Service Manual Owner's manual

ManualsBrandsJLG ManualsSpecial machinery110HX ANSI

Service and Maintenance Manual

Model

100HX

100HX+10

110HX

P/N - 3120636

March 11, 2010

Summary of content (162 pages)

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Service and Maintenance Manual Model 100HX 100HX+10 110HX P/N - 3120636 March 11, 2010
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INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A feed lines to system components can then be disconnected with minimal fluid loss. 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.
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INTRODUCTION REVISON LOG March, 1989 October, 1994 August, 1997 January, 1999 October 8, 1999 May 20, 2002 April 6, 2009 March 11, 2010 A-2 - Original Issue - Revised - Revised - Revised - Revised - Revised - Revised - Revised – JLG Lift – 3120636
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TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) SECTION NO. TITLE PAGE NO. SECTION 2 - PROCEDURES 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 ii General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION NO. 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 3120636 TITLE PAGE NO. Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) SECTION NO. 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 2.36 2.37 TITLE PAGE NO. Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-6. 2-6. 2-6. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-15. 2-14. 2-16. 2-17. 2-18. 2-19. 2-20. 2-21. 2-22. 2-23. 2-24. 2-25. 2-26. 2-27. 2-28. 2-29. 2-30. 2-31. 2-32. 2-33. 2-34. 2-35. 2-36. 2-37. 3120636 TITLE PAGE NO. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF FIGURES (Continued) FIGURE NO. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. vi TITLE PAGE NO. Wiring Diagram - Boom Indicator Pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Wiring Diagram - Dual Fuel (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 Wiring Diagram - Generator (Deutz) . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 2-1 2-2 2-3 2-4 2-5 2-6 2-7 3-1 3-2 3-3 3-4 3-5 3-6 3120636 TITLE PAGE NO. Maximum Tire Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LIST OF TABLES (Continued) TABLE NO. TITLE PAGE NO. This page left blank intentionally.
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 Engine - Deutz F4L912 CAPACITIES Fuel - Diesel Fuel Tank - 28 gallons (98 liters). Oil Capacity - 12.7 quarts (12 liters) Hydraulic Oil Tank - 55 gallons (208 liters). Hydraulic System (Including Tank) - 65 gallons (246 liters). Low (Mid) RPM - 1800 High RPM - 2400 Torque Hub, Drive - 90 oz. (2.7 liters). Alternator Torque Hub, Swing - 17 oz. (0.5 liters). Prior to Oct. 91 85 Amp NOTE: Torque Hubs should be one-half full of lubricant.
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SECTION 1 - SPECIFICATIONS Drive System Hydraulic Filter - Tank Tires. Return - Bypass Type 10 Microns Nominal Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam filled. After March, 1993 - 385/65R22.5, 18 ply rating, foam filled. Hydraulic Filter - Inline Return - Non-Bypass Type 10 Microns Nominal Drive Motor - 2.5 in3 (6.4 cm3) /rev. displacement. Drive Hub - 93.7:1 ratio. Drive Brake - Automatic spring applied, hydraulically released. 1.3 PERFORMANCE DATA Travel Speed Steer System 2.
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SECTION 1 - SPECIFICATIONS Machine Weight 1.4 TORQUE REQUIREMENTS 100HX - 36,400 lbs. (16,511 kg) Table 1-2.Torque Requirements 110HX - 40,410 lbs. (18,330 kg) 100HX+10 - 39,685 lbs. (18,001 kg) 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 Machine Stowed Height 9 ft. 10 in. (3.0 m) Machine Stowed Length 100HX - 36 ft. in. (11.
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SECTION 1 - SPECIFICATIONS Deutz F4L912 Engine Table 1-3.
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SECTION 1 - SPECIFICATIONS  Table 1-4. Mobil EAL Envirosyn H 46 Specs Table 1-6. Mobil DTE 13M Specs Type Synthetic Biodegradable Type Petroleum Base ISO Viscosity Grade 46 ISO Viscosity Grade 32 Specific Gravity .910 Specific Gravity .877 Pour Point, Max -44°F (-44°C) Pour Point, Max -40°F (-40°C) Flash Point, Min. 500°F (260°C) Flash Point, Min. 330°F (166°C) Weight 7.64 lb. per gal. (0.9 kg per liter) Viscosity Viscosity at 104° F (40° C) 45 cSt at 212° F (100° C) 8.
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SECTION 1 - SPECIFICATIONS 3 2 20 5 19 26, 27, 28 22 18, 20 17 22 17 21 21 23, 24 25 25 31 31 9 33 15 35 4 34 8 21 32 1, 5, 16 5 14 14 30 21 29 34 6, 7 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 11 10 Figure 1-1.
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SECTION 1 - SPECIFICATIONS Table 1-8.
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SECTION 1 - SPECIFICATIONS Table 1-8.
