom lift cylinder rod end attach plate, taking care to align holes for bolt attachment. Secure rod end attach pin with bolt, lockwasher and nut.

5. Remove restraining slings from level cylinder.

1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.

3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

6. Remove temporary hydraulic lines from cylinder ports and turntable swing motor hydraulic supply. Reattach hydraulic supply to swing motor.

7. Remove caps from cylinder hydraulic lines and correctly install lines to cylinder.

8. Remove boom support. Place boom in stowed position. Check hydraulic fluid level and adjust accordingly.

2.11 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.

4. Place the cylinder barrel into a suitable holding fixture.

5. Tap around outside of cylinder head retainer, if applicable, and/or cylinder head gland with a suitable hammer to shatter loctite.

6. Using a suitable spanner wrench or chain wrench, loosen the cylinder head retainer, if applicable, and/ or cylinder head gland, and remove from cylinder barrel. If using a chain wrench, keep wrench toward outside (rod side) of gland nut to avoid distorting threads.

7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

2-20 – JLG Lift – 3120636

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

Page 45

SECTION 2 - PROCEDURES

ROD SUPPORTROD SUPPORT

SUPPORT TABLE

ROD CLAMP

PROTECTED

Figure 2-7. Cylinder Rod Support

8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

ONCE THE HEAD GLAND HAS CLEARED THE CYLINDER CASE MOUTH, THE ROD MUST BE SUPPORTED CLOSE TO THE CYLINDER CASE PRIOR TO THE PISTON BEING PULLED PAST THE CYLINDER CASE THREADS. THIS IS DONE TO AVOID DAMAGE TO THE CYLINDER CASE THREADS, AND/OR THE PISTON AND PISTON SEALS.

9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

10. Remove the set screw(s), if applicable, and nut which attach the piston to the rod, and remove the piston. Discard nylon point set screws.

11. Remove the piston rings.

12. Remove and discard the piston o-rings, seal rings, and backup rings.

13. Remove the set screw, if applicable, piston spacer, and wear ring, if applicable, from the rod.

14. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer, if applicable. Discard the o-rings, back-up rings, rod seals, and wiper seals.

3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress threads as necessary.

6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.

7. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

8. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.

9. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

10. If applicable, inspect cylinder head retainer or end cap for surface or thread damage. Repair or replace as necessary.

11. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

12. If applicable, inspect thread ring for scoring or other damage. Dress threads or applicable surfaces as necessary.

13. If applicable, inspect rod and barrel bushings for signs of correct lubrication and excessive wear. Replace as necessary.

14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

3120636 – JLG Lift – 2-21

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SECTION 2 - PROCEDURES

Figure 2-8. Poly-Pak Seal Installation

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is used. See your JLG Parts Manual.



Apply a light film of hydraulic oil to all components prior to assembly.

WHEN INSTALLING NEW “POLY-PAK” TYPE PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO FIGURE 2-8., POLY-PAK SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Table 2-2.Cylinder Piston Nut Torque Specifications.

Nut



Description

Lift Cylinder 600 ft. lbs.

Slave Cylinder 80 ft. lbs.

Master Cylinder 80 ft. lbs.

Steer Cylinder 80 ft. lbs.

Telesco pe Cylinder 600 ft. lbs.

Axle Extension Cylinder 80 ft. lbs.

Axle Lift Cylinder 400 ft. lbs.

Lift Cylinder 400 ft. lbs.

Slave Cylinder 200 ft. lbs.

Torque Value

(Wet)

(814 Nm)

(109 Nm)

(814 Nm)

(109 Nm)

(553 Nm)

Extend - A - Reach

(553 Nm)

(271 Nm)

Setscrew

Torque Value

(Dry)

200 in. lbs.

(22.5 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

100 in. lbs.

(12 Nm)

1. Place a new wiper seal and rod seal into the applicable cylinder head gland grooves.

2. Carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.

3. Carefully slide the piston spacer on the rod. If applicable, align the oil holes in the rod and the spacer. Secure the spacer, if applicable.

4. If applicable, correctly place a new o-ring and backup rings in the inner piston diameter groove.

5. Carefully place the piston on the cylinder rod, ensuring that the o-ring and back-up rings are not damaged or dislodged.

6. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

7. Push the piston onto the rod until it abuts the spacer end and install the attaching nut.

IF CYLINDER IS EQUIPPED WITH A PISTON NUT, APPLY “LOCQUIC PRIMER T” AND LOCTITE #242 TO PISTON NUT THREADS, THEN TIGHTEN NUT TO TORQUE SHOWN IN TABLE 2-2, CYLINDER PISTON NUT TORQUE SPECIFICATIONS.

NOTE: Self-locking setscrews used on piston nuts should be

discarded and replaced whenever they are removed.

8. If applicable, torque the piston nut to the proper torque as outlined in Table 2-2. Spot drill the piston rod at the point where the setscrew is inserted into the piston nut. Install the setscrew(s) which secure the piston attaching nut to the diameter groove.

9. Remove the cylinder rod from the holding fixture.

10. Place new o-rings and seals in the applicable outside diameter grooves of both the piston and the cylinder head.

11. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

12. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

2-22 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

13. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder or, if applicable, until the cylinder head threads engage the threads of the barrel.

14. If applicable, secure the cylinder head retainer using a suitable spanner type wrench in the holes provided.

15. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

16. If applicable, install the cartridge-type holding valve and fittings in the rod port block using new o-rings as applicable. Torque holding valves in accordance with Table 2-3, Holding Valve Torque Specifications.

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD.

Table 2-3.Holding Valve Torque Specifications

Description Torque Value

Sun - 7/8 Hex M20 x 1.5 Thds. 30-35 ft. lbs.

(41-48 Nm)

Sun - 1 1/8 Hex 1/14 UND Thds. 45-50 ft. lbs.

(61-68 Nm)

Sun - 1 1/4 Hex M36 x 2 Thds. 150-160 ft. lbs.

(204-217 Nm)

Racine - 1 1/8 Hex 1 1/16 - 12 Thds. 50-55 ft. lbs.

(68-75 Nm)

Racine - 1 3/8 Hex 1 3/16 - 12 Thds. 75-80 ft. lbs.

(102-109 Nm)

Racine - 1 7/8 Hex 1 5/8 - 12 Thds. 100-110 ft. lbs.

(136-149 Nm)

NOTE: Steps (17) thru (20) apply to the telescope cylinder.

17. Elevate the barrel end of the cylinder to a work bench or other suitable device.

18. Plug the retract port and supply hydraulic power to the extend port.

19. Open the bleeder port plug (TP), venting all trapped air to atmosphere. Retighten the bleeder port plug. Disconnect the hydraulic power source and remove plug from retract port.

20. An alternative to steps (18) thru (20) is to position the barrel horizontally in a suitable holding device, attach a hydraulic power source to both extend and

retract ports, while supporting the cylinder rod, cycle the cylinder a minimum of 5 times with the bleeder port unplugged, venting all trapped air to atmosphere. A suitable hose may be attached to the bleeder port with the end in a container suitable to contain the hydraulic fluid. After all air is vented remove all attached hoses, and install the bleeder port plug. Also plug the extend and retract ports until cylinder is installed in boom.

2.12 BOOM MAINTENANCE

Removal

1. Shut down machine systems.

NOTE: Boom Assembly weighs approximately 10,000 (4536

kg).

2. Using suitable lifting equipment, adequately support boom weight along entire length of retracted boom.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

3. Tag and disconnect hydraulic lines that run along the side of the boom.

4. Remove hardware attaching upper lift cylinder attach pin to boom.

5. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from boom.

6. Using all applicable safety precautions, and only if necessary, operate crane and fully retract lift cylinder.

7. Shut down machine systems.

8. Tag and disconnect all wiring to ground control box.

9. Remove boom length/angle indicator box.

10. Loosen and remove hardware securing boom pivot pin.

11. Ensuring that boom is adequately supported and using a suitable slide hammer, carefully remove pivot pin from boom and turntable structure. Ensure that boom and turntable structure are not damaged.

12. Carefully lift boom assembly clear of turntable and lower to ground or suitably supported work surface.

3120636 – JLG Lift – 2-23

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SECTION 2 - PROCEDURES

Disassembly

NOTE: Left or right is determined facing the machine from

the platform.

1. Loosen the right side powertrack bracket and powertrack and lay on top of boom assembly.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

2. Tag and disconnect hydraulic lines to slave level cylinder and rotator motor.

3. Tag and disconnect wiring to platform control box.

4. Remove the left side powertrack.

5. Remove platform from boom assembly.

6. Remove cotter pins retaining telescope cylinder rod attach pin to base section.

7. Using a suitable brass drift, carefully drive telescope cylinder pin from base section.

8. Remove outer mid section extend chain adjust nut and locknut at upper aft end of base section.

9. Remove bolts, washers and lockwashers attaching outer mid section extend chain attach block to upper aft end of base section. Remove block.

10. Remove fly section extend chain adjust nut and locknut at lower front end of inner mid section.

11. Remove outer mid section retract chain adjust nut and locknut at lower front end of base section.

12. Remove fly section retract chain adjust nut and locknut at lower front end of inner mid section.

NOTE: Note and record the number and thickness of any

wear pad shims during wear pad removal.

13. Remove bolts and lockwashers attaching side wear pads to front of base section. Remove pads and any shims.

14. Remove bolts, washers and lockwashers attaching lower front wear pads and mounting blocks to base section. While supporting assembled fly, outer mid and inner mid sections, remove wear pads, mounting blocks and shims.

   

15. Remove bolts and lockwashers attaching top front wear pad to base section. Remove pad and shims.

16. Using suitable lifting equipment, partially slide assembled inner mid, outer mid and fly sections out of base section.

17. Using suitable straps, tie off outer mid section retract chains to underside of inner mid section as inner mid, outer mid and fly sections are exiting base section.

18. Carefully lift inner mid, outer mid and fly sections clear of base section and lower to a suitably supported work area.

19. Using suitable lifting equipment, support telescope cylinder rod.

20. Remove setscrews securing trunnion pins that secure inner mid section to telescope cylinder.

21. Using a suitable tool, scribe a line on the outer end of each trunnion pin and boom structure as an aid to pin alignment during boom assembly.

22. Using a suitable slide hammer, remove trunnion pins attaching telescope cylinder to inner mid section.

23. Remove cotter pins and chain attach pins attaching outer mid section retract chains to lower aft end of outer mid section and remove chains.

24. Remove setscrews which attach chain sheave pins at lower aft end of inner mid section.

25. Using a suitable brass drift, carefully drive sheave pins from inner mid section and remove sheaves and thrust washers. If necessary, remove bushings from sheaves and replace. Ensure that pins, grease fittings and corresponding boom and sheave surfaces are not damaged.

26. Remove cotter pins and chain attach pins attaching fly section retract chains to lower aft end of fly section and remove chains.

27. Remove setscrews which attach chain sheave pins at lower aft end of outer mid section.

28. Using a suitable brass drift, carefully drive sheave pins from outer mid section and remove sheaves, seals, and thrustwashers. If necessary, remove bushings from sheaves and replace. Ensure that pins, grease fittings and corresponding boom and sheave surfaces are not damaged.

    

2-24 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

29. Pull boom sections out several feet to allow ample clearance for telescope cylinder removal.

30. Remove outer mid section extension chain adjust nut and locknut from clevis at lower aft end of outer mid section.

31. Using suitable lifting equipment, carefully slide telescope cylinder out of fly, outer mid, and inner mid sections, along with extension chain and bar.

32. When approximately one-half of the telescope cylinder is removed from the boom assembly, the extension bar attach to chain will become accessible. Remove cotter pins and clevis pin attaching extension bar to chain and remove bar.

33. Carefully lift telescope cylinder clear of boom assembly and lower to ground or suitably supported work area.

34. Remove bolts attaching outer mid section retract chain adjust block at lower front end of inner mid section and remove block.

