Service Manual Owner manual

ManualsBrandsJLG ManualsSpecial machinery120-SXJ ANSI

Service and Maintenance Manual

P/N - 3121105

July 29, 2004

Models

100SX

110SX

110SXJ

120SXJ

Summary of content (120 pages)

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Service and Maintenance Manual Models 100SX 110SX 110SXJ 120SXJ P/N - 3121105 July 29, 2004
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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 Original Issue Revised Revised Revised Revised Revised Revised A-2 - April 1, 2000 - September 11, 2000 - June 8, 2001 - January 18, 2002 - June 11, 2002 - June 19, 2003 - July 29, 2004 – JLG Lift – 3121105
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH 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) TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH 1.5 1.6 1.7 1.8 1.9 1.10 1.11 PAGE NO. Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Tire Size/Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION 3 - CHASSIS & TURNTABLE 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Disassembly of Cover . . . . . . . . . .
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TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH 4.3 4.4 4.5 4.6 4.7 4.8 4.9 PAGE NO. Adjusting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 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. 4-1. 4-2. 4-3. 4-4. 4-5. 4-7. 4-6. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-8. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. 6-18. 6-19. 6-20. 6-21. 3121105 TITLE PAGE NO. Lubrication Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (Continued) LIST OF FIGURES (continued) FIGURE NO. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. TITLE PAGE NO. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23 120SXJ Hydraulic Schematic - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24 120SXJ Hydraulic Schematic - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES 1.3 Engine Crankcase Deutz F4L912 w/Filter - 13.2 quarts (12.5 liters) PERFORMANCE DATA - 100SX, 110SX & 110SXJ Platform Height Fuel Tank 26 gallons (98 liters) 100SX - 100ft. (30.5 m) 110SX & 110SXJ - 110 ft. (33.5 m) Hydraulic Tank 50 gallons (189 liters) Horizontal Outreach 60 ft. (18.3 m) 1.2 COMPONENT DATA Below Ground Reach (110SX only) NOTE: Tolerance on all engine rpm settings is plus or minus 10%. 12 ft. (3.
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SECTION 1 - SPECIFICATIONS Wheelbase Jib Range of Articulation 10 ft. (3.05 m) 11 ft. (3.35 m) 95 degrees (+15, -80) Ground Clearance Overall Width - Axles Retracted 12.5 in. (32 cm) 8 ft. 2 in. (2.49 m) Gross Weight Overall Width - Axles Extended 100SX - 37,700 lbs. (17,136 kg) 110SX - 41,900 lbs. (19,006 kg) 110SXJ - 41,400 lbs. (18,779 kg) 10 ft. 10 in. (3.3 m) Max. Ground Bearing Pressure Tailswing (Axles Extended) 2 ft. 10 in. (86 cm) 100SX & 110SXJ - 90 psi (6.
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SECTION 1 - SPECIFICATIONS 1.5 Table 1-2.Hydraulic Oil TORQUE REQUIREMENTS Hydraulic System Operating Temperature Range Table 1-1.Torque Requirements Torque Value Ft. Lbs.
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SECTION 1 - SPECIFICATIONS Table 1-5. Mobil DTE 13M Specs Table 1-3. Mobil EAL Envirosyn H 46 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 Figure 1-1.
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SECTION 1 - SPECIFICATIONS Table 1-7.
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SECTION 1 - SPECIFICATIONS 1.7 110SXJ PRESSURE SETTINGS Lift Up - 100-85 Main Valve Lift Down - 100-75 Main - 3450 psi (238 bar) Swing Right & Left - 200-140 Lift Down - 1500 psi (103 bar) Telescope Out - 93-74 Jib (Up) - 3000 psi (207 bar) Platform Rotate Right & Left - 24-36 Jib (Down) - 1400 psi (97 bar) Articulated Jib Up - 15-20 Swing - 1200 psi (83 bar) Articulated Jib Down - 45-55 Platform Level Up - 2500 psi (172 bar) Drive (200ft.