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SECTION 1 - SPECIFICATIONS 1.8 BOOM TAPE 100HX+10. Blue - 53 in. (134.6 cm) With 4620038 Turntable Yellow - Not used 110HX Single Capacity Red - 87 in. (221.0 cm) Blue - Not used White - 138.5 in. (351.8 cm) Yellow - Not used Red - 119.5 in. (303.5 cm) White - 154.5 in. (392.4 cm) 1.9 110HX Dual Capacity Table 1-10.Major Component Weights 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 MAJOR COMPONENT WEIGHTS Component Lbs. KG.
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SECTION 1 - SPECIFICATIONS  1.11 CRITICAL STABILITY WEIGHTS Table 1-11.Critical Stability Weights Component 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. 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.
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UNPLATED CAP SCREWS 3120636 – JLG Lift – 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 Note: 1-1/2 1-1/2 1-1/4 1-1/8 1 7/8 3/4 5/8 9/16 1/2 7/16 3/8 5/16 1/4 10 8 6 4 0.0153 0.0168 0.0232 0.0258 0.0356 0.0374 0.0445 0.0508 0.0808 0.0925 0.1331 0.1473 0.1969 0.2230 0.2700 0.3015 0.3604 0.4061 0.4623 0.5156 0.5740 0.6502 0.8484 0.9474 1.1735 1.2929 1.5392 1.6840 1.9380 2.1742 2.4613 2.7254 2.9337 3.3401 3.5687 4.
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SECTION 1 - SPECIFICATIONS This page left blank intentionally 1-12 – JLG Lift – 3120636
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SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 Cleanliness GENERAL 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.
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SECTION 2 - PROCEDURES Bearings cleaning solvent. Lubricate required, to aid assembly. 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.
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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.
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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.
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SECTION 2 - PROCEDURES Adjustable Relief Meter-Out Poppet Actuator Port "A" Return Port Actuator Port "B" Load Drop Check "B" Solenoid Electro-Hydraulic Reducing Valve Spool Pilot Relief Load Sensing Check Valves Vent Meter-In Spool Meter-In Chambers Valve Inlet Port Gasket Pilot Supply Passages "A" Solenoid Figure 2-1.
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SECTION 2 - PROCEDURES OUTER MID EXTEND OUTER MID RETRACT FLY EXTEND FLY RETRACT Figure 2-2.
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SECTION 2 - PROCEDURES Figure 2-3.
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SECTION 2 - PROCEDURES 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: Inspection Procedure Inspect boom chains for the following conditions: 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.
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SECTION 2 - PROCEDURES Table 2-1.Chain Stretch Tolerance Chain Size Pin to Pin Measurement 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.
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SECTION 2 - PROCEDURES  2.7 ABNORMAL PROTRUSION OR TURNED PINS 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. 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.
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SECTION 2 - PROCEDURES 2. Attach tape measure or cord to bottom of platform. 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. BEFORE RAISING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL. 2. Position LIFT control switch to UP and hold until boom reaches horizontal. 3.
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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. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system. 3.
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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. 2.10 CYLINDER REMOVAL AND INSTALLATION Telescope Cylinder Removal 5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports. 1.
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SECTION 2 - PROCEDURES SETSCREW PISTON SEALS ROD HEAD SEALS ROD SUPPORT PISTON HEAD RETAINER SPACER BARREL TELESCOPE CYLINDER HEAD ROD SUPPORT BLOCK HEAD SEALS HOLDING VALVE PISTON RETAINER SPACER SETSCREW HEAD BARREL ROD AXLE LIFT CYLINDER PISTON SEALS Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine. Figure 2-5.
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SECTION 2 - PROCEDURES HEAD SEALS RETAINER SPACER HEAD PISTON SETSCREW BARREL HOLDING VALVE ROD LIFT CYLINDER PISTON SEALS PISTON HOLDING VALVE SETSCREW HOLDING VALVE NUT PISTON SEALS HEAD SEALS SPACER ROD SLAVE CYLINDER BARREL HEAD Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine. Figure 2-6.
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SECTION 2 - PROCEDURES SETSCREW PISTON SETSCREW SPACER NUT HEAD SEALS PISTON SEALS ROD BARREL STEER CYLINDER HEAD SETSCREW PISTON SEALS ROD HEAD SEALS NUT PISTON SPACER BARREL MASTER CYLINDER HEAD HEAD RETAINER Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine. Figure 2-6.
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SECTION 2 - PROCEDURES HEAD SEALS RETAINER PISTON HEAD SETSCREW NUT BARREL ROD AXLE CYLINDER SPACER PISTON SEALS HEAD SEALS HOLDING VALVE PISTON SETSCREW HEAD BARREL ROD SLAVE CYLINDER (Extend-A-Reach) SPACER PISTON SEALS HOLDING VALVE Note: Due to design changes, the cylinders shown may not be an exact representation of those on your particular machine. Figure 2-6.