NOTE: Note and record number and thickness of any wear

pad shims during wear pad removal.

35. Remove bolts and lockwashers which attach upper aft inner mid section wear pads and remove pads and any shims.

36. Remove bolts, washers and lockwashers which attach bottom wear pads at front of inner mid section and remove pads and any shims.

37. Remove bolts and lockwashers which attach side wear pads at front of inner mid section and remove pads and any shims.

                  

38. Remove bolts and lockwashers which attach top wear pad at front of inner mid section and remove pad and any shims.

39. Using suitable lifting equipment, carefully slide outer mid and fly sections clear of inner mid section and lower to ground or other suitably supported work area.

40. Remove bolts and lockwashers which attach upper aft outer mid section wear pads and remove pads and any shims.

41. Remove bolts and lockwashers which attach bottom wear pads at front of outer mid section and remove pads and any shims.

42. Remove bolts and lockwashers which attach side wear pads at front of outer mid section and remove pads and any shims.

43. Remove bolts and lockwashers which attach top wear pads to front of outer mid section and remove pads and any shims.

44. Remove bolt, washer and lockwasher attaching fly section right hand extend chain sheave attach pin to front of outer mid section.

45. Using a suitable brass drift, carefully drive each sheave pin from the boom section and remove the sheave assemblies. Inspect pins, lubrication fittings and sheave bearings for damage and dirt or foreign material. Replace components as necessary.

46. Repeat steps (42) and (43) for left hand sheave.

47. Using suitable lifting equipment, carefully slide fly section clear of outer mid section and lower to ground or suitably supported work area.

3120636 – JLG Lift – 2-25

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SECTION 2 - PROCEDURES

Figure 2-9. Boom Assembly - Sheet 1 of 2

2-26 – JLG Lift – 3120636

Page 51

SECTION 2 - PROCEDURES

1. Boom Base

2. Inner Mid Boom

3. Outer Mid Boom

4. Fly Boom

5. Telescope Cylinder

6. Outer Mid Extend Chain

7. Fly Extend Chain

8. Fly Retract Chain

9. Outer Mid Retract Chain

10. Tele Cylinder Sheave

11. Sheave

12. Chain Extend Rod

13. Chain Attach Pin

14. Chain Adjustment Assembly

15. Chain Adjustment Assembly

16. Upper Rear Wear Pad

17. Adjustment & Jam Nuts

18. Safety Chain

Figure 2-10. Boom Assembly - Sheet 2 of 2

3120636 – JLG Lift – 2-27

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SECTION 2 - PROCEDURES

Inspection

1. Inspect all sheaves (extend chains, retract chains and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as necessary.

2. Inspect extend chain and retract chain sheave bearings for wear, scoring, or other damage, and for ovality. Replace bearings as necessary, ensuring they are installed flush with sheave surface.

3. Inspect extend chain and retract chain sheave pins for scoring, tapering, ovality and evidence of correct lubrication. Replace pins as necessary.

4. Inspect telescope cylinder sheave pin for tapering, scoring, ovality and evidence of correct lubrication. Replace pin as necessary.

5. Inspect boom pivot pin for wear, scoring or other damage, and for tapering or ovality. Replace pin as necessary.

6. Inspect upper lift cylinder attach pin for tapering, ovality, scoring, wear, or other damage. Ensure pin surfaces are protected prior to installation. Replace pin as necessary.

7. Inspect telescope cylinder trunnion attach pin for tapering, ovality, scoring, wear, or other damage. Replace pin as necessary.

8. Inspect extend chain attach clevis pins for wear, scoring, or other damage. Replace pins as necessary.

9. Inspect telescope cylinder rod attach pin for scoring, wear, or other damage. Replace pin as necessary.

10. Inspect inner diameter of boom pivot bushing for scoring, distortion, wear, or other damage. Replace bushing as necessary.

11. Inspect all wear pads for excessive wear or damage. Replace pads when worn to within 1/8 in. (3.2 mm) of insert.

12. Inspect extend and retract chains and chain attach components for cracks, stretching, distortion, or other damage. Replace components as necessary.

13. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.

14. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.

Assembly

NOTE: When installing fly section wear pads, install same

number and thickness of shims as were removed during disassembly.

1. Install upper aft fly section wear pads and shims, as required, using bolts and lockwashers.

2. Using suitable lifting equipment, carefully slide fly section into outer mid section.

3. Install fly section extend chain sheaves on front of outer mid section and install sheave pins. If necessary, tap pins into place using a soft headed mallet. Secure pins using bolts, washers and lockwashers.

4. Install lubrication fittings in ends of pins and lubricate sheaves with MPG.

NOTE: When installing outer mid section wear pads, install

same number and thickness of shims as were removed during disassembly.

5. Install outer mid section top front wear pads and shims, as required, using bolts and lockwashers.

6. Install outer mid section side front wear pads and shims, as required, using bolts and lockwashers.

7. Install outer mid section bottom front wear pads and shims, as required, using bolts and lockwashers.

8. Install outer mid section upper aft wear pads and shims, as required, using bolts and lockwashers.

9. Using suitable lifting equipment, carefully slide assembled outer mid and fly sections into inner mid section.

NOTE: When installing inner mid section wear pads, install

same number and thickness of shims as were removed during disassembly.

10. Install inner mid section top front wear pads and shims, as required, using bolts and lockwashers.

11. Install inner mid section side front wear pads and shims, as required, using bolts and lockwashers.

12. Install inner mid section bottom front wear pads and shims, as required, using bolts, washers and lockwashers.

      

2-28 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

13. Install inner mid section upper aft wear pads and shims, as required, using bolts and lockwashers.

14. Install fly section retract chain adjust block on lower front end of inner mid section and secure with bolts.

15. Place outer mid section extend chain assembly along telescope cylinder chain rest with chain adjust assembly hanging just below cylinder sheave.

16. Using lightweight motor oil (SAE 20W), adequately lubricate portion of chain occupying cylinder chain rest.

17. Using suitable lifting equipment, maneuver telescope cylinder and outer mid section extend chain assembly into position at aft end of assembled boom sections.

18. With a slight downward angle on the cylinder, insert sheave and chain adjust into boom sections until it is possible to insert chain adjust into attach block at rear of outer mid section. Temporarily install chain adjust and locknuts.

19. Carefully feed telescope cylinder approximately halfway into boom sections, lubricating chain with lightweight motor oil as it passes along chain rest. Attach extension bar to chain and continue inserting into boom sections.

20. Install fly section retract chain sheaves, seals and thrustwashers at aft end of outer mid section.

21. Install sheave pins and if necessary, tap pins into place using a soft headed mallet. Secure pins with setscrews.

22. Install lubrication fittings on ends of pins and lubricate sheaves with MPG.

23. Install fly section retract chains at lower aft end of fly section. Install chain attach pins and flatwashers and secure with cotter pins.

24. Carefully place fly section retract chains around chain sheaves at aft end of inner mid section and through bottom of inner mid section.

          

25. Install fly section retract chain clevis into attach block at lower front end of inner mid section. Install adjust nut and locknut on clevis.

26. Install outer mid section retract chain sheaves and thrust washers at aft end of inner mid section.

27. Install sheave pins and, if necessary, tap pins into place using a soft headed mallet. Secure pins with setscrews.

28. Install lubrication fittings on ends of pins and lubricate sheaves with MPG.

29. Install outer mid section retract chains at lower aft end of outer mid section. Install chain attach pins and flatwashers and secure with cotter pins.

30. Carefully place outer mid section retract chains around chain sheaves at aft end of inner mid section. Tie chains to underside of inner mid section using suitable straps.

31. Using suitable lifting equipment, carefully align holes in telescope cylinder trunnion and holes in aft end of inner mid section.

32. Install trunnion pins, ensuring that holes in pins align with holes in trunnion. If necessary, tap pins into place with a soft headed mallet. Secure pins with setscrews.

33. Using suitable lifting equipment, carefully slide assembled inner mid, outer mid, and fly sections into base section.

34. As sections are being installed, remove straps from outer mid section retract chains and feed attach clevis through holes in bottom of forward end of base section.

35. Install outer mid section retract chain clevis into attach block at lower front end of base boom section. Install adjust nut and locknut on clevis.

              

3120636 – JLG Lift – 2-29

Page 54

SECTION 2 - PROCEDURES

NOTE: When installing base section wear pads, install same

number and thickness of shims as were removed during disassembly.

36. Install base section top front wear pads and shims, as required, using bolts and lockwashers.

37. Install base section lower front wear pads, mounting blocks, and shims, as required, using bolts, washers, and lockwashers.

38. Install base section side front wear pads and shims, as required, using bolts and lockwashers.

39. Carefully align telescope cylinder rod end with holes in aft end of base boom section and install attach pin. If necessary, tap pin into place using a soft headed mallet. Secure pin with cotter pins.

40. Install outer mid section extend chain attach block at aft end of base section and secure with bolts and lockwashers.

41. Install outer mid section extend chain clevis through hole in attach block and secure with adjust nut and locknut.

42. Attach platform to boom assembly.

43. Attach the left side powertrack to boom assembly.

6. If necessary, gently tap pin into position with a soft headed mallet, ensuring that pin plate holes are aligned with attach holes in boom structure. Install pin attaching bolts, washers and lockwashers.

7. Shut down machine systems.

8. Connect hydraulic lines running along side of boom.

9. Install boom length/angle sensor box. Adjust boom length/angle sensor box in accordance with paragraph 2-30.

10. Using all applicable safety precautions, operate machine systems and raise and extend boom fully, noting the performance of the extension cycle. If chattering is apparent, extend chain system requires adjustment.

11. Retract and lower boom, noting performance of retraction cycle. If chattering is apparent, retract chain system requires adjustment.

12. Shut down machine systems.

13. Adjust extend and retract chain systems as required and secure adjustment locknuts.

14. As necessary, lubricate all points requiring lubrication.

44. Connect wiring to platform control box.

45. Connect hydraulic lines to slave level cylinder and rotator motor.

46. Attach the right side powertrack bracket and powertrack to boom assembly.

Installation

1. Using suitable lifting equipment, position assembled boom on turntable so that boom pivot holes in both boom and turntable are aligned.

2. Insert boom pivot pin, ensuring that locating slots in pin are aligned with setscrew locating holes in pin bushings.

3. If necessary, gently tap pin into position with a soft headed mallet. Secure pin with setscrews.

4. Connect all wiring to ground control box.

5. Using all applicable safety precautions, operate lifting equipment in order to position boom lift cylinder so that holes in cylinder rod end and boom structure are aligned. Insert lift cylinder pin.

   

2.13 TILT ALARM SWITCH LEVELING

NOTE: Each machine is equipped with a tilt alarm switch,

factory set to activate at 5 degrees, which will illuminate a warning light, sound a warning horn and cut out 2 Speed Drive. Consult factory for tilt sensor adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs. There are two methods of adjustment, a manual adjustment and an adjustment using a voltmeter.

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.

Manual Adjustment

1. Park the machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure.

NOTE: Ensure switch mounting bracket is level and securely

attached.

2. Level the base of the indicator by tightening the three flange nuts. Tighten each nut through approximately one half of it’s spring’s travel. DO NOT ADJUST THE “X” NUT DURING THE REMAINDER OF THE PROCEDURE.

2-30 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

YELLOW

BLACK

WHITE

RED

Figure 2-11. Tilt Switch Adjustment - Voltmeter

Figure 2-12. Tilt Switch Adjustment - Manual

3. With the electrical connections complete, slowly tighten one of the “Y” nuts until the circuit is closed and the light on the Platform Control Console illuminates.

6. Repeat steps 3 through 5 for the remaining “Y” nut. The switch is now level.

7. Individually push down on one corner at a time; there should be enough travel to cause the switch to trip. If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the “X” nut and repeat steps 3 through 7.