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SECTION 1 - SPECIFICATIONS 1.9 CYLINDER SPECIFICATIONS NOTE: All cylinder dimensions are given in inches (in), with the metric equivalent, centimeters (cm) in parentheses. Table 1-8.Cylinder Specifications Cylinder Bore Stroke Rod Dia. Lift 9.0 (22.9) 43.375 (120.3) 4.0 (10.2) Master Level (100SX, 110SX) 2.5 (6.4) 14.5 (36.8) 1.25 (3.2) Master Level (110SXJ) 2.5 (6.4) 15.1 (38.4) 1.25 (3.2) Slave Level (100SX, 110SX) 2.5 (6.4) 13.875 (35.2) 1.25 (3.2) Slave Level (110SXJ) 3.5 (8.
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SECTION 1 - SPECIFICATIONS 1.10 SERIAL NUMBER LOCATIONS Table 1-9.Critical Stability Weights For machine identification, a serial number plate is affixed to the left side of the frame, below the battery compartment. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame between the front and rear wheels, below the turntable bearing and on the right side of the turntable in the bottom of the valve compartment.
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Figure 1-3.
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SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
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SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
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SECTION 2 - GENERAL Components Removal and Installation Bolt Usage and Torque Application 1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 1.
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SECTION 2 - GENERAL 2.3 3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20 degrees F (-29 degrees C). However, use of this oil will give poor performance at temperatures above 120 degrees F (49 degrees C). Systems using DTE 13 oil should not be operated at temperatures above 200 degrees F (94 degrees C) under any condition. LUBRICATION AND INFORMATION Hydraulic System 1.
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SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Maximum acceptable cylinder drift is to be measured using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. 1. Pinned joints should be disassembled inspected if the following occurs: Platform Drift Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, upper boom fully extended with the rated load in the platform and power off.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 2 - GENERAL Table 2-3.
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SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 DRIVE HUB The final drive consists of two planetary stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load distribution. All torque transmitting components are made of forged quenched and tempered highalloy steels. External gears are carburized. Precision roller bearings support the sprocket or wheel loads. A shaft seal protects the unit against contamination.
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SECTION 3 - CHASSIS & TURNTABLE Assembly of First Stage Planetary Assembly (7) 6. Before installation of motor, CHECK THAT THERE IS 1-2 mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER (62). 1. Pre-freeze planet pins (5) and install into planet carrier (7). 7. Install the motor and reconnect hydraulic lines. 2. Install planet carrier (7) together with planet pins (5) on sun gear (3), and install snap ring (16). 8.
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Figure 3-1.
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1. Planet Gear 2. Planet Gear 3. Sun Gear 4. Shaft Nut 5. Planet Pin 7. Planet Carrier 8. Cover 9. Thrust Button 10. Roller Bearing 11. Roller Bearing 12. Ball Bearing 13. Hex Bolt 3-4 – JLG Lift – 28. Washer 30. Ring Gear 33. O-ring 41. Planet Carrier 42. Sun Gear 43. Sun Gear 45. Planet Pin 46. Roller Bearing 47. Retaining Ring 48. Retaining Ring 51. Cover 52. Thrust Washer 53. Bolt 54. O-ring 55. Spring 60. Spindle 61. Piston 62. Coupler 63. Ring Locator 64. Backup Plate 65. Backup Plate 66.
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SECTION 3 - CHASSIS & TURNTABLE 3.2 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position. 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 3 - CHASSIS & TURNTABLE FORWARD MEASURING POINT MEASURING POINT a. BOOM FULLY ELEVATED AND FULLY RETRACTED b. BOOM AT HORIZONTAL AND FULLY EXTENDED Figure 3-4. Swing Bearing Tolerance Boom Placement TURNTABLE REF. SWING BEARING FRAME REF. MEASURING POINT Figure 3-5.
