JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual 3121105 – PDF DOWNLOAD
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JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual 3121105 – PDF DOWNLOAD
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JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual 3121105 – PDF DOWNLOAD
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. A maintenance program must be followed to ensure that the machine is safe to operate.
- The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.
- Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device.
- Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.
MAINTENANCE
- NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.
- REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.
- DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.
- OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
- KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.
- USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
- NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.
- BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.
- BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS
- KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
- USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual 3121105 – PDF DOWNLOAD
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 – JLG Lift – 3121105
TABLE OF CONTENTS (Continued)
LIST OF FIGURES (continued)
FIGURE NO TITLE PAGE NO
6-22 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 8 of 8 6-23
6-23 120SXJ Hydraulic Schematic – Sheet 1 of 6 6-24
6-24 120SXJ Hydraulic Schematic – Sheet 2 of 6 6-25
6-25 120SXJ Hydraulic Schematic – Sheet 3 of 6 6-26
6-26 120SXJ Hydraulic Schematic – Sheet 4 of 6 6-27
6-27 120SXJ Hydraulic Schematic – Sheet 5 of 6 6-28
6-28 120SXJ Hydraulic Schematic – Sheet 6 of 6 6-29
LIST OF TABLES
TABLE NO TITLE PAGE NO
1-1 Torque Requirements 1-3
1-2 Hydraulic Oil 1-3
1-3 Mobil EAL Envirosyn H 46 Specs 1-4
1-4 Mobil EAL 224 H Specs 1-4
1-5 Mobil DTE 13M Specs 1-4
1-6 Lubrication Specifications 1-4
1-7 Lubrication Chart 1-6
1-8 Cylinder Specifications 1-8
1-9 Critical Stability Weights 1-9
2-1 Inspection and Maintenance 2-2
2-2 Cylinder Drift 2-5
2-3 Inspection and Preventive Maintenance Schedule 2-6
3-1 Controller Settings 3-21
4-1 Chain Stretch Tolerance 4-11
4-2 Boom Marking Tape Installation 4-12
5-1 Cylinder Piston Nut Torque Specifications 5-7
5-2 Holding Valve Torque Specifications 5-8
VIDEO 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