JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121105) -PDF DOWNLOAD EN
TABLE OF CONTENTS:
JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121105) -PDF DOWNLOAD EN
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
Engine – Deutz F4L912 1-1
Torque Hub 1-1
Drive Motor 1-1
1 3 Performance Data – 100SX, 110SX & 110SXJ 1-1
Platform Height 1-1
Horizontal Outreach 1-1
Below Ground Reach (110SX only) 1-1
Swing 1-1
Platform Capacity – Restricted (100SX & 110SX only) 1-1
Platform Capacity – Unrestricted 1-1
Platform Rotator 1-1
Jib Range of Articulation – 110SXJ 1-1
Overall Width – Axles Retracted 1-1
Overall Width – Axles Extended 1-1
Tailswing (Axles Extended) 1-1
Stowed Height 1-1
Stowed Length 1-1
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 4 Performance Data – 120SXJ 1-2
Platform Height 1-2
Horizontal Outreach 1-2
Swing 1-2
Platform Capacity 1-2
Platform Rotator 1-2
Jib Range of Articulation 1-2
Overall Width – Axles Retracted 1-2
Overall Width – Axles Extended 1-2
Tailswing (Axles Extended) 1-2
Stowed Height 1-2
Stowed Length (Working) 1-2
Stowed Length (Transport) 1-2
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
ii – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 5 Torque Requirements 1-3
1 6 Lubrication 1-3
Deutz F4L912 Engine 1-3
Lubrication Specifications 1-4
1 7 Pressure Settings 1-7
Main Valve 1-7
1 8 Function Speeds (In Seconds) 1-7
100SX 1-7
110SX 1-7
110SXJ 1-7
120SXJ 1-7
1 9 Cylinder Specifications 1-8
1 10 Serial Number Locations 1-9
1 11 Critical Stability Weights 1-9
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-3
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-4
Hydraulic System 2-4
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-5
Platform Drift 2-5
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
3121105 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION 3 – CHASSIS & TURNTABLE
3 1 Drive Hub 3-1
Disassembly 3-1
Disassembly of Cover 3-1
Disassembly of the First Stage Planetary Assembly (7) 3-1
Disassembly of Second Stage Planet Gears (1) 3-1
Assembly of First Stage Planetary Assembly (7) 3-2
Assembly of End Cover Unit (8) 3-2
Final Assembly 3-2
Initial Start-up And After Repairs 3-2
Oil Change Interval-Gear Drive 3-2
3 2 Swing Bearing 3-5
Turntable Bearing Mounting Bolt Condition Check 3-5
Bearing Wear Tolerance 3-5
Bearing Replacement 3-7
Swing Bearing Torque Values 3-9
3 3 Swing Torque Hub 3-9
Disassembly 3-9
Cleaning and Inspection 3-9
Assembly 3-11
3 4 Swing Brake 3-12
Cleaning and Inspection 3-14
Assembly 3-14
3 5 Tilt Alarm Switch Leveling 3-15
Manual Adjustment 3-15
Voltmeter Adjustment 3-16
3 6 Load Management System 3-16
Platform Position Indication System 3-16
Overmoment Control System 3-17
Load Management System Daily Check 3-18
3 7 Load Management System Adjustment 3-19
3 8 Turntable Springs 3-19
Removal 3-19
Installation 3-19
3 9 Drive and Steer Controller 3-19
Controller Theory & Definitions 3-19
3 10 Controller Setup 3-20
Lift 3-20
Swing 3-20
Telescope, Level, Rotate, & Jib 3-21
Drive 3-21
3 11 Function Control 3-21
Rotary Selector Controller Theory & Definitions 3-21
Adjustment Procedure 3-22
3 12 Throttle Checks and Adjustments – Deutz F4L-912 Engine 3-22
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-5
Assembly 4-5
Installation 4-7
4 2 Boom Chains 4-7
iv – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Adjusting Procedures 4-7
