Jlg 110HX Service Manual Instrukcja Użytkownika

Service and Maintenance ManualModel110HX100HX+10P/N - 3120864March 11, 2010

viii – JLG Lift – 3120864LIST OF FIGURES (Continued) FIGURE NO. TITLE

SECTION 2 - PROCEDURES2-76 – JLG Lift – 3120864Load Radius Circuit Card - First GenerationLoad Radius Circuit Card - Second GenerationLoad Radius Circ

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-77100HX+10 (110HXER).1. Length Indicator Adjustment.a. Fully retract the boom and place it in the 0 (+3/-

SECTION 2 - PROCEDURES2-78 – JLG Lift – 3120864Figure 2-32. Boom Length/Angle Sensor Configurations

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-79Figure 2-33. Load Radius Card

SECTION 2 - PROCEDURES2-80 – JLG Lift – 31208643. Radius Adjustment.a. With the boom completely retracted and in the 0 (+3/-0) degrees horizontal posi

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-813rd Generation Radius Cards100HX Dual Capacity1. Length Indicator Adjustmenta. Level the frame before b

SECTION 2 - PROCEDURES2-82 – JLG Lift – 3120864Rotate the 5K Ohm potentiometer until you mea-sure 100 Ohms between Pin (3) and Pin (6) on the 6 pin pl

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-832. Boom Angle Sensor Adjustmenta. With the platform level, the boom fully retracted and at 45 (+/- 1) d

SECTION 2 - PROCEDURES2-84 – JLG Lift – 3120864This circuit card operates as follows:A calibrated dc voltage representing the boom angle is sent from

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-85Immediately beyond this point of balance the turntable is permitted to pivot a maximum vertical distanc

3120864 – JLG Lift – ix LIST OF TABLESTABLE NO. TITLE

SECTION 2 - PROCEDURES2-86 – JLG Lift – 3120864TESTSWITCHRESETSWITCH2Figure 2-35. Load Moment Limiting System Monitoring Circuit

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-879. If boom does not stop at white tape or boom can be extended after being retracted 3 meters without r

SECTION 2 - PROCEDURES2-88 – JLG Lift – 3120864Turntables 4620044 and 46200781. Removal.a. Fully retract boom.b. Remove rear turntable cover.c. Remove

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-89JLG Industries requires that a complete annual inspection be performed in accordance with the "Ann

SECTION 2 - PROCEDURES2-90 – JLG Lift – 312086413.Bushings8,1214.Wear Pads8,1215.Cylinders1,5,6,13 1216.Chains**1217.Chain Adjusters918.Sheaves8,1219.

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-9123.Swing Torque Hub1,3,5,6 1024.Swing Brake1,5,6 825.Swing Bearing1129CHASSIS1.Wheel and Tire Assembly1

SECTION 2 - PROCEDURES2-92 – JLG Lift – 3120864 This page left blank intentionally.

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-1SECTION 3. TROUBLESHOOTING3.1 GENERALThis section contains troubleshooting information to be used

SECTION 3 - TROUBLESHOOTING3-2 – JLG Lift – 3120864..Table 3-1. Platform Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYAutomatic leveling ino

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-3Table 3-2. Boom Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVESValve spool st

x – JLG Lift – 3120864LIST OF TABLES (Continued) TABLE NO. TITLE

SECTION 3 - TROUBLESHOOTING3-4 – JLG Lift – 3120864Boom will not raise.Load capacity exceeded (personnel or equip-ment on platform).Reduce load.(Refer

SECTION 3 - TROUBLESHOOTING3120864 – 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 – 3120864BOOM SWING SYSTEMNo response to swing control.Hydraulic system oil low. Replenish oil as necessary.

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-7.Table 3-3. Turntable Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYCONTROL VALVE.Valve Sp

SECTION 3 - TROUBLESHOOTING3-8 – JLG Lift – 3120864.Table 3-4. Chassis Assembly - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPOWER PLANT.Engine will

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-9Switch not functioning properly or improperly adjusted.Adjust, repair, or replace horizontal limit

SECTION 3 - TROUBLESHOOTING3-10 – JLG Lift – 3120864REAR FRAME AXLE AREA.Difficulty encountered when moving machine.Load capacity exceeded. Reduce loa

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-11Machine will not travel in forward.Hydraulic system oil low. Replenish oil as necessary.Restricted