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SECTION 3 - CHASSIS & TURNTABLE 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 3 - CHASSIS & TURNTABLE NOTE: INSTALL BEARING WITH FILL PLUG ON SIDE. (AS CLOSE TO CENTERLINE OF ROTATION AS POSSIBLE.) Figure 3-6. Swing Bearing Bolt Torquing Sequence g. Carefully lower the turntable onto the swing bearing, ensuring that the turntable and bearing align as noted in step i above. IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE. h.
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SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Values 13. Remove and discard inner o-ring (6). 1. Outer Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs. (230 Nm) wet, 220 ft.lbs. (298 Nm) dry. 2. Inner Race - 240 ft.lbs. (325 Nm) Loctite, 170 ft.lbs. (230 Nm) wet, 220 ft.lbs. (298 Nm) dry. 3. Swing Bearing Torquing Sequence, Figure 3-6., Swing Bearing Bolt Torquing Sequence 14. Remove inner thrust washers (8) and thrust bearing (9) from counterbore in carrier assembly 10. 15.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-7.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-8. Torque Hub Carrier Timing 5. Inspect o-ring grooves in hub (24) and cover (1) for burrs or sharp edges. Dress applicable surfaces as necessary. 6. Inspect all thrust washer and bearing surfaces for damage. Repair or replace as necessary. 7. Inspect all threaded components for damage including stretching, thread deformation or twisting. Replace as necessary. 8. Inspect planet shafts (15) for scoring or other damage. Replace as necessary. Assembly 1.
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SECTION 3 - CHASSIS & TURNTABLE i. Align roll pin holes in both shaft (15) and carrier (10) with chamfered portion of shaft hole uppermost. j. Position new roll pin (16) in hole in carrier (10) and drive pin into hole until end of pin is flush with carrier surface. k. Repeat steps (a) through (j) for remaining two cluster gears. 3. Position internal gear (19) on inner end of output shaft (30). 4. Time carrier cluster gears as follows: a.
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SECTION 3 - CHASSIS & TURNTABLE 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 3-9.
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SECTION 3 - CHASSIS & TURNTABLE 3. Remove piston (7) from end cover (2). 4. Remove o-ring (5), back-up ring (6), o-ring (8) and back-up ring (9) from piston (7). NOTE: Be sure to use the same number of springs and spring pattern as recorded during disassembly. Spring retainer (17) was not used in earlier models. 5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21). 5. Remove separators (13) from housing (21). 6.
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SECTION 3 - CHASSIS & TURNTABLE 3.5 TILT ALARM SWITCH LEVELING NOTE: Each machine is equipped with a tilt alarm switch, factory set to activate at 5 degrees, which will illuminate a warning light, sound a warning horn and cut out 2 Speed Drive. Consult factory for tilt sensor adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs. There are two methods of adjustment, a manual adjustment and an adjustment using a voltmeter. 3.
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SECTION 3 - CHASSIS & TURNTABLE flange nuts have been tightened too far. Loosen the “X” nut and repeat steps 3 through 7. these sensors are situated at the rear of the base boom section and housed in a sealed steel box. Voltmeter Adjustment 1. Park machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure. 2. If engine is not running, turn ignition switch to ON. 3.
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SECTION 3 - CHASSIS & TURNTABLE Figure 3-12. 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. A calibrated dc voltage representing the boom length is sent from the boom length sensor to the boom length circuit and presented to the radius generator circuit.
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SECTION 3 - CHASSIS & TURNTABLE 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. Load Management System Daily Check At the beginning of each days’ use, perform check with no load (persons or material) in platform from ground control station. 1. A positive break mechanical limit switch. 1.
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SECTION 3 - CHASSIS & TURNTABLE 3.7 Installation LOAD MANAGEMENT SYSTEM ADJUSTMENT 1. Position boom to horizontal. 1. With boom retracted, limit switch and proximity switch are in neutral position. 2. Install five (5) bolts and turntable springs onto turntable. 2. Extend boom in horizontal position until white tape on inner mid boom is fully exposed, no load in platform. 3. Install five (5) nuts and jam nuts on turntable spring bolts. 3.