Voltmeter Adjustment

1. Park machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure.

2. If engine is not running, turn ignition switch to ON.

3. Connect black lead of voltmeter to ground and red lead to yellow wire protruding from pot on bottom of sensor.

4. Adjust leveling nuts to obtain the highest possible voltage reading.

4. Slowly back off the nut, counting the number of turns, until the circuit is again closed and the light again illuminates.

5. Check voltage at trip point in all four directions. If voltage reading is not symmetrical, repeat step 4 above.



5. Divide the number of turns determined in step 4 in half. Tighten the nut this many turns. The line determined by this nut and the “X” nut is now parallel to the ground.

    

  

3120636 – JLG Lift – 2-31

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SECTION 2 - PROCEDURES

1/32"

2.14 LIMIT SWITCH ADJUSTMENTS

Boom Limit Switch

The boom limit switch is located on the left side of the base section of the boom. The switch will activate when the boom is extended past a set point with the axles retracted. When activated, the switch cuts out Telescope Out and Lift Up. Adjust the limit switch to trip at 10 feet (3 meters) of boom extension.

Horizontal Cut-Out Switch

The horizontal cut-out switch is located on the right side of the boom at the boom pivot pin. When activated, the switch cuts out the High Engine, High Drive and 2 Speed functions. Adjust the switch to activate when the boom reaches horizontal.

2.15 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ F4L-912 ENGINE

NOTE: Never run fuel tank dry. Diesel engines cannot be

restarted after running out of fuel until fuel system has been air-vented or “bled” of air. See Deutz instruction manual for procedure.

2.16 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS - FORD ENGINE

Checks

1. Check that anti-dieseling solenoid is operating. If solenoid is operating, an audible click at the carburetor should be heard when the ignition is switched on.

2. Check throttle linkage for smooth operation by rotating throttle lever by hand to full throttle position, then slowly back to idle position, felling closely for sticking or binding. To accomplish this, the throttle must first be disconnected.

Automatic Choke Adjustments

1. At 70°F the choke plate should be open 1/32" (not touching the choke bore).

2. If the ambient temperature is not 70°F, an additional adjustment is required.

a. Loosen the three cover plate screws.

b. Adjust the cover to open the choke plate 1/32".

1. Disconnect actuator cable from throttle lever. With the aid of an assistant, start the engine and allow it to come up to operating temperature. Adjust throttle lever stop until engine runs at 1800 RPM. Shut down engine. Reattach actuator cable to throttle lever, making sure that low (mid) engine setting remains the same. If necessary, adjust slide pin to contact low (mid) engine limit switch at 1800 RPM. Shut down engine.

2. Start the engine from ground controls and allow to come up to operating temperature. Inside the ground control terminal box, attach a “hot” wire from the 12 Volt power (red) wire at the PLATFORM/ GROUND SELECT switch to terminal 1 (brown/black wire) on the relay circuit card at the top of the ground control terminal box. This will cause the engine to run as if HIGH ENGINE and HIGH DRIVE are activated. Adjust slide pin to contact high engine limit switch at 2500 RPM. Remove “hot” wire from terminal 1 and from PLATFORM/GROUND SELECT switch. Shut down engine.

NOTE: Actuator cable travel must stop slightly before lever

makes contact with throttle lever stop. Failure to do so will burn out actuator.

            

2-32 – JLG Lift – 3120636

Page 57

SECTION 2 - PROCEDURES

ACTUATOR CABLE

ADECO ACTUATOR

LOW ENGINE

HIGH ENGINE LIMIT SWITCH

SLIDE PIN (2)

SLIDE PIN (1)

LIMIT SWITCH

THROTTLE LEVER

THROTTLE LEVER STOP

INJECTION PUMP

ACTUATOR CABLE

ADECO ACTUATOR

Figure 2-13. Throttle Checks and Adjustments - Deutz Engine

3120636 – JLG Lift – 2-33

Page 58

SECTION 2 - PROCEDURES

PC BOARD

DROOP P3

GAIN P2

LOW (MID)

ENGINE

ADJUSTMENT

HIGH ENGINE P1

NOTE

All pots should be sealed with finger nail polish or its equivalent after all adjustments

are completed.

Figure 2-15. Precision Governor Adjustment - Ford Engine - Sheet 2 of 2

2-34 – JLG Lift – 3120636

Page 59

SECTION 2 - PROCEDURES

CHOKE

VACUUM PULLOFF

IDLE SPEED

SCREW

THROTTLE

LEVER

THROTTLE

ROD

LINKAGE

HIGH ENGINE NO LOAD, BUFFER SCREW

FUEL SHUT OFF VALVE

PRECISION

GOVERNOR

ACTUATOR

FUEL

SHUTOFF

VALVE

IDLE

AIR

MIXTURE

Figure 2-14. Precision Governor Adjustment - Ford Engine - Sheet 1 of 2

3120636 – JLG Lift – 2-35

Page 60

SECTION 2 - PROCEDURES

MARK

c. Readjust for ambient temperature by rotating the

cover one (1) mark per 5°F from 70°F. Rotate CCW (lean) if warmer than 70°, CW (rich) if colder than 70°. (If actual temperature is 80°, set at 1/32" and rotate two (2) marks CCW [lean] direction.)

d. Tighten the three cover plate screws and check

for free rotation (no sticking or binding) of the choke shaft.

Carburetor and Governor Adjustments

‘high engine’ (P1) adjusting screw until engine runs at 3000 RPM. Turning the screw CW increases RPM. Turning the screw CCW decreases RPM.

8. While your assistant continues to depress the footswitch, have them place engine speed switch to LOW ENGINE. Turn ‘low (mid) engine’ adjusting screw until engine runs at 1625 RPM. Turning the screw CW increases RPM. Turning the screw CCW decreases RPM. Shut down engine.

NOTE: If engine surges under no load and you cannot get

enough response from adjusting ‘gain’ (P2), try adjusting surge screw on actuator. Loosen surge screw locknut. Disconnect throttle linkage. Turn surge screw CW until linkage arm moves. Manually stroke the linkage fully and allow to return slowly until it stops. Try to move linkage toward return position. If linkage moves, turn surge screw CCW 1/2 turn. Again stroke linkage and allow to return slowly until it stops. Try to move linkage toward return position. If linkage moves, turn surge screw CCW 1/2 turn. Again stroke linkage and allow to return slowly until it stops. Try to move linkage toward return position. If linkage moves, turn surge screw CCW 1/2 turn. Repeat this procedure until linkage does not move after stroking. This will set buffer spring tension properly. Reconnect throttle linkage.

1. With the aid of an assistant, start the engine at the platform console and allow it to come up to operating temperature with the air cleaner installed. Adjust carburetor idle screw until engine idles at 1000 RPM. Shut down engine.

NOTE: Steps 2, 3, and 4 are preliminary settings.

2. With engine shut down, turn ‘low (mid) engine’ adjusting screw CCW to the stop. Do not turn past stop, as this breaks the pot, disabling the governor.

3. On controller, turn ‘high engine’ (P1) adjusting screw 25-30 turns CCW, then 10 turns CW.

4. On controller, turn ‘gain’ (P2) adjusting screw CCW to the stop, then CW until screw slot is vertical (approximately 1/4 turn).

5. On controller, turn ‘droop’ (P3) adjusting screw CCW to the stop, then CW until screw slot is vertical (approximately 1/4 turn). No further adjustment should be necessary to ‘droop’ (P3).

6. With the aid of an assistant at platform control console, start engine and allow to come up to operating temperature. Then have assistant depress footswitch and place engine speed switch to HIGH ENGINE.

7. If engine surging occurs at this point, turn ‘gain’ (P2) adjusting screw CCW until surging ceases. Turn

9. With engine speed switch set to LOW ENGINE, when footswitch is depressed, engine should immediately respond. If response times lags, turn ‘gain’ (P2) adjusting screw CW to improve response time. Turn adjusting screw in small increments only until response time is correct. Turning adjusting screw too far CW can cause surging. (See step (7) above.)

2.17 PRESSURE SETTING PROCEDURES

Sequence Pressure (Prior to 1990)

1. Plug pressure gauge into quick-connect on high drive dump valve. Monitor gauge.

2. On sequence valve, loosen nut at main relief. On sequence valve 4640535 depress plunger; on sequence valve 4640580 use an allen wrench to turn the plunger in. Use plunger to set main relief to 300 psi (21 bar).

3. Loosen nut on sequence cartridge and adjust sequence pressure to 450 psi (31 bar). Tighten nut.

4. Use plunger to set main relief to 3500 psi (241 bar) and tighten nut on main relief cartridge.

5. Remove pressure gauge.

2-36 – JLG Lift – 3120636

Page 61

Pressure Reducing Cartridge

Sequence Cartridge

Main Relief

Install pressure gauge at quick disconnect

Swing Adjustment

Drive Adjustment

Telescope In Adjustment - A Side Telescope In Adjustment - B Side

Lift Down Adjustment - A Side Lift Up Adjustment - B Side

ACCESSORY VALVE

PROPORTIONAL VALVE

Figure 2-16. Pressure Setting Adjustments

(Sheet 1 of 3)

SECTION 2 - PROCEDURES

3120636 – JLG Lift – 2-37

Page 62

SECTION 2 - PROCEDURES

MAIN RELIEF ADJUSTMENT

ROTATE LEFT & ROTATE RIGHT

ADJUSTMENT

STEER LEFT & STEER RIGHT ADJUSTMENT

CHECK POINT FOR LEVEL, STEER, ROTATE, AND MAIN RELIEF

SOLENOID (Bang-Bang) VALVE

Machines Built to 1995

Figure 2-14. Pressure Setting Adjustments (Sheet 2 of 3)

2-38 – JLG Lift – 3120636

Page 63

MAIN RELIEF ADJUSTMENT

ROTATE LEFT & ROTATE RIGHT

ADJUSTMENT

STEER LEFT & STEER RIGHT ADJUSTMENT

CHECK POINT FOR LEVEL, STEER, ROTATE, AND MAIN RELIEF

SOLENOID (Bang-Bang) VALVE

Machines Built 1995 to Present

Figure 2-14. Pressure Setting Adjustments (Sheet 3 of 3)

SECTION 2 - PROCEDURES

3120636 – JLG Lift – 2-39

Page 64

SECTION 2 - PROCEDURES

Sequence Pressure (1990 to Present)

1. Plug pressure gauge into quick-connect on high drive dump valve. Monitor gauge.

2. Run an electrical current to activate the dump valve.

3. Loosen the lock nut on sequence cartridge and adjust sequence pressure to 450 psi (31 bar). Turn the adjusting screw clockwise to increase pressure or counterclockwise to decrease pressure.

4. Tighten the lock nut and remove the electrical current from the dump valve.

5. Remove pressure gauge.

Pilot Pressure

1. Plug pressure gauge into quick-connect on accessory valve at PO port. Monitor gauge.

2. Activate lift down function and bottom out function.

3. Loosen nut on pressure reducing cartridge and adjust cartridge to 550 psi (38 bar). Tighten nut.

4. Release lift down function.

5. Remove pressure gauge.

Proportional Valve

NOTE: Make all proportional valve adjustments with engine

at low rpm and pressure gauge attached to quickconnect on high drive dump valve.

1. Swing Relief.

a. Plug pressure gauge into quick-connect on high

drive dump valve.

b. Lock turntable, activate swing right function, bot-

tom out function and monitor pressure gauge.

c. Remove torque plug at swing right relief and

adjust pressure to 1200 psi (83 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

d. Release swing right function, activate swing left

function, bottom out function and monitor pressure gauge.

e. Remove torque plug at swing left relief and

adjust pressure to 1200 psi (83 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

f. Release swing left function and unlock turntable.

2. Lift Down Relief.

a. Activate lift down function, bottom out function

and monitor pressure gauge.

b. Remove torque plug at lift down relief and adjust

pressure to 1200 psi (83 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

c. Release lift down function.