SECTION 3 - TROUBLESHOOTING3-12 – JLG Lift – 3120864STEERING SYSTEM.No response to steer control.Circuit breaker open. Determine and correct cause; re

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-13Relief valve improperly set or not functioning properly.Reset, repair or replace valves as require

SECTION 1 - SPECIFICATIONS3120864 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank - 98 liters.Hydraulic Oil Tank - 208 liters.Hydrau

SECTION 3 - TROUBLESHOOTING3-14 – JLG Lift – 3120864.Table 3-5. Hydraulic System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYHYDRAULIC SYSTEMS - GEN

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-15Pump not delivering oil.Restricted suction line. Clean, repair, or replace line.Air entering syste

SECTION 3 - TROUBLESHOOTING3-16 – JLG Lift – 3120864Damaged wiring on control switch or auxiliary pump.See proper wiring diagram.Control switch not fu

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-17.Table 3-6. Electrical System - TroubleshootingTROUBLE PROBABLE CAUSE REMEDYPLATFORM CONTROLS.No p

SECTION 3 - TROUBLESHOOTING3-18 – JLG Lift – 3120864INSTRUMENTS AND INDICATORS.Travel warning horn inoperative.Circuit breaker open. Determine and cor

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-19Function speed control will not function.Boom above horizontal. Lower boom.Horizontal limit switch

SECTION 3 - TROUBLESHOOTING3-20 – JLG Lift – 3120864Figure 3-1. Wiring Diagram - Boom Indicator Pendulum

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-21Figure 3-2. Wiring Diagram - Dual Fuel (Ford Engine)

SECTION 3 - TROUBLESHOOTING3-22 – JLG Lift – 3120864Figure 3-3. Wiring Diagram - Generator (Deutz)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-23Figure 3-4. Wiring Diagram - Generator (Ford)

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120864Turning RadiusOutside - 7.1 m w/axles extended.Boom SpeedExtend - 128-156 Seconds.Retract - 93-113 S

SECTION 3 - TROUBLESHOOTING3-24 – JLG Lift – 3120864Figure 3-5. Wiring Diagram - Platform (100HX & 110HX)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-25Figure 3-6. Wiring Diagram - Platform (100HX+10 & 110HXER)

SECTION 3 - TROUBLESHOOTING3-26 – JLG Lift – 3120864Figure 3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-27Figure 3-8. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 2 of 3)

SECTION 3 - TROUBLESHOOTING3-28 – JLG Lift – 3120864Figure 3-9. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 3 of 3)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-29Figure 3-10. Wiring Diagram - 100HX+10 & 110HXER w/Deutz Engine (Sheet 1 of 3)

SECTION 3 - TROUBLESHOOTING3-30 – JLG Lift – 3120864Figure 3-11. Wiring Diagram - 100HX+10 & 110HXER w/Deutz Engine (Sheet 2 of 3)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-31Figure 3-12. Wiring Diagram - 100HX+10 & 110HXER w/Deutz Engine (Sheet 3 of 3)

SECTION 3 - TROUBLESHOOTING3-32 – JLG Lift – 3120864Figure 3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-33Figure 3-14. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 2 of 4)

SECTION 1 - SPECIFICATIONS3120864 – JLG Lift – 1-31.5 LUBRICATIONDeutz F4L912 EngineSingle Viscosity Oils (CD-SE, CD-SF).Multi-Viscosity Oils (CD-SE,

SECTION 3 - TROUBLESHOOTING3-34 – JLG Lift – 3120864Figure 3-15. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-35Figure 3-16. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-36 – JLG Lift – 3120864Figure 3-17. Wiring Diagram - 100HX+10 & 110HXER w/Ford Engine (Sheet 1 of 4)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-37Figure 3-18. Wiring Diagram - 100HX+10 & 110HXER w/Ford Engine (Sheet 2 of 4)

SECTION 3 - TROUBLESHOOTING3-38 – JLG Lift – 3120864Figure 3-19. Wiring Diagram - 100HX+10 & 110HXER w/Ford Engine (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-39Figure 3-20. Wiring Diagram - 100HX+10 & 110HXER w/Ford Engine (Sheet 4 of 4)

SECTION 3 - TROUBLESHOOTING3-40 – JLG Lift – 3120864BLACK 12ORANGE 12BLUE 12RED 12BLK/ORNBLACKBRN/BLUBRN/REDBRN/BLKYEL/ORNORN/REDBLU/ORNBLK/REDYEL/RED

