JLG 100Hx 100Hx+10 110Hx Service & Maintenance Manual (3120636) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 100Hx 100Hx+10 110Hx Service & Maintenance Manual (3120636) – PDF DOWNLOAD
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
ii – JLG Lift – 3120636
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
3120636 – JLG Lift – iii
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
iv – JLG Lift – 3120636
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
3120636 – JLG Lift – v
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
vi – JLG Lift – 3120636
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
3120636 – JLG Lift – vii
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
viii
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M