3. Lift Up Relief.

a. Activate lift up function, bottom out function and

monitor pressure gauge.

b. Remove torque plug at lift up relief and adjust

pressure to 3000 psi (207 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

c. Release lift up function.

4. Telescope In Relief.

a. Activate telescope in function, bottom out func-

tion and monitor pressure gauge.

b. Remove torque plug at telescope in relief and

adjust pressure to 2500 psi (172 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

c. Release telescope in function.

5. Telescope Out Relief.

a. Activate telescope out function, bottom out func-

tion and monitor pressure gauge.

b. Remove torque plug at telescope out relief and

adjust pressure to 1500 psi (103 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

c. Release telescope out function.

6. Drive Relief.

a. Disconnect and cap hose to drive motor and

plug port on drive section of proportional valve. Monitor pressure gauge.

b. Have an assistant activate drive forward.

c. Remove torque plug at drive forward relief and

adjust pressure to 3500 psi (241 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

d. Have assistant deactivate drive forward and acti-

vate drive reverse.

e. Remove torque plug at drive reverse relief and

adjust pressure to 3500 psi (241 bar). Add shims to increase pressure, remove shims to decrease pressure. Install torque plug.

f. Have assistant deactivate drive reverse.

g. Remove plugs from drive ports on proportional

valve and reconnect drive motor hoses to valve.

2-40 – JLG Lift – 3120636

Page 65

SECTION 2 - PROCEDURES

7. Main Relief.

a. Disconnect and cap hoses to drive motor; plug

ports on drive section of proportional valve. Monitor pressure gauge.

b. On accessory valve, loosen nut on main relief

cartridge and back out adjustment two (2) turns (CCW).

c. Have an assistant activate drive function.

d. Slowly turn adjustment in (CW) and watch pres-

sure gauge. Continue turning until gauge stops moving (approximately 3500 psi [241 bar]).

e. Turn adjustment in an additional 1/2 turn. This

will result in a relief setting approximately 200 psi (14 bar) higher than the drive relief setting.

Solenoid Valve

NOTE: Make all solenoid valve adjustments with engine at

low rpm and pressure gauge attached to quick-connect on solenoid valve.

1. Main Relief.

a. Activate platform level up function, bottom out

function and monitor pressure gauge.

b. Remove plug from main relief section and turn

adjusting screw to adjust main relief pressure to 2500 psi (172 bar). Turn adjusting screw CW to increase pressure, CCW to decrease pressure. Replace plug.

c. Release platform level up function.

2. Steer Relief.

a. Activate steer right function, bottom out function

and monitor pressure gauge.

b. Loosen locknut on steer right cartridge and turn

adjusting screw to adjust steer right relief pressure to 2000 psi (138 bar). Turn adjusting screw CW to increase pressure, CCW to decrease pressure. Tighten locknut.

c. Release steer right function, activate steer left

function, bottom out function and monitor pressure gauge.

d. Loosen locknut on steer left cartridge and turn

adjusting screw to adjust steer left relief pressure to 2000 psi (138 bar). Turn adjusting screw CW to increase pressure, CCW to decrease pressure. Tighten locknut.

e. Release steer left function.

   

3. Platform Rotate Relief.

a. Activate platform rotate right function, bottom

out function and monitor pressure gauge.

b. Loosen locknut on platform rotate right cartridge

and turn adjusting screw to adjust platform rotate right relief pressure to 2500 psi (172 bar). Tighten locknut.

c. Release platform rotate right function, activate

platform rotate left function, bottom out function and monitor pressure gauge.

d. Loosen locknut on platform rotate left cartridge

and turn adjusting screw to adjust platform rotate left relief pressure to 2500 psi (172 bar). Tighten locknut.

e. Release platform rotate left function.

Extend-A-Reach Valve (If Equipped)

NOTE: Make extend-a-reach valve adjustment with engine

at low rpm and pressure gauge attached to quickconnect on solenoid valve.

a. Activate extend-a-reach up function, bottom out

function and monitor pressure gauge.

b. Loosen locknut on extend-a-reach up cartridge

and turn adjusting screw to adjust extend-areach up relief pressure to 2500 psi (172 bar). Tighten locknut.

c. Release extend-a-reach up function, activate

extend-a-reach down function, bottom out function and monitor pressure gauge.

d. Loosen locknut on extend-a-reach down car-

tridge and turn adjusting screw to adjust extenda-reach down relief pressure to 700 psi (48 bar). Tighten locknut.

e. Release extend-a-reach down function and

remove pressure gauge from solenoid valve.

3120636 – JLG Lift – 2-41

Page 66

SECTION 2 - PROCEDURES

.0015" Feeler Gauge

Figure 2-17. Swing Bearing Bolt Feeler Gauge Check

2.18 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter. If during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the value specified in the torque chart, after lubricating the bolt threads with loctite #271. After replacing and retorquing bolt or bolts recheck all existing bolts for looseness.

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

2. At the positions indicated on Figure 2-17., Swing Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.

4. Swing the turntable 90 degrees, and check some selected bolts at the new position.

5. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants.

Check the turntable to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

2. At the positions indicated on Figure 2-17., Swing Bearing Bolt Feeler Gauge Check, try and insert the .0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Lower the boom to horizontal and fully extend the boom.

4. At the position indicated on Figure 2-17., Swing Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

Bearing Wear Tolerance

1. From the underside of the machine, at rear center, with the boom fully elevated and fully retracted (Figure 2-18., Swing Bearing Tolerance Boom Placement), measure and record the distance between the swing bearing and the frame using a magnetic base dial indicator. (Figure 2-18., Swing Bearing Tolerance Boom Placement)

2. At the same point, with the boom at horizontal and extended until red marking band on mid section is exposed, measure and record the distance between the swing bearing and frame using a magnetic base dial indicator. (Figure 2-18., Swing Bearing Tolerance Boom Placement)

3. If a difference greater than 0.64 in. (1.625 mm) is determined, the swing bearing should be replaced.

4. If a difference less than 0.64 in. (1.625 mm) is determined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

c. Noise.

d. Rough rotation.

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Page 67

SECTION 2 - PROCEDURES

MEASURING POINT

FORWARD

a. BOOM FULLY ELEVATED

AND FULLY RETRACTED

b. BOOM AT HORIZONTAL

AND FULLY EXTENDED

Figure 2-18. Swing Bearing Tolerance Boom Placement

MEASURING POINT

TURNTABLE REF.

FRAME REF.

SWING BEARING

Figure 2-19. Swing Bearing Tolerance Measuring Point

3120636 – JLG Lift – 2-43

Page 68

SECTION 2 - PROCEDURES

5. If bearing inspection shows no defects, reassemble bearing and return to service.

THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.

Bearing Replacement

1. Removal.

a. From ground control station, operate the boom

lift control and raise boom adequately to provide access to frame opening or, if equipped, to the rotary coupling.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING.

b. Attach an adequate support sling to the boom

and draw all slack from sling. Block the boom if feasible.

NOTE: Steps c and d apply to those machines equipped

with a rotary coupling.

c. From under side of machine frame, remove bolts

and lockwashers which attach rotary coupling retaining yoke to coupling housing.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.

d. Tag and disconnect the hydraulic lines from the

fittings on the top and sides of the rotary coupling. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports.

e. Attach suitable overhead lifting equipment to the

base of the turntable weldment.

f. Use a suitable tool to scribe a line on the inner

race of the swing bearing and on the underside of the turntable. This line will aid in aligning the bearing upon installation. Remove the bolts, nuts and washers which attach the turntable to the bearing inner race. Discard the nuts and bolts.

 

g. Use the lifting equipment to carefully lift the com-

plete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame mounted components.

h. Carefully place the turntable on a suitably sup-

ported trestle.

i. Use a suitable tool to scribe a line on the outer

race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use suitable lifting equipment to remove the bearing from the frame; move the bearing to a clean suitably supported work area.

2. Installation.

NOTE: The following note and steps a thru m pertain to the

use of Devcon and apply only to those machines built prior to mid-1991.

NOTE: Manufacturing tolerances of frames and turntables

are inspected prior to the factory installation of swing bearings to determine the need for use of Devcon filler. When servicing machine swing bearing, apply Devcon filler only to those machines having Devcon previously applied at the factory. If new turntable or frame is being installed contact manufacturer for procedures to determine the need for Devcon application.

a. Use suitable standard tools and equipment to

carefully remove any hardened epoxy residue from the bearing mounting area of frame and turntable.

b. Apply a layer of Devcon (or equivalent) filler

approximately 3 mm thick on the bearing mounting plate on the frame.

c. Use suitable lifting equipment to carefully lower

the swing bearing into position on the frame. Ensure that the scribed line of the outer race of the bearing aligns with the scribed mark on the frame (if a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the frame).

d. Ensure that all frame and bearing attachment

holes are aligned, and install four diametrically opposed bolts or clamps to secure the bearing to the frame. Tighten the bolts or clamps evenly in a diametrical pattern to a torque of 20 ft. lb. (27 Nm).

e. Allow Devcon filler to cure at room temperature

(approximately 70 degrees F [21 degrees C]) for 10 to 16 hours.

2-44 – JLG Lift – 3120636

Page 69

f. After the appropriate interval, release the clamps

or remove the bolts. Use a suitable lifting device to carefully remove the bearing from the frame.

g. Carefully remove any excess filler from the frame

mounting area, from the bearing attachment holes, and from between the gear teeth.

ENSURE THAT TURNTABLE IS ADEQUATELY SUPPORTED WHILE APPLYING DEVCON AND WHILE INSTALLING THE BEARING. EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL.

h. Apply a layer of Devcon (or equivalent) filler

approximately 1/8 in. (3 mm) thick to the underside of the bearing mounting area of the turntable base plate.

i. Use suitable hydraulic jacks to carefully raise the

swing bearing to the underside of the turntable mounting plate. Ensure that the scribed line of the inner race of the bearing aligns with the scribed mark on the turntable (If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the turntable. See Figure 2-20., Swing Bearing Bolt Torquing Sequence).

j. Ensure that all turntable and bearing attachment

holes are aligned, and install four (4) diametrically opposed clamps or bolts and nuts to secure the bearing to the turntable. Tighten the nuts and bolts or clamp evenly in a diametrical pattern to a torque of 20 ft. lb. (27 Nm).

k. Allow the Devcon filler to cure at room tempera-

ture (approximately 70 degrees F [21 degrees C]) for 10 to 16 hours.

l. After the appropriate interval, place a suitable

hydraulic jack under the bearing and release the clamps or remove the nuts and bolts; use the hydraulic jack to carefully remove the bearing from the turntable.

m. Carefully remove excess filler from the turntable

mounting area, from the bearing attachment holes and from between the gear teeth.

n. Position the bearing on the machine frame in the

same position as noted in step c above.

o. Use suitable lifting equipment to carefully lower

SECTION 2 - PROCEDURES

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

p. Apply a light coating of Loctite #277 to the new

bearing bolts, and loosely install the bolts and washers through the frame and outer race of bearing.

IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

q. Following the Torque Sequence diagram shown

in Figure 2-20., tighten the bolts to an initial torque of 180 ft. lbs. (244 Nm). Then following the same sequence tighten the bolts to a final torque of 240 ft. lbs. (325 Nm).

r. Remove the lifting equipment from the bearing.

s. Use suitable lifting equipment to carefully posi-

tion the turntable assembly above the machine frame.

t. Carefully lower the turntable onto the swing

bearing, ensuring that the turntable and bearing align as noted in step i above.

IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

u. Apply a light coating of Loctite #277 to the new

bearing bolts, and install the bolts, washers and nuts through the turntable and inner race of the bearing.

v. Following the Torque Sequence diagram shown

in Figure 2-20., Swing Bearing Bolt Torquing Sequence, tighten the bolts to an initial torque of 180 ft. lbs. (244 Nm). Then following the same sequence tighten the bolts to a final torque of 240 ft. lbs. (325 Nm).

w. Remove the lifting equipment.