Inspection Procedure 4-8
4 3 Wear Pads 4-11
4 4 Limit Switch Adjustments 4-11
Boom Limit Switch 4-11
Horizontal Cut-Out Switch 4-11
4 5 Boom Marking Tape Installation 4-12
4 6 Boom Load Radius Setup Procedures – 100SX Dual Capacity 4-13
Length Indicator Adjustment 4-13
Boom Angle Sensor Adjustment 4-14
Radius Adjustment and Display Lights Setting Procedure 4-14
4 7 Boom Load Radius Setup Procedures – 110SX Single Capacity 4-15
Length Indicator Adjustment 4-15
Boom Angle Sensor Adjustment 4-15
Radius Adjustment and Display Lights Setting Procedure 4-16
4 8 Boom Load Radius Setup Procedures – 110SX Dual Capacity 4-16
Length Indicator Adjustment 4-16
Boom Angle Sensor Adjustment 4-17
Radius Adjustment and Display Lights Setting Procedure 4-17
4 9 Boom Load Radius Setup Procedures – 120SX 4-18
Length Indicator Adjustment 4-18
Boom Angle Sensor Adjustment 4-18
Radius Adjustment and Display Lights Setting Procedure 4-18
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory of Operation 5-1
5 2 Cylinder Checking Procedures 5-1
Cylinder w/o Counterbalance Valves 5-1
Cylinders w/Single Counterbalance Valves 5-1
Cylinders w/Dual Counterbalance Valve 5-2
5 3 Cylinder Removal and Installation 5-2
Telescope Cylinder Removal 5-2
Telescope Cylinder Installation 5-3
Lift Cylinder Removal 5-4
Lift Cylinder Installation 5-4
Master Level Cylinder Removal 5-4
Master Level Cylinder Installation 5-4
5 4 Cylinder Repair 5-5
Disassembly 5-5
Cleaning and Inspection 5-6
Assembly 5-6
5 5 Pressure Setting Procedures 5-8
Main Valve 5-8
Frame Mounted Valves 5-11
SECTION 6 – SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting 6-1
6 3 Hydraulic Circuit Checks 6-1
3121105 – JLG Lift – v
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Point Location 1-5
1-2 Serial Number Locations 1-9
1-3 Torque Chart 1-10
3-1 Drive Hub – Sheet 1 of 2) 3-3
3-2 Drive Hub – Sheet 2 of 2 3-4
3-3 Swing Bearing Bolt Feeler Gauge Check 3-5
3-4 Swing Bearing Tolerance Boom Placement 3-6
3-5 Swing Bearing Tolerance Measuring Point 3-6
3-6 Swing Bearing Bolt Torquing Sequence 3-8
3-7 Swing Torque Hub 3-10
3-8 Torque Hub Carrier Timing 3-11
3-9 Swing Brake 3-13
3-10 Tilt Switch Adjustment – Voltmeter 3-15
3-11 Tilt Switch Adjustment – Manual 3-15
3-12 Control Box Components 3-17
3-13 Typical Card Adjustments 3-20
3-14 Function Control Card Adjustment 3-22
3-15 Throttle Checks and Adjustments – Deutz Engine 3-23
4-1 Boom Assembly – Sheet 1 of 2 4-2
4-2 Boom Assembly – Sheet 2 of 2 4-3
4-3 Typical Boom Assembly 4-8
4-4 Boom Chain Adjustments 4-9
4-5 Boom Marking Tape Installation 4-12
4-7 Load Radius Card 4-13
4-6 Boom Length/Angle Sensor Configurations 4-14
5-1 Cylinder Barrel Support 5-5
5-2 Cylinder Rod Support 5-5
5-3 Poly-Pak Seal Installation 5-6
5-4 Main Valve 5-9
5-5 Main Valve Torque Values 5-10
5-6 Chassis Valve Location 5-13
5-7 Axle Extension Valve 5-14
5-8 Axle Extension Valve Torque Values 5-15
6-1 Electrical Components Installation – Sheet 1 6-2
6-2 Electrical Components Installation – Sheet 2 6-3
6-3 100SX, 110SX Electrical Schematic – Platform – Sheet 1 of 2 6-4
6-4 100SX, 110SX Electrical Schematic – Platform – Sheet 2 of 2 6-5
6-5 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-6
6-6 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-7
6-7 110SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-8
6-8 110SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-9
