Jlg 110HX ANSI Service Manual Instrukcja Użytkownika

Service and Maintenance ManualModel100HX100HX+10110HXP/N - 3120636March 11, 2010

vi – JLG Lift – 3120636LIST OF FIGURES (Continued) FIGURE NO. TITLE

SECTION 2 - PROCEDURES2-76 – JLG Lift – 3120636Table 2-4.Boom Marking Tape Installationw/4620038 TurntableModel Dim. A Dim. B Dim.C110HX Single Capaci

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-772.30 BOOM LENGTH/ANGLE SENSOR ADJUSTMENT PROCEDURES LOAD RADIUS CIRCUIT CARD P/N-0610106 WAS SUPERSEDED

SECTION 2 - PROCEDURES2-78 – JLG Lift – 31206364. \Operational Check.a. With no load in the platform, raise the boom completely and fully extend the b

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-79Load Radius Circuit Card - First GenerationLoad Radius Circuit Card - Second GenerationLoad Radius Circ

SECTION 2 - PROCEDURES2-80 – JLG Lift – 3120636Figure 2-34. Boom Length/Angle Sensor Configurations

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-81Figure 2-35. Load Radius Card

SECTION 2 - PROCEDURES2-82 – JLG Lift – 31206362. Boom Angle Sensor Adjustment.a. With the boom completely retracted and in the 0 (+3/-0) degrees hori

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-833rd Generation Radius Cards100HX Dual Capacity1. Length Indicator Adjustmenta. Level the frame before b

SECTION 2 - PROCEDURES2-84 – JLG Lift – 3120636Rotate the 5K Ohm potentiometer until you mea-sure 100 Ohms between Pin (3) and Pin (6) on the 6 pin pl

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-852. Boom Angle Sensor Adjustmenta. With the platform level, the boom fully retracted and at 45 (+/- 1) d

3120636 – JLG Lift – vii LIST OF TABLESTABLE NO. TITLE

SECTION 2 - PROCEDURES2-86 – JLG Lift – 31206362. Boom Angle Sensor Adjustmenta. With the platform level, the boom fully retracted and at 45 (+/- 1) d

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-87This circuit card operates as follows:A calibrated dc voltage representing the boom angle is sent from

SECTION 2 - PROCEDURES2-88 – JLG Lift – 3120636Immediately beyond this point of balance the turntable is permitted to pivot a maximum vertical distanc

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-89TESTSWITCHRESETSWITCH2Figure 2-37. Load Moment Limiting System Monitoring Circuit

SECTION 2 - PROCEDURES2-90 – JLG Lift – 31206362.32 LOAD MANAGEMENT SYSTEM ADJUSTMENTTurntable 46200381. With boom retracted, limit switch and proximi

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-91Turntables 4620044 and 46200781. Removal.a. Fully retract boom.b. Remove rear turntable cover.c. Remove

SECTION 2 - PROCEDURES2-92 – JLG Lift – 31206362.35 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoint

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-93DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECA

SECTION 2 - PROCEDURES2-94 – JLG Lift – 3120636JLG Industries requires that a complete annual inspection be performed in accordance with the "Ann

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-9513.Bushings8,1214.Wear Pads8,1215.Cylinders1,5,6,13 1216.Chains**1217.Chain Adjusters918.Sheaves8,1219.

viii – JLG Lift – 3120636LIST OF TABLES (Continued) TABLE NO. TITLE

SECTION 2 - PROCEDURES2-96 – JLG Lift – 3120636 23.Swing Torque Hub1,3,5,6 1024.Swing Brake1,5,6 825.Swing Bearing1129CHASSIS1.Wheel and Tire Assembly

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to be used

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120636..Table 3-1. Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYAutomatic leveling ino

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-3Table 3-2. Boom Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVESValve spool st

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120636Boom will not raise.Load capacity exceeded (personnel or equip-ment on platform).Reduce load.(Refer

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-5Pump Volume, Wheel Motor Speed, and High Engine does not operate below horizontal.Damaged wiring o

SECTION 3 - TROUBLESHOOTING3-6 – JLG Lift – 3120636BOOM SWING SYSTEMNo response to swing control.Hydraulic system oil low. Replenish oil as necessary.

