JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121810) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 100SX 110SX 110SXJ 120SXJ Service & Maintenance Manual (3121810) – 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 – 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
3121810 – 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 Swing Bearing Bolt Feeler Gauge Check 3-1
3-2 Swing Bearing Tolerance Boom Placement 3-2
3-3 Swing Bearing Tolerance Measuring Point 3-2
3-4 Swing Bearing Bolt Torquing Sequence 3-4
3-5 Swing Torque Hub 3-6
3-6 Torque Hub Carrier Timing 3-7
3-7 Swing Brake 3-9
3-8 Tilt Switch Adjustment – Voltmeter 3-11
3-9 Tilt Switch Adjustment – Manual 3-11
3-10 Control Box Components 3-13
3-11 Drive and Steer Adjustment 3-16
3-12 Lift and Swing Adjustment 3-17
3-13 Function Control Card Adjustment 3-19
3-14 Throttle Checks and Adjustments – Deutz Engine 3-20
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 4-9
4-4 Boom Chain Adjustments 4-10
4-5 Broken Chain Limit Switch Adjustment 4-12
4-6 Boom Marking Tape Installation – 110SXJ 4-14
4-7 Boom Marking Tape Installation – 100SX, 110SX, and 120SXJ 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
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 6 6-16
6-16 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 2 of 6 6-17
6-17 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 3 of 6 6-18
6-18 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 4 of 6 6-19
6-19 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 5 of 6 6-20
6-20 100SX, 110SX, 110SXJ Hydraulic Schematic – Sheet 6 of 6 6-21
6-21 120SXJ Hydraulic Schematic – Sheet 1 of 6 6-22
6-22 120SXJ Hydraulic Schematic – Sheet 2 of 6 6-23
6-23 120SXJ Hydraulic Schematic – Sheet 3 of 6 6-24
6-24 120SXJ Hydraulic Schematic – Sheet 4 of 6 6-25
6-25 120SXJ Hydraulic Schematic – Sheet 5 of 6 6-26
6-26 120SXJ Hydraulic Schematic – Sheet 6 of 6 6-27
vi – JLG Lift – 3121810
TABLE OF CONTENTS (Continued)
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
4-1 Chain Stretch Tolerance 4-12
4-2 Boom Marking Tape Installation 4-15
5-1 Cylinder Piston Nut Torque Specifications 5-7
5-2 Holding Valve Torque Specifications 5-8
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