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-411870001 - DBRN/ORNYEL/ORNORN/BLKOVERLOADALARM500# LIGHT(BLUE)0# LIGHT(RED)AXLES SETLIGHTBROKEN CHA

SECTION 3 - TROUBLESHOOTING3-42 – JLG Lift – 3120864Figure 3-23. Wiring Schematic - 110HX (EN280) (Sheet 3 of 4)

SECTION 3 - TROUBLESHOOTING3120864 – JLG Lift – 3-431870001 - DFigure 3-24. Wiring Schematic - 110HX (EN280) (Sheet 4 of 4)

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120864Lubrication SpecificationsNOTE: Refer to Lubrication Chart for specific lubrication pro-cedures.Tab

SECTION 3 - TROUBLESHOOTING3-44 – JLG Lift – 3120864This 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 - SPECIFICATIONS3120864 – JLG Lift – 1-51.6 PRESSURE SETTINGSProportional Valve.Drive - 241 bar.Lift Up - 207 bar.Lift Down - 83 bar.Telesco

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 312086410116, 729149835343451, 5, 16415313125212217352202223, 2421172533321421213026, 27, 281918, 20NoteThe

SECTION 1 - SPECIFICATIONS3120864 – JLG Lift – 1-7Table 1-9. Lubrication Chart ComponentsNumber/TypeLube PointsLube & MethodIntervalHoursComments1

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 312086432Boom ChainsN/A Chain Lube/Hot Oil Dip 1200 Includes extend and retract chains33Turntable Pivot Pin

SECTION 1 - SPECIFICATIONS3120864 – JLG Lift – 1-91.8 BOOM TAPE100HX Dual Capacity.Blue - Not used.Yellow - 157.5 cm.Red - 228.6 cm.White- 299.7 cm.11

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31208641.12 BOOM LIMIT SWITCHESThe following table charts the settings for the boom limit switch, horizont

SECTION 1 - SPECIFICATIONS3120864 – JLG Lift – 1-11SIZE412126677891212121416181820202424202432324010111213141618283236404861-1/21-1/23.81003.49254.013

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120864This page left blank intentionally.

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-1SECTION 2. PROCEDURES2.1 GENERALNOTE: The JLG Models 100HX, 110HX and 100HX+10 (110HXER) have been buil

SECTION 2 - PROCEDURES2-2 – JLG Lift – 3120864Bearings1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflam

SECTION 2 - PROCEDURES3120864 – 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 – 3120864A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spoo

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-5Meter-Out PoppetAdjustable ReliefActuator Port "A"Actuator Port "B"Load Drop CheckPi

INTRODUCTION3120864 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - PROCEDURES2-6 – JLG Lift – 3120864FLY EXTENDFLY RETRACTOUTER MID RETRACTOUTER MID EXTENDFigure 2-2. Boom Chain Adjustments

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-7Figure 2-3. Typical Boom Assembly

SECTION 2 - PROCEDURES2-8 – JLG Lift – 3120864An immediate disassembly of the boom assembly and inspection of the boom chains and related components i

SECTION 2 - PROCEDURES3120864 – 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 – 3120864Also, more than one crack can often appear on a link plate. In addition to rusting, this condition can

SECTION 2 - PROCEDURES3120864 – 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 – 31208642. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-134. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After

SECTION 2 - PROCEDURES2-14 – JLG Lift – 3120864BARRELPISTONSPACERHEADROD SUPPORTRODSETSCREWPISTON SEALSHEAD RETAINERRODSUPPORTBLOCKHEAD SEALSTELESCOPE

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-15BARRELHEADRETAINERHEAD SEALSRODPISTONPISTONSEALSHOLDINGVALVESETSCREWSPACERLIFTCYLINDERBARRELHEADHEAD SE

INTRODUCTIONA-2 – JLG Lift – 3120864REVISON LOGJanuary, 1991 - Original IssueMay, 1998 - RevisedOctober 15, 1999 - RevisedMay 22, 2002 - RevisedApril

SECTION 2 - PROCEDURES2-16 – JLG Lift – 3120864BARRELPISTONNUTSPACERHEADHEAD RETAINERRODSETSCREWPISTON SEALSHEAD SEALSMASTERCYLINDERBARRELHEADHEAD SEA

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-17BARRELHEADHEAD SEALSRODSPACERPISTONPISTONSEALSHOLDINGVALVEHOLDINGVALVESETSCREWSLAVECYLINDER(Extend-A-Re

