JLG 110HX Service Manual

Service and Maintenance Manual

Model

100HX

100HX+10

110HX

P/N - 3120636

March 11, 2010

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

AGENERAL

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.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLA­TION.

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.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER­ATO R.

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.

feed lines to system components can then be disconnected
with minimal fluid loss.

CMAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.

• 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.

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

3120636 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

March, 1989 - Original Issue
October, 1994 - Revised
August, 1997 - Revised
January, 1999 - Revised
October 8, 1999 - Revised
May 20, 2002 - Revised
April 6, 2009 - Revised
March 11, 2010 - Revised

A-2 – JLG Lift – 3120636

TABLE OF CONTENTS

SECTION NO. TITLE 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 - Ford LSG-423 & LRG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Ford LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Deutz F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine - Cummins 4B3.9C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Stowed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Stowed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Machine Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maximum Tire Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Ford LSG423 & LRG423 & LRG425 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Deutz F4L912 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Cummins 4B3.9C Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Accessory Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Extend-A-Reach Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.8 Boom Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

With 4620038 Turntable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

With 4620044 or 4620078 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1.10 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

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3120636 – JLG Lift – i

TABLE OF CONTENTS (Continued)

SECTION NO. TITLE PAGE NO.

SECTION 2 - PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Manual Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Proportional Control Valves - Vickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Adjusting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2.8 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.9 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cylinder w/o Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cylinders w/Single Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Cylinders w/Dual Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.10 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Master Level Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.11 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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ii – JLG Lift – 3120636

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

2.12 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2.13 Tilt Alarm Switch Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.14 Limit Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Boom Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Horizontal Cut-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

2.15 Throttle Checks and Adjustments - Deutz F4l-912 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.16 Throttle Checks and Precision Governor Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . .2-32

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Automatic Choke Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Carburetor and Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.17 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Sequence Pressure (Prior to 1990) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Sequence Pressure (1990 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Extend-A-Reach Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

2.18 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Bearing Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2.19 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

2.20 Swing Torque hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2.21 Swing Brake - Ausco - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

2.22 Swing Brake - Mico - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

2.23 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

2.24 Drive Brake - Ausco - Machines Built Prior To March 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

2.25 Drive Brake - Mico - Machines Built March 1992 TO S/N 33476 . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71




3120636 – JLG Lift – iii

TABLE OF CONTENTS (Continued)

SECTION NO. TITLE PAGE NO.

2.26 Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

2.27 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 2-74

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.28 OEM Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

THRESHOLD Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

HI RANGE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

IRS - RAMP RATE Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

LO RANGE Adjustment (CREEP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

2.29 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2.30 Boom Length/angle Sensor Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

1st and 2nd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

3rd Generation Radius Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83

2.31 Load Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Platform Position Indication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

Overmoment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

Overmoment Control Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

Load Management System Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

2.32 Load Management System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

2.33 Turntable Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90

Turntable 4620038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90

Turntables 4620044 and 4620078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

2.34 Pump Coupling Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Lovejoy Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Hayes Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

2.35 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-92

2.36 Platform Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93

2.37 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

iv – JLG Lift – 3120636

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

2-1. Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Boom Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Typical Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-4. Boom Positioning and Support - Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-5. Typical Hydraulic Cylinders - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-6. Typical Hydraulic Cylinders - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-6. Typical Hydraulic Cylinders - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-6. Typical Hydraulic Cylinders - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-6. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2-7. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-8. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-9. Boom Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-10. Boom Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-11. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-12. Tilt Switch Adjustment - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-13. Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

2-15. Precision Governor Adjustment - Ford Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

2-14. Precision Governor Adjustment - Ford Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-16. Pressure Setting Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

2-17. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-18. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

2-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-20. Swing Bearing Bolt Torquing Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2-21. Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2-22. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

2-23. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

2-24. Swing Brake - Ausco - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2-25. Swing Brake - Mico - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

2-26. Swing Brake - Machines Built 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-27. Drive Brake - Ausco (Prior to March 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

2-28. Drive Brake - Mico (March 1992 to S/N 33746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

2-29. Drive Brake - Mico (S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

2-30. Spring Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73

2-31. Boom Marking Tape Installation - 100HX+10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2-32. Boom Marking Tape Installation - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

2-33. Load Radius Card Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

2-34. Boom Length/Angle Sensor Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

2-35. Load Radius Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81

2-36. Control Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87

2-37. Load Moment Limiting System Monitoring Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

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3120636 – JLG Lift – v

LIST OF FIGURES (Continued)

FIGURE NO. TITLE PAGE NO.