6-9 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-10
6-10 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-11
6-11 120SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-12
6-12 120SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-13
6-13 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-14
6-14 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-15
6-15 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 1 of 8 6-16
6-16 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 2 of 8 6-17
6-17 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 3 of 8 6-18
6-18 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 4 of 8 6-19
6-19 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 5 of 8 6-20
6-20 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 6 of 8 6-21
6-21 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 7 of 8 6-22
vi
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
Engine – Deutz F4L912 1-1
Torque Hub 1-1
Drive Motor 1-1
1 3 Performance Data – 100SX, 110SX & 110SXJ 1-1
Platform Height 1-1
Horizontal Outreach 1-1
Below Ground Reach (110SX only) 1-1
Swing 1-1
Platform Capacity – Restricted (100SX & 110SX only) 1-1
Platform Capacity – Unrestricted 1-1
Platform Rotator 1-1
Jib Range of Articulation – 110SXJ 1-1
Overall Width – Axles Retracted 1-1
Overall Width – Axles Extended 1-1
Tailswing (Axles Extended) 1-1
Stowed Height 1-1
Stowed Length 1-1
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 4 Performance Data – 120SXJ 1-2
Platform Height 1-2
Horizontal Outreach 1-2
Swing 1-2
Platform Capacity 1-2
Platform Rotator 1-2
Jib Range of Articulation 1-2
Overall Width – Axles Retracted 1-2
Overall Width – Axles Extended 1-2
Tailswing (Axles Extended) 1-2
Stowed Height 1-2
Stowed Length (Working) 1-2
Stowed Length (Transport) 1-2
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
ii – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 5 Torque Requirements 1-3
1 6 Lubrication 1-3
Deutz F4L912 Engine 1-3
Lubrication Specifications 1-4
1 7 Pressure Settings 1-7
Main Valve 1-7
1 8 Function Speeds (In Seconds) 1-7
100SX 1-7
110SX 1-7
110SXJ 1-7
120SXJ 1-7
1 9 Cylinder Specifications 1-8
1 10 Serial Number Locations 1-9
1 11 Critical Stability Weights 1-9
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-3
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-4
Hydraulic System 2-4
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-5
Platform Drift 2-5
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
3121105 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION 3 – CHASSIS & TURNTABLE
3 1 Drive Hub 3-1
Disassembly 3-1
Disassembly of Cover 3-1
Disassembly of the First Stage Planetary Assembly (7) 3-1
Disassembly of Second Stage Planet Gears (1) 3-1
Assembly of First Stage Planetary Assembly (7) 3-2
Assembly of End Cover Unit (8) 3-2
Final Assembly 3-2
Initial Start-up And After Repairs 3-2
Oil Change Interval-Gear Drive 3-2
3 2 Swing Bearing 3-5
Turntable Bearing Mounting Bolt Condition Check 3-5
Bearing Wear Tolerance 3-5
Bearing Replacement 3-7
Swing Bearing Torque Values 3-9
3 3 Swing Torque Hub 3-9
Disassembly 3-9
Cleaning and Inspection 3-9
Assembly 3-11
3 4 Swing Brake 3-12
Cleaning and Inspection 3-14
Assembly 3-14
3 5 Tilt Alarm Switch Leveling 3-15
Manual Adjustment 3-15
Voltmeter Adjustment 3-16
3 6 Load Management System 3-16