SECTION 2 - PROCEDURES2-18 – JLG Lift – 312086415. Pull boom sections apart several feet.16. Using the lifting equipment, raise the cylinder to obtain

SECTION 2 - PROCEDURES3120864 – 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 – 31208646. Remove temporary hoses from level cylinder and cap them. Plug cylinder ports.7. Using slings, restra

SECTION 2 - PROCEDURES3120864 – 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 – 3120864AssemblyNOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JL

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-2316. If applicable, install the cartridge-type holding valve and fittings in the rod port block using ne

SECTION 2 - PROCEDURES2-24 – JLG Lift – 31208642. Tag and disconnect hydraulic lines to slave level cyl-inder and rotator motor.3. Tag and disconnect

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-2535. Remove bolts and lockwashers which attach upper aft inner mid section wear pads and remove pads and

3120864 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - PROCEDURES2-26 – JLG Lift – 312086417145121616166Figure 2-9. Boom Assembly(Sheet 1 of 2)

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-2771818432189151510111. Boom Base2. Inner Mid Boom3. Outer Mid Boom4. Fly Boom5. Telescope Cylinder6. Out

SECTION 2 - PROCEDURES2-28 – JLG Lift – 31208644. Install lubrication fittings in ends of pins and lubri-cate sheaves with MPG.NOTE: When installing o

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-2935. Install outer mid section retract chain clevis into attach block at lower front end of base boom se

SECTION 2 - PROCEDURES2-30 – JLG Lift – 31208643. With the electrical connections complete, slowly tighten one of the “Y” nuts until the circuit is cl

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-312.14 LIMIT SWITCH ADJUSTMENTSBoom Limit SwitchThe boom limit switch is located on the left side of the

SECTION 2 - PROCEDURES2-32 – JLG Lift – 3120864ACTUATOR CABLEADECO ACTUATORLOW ENGINEHIGH ENGINE LIMIT SWITCHSLIDE PIN (2)SLIDE PIN (1)LIMIT SWITCHTHR

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-332.16 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS - FORD ENGINEChecks1. Check that anti-dieseling

SECTION 2 - PROCEDURES2-34 – JLG Lift – 3120864CHOKECHOKEORVACUUMPULLOFFIDLE SPEEDSCREWTHROTTLELEVERTHROTTLERODLINKAGEHIGH ENGINE NO LOAD,BUFFER SCREW

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-35PC BOARDDROOP P3GAIN P2LOW (MID)ENGINEADJUSTMENTHIGH ENGINE P1NOTEAll pots should be sealed with finger

ii – JLG Lift – 3120864TABLE OF CONTENTS (Continued) SECTION NO. TITLE

SECTION 2 - PROCEDURES2-36 – JLG Lift – 31208642.17 PRESSURE SETTING PROCEDURESSequence Pressure (Prior to 1990)1. Plug pressure gauge into quick-conn

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-376. Drive Relief.a. Disconnect and cap hose to drive motor and plug port on drive section of proportiona

SECTION 2 - PROCEDURES2-38 – JLG Lift – 3120864Pressure ReducingCartridgeSequenceCartridgeMain ReliefInstall pressure gauge atquick disconnectSwing Ad

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-39MAIN RELIEF ADJUSTMENTROTATE LEFT & ROTATE RIGHTADJUSTMENTSTEER LEFT & STEER RIGHTADJUSTMENTCHE

SECTION 2 - PROCEDURES2-40 – JLG Lift – 3120864MAIN RELIEFADJUSTMENTROTATE LEFT & ROTATE RIGHTADJUSTMENTSTEER LEFT & STEER RIGHTADJUSTMENTCHEC

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-412.18 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is designed to replac

SECTION 2 - PROCEDURES2-42 – JLG Lift – 3120864MEASURING POINTMEASURING POINTFORWARDa. BOOM FULLY ELEVATEDAND FULLY RETRACTEDb. BOOM AT HORIZONTALAND

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-43Bearing Replacement1. Removal.a. From ground control station, operate the boom lift control and raise b

SECTION 2 - PROCEDURES2-44 – JLG Lift – 3120864torque of 244 Nm. Then following the same sequence tighten the bolts to a final torque of 298 Nm.i. Rem

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-452.19 DRIVE TORQUE HUBDisassembly1. Position hub over suitable container and remove drain plug (37) from

3120864 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - PROCEDURES2-46 – JLG Lift – 31208641. Bolt2. Bolt3. Lockwasher4. Cover5. Pipe Plug6. Pipe Plug7. Cover Cap8. O-ring9. Disconnect Rod10. O-

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-475. Inspect all needle rollers for scoring, pitting or excessive wear. Replace all rollers as necessary.