 

3120636 – JLG Lift – 2-45

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SECTION 2 - PROCEDURES

INSTALL BEARING WITH FILL PLUG ON SIDE. (AS CLOSE TO CENTERLINE OF ROTATION AS POSSIBLE.)

NOTE:

Figure 2-20. Swing Bearing Bolt Torquing Sequence

x. Install the rotary coupling retaining yoke; apply a

light coating of Loctite Sealant Number TL27741 to the attaching bolts and secure the yoke to the rotary coupling with the bolts and lockwashers.

y. Connect the hydraulic lines to the rotary cou-

pling as tagged prior to removal.

z. At ground control station, use boom lift control

to lower boom to stowed position.

aa.Using all applicable safety precautions, activate

hydraulic system and functionally check swing system for proper and safe operation.

3. Swing Bearing Torquing Sequence, (See Figure 2-

20.)

RETORQUE INNER AND OUTER SWING BEARING BOLTS TO 22O FT.LBS. (298 NM) AFTER FIRST 200 HOURS OF OPERATION AND EVERY 500 HOURS THEREAFTER.

   

Swing Bearing Torque Values

1. Outer Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs. (230 Nm) wet, 220 ft.lbs. (298 Nm) dry.

2. Inner Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs. (230 Nm) wet, 220 ft.lbs. (298 Nm) dry.

2-46 – JLG Lift – 3120636

Page 71

SECTION 2 - PROCEDURES

2.19 DRIVE TORQUE HUB

Disassembly

1. Position hub over suitable container and remove drain plug (37) from unit. Allow oil to completely drain.

2. Remove sixteen bolts (1), four shoulder bolts (2), and twenty lockwashers (3) from cover (4) and lift cover from unit. Remove o-ring (14) from counterbore of cover.

3. Disassemble cover (4) as follows:

a. Remove two bolts (12) securing disconnect cap

(11) to cover and remove disconnect cover.

b. Remove two bolts (12) securing cover cap (7) to

cover and remove cap.

c. Remove disconnect rod (9) from cover cap and

remove o-rings (8 and 10) from cover cap. Discard o-rings.

d. If necessary, remove pipe plugs (5 and 6) from

cover.

4. Remove two thrust washers (15) and thrust bearing (16) from carrier counterbore. One thrust washer may stick to cover. Inspect thrust washers and bearing for wear and replace if necessary.

5. Lift carrier assembly (22) from hub and spindle assembly (30).

6. Disassemble carrier as follows:

stick in carrier counterbore. Inspect thrust washers and thrust bearing for wear and replace if necessary.

10. Lift internal gear (21) out of hub.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

11. Remove keeper ring (40), retaining ring (35), and bearing shim (34) from end of spindle. Remove hub from spindle.

12. Remove bearing cone (32) and seal (31) from spindle (30). Seal will possibly hold bearing cone into hub. If so, remove both from hub. If bearing cups (33) require replacing they can be driven out of hub counterbores. Discard seal and replace with new seal.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

13. To remove cluster gear (27) from carrier, remove retaining ring (25) from planet shaft (23) and drive planet shaft out of carrier.

14. Cluster gear and bearings (27, 29) can now be slid out of carrier and spacer (18) removed from carrier bore. If bearing cups (28) require replacing they can be driven out of cluster gear counterbores.

15. Repeat steps (12) and (13) for remaining cluster gears.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

a. Remove retaining ring (25) from planet shaft

(23).

b. Remove spacer (26) from planet shaft, then,

using a suitable drift, drive planet shaft from carrier, shearing off roll pin. Tap remaining roll pin from carrier using a suitable punch.

c. Remove cluster gear (27) from carrier and

remove bearing cones (29) from cluster gear.

d. If necessary, press bearing cups (28) from clus-

ter gear.

7. Lift ring gear (13) from housing (36). Remove o-ring (14) from counterbore of ring gear and discard.

8. Remove input (sun) gear (17), input spacer (18), and input shaft (20) from spindle (30).

9. Remove two thrust washers (15) and thrust bearing (16) from end of spindle. One thrust washer may

WHEN REBUILDING THE UNIT, O-RINGS AND RETAINING RINGS SHOULD ALWAYS BE REPLACED.

Cleaning and Inspection

1. Thoroughly clean all parts in an approved cleaning solvent.

2. Inspect geared or splined components in primary and secondary planet carriers, input and output sun gears, ring gear, coupling and input shaft for chipped or broken teeth, and excessive or uneven wear patterns. Replace components as necessary.

3. Inspect all thrust washers for scoring, pitting, erosion, discoloration or excessive wear. Replace thrust washers as necessary.

4. Inspect all bearing cones and cups for scoring, pitting or excessive wear. If necessary, using a suitable press, remove bearing cups from hub and replace bearings as a set.

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SECTION 2 - PROCEDURES

1. Bolt

2. Bolt

3. Lockwasher

4. Cover

5. Pipe Plug

6. Pipe Plug

7. Cover Cap

8. O-ring

9. Disconnect Rod

10. O-ring

11. Disconnect Cap

12. Bolt

13. Ring Gear

14. O-ring

15. Thrustwasher

16. Thrust Bearing

17. Input Gear

18. Thrust Spacer

19. Retaining Ring

20. Input Shaft

21. Internal Gear

22. Carrier

23. Planet Shaft

24. Roll Pin

25. Retaining Ring

26. Spacer

27. Cluster Gear

28. Bearing Cup

29. Bearing Cone

30. Spindle

31. Seal

32. Bearing Cup

33. Bearing Cone

34. Bearing Shim

35. Retaining Ring

36. Hub

37. Pipe Plug

38. Magnetic Plug

39. Stud

40. Keeper Ring

41. Retaining Ring

42. Washer

43. Spring

44. Not Used

45. Input Coupling

Figure 2-21. Drive Torque Hub

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SECTION 2 - PROCEDURES

5. Inspect all needle rollers for scoring, pitting or excessive wear. Replace all rollers as necessary.

6. Inspect planet gear pins for grooves, scoring or excessive wear. Replace pins as necessary.

7. Inspect all threaded components for damage including stretching, thread deformation, or twisting. Replace as necessary.

8. Inspect oil seal surfaces in hub and spindle for burrs or sharp edges. Dress applicable surfaces or replace components as necessary.

9. Inspect mating surfaces of hub, ring gear and cover for burrs and sharp edges. Dress applicable surfaces or replace components as necessary.

Assembly

1. If necessary, assemble the hub/spindle assembly (36 and 30) as follows:

a. With large open end of hub (36) up, press bear-

ing cup (33) into hub. If no press is available, bearing cup may be frozen and tapped into place with a non-metallic faced hammer.

d. Install bearing cone (32) into bearing cup.

e. Press seal (31) into hub counterbore with flat

metal side facing out. Use a flat object to ensure that seal is pressed evenly and is flush with hub face.

b. Turn hub over, small diameter up. Install two

pipe plugs (37) into hub.

c. Press bearing cup (33) into small diameter end

of hub. If no press is available, bearing cup may be frozen and tapped into place with a nonmetallic faced hammer.

f. Lower hub onto spindle (30) with large open end

up.

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SECTION 2 - PROCEDURES

g. Place bearing cone (32) over end of spindle and

into bearing cup.

h. Place bearing shim (34) over end of spindle and

against bearing cone.

j. Install retaining ring keeper ring (40) in location

around retaining ring and on bearing shim.

k. With large open end of hub/spindle assembly

facing up, place one spacer washer (42) into spindle counterbore.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

i. Secure retaining ring (35) completely into spin-

dle groove and against bearing shim. Ensure retaining ring is entirely in groove.

l. Place spring (43) into spindle counterbore.

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SECTION 2 - PROCEDURES

m. Set second spacer washer (42) on top of spring.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

n. Compress spacer washer and spring into spin-

dle counterbore and install retaining ring (41) into spindle groove.

3. Lower internal gear (21) onto spindle.

4. Place one thrust bearing (16) between two thrust washers (15) and place them onto spindle pilot.

2. Position hub/spindle assembly (36 and 30) with large open end up.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

5. Install retaining ring (19) in groove of input shaft (20).

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SECTION 2 - PROCEDURES

6. Place input shaft into spindle counterbore of hub/ spindle assembly. The action of the disengaged spring should be checked at this time.

7. Slide thrust spacer (18) onto input shaft.

a. Press bearing cups (28) into both ends of cluster

gear (27) with large inside diameter facing out. Use an arbor type press with an adapter tool.

b. Place planet shaft (23) on a flat surface with

large diameter down. Place one bearing cone (29) over shaft and against shoulder. This should be a slip fit.

BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING.

8. Place o-ring (14) into counterbore of hub/spindle assembly. Use grease or petroleum jelly to hold oring in place.

9. Assemble carrier assembly (22) as follows:

c. Place cluster gear over planet shaft and onto

bearing cone, with large gear on top.

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SECTION 2 - PROCEDURES

d. Place another bearing cone (29) over planet

shaft and into cluster gear. This is a slip fit.

e. Slide largest spacer (26) onto planet shaft.

g. See if retaining ring (25) will fit onto planet shaft

groove. If not, try smaller spacer (26) until retaining ring fits. This will set bearings at 0.000-0.152 mm.

h. Place carrier on edge of a table with one set of

holes hanging over the edge. Side with roll pin hole should be down.

f. Bearings in cluster gear must be seated by

applying 25-50 lbs. (11-23 kg) against them and rotating cluster gear at the same time. This can be done by sliding a second spacer (26) over planet shaft and pushing downward while rotating the gear.

      

i. Place bearing cones (29) into cluster gear.

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SECTION 2 - PROCEDURES

j. Place cluster gear into carrier with large gear up.

k. Slide planet shaft through carrier and cluster

gear from bottom side. Slot in planet shaft must line up with roll pin hole in edge of carrier.

m. Place carrier on table with something under

planet shaft to hold it in correct position and install retaining ring (25).

EYE PROTECTION SHOULD BE WORN DURING THIS OPERATION.

n. Drive roll pin (24) into carrier. Use a punch to

drive roll pin completely into planet shaft.

l. While holding planet shaft in position, slide cor-

rect spacer onto planet shaft.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

o. Repeat steps (a) through (n) for remaining two

cluster gears.

10. Time carrier gears as follows:

a. Place carrier assembly on a flat surface, posi-

tioning two top gears at ten o’clock and two o’clock, and one bottom gear at six o’clock as shown in Figure 2-22., Torque Hub Carrier Timing.

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SECTION 2 - PROCEDURES

b. Find marked (punch mark) teeth on large gears.

Rotate gears until punch mark is located in a straight up, 12 o’clock, position. Punch marks at ten o’clock and two o’clock will be located just under edge of carrier and not readily visible.

11. Taking care to ensure that timing is maintained, install ring gear (13) in mesh with large diameter cluster gear. Side of ring gear with long shoulder is installed down.

12. While holding ring gear in mesh with carrier assembly, lower into internal gear (21). Small diameter cluster gear will mesh with internal gear. Slight rotation of ring gear may be necessary.

13. Locate the one hole on underside of ring gear that has an “X” stamped beside it. This hole should be positioned in line with one of four counterbored holes in face of hub. These holes have been counterbored to accept four shoulder bolts upon installation of cover.

14. Thrust spacer (18) and input gear (17) are installed onto input shaft (20). Counterbore in input gear should be facing thrust spacer.