3-1. Wiring Diagram - Boom Indicator Pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-2. Wiring Diagram - Dual Fuel (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-3. Wiring Diagram - Generator (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-4. Wiring Diagram - Generator (Ford) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-5. Wiring Diagram - Platform (100HX & 110HX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Wiring Diagram - Platform (100HX+10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 2 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-9. Wiring Diagram - 100HX & 110HX w/Deutz Engine (Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-10. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-11. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-12. Wiring Diagram - 100HX+10 w/Deutz Engine (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-13. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-14. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-15. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-16. Wiring Diagram - 100HX & 110HX w/Ford Engine (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-17. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-18. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-19. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-20. Wiring Diagram - 100HX+10 w/Ford Engine (Sheet 4 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

vi – JLG Lift – 3120636

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Maximum Tire Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-4 Mobil EAL Envirosyn H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-5 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-6 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-7 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-8 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

2-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-2 Cylinder Piston Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-4 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

2-5 Card Adjustment - 1st and 2nd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

2-6 Card Adjustment - 3rd Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78

2-7 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94

3-1 Platform Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 Turntable Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-6 Electrical System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3120636 – JLG Lift – vii

LIST OF TABLES (Continued)

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

viii – JLG Lift – 3120636

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank - 28 gallons (98 liters).

Hydraulic Oil Tank - 55 gallons (208 liters).

Hydraulic System (Including Tank) - 65 gallons (246 liters).

Torque Hub, Drive - 90 oz. (2.7 liters).

Torque Hub, Swing - 17 oz. (0.5 liters).

NOTE: Torque Hubs should be one-half full of lubricant.

(EPGL-90)

Engine Crankcase

Ford LSG423 & LRG423 w/Filter - 5 quarts (4.7 liters)
Ford LRG425 w/Filter - 4.5 quarts (4.25 liters)
Deutz F4L912 w/Filter - 11 liters.

1.2 COMPONENT DATA

NOTE: Tolerance on all engine rpm settings is plus or minus

10%.

Engine - Ford LSG-423 & LRG-423

Fuel - Gasoline

Oil Capacity - 5 quarts (4.7 liters) w/Filter, 4 quarts (3.8
liters) w/o Filter

Cooling System - 16 quarts (15 liters)

Idle RPM - 850 no load

Low (Mid) RPM - 1800 no load

High RPM - 3000 no load

Alternator - 40 Amp

Battery - 1000 CCA, 210 minutes reserve capacity, 12VDC

Engine - Deutz F4L912

Fuel - Diesel

Oil Capacity - 12.7 quarts (12 liters)

Low (Mid) RPM - 1800

High RPM - 2400

Alternator -

Prior to Oct. 91 85 Amp

Oct 91 to Present 55 Amp

Battery - 1000 cold cranking Amps, 210 minutes reserve
capacity, 12 VDC

Fuel Consumption

Low RPM - 2.4 gph (9.1 lph)

High RPM - 3.8 gph (14.2 lph)

Horsepower - 70 @ 2400 RPM, no load

Engine - Cummins 4B3.9C

Fuel - Diesel

Oil Capacity - 10 quarts (9.5 liters) w/o Filter

Cooling System Capacity - 21.4 quarts (20.2 liters)

Engine Capacity - 7.4 quarts (7 liters)
Radiator capacity - 14 quarts (13.2 liters)

Low (Mid) RPM - 1800

High RPM - 2400.

Alternator - 60 Amp.

Battery - 1000 CCA, 210 minutes reserve capacity, 

12 VDC.

Horsepower - 76 @ 2400 RPM, no load.

Fuel Consumption

LSG-423 - 4.6gph (17.4 lph)
LRG-423 - 4.3gph (16.2 lph)

Horsepower

LSG-423 - 54 @ 3000 RPM, no load
LRG-425 - 66 @ 3000 RPM, no load

Engine - Ford LRG-425

Fuel - Gasoline

No. of Cylinders - 4

BHP at Max. RPM - 70

RPM Setting (No Load) - Mid - 1500

3120636 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Drive System

Tires.

Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam

filled.

After March, 1993 - 385/65R22.5, 18 ply rating, foam

filled.

Drive Motor - 2.5 in3 (6.4 cm3) /rev. displacement.

Drive Hub - 93.7:1 ratio.

Drive Brake - Automatic spring applied, hydraulically
released.

Steer System

Tires.

Prior to March, 1993 - 15 x 22.5, 16 ply rating, foam

filled.