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SECTION 2 - PROCEDURES HEAD SEALS PISTON RETAINER SETSCREW HEAD HOLDING VALVE BARREL ROD SPACER EXTEND-A-REACH LIFT CYLINDER PISTON SEALS NUT 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. 8. Using another lifting device, support the sheave wheel end of the cylinder and remove the cylinder from the boom assembly. 2.
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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. 2. Using auxiliary power, retract the lift cylinder rod completely. 7. Install the two (2) extension chain adjusting nuts at the aft end of the base boom. 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. 8.
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SECTION 2 - PROCEDURES 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting. 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 DO NOT FULLY EXTEND CYLINDER TO END OF STROKE.
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SECTION 2 - PROCEDURES 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. 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.
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SECTION 2 - PROCEDURES Assembly Table 2-2.Cylinder Piston Nut Torque Specifications. Nut Torque Value (Wet) Setscrew Torque Value (Dry) Lift Cylinder 600 ft. lbs. (814 Nm) 200 in. lbs. (22.5 Nm) Slave Cylinder 80 ft. lbs. (109 Nm) 100 in. lbs. (12 Nm) Master Cylinder 80 ft. lbs. (109 Nm) 100 in. lbs. (12 Nm) Steer Cylinder 80 ft. lbs. (109 Nm) 100 in. lbs. (12 Nm) Telescope Cylinder 600 ft. lbs. (814 Nm) 100 in. lbs. (12 Nm) Axle Extension Cylinder 80 ft. lbs. (109 Nm) 100 in. lbs.
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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. 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.
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SECTION 2 - PROCEDURES Disassembly 15. Remove bolts and lockwashers attaching top front wear pad to base section. Remove pad and shims. 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.
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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.
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SECTION 2 - PROCEDURES 16 12 17 16 5 16 14 6 Figure 2-9.
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SECTION 2 - PROCEDURES 1. 2. 3. 4. 5. 6. 7. 8. 9. Boom Base Inner Mid Boom Outer Mid Boom Fly Boom Telescope Cylinder Outer Mid Extend Chain Fly Extend Chain Fly Retract Chain Outer Mid Retract Chain 10. 11. 12. 13. 14. 15. 16. 17. 18. Tele Cylinder Sheave Sheave Chain Extend Rod Chain Attach Pin Chain Adjustment Assembly Chain Adjustment Assembly Upper Rear Wear Pad Adjustment & Jam Nuts Safety Chain 13 10 1 18 2 3 4 8 7 18 9 15 15 11 Figure 2-10.
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SECTION 2 - PROCEDURES Inspection Assembly 1. Inspect all sheaves (extend chains, retract chains and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as necessary. 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.
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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.
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SECTION 2 - PROCEDURES 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. 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. 7. Shut down machine systems. 8.
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SECTION 2 - PROCEDURES RED WHITE BLACK YELLOW Figure 2-11. Tilt Switch Adjustment - Voltmeter 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. X Y Y 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.
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SECTION 2 - PROCEDURES 2.14 LIMIT SWITCH ADJUSTMENTS 2.16 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS - FORD ENGINE 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. Checks 1.
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SECTION 2 - PROCEDURES ACTUATOR CABLE THROTTLE LEVER INJECTION PUMP THROTTLE LEVER STOP ADECO ACTUATOR ADECO ACTUATOR ACTUATOR CABLE SLIDE PIN (1) LIMIT SWITCH HIGH ENGINE LIMIT SWITCH LOW ENGINE SLIDE PIN (2) Figure 2-13.
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SECTION 2 - PROCEDURES LOW (MID) ENGINE ADJUSTMENT PC BOARD NOTE All pots should be sealed with finger nail polish or its equivalent after all adjustments are completed. GAIN P2 DROOP P3 HIGH ENGINE P1 Figure 2-15.
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SECTION 2 - PROCEDURES CHOKE VACUUM PULLOFF FUEL SHUTOFF VALVE CHOKE IDLE SPEED SCREW OR THROTTLE LEVER FUEL SHUT OFF VALVE THROTTLE ROD LINKAGE IDLE AIR MIXTURE HIGH ENGINE NO LOAD, BUFFER SCREW PRECISION GOVERNOR ACTUATOR Figure 2-14.
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SECTION 2 - PROCEDURES 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.) ‘high engine’ (P1) adjusting screw until engine runs at 3000 RPM. Turning the screw CW increases RPM. Turning the screw CCW decreases RPM. 8.
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SECTION 2 - PROCEDURES Lift Down Adjustment - A Side Lift Up Adjustment - B Side Telescope In Adjustment - A Side Telescope In Adjustment - B Side Drive Adjustment Swing Adjustment Install pressure gauge at quick disconnect PROPORTIONAL VALVE Main Relief Pressure Reducing Cartridge Sequence Cartridge ACCESSORY VALVE Figure 2-16.