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-7.Table 3-3. Turntable Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVE.Valve Sp

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120636.Table 3-4. Chassis Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPOWER PLANT.Engine will

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-9Switch not functioning properly or improperly adjusted.Adjust, repair, or replace horizontal limit

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank - 28 gallons (98 liters).Hydraulic Oil Tank - 55 g

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120636REAR FRAME AXLE AREA.Difficulty encountered when moving machine.Load capacity exceeded. Reduce loa

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-11Machine will not travel in forward.Hydraulic system oil low. Replenish oil as necessary.Restricted

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120636STEERING SYSTEM.No response to steer control.Circuit breaker open. Determine and correct cause; re

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-13Relief valve improperly set or not functioning properly.Reset, repair or replace valves as require

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120636.Table 3-5. Hydraulic System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHYDRAULIC SYSTEMS - GEN

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-15Pump not delivering oil.Restricted suction line. Clean, repair, or replace line.Air entering syste

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120636Damaged wiring on control switch or auxiliary pump.See proper wiring diagram.Control switch not fu

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-17.Table 3-6. Electrical System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM CONTROLS.No p

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120636INSTRUMENTS AND INDICATORS.Travel warning horn inoperative.Circuit breaker open. Determine and cor

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-19Function speed control will not function.Boom above horizontal. Lower boom.Horizontal limit switch

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120636Drive SystemTires.Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam filled.After March, 1993 -

SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120636Figure 3-1. Wiring Diagram - Boom Indicator Pendulum

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-21Figure 3-2. Wiring Diagram - Dual Fuel (Ford Engine)

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120636Figure 3-3. Wiring Diagram - Generator (Deutz)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-23Figure 3-4. Wiring Diagram - Generator (Ford)

SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 3120636Figure 3-5. Wiring Diagram - Platform (100HX & 110HX)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-25Figure 3-6. Wiring Diagram - Platform (100HX+10)

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 3120636Figure 3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-27Figure 3-8. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 2 of 3)

SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 3120636Figure 3-9. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 3 of 3)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-29Figure 3-10. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 1 of 3)

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-3Machine Weight100HX - 36,400 lbs. (16,511 kg)110HX - 40,410 lbs. (18,330 kg)100HX+10 - 39,685 lbs. (

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 3120636Figure 3-11. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 2 of 3)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-31Figure 3-12. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 3 of 3)

SECTION 3 - TROUBLESHOOTING3-32 – JLG Lift – 3120636Figure 3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-33Figure 3-14. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-34 – JLG Lift – 3120636Figure 3-15. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-35Figure 3-16. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-36 – JLG Lift – 3120636Figure 3-17. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-37Figure 3-18. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-38 – JLG Lift – 3120636Figure 3-19. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120636 – JLG Lift – 3-39Figure 3-20. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 4 of 4)

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120636Deutz F4L912 EngineSingle Viscosity Oils (CD-SE, CD-SF)Multi-Viscosity Oils (CD-SE, CD-SF)* This vis

SECTION 3 - TROUBLESHOOTING3-40 – JLG Lift – 3120636This page left blank intentionally.