Platform Position Indication System 3-16
Overmoment Control System 3-17
Load Management System Daily Check 3-18
3 7 Load Management System Adjustment 3-19
3 8 Turntable Springs 3-19
Removal 3-19
Installation 3-19
3 9 Drive and Steer Controller 3-19
Controller Theory & Definitions 3-19
3 10 Controller Setup 3-20
Lift 3-20
Swing 3-20
Telescope, Level, Rotate, & Jib 3-21
Drive 3-21
3 11 Function Control 3-21
Rotary Selector Controller Theory & Definitions 3-21
Adjustment Procedure 3-22
3 12 Throttle Checks and Adjustments – Deutz F4L-912 Engine 3-22
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-5
Assembly 4-5
Installation 4-7
4 2 Boom Chains 4-7
iv – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Adjusting Procedures 4-7
Inspection Procedure 4-8
4 3 Wear Pads 4-11
4 4 Limit Switch Adjustments 4-11
Boom Limit Switch 4-11
Horizontal Cut-Out Switch 4-11
4 5 Boom Marking Tape Installation 4-12
4 6 Boom Load Radius Setup Procedures – 100SX Dual Capacity 4-13
Length Indicator Adjustment 4-13
Boom Angle Sensor Adjustment 4-14
Radius Adjustment and Display Lights Setting Procedure 4-14
4 7 Boom Load Radius Setup Procedures – 110SX Single Capacity 4-15
Length Indicator Adjustment 4-15
Boom Angle Sensor Adjustment 4-15
Radius Adjustment and Display Lights Setting Procedure 4-16
4 8 Boom Load Radius Setup Procedures – 110SX Dual Capacity 4-16
Length Indicator Adjustment 4-16
Boom Angle Sensor Adjustment 4-17
Radius Adjustment and Display Lights Setting Procedure 4-17
4 9 Boom Load Radius Setup Procedures – 120SX 4-18
Length Indicator Adjustment 4-18
Boom Angle Sensor Adjustment 4-18
Radius Adjustment and Display Lights Setting Procedure 4-18
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory of Operation 5-1
5 2 Cylinder Checking Procedures 5-1
Cylinder w/o Counterbalance Valves 5-1
Cylinders w/Single Counterbalance Valves 5-1
Cylinders w/Dual Counterbalance Valve 5-2
5 3 Cylinder Removal and Installation 5-2
Telescope Cylinder Removal 5-2
Telescope Cylinder Installation 5-3
Lift Cylinder Removal 5-4
Lift Cylinder Installation 5-4
Master Level Cylinder Removal 5-4
Master Level Cylinder Installation 5-4
5 4 Cylinder Repair 5-5
Disassembly 5-5
Cleaning and Inspection 5-6
Assembly 5-6
5 5 Pressure Setting Procedures 5-8
Main Valve 5-8
Frame Mounted Valves 5-11
SECTION 6 – SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting 6-1
6 3 Hydraulic Circuit Checks 6-1
3121105 – JLG Lift – v
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Point Location 1-5
1-2 Serial Number Locations 1-9
1-3 Torque Chart 1-10
3-1 Drive Hub – Sheet 1 of 2) 3-3
3-2 Drive Hub – Sheet 2 of 2 3-4
3-3 Swing Bearing Bolt Feeler Gauge Check 3-5
3-4 Swing Bearing Tolerance Boom Placement 3-6
3-5 Swing Bearing Tolerance Measuring Point 3-6
3-6 Swing Bearing Bolt Torquing Sequence 3-8
3-7 Swing Torque Hub 3-10
3-8 Torque Hub Carrier Timing 3-11
3-9 Swing Brake 3-13
3-10 Tilt Switch Adjustment – Voltmeter 3-15
3-11 Tilt Switch Adjustment – Manual 3-15
3-12 Control Box Components 3-17
3-13 Typical Card Adjustments 3-20
3-14 Function Control Card Adjustment 3-22
3-15 Throttle Checks and Adjustments – Deutz Engine 3-23
4-1 Boom Assembly – Sheet 1 of 2 4-2
4-2 Boom Assembly – Sheet 2 of 2 4-3
4-3 Typical Boom Assembly 4-8
4-4 Boom Chain Adjustments 4-9
4-5 Boom Marking Tape Installation 4-12
4-7 Load Radius Card 4-13
4-6 Boom Length/Angle Sensor Configurations 4-14