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SECTION 2 - PROCEDURES STEER LEFT & STEER RIGHT ADJUSTMENT CHECK POINT FOR LEVEL, STEER, ROTATE, AND MAIN RELIEF MAIN RELIEF ADJUSTMENT ROTATE LEFT & ROTATE RIGHT ADJUSTMENT SOLENOID (Bang-Bang) VALVE Machines Built to 1995 Figure 2-14.
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SECTION 2 - PROCEDURES STEER LEFT & STEER RIGHT ADJUSTMENT CHECK POINT FOR LEVEL, STEER, ROTATE, AND MAIN RELIEF MAIN RELIEF ADJUSTMENT ROTATE LEFT & ROTATE RIGHT ADJUSTMENT SOLENOID (Bang-Bang) VALVE Machines Built 1995 to Present Figure 2-14.
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SECTION 2 - PROCEDURES Sequence Pressure (1990 to Present) 1. Plug pressure gauge into quick-connect on high drive dump valve. Monitor 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. 2. Run an electrical current to activate the dump valve. c. Release lift down function. 3. Loosen the lock nut on sequence cartridge and adjust sequence pressure to 450 psi (31 bar).
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SECTION 2 - PROCEDURES 7. Main Relief. 3. Platform Rotate Relief. a. Disconnect and cap hoses to drive motor; plug ports on drive section of proportional valve. Monitor pressure gauge. 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. b.
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SECTION 2 - PROCEDURES 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position. 2.18 SWING BEARING Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bearing 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.
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SECTION 2 - PROCEDURES FORWARD MEASURING POINT MEASURING POINT a. BOOM FULLY ELEVATED AND FULLY RETRACTED b. BOOM AT HORIZONTAL AND FULLY EXTENDED Figure 2-18. Swing Bearing Tolerance Boom Placement TURNTABLE REF. SWING BEARING FRAME REF. MEASURING POINT Figure 2-19.
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SECTION 2 - PROCEDURES 5. If bearing inspection shows no defects, reassemble bearing and return to service. g. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame mounted components. 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.
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SECTION 2 - PROCEDURES 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.
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SECTION 2 - PROCEDURES NOTE: INSTALL BEARING WITH FILL PLUG ON SIDE. (AS CLOSE TO CENTERLINE OF ROTATION AS POSSIBLE.) 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 coupling as tagged prior to removal. z.
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SECTION 2 - PROCEDURES stick in carrier counterbore. Inspect thrust washers and thrust bearing for wear and replace if necessary. 2.19 DRIVE TORQUE HUB 10. Lift internal gear (21) out of hub. Disassembly 1. Position hub over suitable container and remove drain plug (37) from unit. Allow oil to completely drain. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL. 2. Remove sixteen bolts (1), four shoulder bolts (2), and twenty lockwashers (3) from cover (4) and lift cover from unit.
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SECTION 2 - PROCEDURES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45.
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SECTION 2 - PROCEDURES 5. Inspect all needle rollers for scoring, pitting or excessive wear. Replace all rollers as necessary. d. Install bearing cone (32) into bearing cup. 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.
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SECTION 2 - PROCEDURES g. Place bearing cone (32) over end of spindle and into bearing cup. j. Install retaining ring keeper ring (40) in location around retaining ring and on bearing shim. h. Place bearing shim (34) over end of spindle and against bearing cone. k. With large open end of hub/spindle assembly facing up, place one spacer washer (42) into spindle counterbore. l. Place spring (43) into spindle counterbore. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. i.
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SECTION 2 - PROCEDURES 3. Lower internal gear (21) onto spindle. m. Set second spacer washer (42) on top of spring. 4. Place one thrust bearing (16) between two thrust washers (15) and place them onto spindle pilot. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. n. Compress spacer washer and spring into spindle counterbore and install retaining ring (41) into spindle groove. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. 2.
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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. 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. 7. Slide thrust spacer (18) onto input shaft. b. Place planet shaft (23) on a flat surface with large diameter down. Place one bearing cone (29) over shaft and against shoulder.
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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. 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. e. Slide largest spacer (26) onto planet shaft. 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.
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SECTION 2 - PROCEDURES m. Place carrier on table with something under planet shaft to hold it in correct position and install retaining ring (25). 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. 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.
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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. 13.
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SECTION 2 - PROCEDURES 16. Assemble cover assembly as follows: d. Push disconnect rod into bore of cover cap. a. Screw pipe plugs (5 and 6) into cover 4. 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). b. Install o-ring (8) over cover cap (7). c. Install o-ring (10) into bore of cover cap 7. Disconnect rod (9) may be used to push o-ring down to groove in cover cap bore. f.