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SECTION 3 - CHASSIS & TURNTABLE Current Regulated Output This controller output is also current regulated. This controller was designed to output from 20 to 130 milliamps through a 17 Q coil using a 12 volt supply. Ohms Law dictates that the Current is always equal Voltage divided by Resistance. If the supply voltage or the coil resistance should change, Ohms Law dictates that the output current must also change which will affect the speed of the function accordingly.
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SECTION 3 - CHASSIS & TURNTABLE Telescope, Level, Rotate, & Jib 3.11 FUNCTION CONTROL 1. Connect Amp Meter inline between the function card plug pin #4 and red/wht 50-1 wire. 2. Turn function control knob fully CCW (Do not go into snail mode). Operate telescope switch and adjust threshold trimpot. 3. Fully turn knob CW operate the telescope siwtch. Adjust HI range trimpot. 4. With the knob turned fully CW, operate the level switch. Adjust the LO trimpot. 5.
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SECTION 3 - CHASSIS & TURNTABLE Dual Range This Rotary Selector Controller is capable of providing two, independently adjustable, maximum output ranges with the same amount of knob travel. The Hi Range would normally be adjusted for full flow (maximum function speed) of the valve at full handle travel. The LO Range would provide some portion of the Hi Range setting, providing reduced oil flow to the valve, with the knob at full travel.
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SECTION 3 - CHASSIS & TURNTABLE 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 3-15.
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SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally.
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SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 Disassembly BOOM MAINTENANCE NOTE: Left or right is determined facing the machine from the platform. Removal 1. Shut down machine systems. 1. Loosen the right side powertrack bracket and powertrack and lay on top of boom assembly. NOTE: Boom Assembly weighs approximately 10,000 (4536 kg). 2. Using suitable lifting equipment, adequately support boom weight along entire length of retracted boom.
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SECTION 4 - BOOM & PLATFORM 16 12 17 16 5 16 14 6 Figure 4-1.
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SECTION 4 - BOOM & PLATFORM 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 4-2.
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SECTION 4 - BOOM & PLATFORM 15. Remove bolts and lockwashers attaching top front wear pad to base section. Remove pad and shims. 29. Pull boom sections out several feet to allow ample clearance for telescope cylinder removal. 16. Using suitable lifting equipment, partially slide assembled inner mid, outer mid and fly sections out of base section. 30. Remove outer mid section extension chain adjust nut and locknut from clevis at lower aft end of outer mid section. 17.
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SECTION 4 - BOOM & PLATFORM 42. Remove bolts and lockwashers which attach side wear pads at front of outer mid section and remove pads and any shims. 8. Inspect extend chain attach clevis pins for wear, scoring, or other damage. Replace pins as necessary. 43. Remove bolts and lockwashers which attach top wear pads to front of outer mid section and remove pads and any shims. 9. Inspect telescope cylinder rod attach pin for scoring, wear, or other damage. Replace pin as necessary. 44.
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SECTION 4 - BOOM & PLATFORM 7. Install outer mid section bottom front wear pads and shims, as required, using bolts and lockwashers. 8. Install outer mid section upper aft wear pads and shims, as required, using bolts and lockwashers. 9. Using suitable lifting equipment, carefully slide assembled outer mid and fly sections into inner mid section. NOTE: When installing inner mid section wear pads, install same number and thickness of shims as were removed during disassembly. 10.
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SECTION 4 - BOOM & PLATFORM 5. Using all applicable safety precautions, operate lifting equipment in order to position boom lift cylinder so that holes in cylinder rod end and boom structure are aligned. Insert lift cylinder pin. 35. Install outer mid section retract chain clevis into attach block at lower front end of base boom section. Install adjust nut and locknut on clevis. NOTE: When installing base section wear pads, install same number and thickness of shims as were removed during disassembly. 6.
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SECTION 4 - BOOM & PLATFORM 8. Recheck outer mid section retract chain. 9. Recheck fly section extend chain. 10. Recheck fly section retract chain. 11. Repeat steps (2) thru (10) if necessary. 12. Check for proper operation of boom. JLG Industries, Inc. requires a complete boom disassembly, per the instructions outlined in Section 4.1, Boom Maintenance, every two years. All boom chains and related components (i.e., sheaves, pins, sprockets, wear pads, etc.