5-1 Cylinder Barrel Support 5-5
5-2 Cylinder Rod Support 5-5
5-3 Poly-Pak Seal Installation 5-6
5-4 Main Valve 5-9
5-5 Main Valve Torque Values 5-10
5-6 Chassis Valve Location 5-13
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION A – INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS
A General A-1
B Hydraulic System Safety A-1
C Maintenance A-1
SECTION 1 – SPECIFICATIONS
1 1 Capacities 1-1
1 2 Component Data 1-1
Engine – Deutz F4L912 1-1
Torque Hub 1-1
Drive Motor 1-1
1 3 Performance Data – 100SX, 110SX & 110SXJ 1-1
Platform Height 1-1
Horizontal Outreach 1-1
Below Ground Reach (110SX only) 1-1
Swing 1-1
Platform Capacity – Restricted (100SX & 110SX only) 1-1
Platform Capacity – Unrestricted 1-1
Platform Rotator 1-1
Jib Range of Articulation – 110SXJ 1-1
Overall Width – Axles Retracted 1-1
Overall Width – Axles Extended 1-1
Tailswing (Axles Extended) 1-1
Stowed Height 1-1
Stowed Length 1-1
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 4 Performance Data – 120SXJ 1-2
Platform Height 1-2
Horizontal Outreach 1-2
Swing 1-2
Platform Capacity 1-2
Platform Rotator 1-2
Jib Range of Articulation 1-2
Overall Width – Axles Retracted 1-2
Overall Width – Axles Extended 1-2
Tailswing (Axles Extended) 1-2
Stowed Height 1-2
Stowed Length (Working) 1-2
Stowed Length (Transport) 1-2
Wheelbase 1-2
Ground Clearance 1-2
Gross Weight 1-2
Max Ground Bearing Pressure 1-2
Drive Speed 1-2
Gradeability 1-2
Turning Radius (Inside) 1-2
ii – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Turning Radius (Outside) 1-2
Tire Size/Type 1-2
1 5 Torque Requirements 1-3
1 6 Lubrication 1-3
Deutz F4L912 Engine 1-3
Lubrication Specifications 1-4
1 7 Pressure Settings 1-7
Main Valve 1-7
1 8 Function Speeds (In Seconds) 1-7
100SX 1-7
110SX 1-7
110SXJ 1-7
120SXJ 1-7
1 9 Cylinder Specifications 1-8
1 10 Serial Number Locations 1-9
1 11 Critical Stability Weights 1-9
SECTION 2 – GENERAL
2 1 Machine Preparation, Inspection, and Maintenance 2-1
General 2-1
Preparation, Inspection, and Maintenance 2-1
Pre-Start Inspection 2-1
Pre-Delivery Inspection and Frequent Inspection 2-1
Annual Machine Inspection 2-1
Preventative Maintenance 2-1
2 2 Service and Guidelines 2-2
General 2-2
Safety and Workmanship 2-2
Cleanliness 2-2
Components Removal and Installation 2-3
Component Disassembly and Reassembly 2-3
Pressure-Fit Parts 2-3
Bearings 2-3
Gaskets 2-3
Bolt Usage and Torque Application 2-3
Hydraulic Lines and Electrical Wiring 2-3
Hydraulic System 2-3
Lubrication 2-3
Battery 2-3
Lubrication and Servicing 2-3
2 3 Lubrication and Information 2-4
Hydraulic System 2-4
Hydraulic Oil 2-4
Changing Hydraulic Oil 2-4
Lubrication Specifications 2-4
2 4 Cylinder Drift Test 2-5
Platform Drift 2-5
Cylinder Drift 2-5
2 5 Pins and Composite Bearing Repair Guidelines 2-5
3121105 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
SECTION 3 – CHASSIS & TURNTABLE
3 1 Drive Hub 3-1
Disassembly 3-1
Disassembly of Cover 3-1
Disassembly of the First Stage Planetary Assembly (7) 3-1
Disassembly of Second Stage Planet Gears (1) 3-1
Assembly of First Stage Planetary Assembly (7) 3-2
Assembly of End Cover Unit (8) 3-2
Final Assembly 3-2
Initial Start-up And After Repairs 3-2
Oil Change Interval-Gear Drive 3-2
3 2 Swing Bearing 3-5
Turntable Bearing Mounting Bolt Condition Check 3-5
Bearing Wear Tolerance 3-5
Bearing Replacement 3-7
Swing Bearing Torque Values 3-9
3 3 Swing Torque Hub 3-9