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SECTION 2 - PROCEDURES 19. Install sixteen Grade 8 bolts (1) and lockwashers (3) in remaining holes. 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. 20. Tighten bolts and shoulder bolts evenly and torque to 100-110 ft.lbs. (14-15 kgm). 17. Place cover assembly (4) onto ring gear (13).
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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. dle rollers (13) on each shaft are not damaged or lost. 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). c. Lift cluster gears (11) from carrier (10) and remove thrust washers (12), needle rollers (13) and roller spacer (14). d.
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SECTION 2 - PROCEDURES Figure 2-23.
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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. c. Apply a liberal coating of petroleum or multi-purpose grease to inner diameter of cluster gear (11). d. Position spacer (14) at the approximate midpoint of the gear diameter. e.
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SECTION 2 - PROCEDURES 10. Position o-ring (6) in groove in hub (24). 3. Bearing (18) is pressed onto shaft (7) and must be removed before removal of rotating discs (11) and stationary discs (12). 11. While holding ring gear (7) and carrier assembly (10), insert smaller diameter of cluster gears (11) into internal gear (19). 4. Further disassembly is not recommended unless necessary for the replacement of specific parts. 12.
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SECTION 2 - PROCEDURES Figure 2-24.
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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. 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. 2. When pressing the bearing onto the shaft, press on the inner race of the bearing and support the shaft properly. 5. Remove o-ring (38), back-up ring (39), o-ring (41) and back-up ring (42) from piston. 3.
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SECTION 2 - PROCEDURES Figure 2-25.
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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. 2.23 SWING BRAKE - MACHINES BUILT 1992 TO PRESENT 1. Separate end cover (2) from housing (21) by removing capscrews (1). 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).
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SECTION 2 - PROCEDURES 25 24 23 22 21 17 19 18 16 20 15 14 26 13 12 11 12 3 9 11 8 10 7 6 5 4 2 1 24 25 1. 2. 3. 4. 5. 6. 7. 8. 9. Capscrew End Cover Bleeder Screw Case Seal O-ring Back-Up Ring Piston O-ring Backup Ring 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Disc Friction Disc Separators Return Plate Spring Spring Spring Retainer Retaining Ring 19. 20. 21. 22. 23. 24. 25. 26. Bearing Dowel Pin Housing Retaining Ring Rotary Oil Seal O-ring Gasket Pin Figure 2-26.
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SECTION 2 - PROCEDURES 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).
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SECTION 2 - PROCEDURES 1. 2. 3. 4. 5. 6. 7. 8. 9. Housing Gasket Bearing Oil Seal Spring Retainer Compression Spring Splined Shaft Torque Pin Primary Disc 10. 11. 12. 13. 14. 15. 16. 17. 18. Separator Disc Rotating Disc Stationary Disc Piston Back-Up Ring O-ring Back-Up Ring O-ring Bearing Figure 2-27.
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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).
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SECTION 2 - PROCEDURES Figure 2-28.
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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.
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SECTION 2 - PROCEDURES 29 28 1 15 54 2 3 56 52 53 17 58 22 23 22 23 51 20 21 57 18 19 11 14 13 25 55 28 29 1. 2. 3. 4. 5. 6. 7. 8. 9. Capscrew End Cover Bleeder Screw Case Seal O-ring Back-Up Ring Piston O-ring Backup Ring 10. 11. 12. 13. 14. 15. 16. 17. 18. Shaft Disc Friction Disc Separators Return Plate Spring Spring Spring Guide Retaining Ring 19. 20. 21. 22. 23. 24. 25. 26. Bearing Dowel Pin Housing Retaining Ring Rotary Oil Seal O-ring Gasket Pin Figure 2-29.
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SECTION 2 - PROCEDURES Inspection NOTE: Discs (8 & 23) and friction discs (22) should remain dry during installation. No oil contaminate disc surfaces. 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.
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SECTION 2 - PROCEDURES HI RANGE Adjustment 2.27 FREE WHEELING OPTION 1. Move handle all the way forward. To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. 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. 1. Chock wheels securely if not on flat level surface. 2. Disconnect both drive hubs by inverting disconnect caps in center of hubs. 4.
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SECTION 2 - PROCEDURES 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 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.
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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 50in. (127.0 cm) 84 in. (213.4 cm) 135 in. (342.9 cm) 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.
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SECTION 2 - PROCEDURES 2. Boom Angle Sensor Adjustment. 2.30 BOOM LENGTH/ANGLE SENSOR ADJUSTMENT PROCEDURES a. With the boom completely retracted and in the 0 degrees horizontal position, measure the voltage at TP3 on the load radius circuit card and at the yellow wire on the boom angle sensor. LOAD RADIUS CIRCUIT CARD P/N-0610106 WAS SUPERSEDED WITH LOAD RADIUS CIRCUIT CARD P/N-0610130.