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SECTION 4 - BOOM & PLATFORM Figure 4-4.
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SECTION 4 - BOOM & PLATFORM heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set. b. Lubrication: One of the most important but often overlooked factors is adequate lubrication. In addition to reducing internal friction, maintaining a film of oil on all chain surfaces will inhibit rusting and corrosion.
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SECTION 4 - BOOM & PLATFORM rolling grain of the material. Table 4-1. Chain Stretch Tolerance 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. Two conditions must be present - corrosive agent and static stress. In the chain, static stress is present at the aperture due to the press fit pin.
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SECTION 4 - BOOM & PLATFORM 4.5 BOOM MARKING TAPE INSTALLATION Figure 4-5. Boom Marking Tape Installation Table 4-2.Boom Marking Tape Installation w/o Boom Wipers Model 100SX Dual Capacity 120SXJ Single Capacity 110SX Dual Capacity 110SXJ Single Capacity Dim. A Dim. B Dim.C 51-1/4 in. (130.2 cm) 90 in. (228.6 cm) 123 in. (312.4 cm) N/A 54-7/8 in. (139.4 cm) 90 in. (228.6 cm) 85-1/2 in. (217.2 cm) 122-1/2 in. (311.2 cm) 160-1/2 in. (407.7 cm) N/A 78-3/8 (199.1 cm) 129-3/8 in. (328.
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SECTION 4 - BOOM & PLATFORM 4.6 BOOM LOAD RADIUS SETUP PROCEDURES - 100SX DUAL CAPACITY NOTE: The boom length and angle sensor adjustments need to be made before the display lights are adjusted. board). Measure between Pin (6) of the socket on the circuit board and ground (TB1-1), adjust potentiometer P5 to a value of 1.610 Ohms (+/- 0.005 Ohms).
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SECTION 4 - BOOM & PLATFORM NOTE: The boom length/angle sensor is factory set and normally does not require adjusting unless it is removed from the base boom for maintenance purposes, etc. Figure 4-6. Boom Length/Angle Sensor Configurations Boom Angle Sensor Adjustment 1. 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. 2.
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SECTION 4 - BOOM & PLATFORM 4. Telescope the boom until the leading edge of the yellow marking tape is exposed from the mid boom. Adjust potentiometer P2 until the yellow light just turns on and the blue light turns off. 5. Telescope the boom until the leading edge of the red marking tape is exposed from the mid boom. Adjust potentiometer P3 until the red light just turns on and the yellow light turns off. Length Indicator Adjustment 1. Level the frame before beginning any adjustments. 2.
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SECTION 4 - BOOM & PLATFORM Radius Adjustment and Display Lights Setting Procedure 4.8 1. On the Load Radius Circuit Card, measure TP11 and adjust potentiometer P6 for a reading of 0.0 Volts DC. NOTE: The boom length and angle sensor adjustments need to be made before the display lights are adjusted. 2. On the Load Radius Circuit Card, measure TP8 and adjust potentiometer P2 for a reading of 2.548 Volts DC. 3. On the Load Radius Circuit Card, measure TP9 and adjust potentiometer P3 for a reading of 5.
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SECTION 4 - BOOM & PLATFORM Boom Angle Sensor Adjustment 1. 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. 2. 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. 6. Extend the boom until the red tape is approximately 6 inches out of the base boom.
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SECTION 4 - BOOM & PLATFORM 4.9 BOOM LOAD RADIUS SETUP PROCEDURES - 120SX NOTE: The boom length and angle sensor adjustments need to be made before the display lights are adjusted. The boom length and angle sensor is factory set and does not normally require adjusting unless it is removed from the base boom for maintenance. Length Indicator Adjustment 1. Level the frame before beginning any adjustments. 2. Make all adjustments with the engine running unless otherwise noted. 7.