15. Place one thrust bearing (16) between two thrust washers (15) and place into carrier counterbore.

              

    

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SECTION 2 - PROCEDURES

16. Assemble cover assembly as follows:

a. Screw pipe plugs (5 and 6) into cover 4.

b. Install o-ring (8) over cover cap (7).

d. Push disconnect rod into bore of cover cap.

e. Locate large clearance hole in cover cap over

pipe plug in cover and install cover cap in cover. Use two bolts (12) torqued to 70 to 80 in.lbs. (8192 kgcm).

c. Install o-ring (10) into bore of cover cap 7. Dis-

connect rod (9) may be used to push o-ring down to groove in cover cap bore.

f. Install disconnect cap (11) to cover cap with two

remaining bolts (12) torqued to 70 to 80 in.lbs. (81-92 kgcm).

    

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BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING.

g. Place o-ring (5) into cover counterbore. Use

petroleum jelly to hold o-ring into place.

17. Place cover assembly (4) onto ring gear (13). Rotate cover assembly until pipe plug (6) is located 90 degrees and 180 degrees from pipe plugs (38) in opposite end of hub.

SECTION 2 - PROCEDURES

19. Install sixteen Grade 8 bolts (1) and lockwashers (3) in remaining holes.

20. Tighten bolts and shoulder bolts evenly and torque to 100-110 ft.lbs. (14-15 kgm).

18. Secure cover assembly and ring gear to hub with four shoulder bolts (2) and lockwashers 3. Shoulder bolts fit into four counterbored holes in hub. It may be necessary to start bolts into hub by tapping lightly on bolts with a hammer.

21. Install coupling (45) into spindle onto input shaft.

2.20 SWING TORQUE HUB

Disassembly

1. Remove oil plugs (25 and 26) and drain oil from unit into a suitable container. Replace drain plugs.

NOTE: The screws, hub pinion gear, and retaining plate ref-

erenced in steps (2) and (3) are not shown in Figure 2-20, but are attached to the hub output shaft (item

30).

2. Remove the two screws which attach the hub pinion gear retaining plate and remove plate.

3. Carefully remove pinion gear from splined hub output shaft.

4. Using suitable protection, clamp drive hub assembly in a vise or suitable holding fixture.

5. Remove four shoulder bolts (3) and lockwashers (4) from counterbored holes in cover of drive hub assembly.

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SECTION 2 - PROCEDURES

Figure 2-22. Torque Hub Carrier Timing

6. Remove remaining eight bolts (2) which attach cover (1) to ring gear 7.

7. Carefully remove cover assembly (1) from input gear (18) together with outer thrust washers (8) and thrust bearing 9. Remove and discard outer o-ring (6).

8. Remove thrust washer (17) from small diameter of input gear (18).

9. Carefully withdraw input gear (18) from cluster gear (11) and output shaft (30).

10. Rotate ring gear (7) and check that each of the three cluster gears (11) incorporates a punched timing mark.

11. Carefully withdraw ring gear (7) from assembly.

12. Carefully withdraw carrier assembly (10) from internal gear (19).

13. Remove and discard inner o-ring (6).

14. Remove inner thrust washers (8) and thrust bearing (9) from counterbore in carrier assembly 10.

15. Carefully withdraw internal gear (19) from output shaft (30).

16. If necessary, disassemble planet carrier assembly (10) as follows:

a. Remove three pins (16) by gently tapping a suit-

able punch against the roll pin until the pin is driven into planet shaft (15).

b. Using a suitable drift, carefully and gently tap

shafts (15) from carrier (10), ensuring that nee-

dle rollers (13) on each shaft are not damaged or lost.

c. Lift cluster gears (11) from carrier (10) and

remove thrust washers (12), needle rollers (13) and roller spacer (14).

d. Drive roll pins (16) from shafts (15) and discard

pins.

17. If necessary, disassemble hub and shaft assembly (24) as follows:

a. Using suitable snap ring pliers, remove retaining

ring (20) from groove in output shaft (30).

b. Remove spacer shim (21) from output shaft.

c. Place hub in a suitable hand-operated hydraulic

press with external portion of shaft (30) down and with suitable block supporting hub (24).

d. Using suitable protection between inner end of

shaft (30) and press cylinder drift, operate press and carefully press shaft from inner bearing assembly (22 and 23).

e. Remove seal (29) from shaft and discard seal.

f. Remove bearing cone (22) from cup (23).

g. Using press, remove bearing cups (23 and 27)

from hub (24) and cone (28) from shaft (30).

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect bearing components (22, 23, 27, 28) for damage, pitting, corrosion or excessive wear. Replace bearings as a complete set if necessary.

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SECTION 2 - PROCEDURES

Figure 2-23. Swing Torque Hub

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SECTION 2 - PROCEDURES

3. Inspect all thrust washers for scoring or excessive wear.

4. Inspect all geared or splined components for chipped or broken teeth and for excessive or uneven wear patterns.

5. Inspect o-ring grooves in hub (24) and cover (1) for burrs or sharp edges. Dress applicable surfaces as necessary.

6. Inspect all thrust washer and bearing surfaces for damage. Repair or replace as necessary.

7. Inspect all threaded components for damage including stretching, thread deformation or twisting. Replace as necessary.

8. Inspect planet shafts (15) for scoring or other damage. Replace as necessary.

Assembly

1. If necessary, assemble hub and shaft assembly.

a. Using a suitable hydraulic press, install bearing

cups (23 and 27) into hub (24).

b. Using the hydraulic press, install bearing cone

(28) onto output shaft (30).

c. Correctly position shaft (30) into hub (24) with

cone (28) in cup (27).

d. Using a suitable shaft support in the hydraulic

press, install bearing cone (22) on shaft (30) until cone abuts bearing cup (23).

e. Position spacer shim (21) on shaft (30) between

retainer ring groove and bearing cone (22).

f. Using suitable snap ring pliers, install retaining

ring (20) on shaft (30).

g. Using the hydraulic press, install a new seal (29)

over shaft and into hub (24). Ensure that seal is installed squarely.

h. Check that output shaft (30) rotates freely in the

hub. The oil seal will create a small amount of drag. By tapping the outside of the shaft with a soft headed mallet, any excessive tightness will be reduced.

2. If necessary, assemble planet carrier assembly (10) as follows:

a. Apply a light coating of petroleum jelly or multi-

purpose grease to flanged surface of thrust washers (12).

b. Position thrust washers (12) in carrier (10) with

tang in appropriate carrier cutaway portion. Ensure that washers are flat against surface on both sides of carrier.

c. Apply a liberal coating of petroleum or multi-pur-

pose grease to inner diameter of cluster gear (11).

d. Position spacer (14) at the approximate midpoint

of the gear diameter.

e. On each side of spacer (14), position needle roll-

ers (13) in inner diameter of gear.

f. Position assembled cluster gear (11) into carrier

(10) between the two thrust washers (12). Ensure that larger gear is on the roll pin side of carrier.

g. Position planet shaft (15) into carrier hole, with

shaft roll pin hole on same side as carrier roll pin hole.

h. Continue inserting shaft through thrust washers

(12) and cluster gear 11. Ensure that needle rollers (13) are not displaced.

i. Align roll pin holes in both shaft (15) and carrier

(10) with chamfered portion of shaft hole uppermost.

j. Position new roll pin (16) in hole in carrier (10)

and drive pin into hole until end of pin is flush with carrier surface.

k. Repeat steps (a) through (j) for remaining two

cluster gears.

3. Position internal gear (19) on inner end of output shaft (30).

4. Time carrier cluster gears as follows:

a. Place carrier assembly on a flat surface, posi-

tioning two top gears at ten o’clock and two o’clock, and one bottom gear at six o’clock as shown in Figure 2-22., Torque Hub Carrier Timing.

b. Find marked (punch mark) teeth on large gears.

Rotate gears until punch mark is located in a straight up, 12 o’clock, position. Punch marks at ten o’clock and two o’clock will be located just under edge of carrier and not readily visible.

5. Place ring gear (7) over cluster gears (11), with raised shoulder of ring gear facing down.

6. While holding ring gear (7) in position, invert carrier assembly (10) so that ring gear and larger diameter of cluster gears (11) are facing down.

7. Apply a light coating of petroleum jelly or multi-purpose grease to inner thrust washer (8) and thrust bearing (9).

8. Position thrust washer (8), thrust bearing (9), and thrust washer (8) into applicable groove of carrier assembly (10).

9. Apply a light coating of petroleum jelly or multi-purpose grease to new inner o-ring (6).

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SECTION 2 - PROCEDURES

10. Position o-ring (6) in groove in hub (24).

11. While holding ring gear (7) and carrier assembly (10), insert smaller diameter of cluster gears (11) into internal gear (19).

12. Rotate ring gear (7) until hole marked “X” is located over hub shaft assembly (24).

13. Insert input gear (18) into carrier assembly (10) so that input gear and larger diameter of cluster gears (11) are in mesh. Check that carrier assembly (10) rotates freely.

14. Position thrust washer (17) on shaft of input gear (18).

15. Apply a light coating of petroleum jelly or multi-purpose grease to new outer o-ring (6).

16. Position o-ring (6) into groove of cover (1).

17. Apply a light coating of petroleum jelly or multi-purpose grease to outer thrust washers (8) and thrust bearing (9).

18. Position outer thrust washer (8), thrust bearing (9) and thrust washer (8) in cover (1).

19. Position cover (1) on ring gear (7) with oil check plug (5) in cover located at 90° from oil fill plugs (25 and 26) in hub (24).

20. Install four shoulder bolts (3) and lockwashers (4) into appropriate counterbored holes in hub (24).

21. Install eight bolts (2) which attach cover (1) to ring gear (7) and hub (24) and tighten to a torque of 2327 ft.lbs. (3.2-3.7 kgm).

22. Carefully install hub pinion gear on splined output shaft. If necessary, gently tap into position with a soft headed mallet.

23. Apply No. 2 Lift Grade Loctite to pinion gear retaining plate screws.

24. Position gear retaining plate and install attaching screws.

25. Remove oil fill plug (25 or 26) and fill hub assembly with approximately one quart of approved extreme pressure gear lubricant. Install fill plug.

3. Bearing (18) is pressed onto shaft (7) and must be removed before removal of rotating discs (11) and stationary discs (12).

4. Further disassembly is not recommended unless necessary for the replacement of specific parts.

5. If further disassembly is required, remove shaft (7) and stack sub-assembly from housing (1) by lightly tapping or pressing on the small external spline end of the shaft and removing the shaft, bearings and stack from housing.

6. Remove bearing (18), stationary disc (12), rotating disc (11), springs (10) and primary disc 9.

7. Remove bearing (3) from shaft, taking care not to damage seal 4. Remove seal.

8. Remove springs (6) and spring retainer (5) from housing.

9. Remove piston (13) from power plate by introducing low pressure air (15 psi [10 bar]) into the hydraulic inlet. Direct piston away from operator.

10. Remove o-rings (15 and 17) and back-up rings (14 and 16) from piston OD and ID grooves. Back-up rings will be damaged and should not be removed if replacement is not planned.

11. Pressure relief valve (23) can be removed and inspected to assure spring loaded ball moves freely and is contamination free.

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for damage, excessive wear, cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces.

NOTE: Bearings may be re-used if, after thorough inspec-

tion, they are found to be in good condition.

Assembly

2.21 SWING BRAKE - AUSCO - MACHINES BUILT TO 1992

Disassembly

1. With shaft protruding downward, remove bolts (22) alternately and evenly to reduce spring tension.

2. Remove power plate (21) and gasket (2).

NOTE: Lubricate all seals, o-rings, cylinder of the power

plate and piston with clean hydraulic oil prior to assembly.

1. Assemble piston (13) into power plate (21) using a shop press, being careful not to damage the o-rings or back-up rings. Visually align the center of the cutouts in piston with torque pin (8) holes in power plate. Avoid pushing the piston all the way to the bottom of the cylinder in the power plate. Try to keep

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SECTION 2 - PROCEDURES

Figure 2-24. Swing Brake - Ausco - Machines Built to 1992

2-62 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

the top surface of the piston flush to 1/8 in. (3.2 mm) below the machined surface of the power plate.