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SECTION 2 - PROCEDURES Table 2-5.Card Adjustment - 1st and 2nd Generation Boom Radius Use Procedure Model Length Indicator Boom Angle Sensor 100HX 2.5 Volts 0.18 Volts 110HX 2.0 Volts 0.20 Volts 100HX+10 2.5 Volts 0.18 Volts Table 2-6.Card Adjustment - 3rd Generation Boom Radius Use Procedure Adjustment Location 100HX Dual Capacity 110HX Single Capacity 110HX Dual Capacity 100HX+10 Single Capacity P1 1.114 Volts 1.151 Volts 1.151 Volts 1.018 Volts P2 1.585 Volts 2.548 Volts 2.
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SECTION 2 - PROCEDURES Load Radius Circuit Card - First Generation Load Radius Circuit Card - Second Generation Load Radius Circuit Card - Third Generation Figure 2-33.
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SECTION 2 - PROCEDURES Figure 2-34.
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SECTION 2 - PROCEDURES Figure 2-35.
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SECTION 2 - PROCEDURES 2. Boom Angle Sensor Adjustment. a. With the boom completely retracted and in the 0 (+3/-0) degrees horizontal position, measure the voltage at TP3 on the load radius circuit card and at the yellow wire on the boom angle sensor. b.
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SECTION 2 - PROCEDURES 3rd Generation Radius Cards 3. Radius Adjustment and Display Lights Setting Procedure 100HX Dual Capacity a. On the Load Radius Circuit Card, measure TP11 and adjust potentiometer P6 for a reading of 0.0 Volts DC. 1. Length Indicator Adjustment a. Level the frame before beginning any adjustments. b. On the Load Radius Circuit Card, measure TP8 and adjust potentiometer P2 for a reading of 1.585 Volts DC. b. Make all adjustments with the engine running unless otherwise noted. c.
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SECTION 2 - PROCEDURES Rotate the 5K Ohm potentiometer until you measure 100 Ohms between Pin (3) and Pin (6) on the 6 pin plug connector which mates with J2.  Tighten the three (3) screws on the 5K Ohm potentiometer in the boom cable reel. 110HX Single Capacity 1. Length Indicator Adjustment a. Level the frame before beginning any adjustments. b. Make all adjustments with the engine running unless otherwise noted. g. Turn the power on and measure TP2. It should be 1.120 Volts DC.
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SECTION 2 - PROCEDURES 2. Boom Angle Sensor Adjustment 110HX Dual Capacity a. With the platform level, the boom fully retracted and at 45 (+/- 1) degrees elevation, measure the DC voltage at TP5 on the Load Radius Circuit Card. 1. Length Indicator Adjustment a. Level the frame before beginning any adjustments. b. Make all adjustments with the engine running unless otherwise noted. b. Loosen the three screws securing the sensor to the box and rotate the sensor until 7.1 (+/- 0.
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SECTION 2 - PROCEDURES 2. Boom Angle Sensor Adjustment 2.31 LOAD MANAGEMENT SYSTEM a. With the platform level, the boom fully retracted and at 45 (+/- 1) degrees elevation, measure the DC voltage at TP5 on the Load Radius Circuit Card. b. Loosen the three screws securing the sensor to the box and rotate the sensor until 7.1 (+/- 0.1) Volts DC is measured at TP5. Tighten the screws on the sensor. c. Return the boom to horizontal. 3. Radius Adjustment and Display Lights Setting Procedure a.
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SECTION 2 - PROCEDURES MONITORING TIMER RELAYS TEST SWITCH RESET SWITCH MONITOR LATCHING RELAYS LOAD MOMENT CIRCUIT CARD LOAD RADIUS CIRCUIT CARD MONITOR RELAY MODULE LOAD MOMENT CIRCUIT CARD Figure 2-36. Control Box Components This circuit card operates as follows: A calibrated dc voltage representing the boom angle is sent from the boom angle sensor to the angle cosine circuit. This voltage is converted to the cosine of the angle and presented to the radius generator circuit.
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SECTION 2 - PROCEDURES Immediately beyond this point of balance the turntable is permitted to pivot a maximum vertical distance of 3 mm. This movement is sensed by two independent switches which power two independent control circuit channels. 1. A positive break mechanical limit switch. 2. An inductive proximity switch.
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TEST SWITCH 2 RESET SWITCH SECTION 2 - PROCEDURES Figure 2-37.
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SECTION 2 - PROCEDURES 2.32 LOAD MANAGEMENT SYSTEM ADJUSTMENT 2.33 TURNTABLE SPRINGS Turntable 4620038 Turntable 4620038 1. Removal. 1. With boom retracted, limit switch and proximity switch are in neutral position. a. Fully retract boom. b. Remove six (6) nuts and jam nuts from beneath turntable which attach to turntable spring bolts. 2. Extend boom in horizontal position until white tape on inner mid boom is fully exposed, no load in platform. c. Remove cover from load management switches.