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SECTION 4 - BOOM & PLATFORM 5. Extend the boom until the red tape is approximately 6 inches out of the base boom. Adjust P4 until the amber LED (DS2) on the Load Moment Circuit card goes out. This determines the length of the boom (critical length) where the lift down speed limiter is turned on.
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SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 1. Cylinders are of the double acting type. Systems incorporating double acting cylinders are as follows: Lift, Telescope, Steer, Master Level, Slave Level, Axle Extend, Frame Lift (if equipped) and Extend-AReach (if equipped). A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions.
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SECTION 5 - HYDRAULICS 5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports. 6. If used, remove boom prop or lifting device from boom, activate hydraulic system and run cylinder through one complete cycle to check for leaks. 5.3 CYLINDER REMOVAL AND INSTALLATION Telescope Cylinder Removal 1. Place machine on a flat and level surface, with axles extended and the boom fully retracted and in the horizontal position.
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SECTION 5 - HYDRAULICS 7. Install the two (2) extension chain adjusting nuts at the aft end of the base boom. 15. Remove the three (3) bolts, washers and lockwashers attaching the chain adjust bracket to the aft end of the base boom and remove bracket. 8. Install the rod support bracket at the aft end of the base boom. 16. Pull boom sections apart several feet. 17. Using the lifting equipment, raise the cylinder to obtain sufficient clearance for removal of the cylinder. 18.
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SECTION 5 - HYDRAULICS Lift Cylinder Removal 3. Tag, disconnect and cap hydraulic lines to level cylinder. 1. Place the machine on a flat and level surface. Start the engine and place the boom in a horizontal position. Shut down the engine and attach a suitable support device to the boom. NOTE: When disconnecting hydraulic lines, any residual hydraulic fluid should be drained into a suitable container. 4. Make up two temporary hose assemblies (3/8 In. x 10 ft.
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SECTION 5 - HYDRAULICS 5.4 4. Place the cylinder barrel into a suitable holding fixture. Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite. CYLINDER REPAIR NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. 5. Using a suitable spanner wrench, loosen the cylinder head retainer, if applicable, and/or cylinder head gland, and remove from cylinder barrel.
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SECTION 5 - HYDRAULICS 10. Remove the piston rings. 11. Remove and discard the piston o-rings, seal rings, and backup rings. 12. If applicable, inspect thread ring for scoring or other damage. Dress threads or applicable surfaces as necessary. 12. Remove the set screw, if applicable, piston spacer, and wear ring, if applicable, from the rod. 13. If applicable, inspect rod and barrel bushings for signs of correct lubrication and excessive wear. Replace as necessary. 13.
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SECTION 5 - HYDRAULICS 3. Carefully slide the piston spacer on the rod. If applicable, align the oil holes in the rod and the spacer. Secure the spacer, if applicable. 4. If applicable, correctly place a new o-ring and backup rings in the inner piston diameter groove. 5. Carefully place the piston on the cylinder rod, ensuring that the o-ring and back-up rings are not damaged or dislodged. 6.
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SECTION 5 - HYDRAULICS 5.5 IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD. PRESSURE SETTING PROCEDURES Main Valve 1. Main Relief. Table 5-2. Holding Valve Torque Specifications Description Torque Value Sun - 7/8 hex M20 x 1.5 thds 30-35 ft. lb.
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SECTION 5 - HYDRAULICS * Adjustable on SXJ Models Only 1. 2. 3. 4. 5. Main Pressure Adjustment Swing Flow Control Lift Down Pressure Lift Down Speed Control Lift Down Slow Down 6. Swing Pressure 7. E.A.R. Pressure (Down) 8. E.A.R. Pressure (Up) 9. Rotate Pressure (Right) 10. Rotate Pressure (Left) 11. Rotate (Right) Flow Control 12. Rotate (Left) Flow Control 13. Level Up Pressure 14. Level Down Pressure 15. Level 16. Rotate 17. E.A.R. 18. Swing 19. Lift 20. Flow Control 21. Lift Flow Control 22.
