JLG 100HX 100HX+10 Service & Maintenance Manual 3120864 – PDF DOWNLOAD
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JLG 100HX 100HX+10 Service & Maintenance Manual 3120864 – PDF DOWNLOAD
Language : English
Pages : 162
Downloadable : Yes
File Type : PDF
DESCRIPTION:
JLG 100HX 100HX+10 Service & Maintenance Manual 3120864 – PDF DOWNLOAD
GENERAL
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.
- 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.
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. 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 feed lines to system components can then be disconnected with minimal fluid loss.
MAINTENANCE
- 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
JLG 100HX 100HX+10 Service & Maintenance Manual 3120864 – PDF DOWNLOAD
Section A INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS 3
A General 3
B Hydraulic System Safety 3
C Maintenance 3
Section 1 SPECIFICATIONS 13
1 1 Capacities 13
1 2 Component Data 13
Engine – Diesel 13
Drive System 13
Steer System 13
Swing System 13
Hydraulic Pump 13
Auxiliary Power Pump 13
Hydraulic Filter – Tank 13
Hydraulic Filter – Inline 13
1 3 Performance Data 13
Travel Speed 13
Gradeability 13
Turning Radius 14
Boom Speed 14
Swing Speed 14
Boom Elevation 14
Machine Weight 14
Machine Stowed Height 14
Machine Stowed Length 14
Machine Width 14
Wheelbase 14
Maximum Tire Loads 14
1 4 Torque Requirements 14
1 5 Lubrication 15
Deutz F4L912 Engine 15
Lubrication Specifications 16
1 6 Pressure Settings 17
1 7 Cylinder Specifications 17
1 8 Boom Tape 21
1 9 Major Component Weights 21
1 10 Serial Number Locations 21
1 11 Critical Stability Weights 21
1 12 Boom Limit Switches 22
Section 2 PROCEDURES 25
2 1 General 25
2 2 Servicing and Maintenance Guidelines 25
General 25
Safety and Workmanship 25
Cleanliness 25
Components Removal and Installation 25
Component Disassembly and Reassembly 25
Pressure-Fit Parts 25
Bearings 26
Gaskets 26
Bolt Usage and Torque Application 26
Hydraulic Lines and Electrical Wiring 26
Hydraulic System 26
Lubrication 26
Battery 26
Lubrication and Servicing 26
2 3 Lubrication Information 26
Hydraulic System 26
Hydraulic Oil 27
Changing Hydraulic Oil 27
Lubrication Specifications 27
2 4 Cylinders – Theory of Operation 27
2 5 VALVES – THEORY OF OPERATION 27
Solenoid Control Valves (Bang-Bang) 27
Manual Hydraulic Control Valves 28
Proportional Control Valves – Vickers 28
Relief Valves 28
Crossover Relief Valves 28
2 6 Boom Chains 28
Adjusting Procedures 28
Inspection Procedure 32
Auxiliary Boom Chains 34
2 7 Wear Pads 34
2 8 Drift Test 34
Telescope Cylinder 34
Lift Cylinder 35
2 9 Cylinder Checking Procedures 35
Cylinder w/o Counterbalance Valves 35
Cylinders w/Single Counterbalance Valves 36
Cylinders w/Dual Counterbalance Valve 37
2 10 Cylinder Removal and Installation 37
Telescope Cylinder Removal 37
Telescope Cylinder Installation 42
Lift Cylinder Removal 43
Lift Cylinder Installation 43
Master Level Cylinder Removal 43
Master Level Cylinder Installation 44
2 11 Cylinder Repair 44
Disassembly 44
Cleaning and Inspection 45
Assembly 46
2 12 Boom Maintenance 47
Removal 47
Disassembly 47
Inspection 49
Assembly 49
Installation 53
2 13 Tilt Alarm Switch Leveling 53
Manual Adjustment 53
Voltmeter Adjustment 54
2 14 Limit Switch Adjustments 55
Boom Limit Switch 55
Horizontal Cut-Out Switch 55
2 15 Throttle Checks and Adjustments – Deutz F4l-912 Engine 55
2 16 Throttle Checks and Precision Governor Adjustments – Ford Engine 57
Checks 57
Choke Adjustments 57
Carburetor and Governor Adjustments 57
2 17 Pressure Setting Procedures 60
Sequence Pressure (Prior to 1990) 60
Sequence Pressure (1990 to Present) 60
Pilot Pressure 60
Proportional Valve 60
Solenoid Valve 61
Extend-A-Reach Valve (If Equipped) 61
2 18 Swing Bearing 65
Turntable Bearing Mounting Bolt Condition Check 65
Bearing Wear Tolerance 65
Bearing Replacement 67
Swing Bearing Torque Values 68
2 19 Drive Torque Hub 69
Disassembly 69
Cleaning and Inspection 69
Assembly 71
2 20 Swing Torque hub 80
Disassembly 80
Cleaning and Inspection 82
Assembly 82
2 21 Swing Brake – Ausco – Machines Built To 1992 83
Disassembly 83
Cleaning and Inspection 85
Assembly 85
2 22 Swing Brake – Mico – Machines Built To 1992 85
Cleaning and Inspection 85
Assembly 87
2 23 Swing Brake – Machines Built 1992 To Present 87
Cleaning and Inspection 89
Assembly 89
2 24 Drive Brake – Ausco – Machines Built Prior To March 1992 89
Disassembly 89
Inspection 91
Assembly 91
2 25 Drive Brake – Mico – Machines Built March 1992 TO S/N 33476 91
Disassembly 91
Cleaning and Inspection 93
Assembly 93
2 26 Drive Brake – Mico – Machines Built S/N 33476 To Present 93
Disassembly 93
Inspection 95
Assembly 95
2 27 Free Wheeling Option 96
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc 96
To Engage Drive Motors and Brakes (Normal Operation) 96
2 28 OEM Controllers 96
THRESHOLD Adjustment 97
HI RANGE Adjustment 97
IRS – RAMP RATE Adjustment 97
LO RANGE Adjustment (CREEP) 97
2 29 Boom Marking Tape Installation 97
2 30 Boom Length/angle Sensor Adjustment Procedures 97
1st, and 2nd Generation Radius Cards 97
3rd Generation Radius Cards 105
2 31 Load Management System 107
Platform Position Indication System 107
Overmoment Control System 108
Overmoment Control Monitoring System 109
Load Management System Daily Check 109
2 32 Load Management System Adjustment 111
Turntable 4620038 111
Turntables 4620044 and 4620078 111
2 33 Turntable Springs 111
Turntable 4620038 111
Turntables 4620044 and 4620078 112
2 34 Pump Coupling Conversion Procedures 112
Lovejoy Coupling 112
Hayes Coupling 112
2 35 Platform Rotator Brake 112
2 36 Preventive Maintenance and Inspection Schedule 112
Section 3 TROUBLESHOOTING 117
3 1 General 117
3 2 Troubleshooting 117
3 3 Hydraulic Circuit Checks 117
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