2. When pressing the bearing onto the shaft, press on the inner race of the bearing and support the shaft properly.

3. Rotating discs must be clean and dry. Worn or heavily scored discs must be replaced.

4. Press bearing (3) into housing 1. Bearing must be seated against shoulder in housing.

5. Before installing seal (4), lubricate lip of seal with system hydraulic fluid or other suitable lubricant. Face lip of seal toward outside of brake in order to keep gear box oil or other external contaminants out of brake. Using a shop press, install seal (4) by pressing evenly around OD of seal. Use care to avoid cocking seal.

6. Install shaft (7) into housing. Support inner race of bearing (3) when pressing bearing onto shaft.

7. Install gasket 2. Align properly. After installing all remaining brake components, install bearing (18). Properly support shaft when pressing bearing onto shaft.

8. Install power plate sub-assembly. Use a shop press to evenly lower plate into position. There should be no gap at the OD when power plate is properly seated against housing. If a shop press is not available, use assembly bolts (22). Tighten sequentially, one at a time, until power plate is properly seated. Torque bolts to 50 to 60 ft. lb. (68 to 81 Nm).

9. If replacement of pressure relief valve is necessary, install 1/2 to 3/4 turns beyond finger tight.

10. Bleed air from brake via bleeder screw.

4. Remove piston (40) from end cover by inserting two 1/4-20 UNC bolts into threaded holes in piston. By turning and pulling, piston can be removed from bore.

5. Remove o-ring (38), back-up ring (39), o-ring (41) and back-up ring (42) from piston.

6. Remove separators (49) from housing (56).

7. Remove shaft assembly, consisting of shaft (45), discs (46, 50), friction plates (48), springs (47), snap ring (44) and bearings (3, 54) from housing by pressing or using a soft mallet on male end of shaft.

8. Remove springs (47) from between tabs of discs (46, 50).

9. Remove bearings (37, 54) from shaft (45) with appropriate bearing puller. The discs and friction discs will then slide off male end of shaft. Remove snap ring and shaft.

10. Remove dowel pins (53), springs (51, 52) and o-ring (55) from housing.

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks, and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly

2.22 SWING BRAKE - MICO - MACHINES BUILT TO 1992

1. Separate end cover (34) from housing (56) by removing capscrews (31) and lockwashers (32).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 1,500 LB. (680 KG). THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Tap cover with a soft mallet in order to dislodge bearing from cover.

3. Remove o-ring (36), square-ring (35), pipe plug (33) and bleeder (43) from end cover.

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Insert new o-ring (55), dowel pins (53) and springs (51, 52) in housing (56).

2. Install new bearing (54) in housing and press until bearing bottoms on shoulder in housing.

3. Position new large diameter disc (50) in housing with tabs guided by dowel pins (53) until disc rests on springs (51, 52).

DISCS (46,50) AND FRICTION DISCS (48) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

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SECTION 2 - PROCEDURES

Figure 2-25. Swing Brake - Mico - Machines Built to 1992

2-64 – JLG Lift – 3120636

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SECTION 2 - PROCEDURES

4. Place a new friction disc (48) on bottom disc (50), centering it as closely as possible. Insert one spring (47) on each dowel pin.

5. Add additional new discs (46), new friction discs (48) and springs (47) as required for specific model.

6. Install snap ring (44) on shaft (45). Insert shaft (45) thru friction discs (48) until shaft contacts bearing (54). Press shaft (45) until it shoulders on inner race of bearing. A small preload will exist on snap ring (44) at this point.

7. Insert separators (49) over spiral pins in housing (56). Separators will contact top of bottom disc (50) when properly installed.

8. Install new o-ring (38), new back-up ring (39), new oring (41) and new back-up ring (42) on piston (40). Insert piston (40) into end cover (34), being careful not to shear o-rings or back-up rings. Inserting 1/420 UNC bolts in piston may simplify installation.

9. Install new o-ring (36), new bearing (37), new square ring (35), pipe plug (33) and bleeder screw (43) in end cover.

10. Position end cover (34) on housing, aligning dowel pin (53) with holes in end cover.

11. Install capscrews (31) and lockwashers (32). Tighten evenly to draw end cover (34) to housing and bearing (37) onto shaft (45). Torque capscrews to 68 Nm.

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

2.23 SWING BRAKE - MACHINES BUILT 1992 TO PRESENT

1. Separate end cover (2) from housing (21) by removing capscrews (1).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (4) from the housing (21), then remove bleeder screw (3) from the end cover (2).

3. Remove piston (7) from end cover (2).

4. Remove o-ring (5), back-up ring (6), o-ring (8) and back-up ring (9) from piston (7).

5. Remove separators (13) from housing (21).

6. Remove stack assembly, consisting of discs (11), return plate (14) and friction discs (12) from housing (21).

NOTE: Not all models use the same number of springs or

spring pattern. Record this information for assembly purposes. Spring retainer (17) was not used in earlier models.

7. Remove dowel pins (20), springs (15 & 16) and spring retainer (17) from housing (21).

12. Press on inner ring of bearing (37) until it shoulders on shaft (45) to eliminate binding on bearings. Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing (54).

PRESS FORCE SHOULD BE LIMITED TO 2,000 LB. (907 KG) MAXIMUM TO AVOID POSSIBLE DAMAGE TO SNAP RING (44).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

 

8. Remove retaining ring (18) from housing (21).

9. Remove shaft by pressing or using a soft mallet on male end of shaft (10).

NOTE: Earlier models did not use retaining ring (22).

10. Remove retaining ring (22) and bearing (19) from shaft (10).

11. Press Rotary oil seal (23) from housing (21).

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks, and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

3120636 – JLG Lift – 2-65

Page 90

SECTION 2 - PROCEDURES

1. Capscrew

2. End Cover

3. Bleeder Screw

4. Case Seal

5. O-ring

6. Back-Up Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Disc

12. Friction Disc

13. Separators

14. Return Plate

15. Spring

16. Spring

17. Spring Retainer

18. Retaining Ring

19. Bearing

20. Dowel Pin

21. Housing

22. Retaining Ring

23. Rotary Oil Seal

24. O-ring

25. Gasket

26. Pin

Figure 2-26. Swing Brake - Machines Built 1992 to Present

2-66 – JLG Lift – 3120636

Page 91

Assembly

SECTION 2 - PROCEDURES

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Clean all parts thoroughly before assembly.

2. Press new rotary oil seal (23) into housing (21). Note direction of the seal.

NOTE: Earlier models did not use retaining ring (22).

3. Install new bearing (19) and retaining ring (22) on shaft (10).

4. Insert shaft assembly and retaining ring (18) in housing (21).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly. Spring retainer (17) was not used in earlier models.

5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21).

6. Position new large diameter return plate (14) in housing with tabs guided by dowel pins (20) until disc rests on springs (15 & 16).

DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

7. Place a new friction disc (12) on shaft (10) until it contacts return plate (14).

8. Add additional new discs (11) and new friction discs (12) as required to complete assembly.

9. Insert separators (13) in holes of return plate.

10. Install new o-ring (5), new backup ring (6), new oring (8) and new back-up ring (9) on piston (7). Note order of o-rings and back-up rings. Insert piston (7) into end cover (2) being careful not to shear o-rings or back-up rings.

11. Install new case seal (4) in housing (21) then install bleeder screw (3) in end cover (2).

12. Position end cover (2) on housing (21) aligning dowel pins (20) with holes in end cover.

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

2.24 DRIVE BRAKE - AUSCO - MACHINES BUILT PRIOR TO MARCH 1992

Disassembly

1. With shaft protrusion downward, remove bolts (21) alternately, power plate (20) and gasket 2.

2. Bearing (18) is pressed onto shaft (7) and must be removed before removal of rotating discs (11) and stationary discs (12).

3. Remove shaft and stack subassembly from housing by lightly tapping or pressing on the small external spline end of the shaft and removing the shaft, bearings and stack from the housing (1).

4. Remove bearing (18), stationary discs (12), rotating discs (11), springs (10) and primary disc 9.

5. Remove bearing (3) from shaft, using care not to damage seal 4. Remove seal and inspect sealing lip and OD for damage. If damaged, replace per reassembly instructions.

6. Remove springs (6) and spring retainer (5) from housing (1).

7. Remove piston (13) from power plate by introducing low pressure air (15 psi [1 Bar]) into the hydraulic inlet. Make sure piston is directed away from the operator. Remove o-rings (15 and 17) and back-up rings (14 and 16) from piston OD and ID grooves.

8. Pressure relief valve (22) can be removed and inspected to assure spring-loaded ball moves freely and is free of contaminants.

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

13. Press on inner ring of bearing (37) until it shoulders on shaft (45) to eliminate binding on bearings. Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing (54).

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

3120636 – JLG Lift – 2-67

Page 92

SECTION 2 - PROCEDURES

1. Housing

2. Gasket

3. Bearing

4. Oil Seal

5. Spring Retainer

6. Compression Spring

7. Splined Shaft

8. Torque Pin

9. Primary Disc

10. Separator Disc

11. Rotating Disc

12. Stationary Disc

13. Piston

14. Back-Up Ring

15. O-ring

16. Back-Up Ring

17. O-ring

18. Bearing

Figure 2-27. Drive Brake - Ausco (Prior to March 1992)

2-68 – JLG Lift – 3120636

Page 93

SECTION 2 - PROCEDURES

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Cylinder of the power plate, piston and o-rings must be clean prior to assembly, and pre-lubed with system hydraulic fluid.

2. Assemble piston (13) into power plate (20) using a shop press, being careful not to damage o-rings or teflon back-up rings. Visually align center of cutouts in piston (13) with torque pin (8) holes in power plate (20).

NOTE: Avoid pushing the piston all the way to the bottom of

the cylinder in the power plate. Generally, try to keep the top surface of the piston flush to 3.2 mm below the machined surface of the power plate.

3. When pressing bearing onto shaft, press on inner race of bearing and support shaft properly.

4. Rotating discs must be clean and dry. There should be no presence of oil on any lining material or mating surfaces of the stationary discs. Worn or heavily scored rotating discs must be replaced.

5. Press bearing (3) into housing 1. Bearing must be seated against shoulder in housing.

6. Before installing seal (4), lubricate lip of seal with system hydraulic fluid. Use a shop press to install seal. Face lip of seal toward outside of brake in order to keep gear box oil or other external contaminants out of brake.

7. Install seal (4) into housing by pressing evenly around OD of seal. Use care to avoid cocking. Back of seal must be installed flush to surface of housing.

8. Install shaft (7) into housing. Support inner race of bearing (3) when pressing shaft into bearing.

9. Install gasket 2. Be sure to properly align. After installing all remaining internal components of brake, install bearing (18). Properly support shaft when pressing bearing onto shaft.

10. Install power plate sub-assembly. Use a shop press to evenly lower plate into position. There should be no gap at OD when power plate is properly seated against housing. If a shop press is not available, use assembly bolts (21). Tighten sequentially, one turn at a time, until power plate is properly seated. Torque to 50-60 ft.lbs. (68-81 Nm).

11. If replacement of pressure relief valve (22) is necessary, install 1/2 to 3/4 turns beyond finger tight.

12. Install in place between motor and torque hub. After connecting hydraulic line to brake, bleed air from brake via bleeder screw.

2.25 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476

Disassembly

1. Separate end cover (2) from housing (21) by removing capscrews (1).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LBS. (1,360 KG) MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (4) from the housing (21), then remove bleeder screw (3) from the end cover (2).

3. Remove piston (7) from end cover (2).

4. Remove o-ring (5), back-up ring (6), o-ring (8) and back-up ring (9) from piston (7).

5. Remove separators (13) from housing (21).

6. Remove stack assembly, consisting of discs (11), return plate (14) and friction discs (12) from housing (21).

NOTE: Not all models use the same number of springs or

spring pattern. Record this information for assembly purposes. Spring retainer (17) was not used in earlier models.