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-5Lubrication SpecificationsRefer to Lubrication Chart for specific lubrication proce-dures.Table 1-

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 312063610116, 729149835343451, 5, 16415313125212217352202223, 2421172533321421213026, 27, 281918, 20NoteThe

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-7Table 1-8. Lubrication Chart ComponentsNumber/TypeLube PointsLube & MethodIntervalHoursComments1

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31206361.6 PRESSURE SETTINGSProportional ValveDrive - 3500 psi (241 bar)Lift Up - 3000 psi (207 bar)Lift Do

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-91.8 BOOM TAPEWith 4620038 Turntable110HX Single CapacityBlue - Not usedYellow - Not usedRed - 119.5

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31206361.11 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS THE COUNTERWEIGH

SECTION 1 - SPECIFICATIONS3120636 – JLG Lift – 1-11SIZE412126677891212121416181820202424202432324010111213141618283236404861-1/21-1/23.81003.49254.013

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120636This page left blank intentionally

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALNOTE: The JLG Models 100HX, 110HX and 100HX+10 have been built with two

SECTION 2 - PROCEDURES2-2 – JLG Lift – 3120636Bearings1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflam

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-3NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing com

SECTION 2 - PROCEDURES2-4 – JLG Lift – 3120636A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spoo

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-5Meter-Out PoppetAdjustable ReliefActuator Port "A"Actuator Port "B"Load Drop CheckPi

INTRODUCTION3120636 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - PROCEDURES2-6 – JLG Lift – 3120636FLY EXTENDFLY RETRACTOUTER MID RETRACTOUTER MID EXTENDFigure 2-2. Boom Chain Adjustments

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-7Figure 2-3. Typical Boom Assembly

SECTION 2 - PROCEDURES2-8 – JLG Lift – 3120636An immediate disassembly of the boom assembly and inspection of the boom chains and related components i

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-92. Lubrication: One of the most important but often overlooked factors is adequate lubrication. In addi-

SECTION 2 - PROCEDURES2-10 – JLG Lift – 3120636Also, more than one crack can often appear on a link plate. In addition to rusting, this condition can

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-11BEFORE RAISING AND EXTENDING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM AND AHEAD OF PLA

SECTION 2 - PROCEDURES2-12 – JLG Lift – 31206362. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-13drops per minute or more, cylinder repairs must be made. If the retract port is leaking, the piston sea

SECTION 2 - PROCEDURES2-14 – JLG Lift – 3120636BARRELPISTONSPACERHEADROD SUPPORTRODSETSCREWPISTON SEALSHEAD RETAINERRODSUPPORTBLOCKHEAD SEALSTELESCOPE

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-15BARRELHEADRETAINERHEAD SEALSRODPISTONPISTONSEALSHOLDINGVALVESETSCREWSPACERLIFTCYLINDERBARRELHEADHEAD SE

INTRODUCTIONA-2 – JLG Lift – 3120636REVISON LOGMarch, 1989 - Original IssueOctober, 1994 - RevisedAugust, 1997 - RevisedJanuary, 1999 - RevisedOctober

SECTION 2 - PROCEDURES2-16 – JLG Lift – 3120636BARRELPISTONNUTSPACERHEADHEAD RETAINERRODSETSCREWPISTON SEALSHEAD SEALSMASTERCYLINDERBARRELHEADHEAD SEA

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-17BARRELHEADHEAD SEALSRODSPACERPISTONPISTONSEALSHOLDINGVALVEHOLDINGVALVESETSCREWSLAVECYLINDER(Extend-A-Re

SECTION 2 - PROCEDURES2-18 – JLG Lift – 31206361. Pull boom sections apart several feet.2. Using the lifting equipment, raise the cylinder to obtain s

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-196. Install the chain adjust bracket and install the three (3) bolts, washers and lockwashers which atta

SECTION 2 - PROCEDURES2-20 – JLG Lift – 31206366. Remove temporary hoses from level cylinder and cap them. Plug cylinder ports.7. Using slings, restra

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-218. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw th

SECTION 2 - PROCEDURES2-22 – JLG Lift – 3120636AssemblyNOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JL

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-2313. Continue pushing the rod into the barrel until the cyl-inder head gland can be inserted into the ba

SECTION 2 - PROCEDURES2-24 – JLG Lift – 3120636DisassemblyNOTE: Left or right is determined facing the machine from the platform.1. Loosen the right s

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-2529. Pull boom sections out several feet to allow ample clearance for telescope cylinder removal.30. Rem