Disassembly 3-9
Cleaning and Inspection 3-9
Assembly 3-11
3 4 Swing Brake 3-12
Cleaning and Inspection 3-14
Assembly 3-14
3 5 Tilt Alarm Switch Leveling 3-15
Manual Adjustment 3-15
Voltmeter Adjustment 3-16
3 6 Load Management System 3-16
Platform Position Indication System 3-16
Overmoment Control System 3-17
Load Management System Daily Check 3-18
3 7 Load Management System Adjustment 3-19
3 8 Turntable Springs 3-19
Removal 3-19
Installation 3-19
3 9 Drive and Steer Controller 3-19
Controller Theory & Definitions 3-19
3 10 Controller Setup 3-20
Lift 3-20
Swing 3-20
Telescope, Level, Rotate, & Jib 3-21
Drive 3-21
3 11 Function Control 3-21
Rotary Selector Controller Theory & Definitions 3-21
Adjustment Procedure 3-22
3 12 Throttle Checks and Adjustments – Deutz F4L-912 Engine 3-22
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-5
Assembly 4-5
Installation 4-7
4 2 Boom Chains 4-7
iv – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Adjusting Procedures 4-7
Inspection Procedure 4-8
4 3 Wear Pads 4-11
4 4 Limit Switch Adjustments 4-11
Boom Limit Switch 4-11
Horizontal Cut-Out Switch 4-11
4 5 Boom Marking Tape Installation 4-12
4 6 Boom Load Radius Setup Procedures – 100SX Dual Capacity 4-13
Length Indicator Adjustment 4-13
Boom Angle Sensor Adjustment 4-14
Radius Adjustment and Display Lights Setting Procedure 4-14
4 7 Boom Load Radius Setup Procedures – 110SX Single Capacity 4-15
Length Indicator Adjustment 4-15
Boom Angle Sensor Adjustment 4-15
Radius Adjustment and Display Lights Setting Procedure 4-16
4 8 Boom Load Radius Setup Procedures – 110SX Dual Capacity 4-16
Length Indicator Adjustment 4-16
Boom Angle Sensor Adjustment 4-17
Radius Adjustment and Display Lights Setting Procedure 4-17
4 9 Boom Load Radius Setup Procedures – 120SX 4-18
Length Indicator Adjustment 4-18
Boom Angle Sensor Adjustment 4-18
Radius Adjustment and Display Lights Setting Procedure 4-18
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory of Operation 5-1
5 2 Cylinder Checking Procedures 5-1
Cylinder w/o Counterbalance Valves 5-1
Cylinders w/Single Counterbalance Valves 5-1
Cylinders w/Dual Counterbalance Valve 5-2
5 3 Cylinder Removal and Installation 5-2
Telescope Cylinder Removal 5-2
Telescope Cylinder Installation 5-3
Lift Cylinder Removal 5-4
Lift Cylinder Installation 5-4
Master Level Cylinder Removal 5-4
Master Level Cylinder Installation 5-4
5 4 Cylinder Repair 5-5
Disassembly 5-5
Cleaning and Inspection 5-6
Assembly 5-6
5 5 Pressure Setting Procedures 5-8
Main Valve 5-8
Frame Mounted Valves 5-11
SECTION 6 – SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting 6-1
6 3 Hydraulic Circuit Checks 6-1
3121105 – JLG Lift – v
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1-1 Lubrication Point Location 1-5
1-2 Serial Number Locations 1-9
1-3 Torque Chart 1-10
3-1 Drive Hub – Sheet 1 of 2) 3-3
3-2 Drive Hub – Sheet 2 of 2 3-4
3-3 Swing Bearing Bolt Feeler Gauge Check 3-5
3-4 Swing Bearing Tolerance Boom Placement 3-6
3-5 Swing Bearing Tolerance Measuring Point 3-6
3-6 Swing Bearing Bolt Torquing Sequence 3-8
3-7 Swing Torque Hub 3-10
3-8 Torque Hub Carrier Timing 3-11
3-9 Swing Brake 3-13
3-10 Tilt Switch Adjustment – Voltmeter 3-15
3-11 Tilt Switch Adjustment – Manual 3-15
3-12 Control Box Components 3-17
3-13 Typical Card Adjustments 3-20
3-14 Function Control Card Adjustment 3-22
3-15 Throttle Checks and Adjustments – Deutz Engine 3-23