After March, 1993 - 385/65R22.5, 18 ply rating, foam

filled.

Toe-In - Adjust for 1/4in. (6.4 mm) overall.

Swing System

Swing Motor - 10.3 in3 (26.2 cm3)/rev. displacement.

Swing Hub - 69.5:1 ratio.

Swing Brake - Automatic spring applied, hydraulically
released.

Hydraulic Pump

Hydraulic Filter - Tank

Return - Bypass Type

10 Microns Nominal

Hydraulic Filter - Inline

Return - Non-Bypass Type

10 Microns Nominal

1.3 PERFORMANCE DATA

Travel Speed

2.8 mph (4.5 kmh)

Gradeability

25% or 14° slope, hard surface.

Turn ing Ra d ius

Outside - 22ft. 10 1/4 in. (7.1 m) w/axles extended.

Boom Speed

Extend - 128-156 Seconds.

Retract - 93-113 Seconds.

Lift Up - 65-80 Seconds

Lift Down - 52-64 Seconds.

Swing Speed

360° - 260-350 Seconds

1st Section - 15.0 gpm (56.8 lpm)

2nd Section - 9.0 gpm (34.1 lpm)

3rd Section - 9.0 gpm (34.1 lpm)

Auxiliary Power Pump

18.0 lpm

12 Volts DC motor

Clockwise rotation

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Boom Elevation

Models 100HX/110HX

+75° (above horizontal) to -21° (below horizontal)

Model 100HX+10

Main Boom - +75° (above horizontal) to -21° (below

horizontal)

Extend-a-Reach - +15° (above horizontal) to -80°

(below horizontal)

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1-2 – JLG Lift – 3120636

SECTION 1 - SPECIFICATIONS

Table 1-1.Maximum Tire Loads

Max. Load

Max Bearing Pressure

Description Lbs. Kg PSI

kg/cm

2

100HX 19900 9027 145 10

100HX+10 23740 10769 172 11.8

110 HX 21540 9771 156 10.7

Table 1-2.Torque Requirements

Description

Torque Value

Interval

Hours

Ft. Lbs. Nm

Bearing to Chassis 220 298 50/600*

Bearing to Turntable 220 298 50/600*

Wheel Lugs 300 407 100

Turntable Springs 75 102 200

Boom Chains 59 80 500

Platform Rotator Bolt 140 190 500

* Check swing bearing bolts for security after first 50 hours of
operation and every 600 hours thereafter.

Machine Weight

100HX - 36,400 lbs. (16,511 kg)

110HX - 40,410 lbs. (18,330 kg)

100HX+10 - 39,685 lbs. (18,001 kg)

Machine Stowed Height

9 ft. 10 in. (3.0 m)

Machine Stowed Length

100HX - 36 ft. in. (11.0 m)

110HX - 38 ft. 7 in. (11.8 m)

100HX+10 - 44 ft. 2 in. (13.5 m)

Machine Width

With axles retracted - 8 ft. 6 in. (2.6 m)

With axles extended - 10 ft. 10 in. (3.3 m)

Wheelbase

11 ft. (3.4 m)

Maximum Tire Loads



1.4 TORQUE REQUIREMENTS

NOTE: See Procedure Section for tightening sequence of

turntable bearing bolts.

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to
determine proper torque value.

1.5 LUBRICATION

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3120636 – JLG Lift – 1-3

Ford LSG423 & LRG423 & LRG425 Engines

Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD)

When Outside Temp is Consistently

-10° to +60° F (-24° to +16° C) *10W

+10° to +90° F (-12° C to +32° C) 20W-20

Above +32° F (0° C) 30

Above +50° F (+10° C) 40

Multi-Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

Below +10° F(-12° C) *5W-20

Below +60° F(+16° C) 5W-30

-10° to +90° F(-24° to +32° C) 10W-30

Above -10° F(-24° C) 10W-40 or 10W-50

Above +20° F( -7° C) 20W-40 or 20W-50

* This viscosity can be used at colder temperatures only
with engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

SECTION 1 - SPECIFICATIONS

Deutz F4L912 Engine

Single Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

-20° to +25° F (-29° to -4° C) *10W

+15° to +50° F (-10° C to +10° C) 20W-20

+40° to +85° F (+4° to +30° C) 30

Above 75° F (+24° C) 40

Multi-Viscosity Oils (CD-SE, CD-SF)

When Outside Temp is Consistently

-40° to +75° F(-40° to +24° C) *5W-20

-5° to +70° F(-21° to +21° C) 10W-30

-5° to +85° F(-21° to +30° C) 10W-40

+15° to +75° F(-10° to +24° C) 15W-30

Above +15° F(-10° C) 15W-40

* This viscosity can be used at colder temperatures only
with engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

Table 1-3.Hydraulic Oil

Hydraulic System Operating

Temperature Range

0° to +23° F(-18° to -5° C) 10W

0° to +210° F(-18° to +100° C) 10W-20, 10W-30

+50° to +210° F(+10° to +99° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152 .