7. Remove dowel pins (20), springs (15 & 16) and spring retainer (17) from housing (21).

8. Remove retaining ring (18) from housing (21).

9. Remove shaft by pressing or using a soft mallet on male end of shaft (10).

NOTE: Earlier models did not use retaining ring (22).

10. Remove retaining ring (22) and bearing (19) from shaft (10).Press Rotary oil seal (23) from housing (21).

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks, and chips. Replace parts as necessary.

3120636 – JLG Lift – 2-69

Page 94

SECTION 2 - PROCEDURES

Figure 2-28. Drive Brake - Mico (March 1992 to S/N 33746)

2-70 – JLG Lift – 3120636

Page 95

SECTION 2 - PROCEDURES

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Clean all parts thoroughly before assembly.

2. Press new rotary oil seal (23) into housing (21). Note direction of the seal.

NOTE: Earlier models did not use retaining ring (22).

3. Install new bearing (19) and retaining ring (22) on shaft (10).

4. Insert shaft assembly and retaining ring (18) in housing (21).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly. Spring retainer (17) was not used in earlier models.

5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21).

6. Position new large diameter return plate (14) in housing with tabs guided by dowel pins (20) until disc rests on springs (15 & 16).

DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

7. Place a new friction disc (12) on shaft (10) until it contacts return plate (14).

8. Add additional new discs (11) and new friction discs (12) as required to complete assembly.

9. Insert separators (13) in holes of return plate.

11. Install new case seal (4) in housing (21) then install bleeder screw (3) in end cover (2).

12. Position end cover (2) on housing (21) aligning dowel pins (20) with holes in end cover.

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

2.26 DRIVE BRAKE - MICO - MACHINES BUILT S/N 33476 TO PRESENT

Disassembly

1. With the shaft protrusion downward, remove end cover (13) by removing capscrews (12).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 681 KG. THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (1362 KG MAXIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (11) from housing (7) then remove bleeder screw (14) from end cover (13).

3. Remove piston (24) from end cover (13).

4. Remove o-ring (19), back-up ring (18), o-ring (21) and back-up ring (20) from piston (24).

5. Remove separators (10) from housing (7).

6. Remove stack assembly, consisting of discs (23), return plate (8) and friction discs (22) from housing (7).

7. Remove dowel pins (17), springs (5 & 6) from housing (7).

8. Remove retaining ring (3) from housing (7).

9. Remove shaft by pressing or using a soft mallet on male end of shaft (4).

10. Remove retaining ring (15) bearing (2) from shaft (4).

11. Press rotary seal (1) from housing (7).

3120636 – JLG Lift – 2-71

Page 96

SECTION 2 - PROCEDURES

1. Capscrew

2. End Cover

3. Bleeder Screw

4. Case Seal

5. O-ring

6. Back-Up Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Disc

12. Friction Disc

13. Separators

14. Return Plate

15. Spring

16. Spring

17. Spring Guide

18. Retaining Ring

19. Bearing

20. Dowel Pin

21. Housing

22. Retaining Ring

23. Rotary Oil Seal

24. O-ring

25. Gasket

26. Pin

52 53

Figure 2-29. Drive Brake - Mico (S/N 33476 to Present)

2-72 – JLG Lift – 3120636

Page 97

SECTION 2 - PROCEDURES

Figure 2-30. Spring Loading

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are inspection, they are found to be in good condition.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Press new rotary seal (1) into housing (7). Note the direction of seal.

2. Install new bearing (2) on shaft (4).

3. Install shaft assembly and retaining ring (3) into housing (7).

4. Install dowel pins (17), spring retainer (16), and springs (5 & 6) into housing (7).

NOTE: Discs (8 & 23) and friction discs (22) should remain

dry during installation. No oil contaminate disc surfaces.

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.

5. Position new large diameter return plate (8) in housing with tabs guided by dowel pins (17) until disc rests on springs (5 & 6).

6. Place new disc (22) on shaft (4) until it contacts return plate (8).

7. Add additional discs (23) as required to complete assembly.

8. Insert separators (10) in holes of return plate (8).

9. Install new o-ring (19), new back-up ring (18), new oring (20) and new back-up ring (21) on piston (24). Insert piston (24) into end cover (13) being careful not to shear o-rings or back-up rings.

10. Install new case seal (11) in housing (7) then install bleeder screw (14) in end cover.

11. Position end cover (13) on housing (7) aligning dowel pins (17) with holes in end cover.

12. Insert capscrews (12) and tighten evenly to draw end cover (13) to housing (7). Torque capscrews to 55 ft. lbs. (75 Nm).

3120636 – JLG Lift – 2-73

Page 98

SECTION 2 - PROCEDURES

2.27 FREE WHEELING OPTION

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

1. Chock wheels securely if not on flat level surface.

2. Disconnect both drive hubs by inverting disconnect caps in center of hubs.

3. If equipped, move steer/tow selector valve to float (tow) position by pulling valve knob out.

To E n g a g e D r i v e M o t o r s and Brakes (Normal Operation)

1. If equipped, move steer/tow selector valve to steer position by pushing valve knob in.

2. Connect both drive hubs by inverting disconnect cap in center of hub.

3. Remove chocks from wheels as required.

2.28 OEM CONTROLLERS

LED’s on the circuit board show if the controller works. The A Terminal LED lights when the handle is moved in the A direction, B Terminal LED in the B direction.

ADJUSTMENTS MUST BE MADE IN THE ORDER LISTED.

HI RANGE Adjustment

1. Move handle all the way forward.

2. Back off controller approximately 10°.

3. If function slows down, controller is at or below maximum output. If this is satisfactory, do not adjust further.

4. If function speed is too slow, turn HI RANGE trimpot CW to increase speed. If function speed is too fast, turn trimpot CCW to decrease speed.

5. If necessary, repeat steps (1) through 4.

IRS - RAMP RATE Adjustment

1. Turning RAMP RATE trimpot CW increases the time to turn ON or OFF; CCW decreases the time it takes to turn ON or OFF when handle is moved.

2. Trimpot has a wide adjustment range, therefore it will be necessary to make 2 or 3 turns to notice a difference in function response.d.

LO RANGE Adjustment (CREEP)

1. Turn CREEP switch on and completely stroke handle.

2. Adjust LO RANGE trimpot for desired output or function speed. CW increases speed/output, CCW decreases speed/output.

Before making adjustments, position CREEP switch to OFF, IGNITION switch to ON and depress footswitch.

THRESHOLD Adjustment

1. Move controller handle approximately one (1) inch (2.5 cm), until LED light comes on.

2. Adjust THRESHOLD trimpot CW to increase function speed, CCW to decrease speed.

3. Adjust trimpot so that function just starts to move after LED light comes on.

           

2-74 – JLG Lift – 3120636

Page 99

2.29 BOOM MARKING TAPE INSTALLATION

NOTE: SEE TABLE 2-4 FOR PROPER DIMENSIONS.

Figure 2-31. Boom Marking Tape Installation - 100HX+10

NOTE: SEE TABLE 2-4 FOR PROPER DIMENSIONS.

Figure 2-32. Boom Marking Tape Installation - 100HX and 110HX

SECTION 2 - PROCEDURES

Boom marking tape installation for Models 100HX, 110HX and 100HX+10 is shown in Figure 2-31. and Figure 2-32. and Table 2-4.

3120636 – JLG Lift – 2-75

Page 100

SECTION 2 - PROCEDURES

Table 2-4.Boom Marking Tape Installation

w/4620038 Turntable

Model Dim. A Dim. B Dim.C

110HX Single Capacity N/R 119-1/2 in. (303.5 cm) 154-1/2 in. (392.4 cm)

110HX Dual Capacity 82-1/2 in. 209.6 cm) 119-1/2 in. (303.5 cm) 154-1/2 in. (392.4 cm

100HX+10 50in. (127.0 cm) 84 in. (213.4 cm) 135 in. (342.9 cm)

w/4620044 or 4620078 Turntable

w/o Boom Wipers

Model Dim. A Dim. B Dim.C

110HX Dual Capacity 51-1/4 in. (130.2 cm) 90 in. (228.6 cm) 123 in. (312.4 cm)

110HX Single Capacity N/A 112-1/2 in. (285.8 cm) 160-1/2 in. (407.7 cm)

110HX Dual Capacity 85-1/2 in. (217.2 cm) 122-1/2 in. (311.2 cm) 160-1/2 in. (407.7 cm)

100HX+10 41-1/4 in. (104.8 cm) 80 in. (203.2 cm) 131 in. (332.7 cm)

w/Boom Wipers Installation 0239257

Model Dim. A Dim. B Dim. C

100HX Dual Capacity 50-1/4 in. (127.6 cm) 89 in. (226.1 cm) 122in. (309.9 cm)

110HX Single Capacity N/A 121-1/2 in. (308.6 cm) 159-1/2 in. (405.1 cm)

110HX Dual Capacity 83-3/8 in. (211.8 cm) 121-1/2 in. (308.6 cm) 159-1/2 in. (405.1 cm)

100HX+10 40-1/4 in. (102.2 cm) 79 in. (200.7 cm) 130 in. (330.2 cm)

w/Boom Wipers Installation 0253303

Model Dim. A Dim. B Dim. C

100HX Dual Capacity 49-1/8 in (124.8 cm) 87-7/8 in. (223.2 cm) 120-7/8 in. (307.8 cm)

110HX Single Capacity N/A 120- 3/8 in. (305.8 cm) 158-3/8 in. (402.3)

110HX Dual Capacity 83-3/8 in. (211.8 cm) 120-3/8 in. (305.8 cm) 158-3/8 in. (402.3)

2-76 – JLG Lift – 3120636

JLG 110HX Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

AGENERAL

B HYDRAULIC SYSTEM SAFETY

CMAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

1.2 COMPONENT DATA

1.3 PERFORMANCE DATA

1.4 TORQUE REQUIREMENTS

1.5 LUBRICATION

1.6 PRESSURE SETTINGS

1.7 CYLINDER SPECIFICATIONS

1.8 BOOM TAPE

1.9 MAJOR COMPONENT WEIGHTS

1.10 SERIAL NUMBER LOCATIONS

1.11 CRITICAL STABILITY WEIGHTS

SECTION 2. PROCEDURES

2.1 GENERAL

2.2 SERVICING AND MAINTENANCE GUIDELINES

2.3 LUBRICATION INFORMATION

2.4 CYLINDERS - THEORY OF OPERATION

2.5 VALVES - THEORY OF OPERATION

2.6 BOOM CHAINS

2.7 WEAR PADS

2.8 DRIFT TEST

2.9 CYLINDER CHECKING PROCEDURES

2.10 CYLINDER REMOVAL AND INSTALLATION

2.11 CYLINDER REPAIR

2.12 BOOM MAINTENANCE

2.13 TILT ALARM SWITCH LEVELING

2.14 LIMIT SWITCH ADJUSTMENTS

2.15 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ F4L-912 ENGINE

2.16 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS - FORD ENGINE

2.17 PRESSURE SETTING PROCEDURES

2.18 SWING BEARING

2.19 DRIVE TORQUE HUB

2.20 SWING TORQUE HUB

2.21 SWING BRAKE - AUSCO - MACHINES BUILT TO 1992

2.22 SWING BRAKE - MICO - MACHINES BUILT TO 1992

2.23 SWING BRAKE - MACHINES BUILT 1992 TO PRESENT

2.24 DRIVE BRAKE - AUSCO - MACHINES BUILT PRIOR TO MARCH 1992

2.25 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476

2.26 DRIVE BRAKE - MICO - MACHINES BUILT S/N 33476 TO PRESENT

2.27 FREE WHEELING OPTION

2.28 OEM CONTROLLERS

2.29 BOOM MARKING TAPE INSTALLATION