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SECTION 2 - PROCEDURES Turntables 4620044 and 4620078 2.34 PUMP COUPLING CONVERSION PROCEDURES 1. Removal. b. Remove rear turntable cover. The following procedures are provided to assist in the conversion from a solid pump coupling to a Lovejoy or Hayes pump coupling. c. Remove five (5) nuts and jam nuts from beneath turntable which attach to turntable spring bolts. Lovejoy Coupling a. Fully retract boom. d.
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SECTION 2 - PROCEDURES 2.35 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS From a hydrostatic component standpoint, the goal at system start up is to put into functional operation, the hydrostatic system in such a way as to preserve the designed life span of the system. The following start-up procedure should be adhered to whenever a new pump or motor is initially installed into a machine, or a system is restarted after either a pump or motor has been removed and/or replaced.
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SECTION 2 - PROCEDURES DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START-UP. Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes. Shut down engine, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed. The machine is now ready for operation.
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SECTION 2 - PROCEDURES JLG Industries requires that a complete annual inspection be performed in accordance with the "Annual Machine Inspection Report" form. Forms are supplied with each new machine and are also available from JLG Customer Service. Forms must be completed and returned to JLG Industries. 6. Check for presence of excessive dirt or foreign material. 7. Check for proper operation and freedom of movement. 8. Check for excessive wear or damage. 9. Check for proper tightness and adjustment.
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SECTION 2 - PROCEDURES Table 2-7.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY WEEKLY MONTHLY 13. Bushings 8,12 14. Wear Pads 8,12 15. Cylinders 16. Chains** 17. Chain Adjusters 18. Sheaves 19. Radius Limit Tape 1,5,6,13 3 MONTH 6 MONTH YEARLY 12 12 9 8,12 1,2 TURNTABLE 1. Engine Oil (see mfg. manual) 3 5 2. Battery 3 5 3. Radiator 3 5 4. Air Cleaner 1 14 5. Exhaust System 1 6. Engine Mount 7. Ground Controls 8.
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SECTION 2 - PROCEDURES Table 2-7.Preventive Maintenance and Inspection Schedule INTERVAL AREA DAILY 23. Swing Torque Hub 24. Swing Brake 25. Swing Bearing WEEKLY MONTHLY 1,3,5,6 3 MONTH 6 MONTH YEARLY 10 1,5,6 8 1 12 9 10 CHASSIS 1. Wheel and Tire Assembly 2. Drive Motors 1,5,6 3. Drive Torque Hubs** 1,5,6 3 4. Drive Brakes 1,5,6 8 5. Steer Cylinders 1 1,5,6,13 12 6. Steer Components 1 4,6 8,12 7. Tie Rod Lock Pin 1 8 8. Hydraulic Hoses and Tubing 1 5 9.
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SECTION 3 - TROUBLESHOOTING SECTION 3. TROUBLESHOOTING 3.1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
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SECTION 3 - TROUBLESHOOTING . Table 3-1. Platform Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Automatic leveling inoperative. Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary. Restricted or broken hydraulic line or fitting on slave cylinder or main lift cylinder. Clean, repair, or replace line or fitting. Worn seal(s) in slave level or main lift cylinder. Replace seal(s).
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SECTION 3 - TROUBLESHOOTING Table 3-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking. Dirt in oil causing excessive temperature buildup. Flush system and change oil using recommended viscosity Moisture in oil. Flush system and change oil using recommended viscosity Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting. Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary.
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SECTION 3 - TROUBLESHOOTING Table 3-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Boom will not raise. Load capacity exceeded (personnel or equipment on platform). Reduce load.(Refer to capacity placard.) Hydraulic system oil low. Replenish oil as necessary. Electrical failure to valves. See proper wiring diagram. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Control valve not functioning properly. Repair or replace valve.
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SECTION 3 - TROUBLESHOOTING Table 3-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pump Volume, Wheel Motor Speed, and High Engine does not operate below horizontal. Damaged wiring on level limit switch. Repair or replace wiring. Solenoid failure. Replace solenoid. Tripped circuit breaker. Reset circuit breaker. Damaged level limit switch. Replace switch, repair or replace holder. Defective relay, main terminal box. Replace relay. Defective platform switch. Replace switch.
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SECTION 3 - TROUBLESHOOTING Table 3-2. Boom Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM SWING SYSTEM No response to swing control. Hydraulic system oil low. Replenish oil as necessary. Swing control switch not functioning. Repair or replace swing control switch. Restricted or broken supply line on valve bank or hydraulic pump. Clean or replace line. Control valve not functioning properly. Repair or replace valve. Swing motor not functioning properly. Repair or replace motor.
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SECTION 3 - TROUBLESHOOTING . Table 3-3. Turntable Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY CONTROL VALVE. Valve Spool Sticking. Dirt in oil causing excessive temperature builtup. Change oil using recommended viscosity and flush system. Incorrect valve mounting causing warping of the unit. Loosen valve and check mounting.Repair as necessary. Valve spool scored. Remove valve and repair or replace as necessary. Return spring weak or broken.