SECTION 2 - PROCEDURES2-48 – JLG Lift – 3120864f. Lower hub onto spindle (30) with large open end up.g. Place bearing cone (32) over end of spindle an

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-49l. Place spring (43) into spindle counterbore.m. Set second spacer washer (42) on top of spring.EYE PRO

SECTION 2 - PROCEDURES2-50 – JLG Lift – 31208645. Install retaining ring (19) in groove of input shaft (20).6. Place input shaft into spindle counterb

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-51c. Place cluster gear over planet shaft and onto bearing cone, with large gear on top.d. Place another

SECTION 2 - PROCEDURES2-52 – JLG Lift – 3120864i. Place bearing cones (29) into cluster gear.j. Place cluster gear into carrier with large gear up.k.

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-53o. Repeat steps (a) through (n) for remaining two cluster gears.10. Time carrier gears as follows:a. Pl

SECTION 2 - PROCEDURES2-54 – JLG Lift – 312086415. Place one thrust bearing (16) between two thrust washers (15) and place into carrier counterbore.16

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-55f. Install disconnect cap (11) to cover cap with two remaining bolts (12) torqued to 70 to 80 in.lbs. (

iv – JLG Lift – 3120864TABLE OF CONTENTS (Continued) SECTION NO. TITLE

SECTION 2 - PROCEDURES2-56 – JLG Lift – 31208642.20 SWING TORQUE HUBDisassembly1. Remove oil plugs (25 and 26) and drain oil from unit into a suitable

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-57Figure 2-21. Swing Torque Hub

SECTION 2 - PROCEDURES2-58 – JLG Lift – 3120864a. Using suitable snap ring pliers, remove retaining ring (20) from groove in output shaft (30).b. Remo

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-59o’clock, and one bottom gear at six o’clock as shown in Figure 2-19.b. Find marked (punch mark) teeth o

SECTION 2 - PROCEDURES2-60 – JLG Lift – 31208641. Gasket2. Bolt (Model 28653)Flanged Bolt (Model 37265V)3. Lockwasher (Model 28653 Only)4. Power Plate

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-61Cleaning and Inspection1. Clean all parts thoroughly.2. Closely inspect all parts for damage, excessive

SECTION 2 - PROCEDURES2-62 – JLG Lift – 312086441. O-ring42. Back-Up Ring43. Bleeder44. Retaining Ring45. Shaft46. Disc47. Spring48. Friction Disc49.

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-634. Closely inspect bearings and bearing contact sur-faces. Replace as necessary.NOTE: Bearings may be r

SECTION 2 - PROCEDURES2-64 – JLG Lift – 31208641. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ring9. Backup

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-65NOTE: Earlier models did not use retaining ring (22).10. Remove retaining ring (22) and bearing (19) fr

3120864 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 2 - PROCEDURES2-66 – JLG Lift – 31208641. Housing2. Gasket3. Bearing4. Oil Seal5. Spring Retainer6. Compression Spring7. Splined Shaft8

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-67operator. Remove o-rings (15 and 17) and back-up rings (14 and 16) from piston OD and ID grooves.8. Pre

SECTION 2 - PROCEDURES2-68 – JLG Lift – 31208641. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ring9. Backup

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-698. Remove retaining ring (18) from housing (21).9. Remove shaft by pressing or using a soft mallet on m

SECTION 2 - PROCEDURES2-70 – JLG Lift – 31208641. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ring9. Backup

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-716. Remove stack assembly, consisting of discs (23), return plate (8) and friction discs (22) from housi

SECTION 2 - PROCEDURES2-72 – JLG Lift – 31208648. Insert separators (10) in holes of return plate (8).9. Install new o-ring (19), new back-up ring (18

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-73THRESHOLD Adjustment1. Move controller handle approximately one (1) inch (2.5 cm), until LED light come

SECTION 2 - PROCEDURES2-74 – JLG Lift – 3120864c. Set TP1 on the load radius circuit card to 1.8 Volts by adjusting trimpot TP1, then proceed with the

SECTION 2 - PROCEDURES3120864 – JLG Lift – 2-75d. Engage LIFT DOWN until the blue light turns off and the red light turns on. When the red light turns