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SECTION 5 - HYDRAULICS A. 18-20 ft.lbs. (24.5 - 27.2 Nm) B. 33-37 ft.lbs. (44.9 - 50.3 Nm) C. 25-27 ft. lbs. (34 - 36.7 Nm) Figure 5-5.
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SECTION 5 - HYDRAULICS 2. Lift Down Relief. 6. Platform Level Relief. a. Monitor pressure gauge at quick-connect (G port) on main valve. a. Monitor pressure gauge at quick-connect on main valve at Port 11. b. Bottom out Lift Down function. b. Bottom out Platform Level Down function. c. Loosen nut at lift down relief and adjust pressure to 1500 psi (103 bar) using an Allen wrench. Tighten nut. c. Loosen nut on platform level down relief and adjust to 2200 psi (152 bar).Tighten nut. d.
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SECTION 5 - HYDRAULICS 2. Front Steer. a. Steer Select Switch should be in front steer. b. Operate steer switch right or left to set rear steer pressure. c. Pressure should be 2850 psi (197 bar). 3. Axles. FRONT AXLE ADJUSTMENTS REAR AXLE ADJUSTMENTS a. Select Switch should be in Axle position, Steer Select switch should be in Front Wheel Steer position. b. Operate axles in and out. c. Pressure should be: Axles Out - 2500 psi (172 bar) Axles In - 2500 psi (172 bar).
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SECTION 5 - HYDRAULICS Figure 5-6.
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SECTION 5 - HYDRAULICS Figure 5-7.
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SECTION 5 - HYDRAULICS A. 18-20 ft.lbs. (24.5 - 27.2 Nm) B. 52-60 ft.lbs. (70.7 - 81.6 Nm) C. 25-27 ft. lbs. (34 - 36.7 Nm) Figure 5-8.
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SECTION 6 - SCHEMATICS SECTION 6. SCHEMATICS 6.1 GENERAL 6.3 This section contains schematics 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. 6.2 HYDRAULIC CIRCUIT CHECKS The best place to begin the problem analysis is at the power source (pump).
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SECTION 6 - SCHEMATICS Figure 6-1.
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SECTION 6 - SCHEMATICS Figure 6-2.
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SECTION 6 - SCHEMATICS Figure 6-3.
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SECTION 6 - SCHEMATICS 1870122 E Figure 6-4.
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SECTION 6 - SCHEMATICS Figure 6-5.
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SECTION 6 - SCHEMATICS 1870122 E Figure 6-6.
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SECTION 6 - SCHEMATICS Figure 6-7.
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SECTION 6 - SCHEMATICS 1870121 E Figure 6-8.
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SECTION 6 - SCHEMATICS Figure 6-9.
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SECTION 6 - SCHEMATICS 1870121 E Figure 6-10.
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SECTION 6 - SCHEMATICS Figure 6-11.
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SECTION 6 - SCHEMATICS 1870115 E Figure 6-12.
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SECTION 6 - SCHEMATICS Figure 6-13.
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SECTION 6 - SCHEMATICS 1870115 E Figure 6-14.
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SECTION 6 - SCHEMATICS Figure 6-15.
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SECTION 6 - SCHEMATICS 2792447 C Figure 6-16.
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SECTION 6 - SCHEMATICS Figure 6-17.
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SECTION 6 - SCHEMATICS 2792447 C Figure 6-18.
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SECTION 6 - SCHEMATICS Figure 6-19.
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SECTION 6 - SCHEMATICS 2792447 C Figure 6-20.
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SECTION 6 - SCHEMATICS Figure 6-21.
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SECTION 6 - SCHEMATICS 2792447 C Figure 6-22.
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SECTION 6 - SCHEMATICS Figure 6-23.
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SECTION 6 - SCHEMATICS 2792407 B Figure 6-24.
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SECTION 6 - SCHEMATICS Figure 6-25.
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SECTION 6 - SCHEMATICS 2792407 B Figure 6-26.
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SECTION 6 - SCHEMATICS Figure 6-27.
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SECTION 6 - SCHEMATICS 2792407 B Figure 6-28.
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Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.