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SECTION 3 - TROUBLESHOOTING . Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY POWER PLANT. Engine will not start. Station power selector switch not in required position. Actuate switch as required. Circuit breaker open. Determine and correct cause; reset circuit breaker. Defective starter motor. Replace starter motor. Damaged wiring in ignition circuit (broken wire on starter). Repair, replace wiring. Ignition switch not functioning properly. Replace switch.
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SECTION 3 - TROUBLESHOOTING Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Switch not functioning properly or improperly adjusted. Adjust, repair, or replace horizontal limit switch. Excessive load on engine. Reduce load. Engine worn badly. Rebuild engine. Engine improperly timed. Time engine. Engine overheating. Determine cause of overheating and remedy. Dirty fuel filter. Replace filter. Fuel line pinched. Replace fuel line.
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SECTION 3 - TROUBLESHOOTING Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY REAR FRAME AXLE AREA. Difficulty encountered when moving machine. Load capacity exceeded. Reduce load. Apply loads only in accordance with load capacity indicator. Flow divider sticking. Repair or replace flow divider. Machine being moved up too steep a grade. Remove machine from grade and check that drive system operates correctly. Grade too steep.
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SECTION 3 - TROUBLESHOOTING Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine will not travel in forward. Hydraulic system oil low. Replenish oil as necessary. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Control valve not functioning properly. Repair or replace valve. Drive motor(s) not functioning properly. Repair or replace motor(s). Circuit breaker open. Determine and correct cause; reset circuit breaker.
PAGE 132
SECTION 3 - TROUBLESHOOTING Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY STEERING SYSTEM. No response to steer control. Circuit breaker open. Determine and correct cause; reset circuit breaker. If equipped, steer/tow selector in "tow" position. Actuate control to "steer" position (Valve knob in). Hydraulic system oil low. Replenish oil as necessary. Hydraulic system pressure too low. Adjust pressure. Damaged wiring on control switch or solenoid valve.
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SECTION 3 - TROUBLESHOOTING Table 3-4. Chassis Assembly - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Relief valve improperly set or not functioning properly. Reset, repair or replace valves as required. Steer cylinder not functioning properly. Repair or replace cylinder. Wiring on control switch is damaged. See proper wiring diagram. Wiring on solenoid valve damaged. Repair or replace wiring. Coil in solenoid damaged. Replace coil. No oil flow or pressure to steer circuit.
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SECTION 3 - TROUBLESHOOTING . Table 3-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEMS - GENERAL. Hydraulic pump noisy. Air entering system through broken line or fitting. (Suction Side.) Repair or replace line or fitting. Suction screen dirty. Clean suction screen. Air bubbles in oil. (Reservoir oil too low. Replenish oil as required. Suction hose squeezed shut. Determine cause and repair. Oil filter dirty. Replace hydraulic filter.
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SECTION 3 - TROUBLESHOOTING Table 3-5. Hydraulic System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pump not delivering oil. Restricted suction line. Clean, repair, or replace line. Air entering system through broken line or fitting. Repair or replace line or fitting. Broken pump drive shaft/pump coupling. Repair or replace pump/pump coupling.
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SECTION 3 - TROUBLESHOOTING Table 3-5. Hydraulic System - Troubleshooting TROUBLE 3-16 PROBABLE CAUSE REMEDY Damaged wiring on control switch or auxiliary pump. See proper wiring diagram. Control switch not functioning properly. Replace switch. Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting. Pump motor solenoid not functioning properly. Replace solenoid. Pump motor not functioning properly. Repair or replace motor.
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SECTION 3 - TROUBLESHOOTING . Table 3-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY PLATFORM CONTROLS. No power to platform controls. 15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches are making contact when pedal is depressed. Repair or replace footswitch as necessary. Contact block in footswitch malfunctioning. Repair, replace or adjust contact block as required. Faulty power circuit wiring. Check wiring continuity.
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SECTION 3 - TROUBLESHOOTING Table 3-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY INSTRUMENTS AND INDICATORS. Travel warning horn inoperative. Circuit breaker open. Determine and correct cause; reset circuit breaker. Damaged wiring in horn circuit. Repair or replace wiring. Damaged horn. Replace horn. Damaged wiring in hourmeter circuit. Repair or replace wiring. Defective pressure switch. Replace pressure switch. Inoperative hourmeter. Replace hourmeter.
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SECTION 3 - TROUBLESHOOTING Table 3-6. Electrical System - Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Function speed control will not function. 3120636 Boom above horizontal. Lower boom. Horizontal limit switch malfunctioning. Repair or replace limit switch. Defective pump section. Repair or replace pump section. Electrical malfunction. See correct wiring diagram.
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3120636 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +55 19 3295 1025 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.