3120636 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - PROCEDURES2-26 – JLG Lift – 312063617145121616166Figure 2-9. Boom Assembly - Sheet 1 of 2

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-2771818432189151510111. Boom Base2. Inner Mid Boom3. Outer Mid Boom4. Fly Boom5. Telescope Cylinder6. Out

SECTION 2 - PROCEDURES2-28 – JLG Lift – 3120636Inspection1. Inspect all sheaves (extend chains, retract chains and telescope cylinder) for excessive g

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-2913. Install inner mid section upper aft wear pads and shims, as required, using bolts and lockwashers.1

SECTION 2 - PROCEDURES2-30 – JLG Lift – 3120636NOTE: When installing base section wear pads, install same number and thickness of shims as were remove

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-313. With the electrical connections complete, slowly tighten one of the “Y” nuts until the circuit is cl

SECTION 2 - PROCEDURES2-32 – JLG Lift – 31206362.14 LIMIT SWITCH ADJUSTMENTSBoom Limit SwitchThe boom limit switch is located on the left side of the

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-33ACTUATOR CABLEADECO ACTUATORLOW ENGINEHIGH ENGINE LIMIT SWITCHSLIDE PIN (2)SLIDE PIN (1)LIMIT SWITCHTHR

SECTION 2 - PROCEDURES2-34 – JLG Lift – 3120636PC BOARDDROOP P3GAIN P2LOW (MID)ENGINEADJUSTMENTHIGH ENGINE P1NOTEAll pots should be sealed with finger

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-35CHOKECHOKEORVACUUMPULLOFFIDLE SPEEDSCREWTHROTTLELEVERTHROTTLERODLINKAGEHIGH ENGINE NO LOAD,BUFFER SCREW

ii – JLG Lift – 3120636TABLE OF CONTENTS (Continued) SECTION NO. TITLE

SECTION 2 - PROCEDURES2-36 – JLG Lift – 3120636c. Readjust for ambient temperature by rotating the cover one (1) mark per 5°F from 70°F. Rotate CCW (l

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-37Pressure ReducingCartridgeSequenceCartridgeMain ReliefInstall pressure gauge atquick disconnectSwing Ad

SECTION 2 - PROCEDURES2-38 – JLG Lift – 3120636MAIN RELIEF ADJUSTMENTROTATE LEFT & ROTATE RIGHTADJUSTMENTSTEER LEFT & STEER RIGHTADJUSTMENTCHE

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-39MAIN RELIEFADJUSTMENTROTATE LEFT & ROTATE RIGHTADJUSTMENTSTEER LEFT & STEER RIGHTADJUSTMENTCHEC

SECTION 2 - PROCEDURES2-40 – JLG Lift – 3120636Sequence Pressure (1990 to Present)1. Plug pressure gauge into quick-connect on high drive dump valve.

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-417. Main Relief.a. Disconnect and cap hoses to drive motor; plug ports on drive section of proportional

SECTION 2 - PROCEDURES2-42 – JLG Lift – 31206362.18 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is designed to replac

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-43MEASURING POINTMEASURING POINTFORWARDa. BOOM FULLY ELEVATEDAND FULLY RETRACTEDb. BOOM AT HORIZONTALAND

SECTION 2 - PROCEDURES2-44 – JLG Lift – 31206365. If bearing inspection shows no defects, reassemble bearing and return to service.THE SWING BEARING I

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-45f. After the appropriate interval, release the clamps or remove the bolts. Use a suitable lifting devic

3120636 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - PROCEDURES2-46 – JLG Lift – 3120636x. Install the rotary coupling retaining yoke; apply a light coating of Loctite Sealant Number TL277-41

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-472.19 DRIVE TORQUE HUBDisassembly1. Position hub over suitable container and remove drain plug (37) from

SECTION 2 - PROCEDURES2-48 – JLG Lift – 31206361. Bolt2. Bolt3. Lockwasher4. Cover5. Pipe Plug6. Pipe Plug7. Cover Cap8. O-ring9. Disconnect Rod10. O-

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-495. Inspect all needle rollers for scoring, pitting or excessive wear. Replace all rollers as necessary.