4-1 Boom Assembly – Sheet 1 of 2 4-2
4-2 Boom Assembly – Sheet 2 of 2 4-3
4-3 Typical Boom Assembly 4-8
4-4 Boom Chain Adjustments 4-9
4-5 Boom Marking Tape Installation 4-12
4-7 Load Radius Card 4-13
4-6 Boom Length/Angle Sensor Configurations 4-14
5-1 Cylinder Barrel Support 5-5
5-2 Cylinder Rod Support 5-5
5-3 Poly-Pak Seal Installation 5-6
5-4 Main Valve 5-9
5-5 Main Valve Torque Values 5-10
5-6 Chassis Valve Location 5-13
5-7 Axle Extension Valve 5-14
5-8 Axle Extension Valve Torque Values 5-15
6-1 Electrical Components Installation – Sheet 1 6-2
6-2 Electrical Components Installation – Sheet 2 6-3
6-3 100SX, 110SX Electrical Schematic – Platform – Sheet 1 of 2 6-4
6-4 100SX, 110SX Electrical Schematic – Platform – Sheet 2 of 2 6-5
6-5 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-6
6-6 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-7
6-7 110SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-8
6-8 110SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-9
6-9 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-10
6-10 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-11
6-11 120SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-12
6-12 120SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-13
6-13 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-14
6-14 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-15
6-15 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 1 of 8 6-16
6-16 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 2 of 8 6-17
6-17 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 3 of 8 6-18
6-18 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 4 of 8 6-19
6-19 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 5 of 8 6-20
6-20 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 6 of 8 6-21
6-21 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 7 of 8 6-22
vi5-8 Axle Extension Valve Torque Values 5-15
6-1 Electrical Components Installation – Sheet 1 6-2
6-2 Electrical Components Installation – Sheet 2 6-3
6-3 100SX, 110SX Electrical Schematic – Platform – Sheet 1 of 2 6-4
6-4 100SX, 110SX Electrical Schematic – Platform – Sheet 2 of 2 6-5
6-5 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-6
6-6 100SX, 110SX Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-7
6-7 110SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-8
6-8 110SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-9
6-9 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-10
6-10 110SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-11
6-11 120SXJ Electrical Schematic – Platform – Sheet 1 of 2 6-12
6-12 120SXJ Electrical Schematic – Platform – Sheet 2 of 2 6-13
6-13 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 1 of 2 6-14
6-14 120SXJ Electrical Schematic – Boom, Turntable, Chassis – Sheet 2 of 2 6-15
6-15 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 1 of 8 6-16
6-16 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 2 of 8 6-17
6-17 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 3 of 8 6-18
6-18 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 4 of 8 6-19
6-19 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 5 of 8 6-20
6-20 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 6 of 8 6-21
6-21 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 7 of 8 6-22
vi
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M