JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121810) EN
TABLE OF CONTENTS:
JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121810) 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 – Australia Spec 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 – 3121810
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
SECTION 3 – CHASSIS & TURNTABLE
3 1 Swing Bearing 3-1
Turntable Bearing Mounting Bolt Condition Check 3-1
Bearing Wear Tolerance 3-1
3121810 – JLG Lift – iii
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
Bearing Replacement 3-3
Swing Bearing Torque Values 3-5
3 2 Swing Torque hub 3-5
Disassembly 3-5
Cleaning and Inspection 3-5
Assembly 3-7
3 3 Swing Brake 3-8
Cleaning and Inspection 3-10
Assembly 3-10
3 4 Tilt Alarm Switch Leveling 3-11
Manual Adjustment 3-11
Voltmeter Adjustment 3-12
3 5 Load Management System 3-12
Platform Position Indication System 3-12
Overmoment Control System 3-13
Overmoment Control Monitoring System 3-14
Load Management System Daily Check 3-14
3 6 Load Management System Adjustment 3-15
3 7 Turntable Springs 3-15
Removal 3-15
Installation 3-15
3 8 Drive and Steer Controller 3-15
Controller Theory & Definitions 3-15
Adjustment Procedures 3-16
3 9 Lift and Swing Controller 3-17
Adjustment 3-17
3 10 Function Control 3-18
Rotary Selector Controller Theory & Definitions 3-18
Adjustment Procedure 3-19
3 11 Throttle Checks and Adjustments – Deutz F4L-912 Engine 3-19
SECTION 4 – BOOM & PLATFORM
4 1 Boom Maintenance 4-1
Removal 4-1
Disassembly 4-1
Inspection 4-5
Assembly 4-6
Installation 4-7
4 2 Boom Chains 4-8
Adjusting Procedures 4-8
Inspection Procedure 4-9
4 3 Wear Pads 4-13
4 4 Limit Switch Adjustments 4-13
Boom Limit Switch 4-13
Horizontal Cut-Out Switch 4-13
4 5 Boom Marking Tape Installation 4-14
4 6 BOOM LOAD RADIUS SETUP PROCEDURES – 100SX 4-15
Length Indicator Adjustment 4-15
Boom Angle Sensor Adjustment 4-16
Radius Adjustment and Display Lights Setting Procedure 4-16
4 7 BOOM LOAD RADIUS SETUP PROCEDURES -110SXJ 4-17
Length Indicator Adjustment 4-17
Boom Angle Sensor Adjustment 4-17
Radius Adjustment and Display Lights Setting Procedure 4-18
iv – JLG Lift – 3121810
TABLE OF CONTENTS (Continued)
TABLE OF CONTENTS (continued)
SUBJECT – SECTION, PARAGRAPH PAGE NO
4 8 BOOM LOAD RADIUS SETUP PROCEDURES – 110SX 4-19
Length Indicator Adjustment 4-19
Boom Angle Sensor Adjustment 4-19
Radius Adjustment and Display Lights Setting Procedure 4-19
4 9 BOOM LOAD RADIUS SETUP PROCEDURES – 120SXJ 4-20
Length Indicator Adjustment 4-20
Boom Angle Sensor Adjustment 4-21
Radius Adjustment and Display Lights Setting Procedure 4-21
SECTION 5 – HYDRAULICS
5 1 Cylinders – Theory of Operation 5-1
5 2 Cylinder Checking Procedures 5-1
Cylinder w/o Counterbalance Valves – Steer Cylinders, Master Level Cylinder,
Frame Jack Cylinders 5-1
Cylinders w/Single Counterbalance Valves – Lift Cylinder, Telescope Cylinder,
Jib Cylinder 5-1
Cylinders w/Dual Counterbalance Valve – Axle Extension Cylinders,
Telescope Cylinder, Platform Slave Level Cylinder 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
SECTION 6 – SCHEMATICS
6 1 General 6-1
6 2 Troubleshooting 6-1
6 3 Hydraulic Circuit Checks 6-1
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
Andres –
Just maybe a bit user friendlier! I was kinda confused initially before noticing ‘download’ window. Should be a bit more visible. I think. Otherwise everytning is great, I recommend!