SECTION 2 - PROCEDURES2-50 – JLG Lift – 3120636g. Place bearing cone (32) over end of spindle and into bearing cup.h. Place bearing shim (34) over end

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-51m. Set second spacer washer (42) on top of spring.EYE PROTECTION SHOULD BE WORN DURING RETAINING RING I

SECTION 2 - PROCEDURES2-52 – JLG Lift – 31206366. Place input shaft into spindle counterbore of hub/spindle assembly. The action of the disengaged spr

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-53d. Place another bearing cone (29) over planet shaft and into cluster gear. This is a slip fit.e. Slide

SECTION 2 - PROCEDURES2-54 – JLG Lift – 3120636j. Place cluster gear into carrier with large gear up.k. Slide planet shaft through carrier and cluster

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-55b. Find marked (punch mark) teeth on large gears. Rotate gears until punch mark is located in a straigh

iv – JLG Lift – 3120636TABLE OF CONTENTS (Continued) SECTION NO. TITLE

SECTION 2 - PROCEDURES2-56 – JLG Lift – 312063616. Assemble cover assembly as follows:a. Screw pipe plugs (5 and 6) into cover 4.b. Install o-ring (8)

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-57BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING.g. Place o-ring (5) into cover counterbo

SECTION 2 - PROCEDURES2-58 – JLG Lift – 31206366. Remove remaining eight bolts (2) which attach cover (1) to ring gear 7.7. Carefully remove cover ass

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-59Figure 2-23. Swing Torque Hub

SECTION 2 - PROCEDURES2-60 – JLG Lift – 31206363. Inspect all thrust washers for scoring or excessive wear.4. Inspect all geared or splined components

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-6110. Position o-ring (6) in groove in hub (24).11. While holding ring gear (7) and carrier assembly (10)

SECTION 2 - PROCEDURES2-62 – JLG Lift – 3120636Figure 2-24. Swing Brake - Ausco - Machines Built to 1992

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-63the top surface of the piston flush to 1/8 in. (3.2 mm) below the machined surface of the power plate.2

SECTION 2 - PROCEDURES2-64 – JLG Lift – 3120636Figure 2-25. Swing Brake - Mico - Machines Built to 1992

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-654. Place a new friction disc (48) on bottom disc (50), centering it as closely as possible. Insert one

3120636 – JLG Lift – v LIST OF FIGURESFIGURE NO. TITLE

SECTION 2 - PROCEDURES2-66 – JLG Lift – 31206361. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ring9. Backup

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-67AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly.1. Clean all p

SECTION 2 - PROCEDURES2-68 – JLG Lift – 31206361. Housing2. Gasket3. Bearing4. Oil Seal5. Spring Retainer6. Compression Spring7. Splined Shaft8

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-69AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulic oil prior to assembly.1. Cylinder of

SECTION 2 - PROCEDURES2-70 – JLG Lift – 3120636Figure 2-28. Drive Brake - Mico (March 1992 to S/N 33746)

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-713. Discard seals and o-rings.4. Closely inspect bearings and bearing contact sur-faces. Replace as nece

SECTION 2 - PROCEDURES2-72 – JLG Lift – 31206361. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ring9. Backup

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-73Inspection1. Clean all parts thoroughly.2. Closely inspect all parts for excessive wear, cracks and chi

SECTION 2 - PROCEDURES2-74 – JLG Lift – 31206362.27 FREE WHEELING OPTIONTo Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.1. Chock whe

SECTION 2 - PROCEDURES3120636 – JLG Lift – 2-752.29 BOOM MARKING TAPE INSTALLATIONBoom marking tape installation for Models 100HX, 110HX and 100HX+10