NOTE: When temperatures remain consistently below 20

degrees F (-7 degrees C.), JLG Industries recom­mends the use of Mobil DTE11.

NOTE: Aside from JLG recommendations, it is not advisable

to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities. If use of hydraulic oil other
than Mobilfluid 424 is desired, contact JLG Indus­tries for proper recommendations.

SAE Viscosity

Grade

Cummins 4B3.9C Engine

Single Viscosity Oils

When Outside Temp is Consistently

-22° to +23° F (-30° to -5° C) 10W

+14° to +50° F (-10° C to +10° C) 20W-20

+41° to +86° F (+5° to +30° C) 30

Above 77° F (+25° C) 40

Multi-Viscosity Oils (MS, SD, SE).

When Outside Temp is Consistently

-40° to +77° F(-40° to +25° C) 5W-20

-4° to +68° F(-20° to +20° C) 10W-30

-4° to +86° F(-20° to +30° C) 10W-40

+14° to +77° F(-10° to +25° C) 15W-30

Above +14° F(-10° C) 15W-40

NOTE: Crankcase oil should meet one of the following API

classification grades: SE/CC, SE/CD, SF/CC, SF/
CD.

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

1-4 – JLG Lift – 3120636

SECTION 1 - SPECIFICATIONS



Table 1-4. Mobil EAL Envirosyn H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point, Max

Flash Point, Min.

Weight

Viscosity

at 104° F (40° C) 45 cSt

at 212° F (100° C) 8.0 cSt

Viscosity Index 153

Table 1-5. Mobil EAL 224 H Specs

Type Biodegradable Vegetable Oil

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max

Flash Point, Min.

Weight

Viscosity

at 104° F (40° C) 37 cSt

at 212° F (100° C) 8.4 cSt

Viscosity Index 213

Operating Temp 0-180° F (-17 - -162°C)

Note: Must be stored above 32° F (14° C)

-44°F (-44°C)

500°F (260°C)

7.64 lb. per gal.
(0.9 kg per liter)

-25°F (-32°C)

428°F (220°C)

7.64 lb. per gal.
(0.9 kg per liter)

Table 1-6. Mobil DTE 13M Specs

Ty pe Petroleum Base

ISO Viscosity Grade 32

Specific Gravity .877

Pour Point, Max

Flash Point, Min.

Viscosity

at 104° F (40° C) 33 cSt

at 212° F (100° C) 6.5 cSt

Viscosity Index 140

-40°F (-40°C)

330°F (166°C)

Lubrication Specifications

Table 1-7.Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 35 0

degrees F. Excellent water resistance and adhesive qualities;
and being of extreme pressure type (Timken OK 40 pounds
minimum).

EPGL Extreme Pressure Gear Lube (oil) meetin g API Service Classi-

fication GL-5 or Mil-Spec Mil-L- 2105.

HO Hydraulic Oil. API Service Classification GL-3, SAE 10W-20,

Viscosity Index 152.

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

Refer to Lubrication Chart for specific lubrication proce-



dures.

3120636 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

1011

6, 7

29

14

9

8

35

34

34

5

1, 5, 16

4

15

31

31

25

21

22

17

3

5

2

20

22

23, 24

21

17

25

33

32

14

21

21

30

26, 27, 28

19

18, 20

Note

The lubrication intervals in this

chart are equivalent to the following:

150 hours = 3 months
300 hours = 6 months

600 hours = 1 year

1200 hours = 2 years

Figure 1-1. Lubrication Diagram

1-6 – JLG Lift – 3120636

Table 1-8. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Components

Master Cylinder - Barrel End

1

Master Cylinder - Rod End

2

Boom Pivot Bushings

3

Lift Cylinder - Rod End

4

Lift Cylinder - Barrel End

5

Slave Cylinder - Rod End

6

Slave Cylinder - Shaft End

7

Extend-A-Reach Cylinder - Rod End

8

Extend-A-Reach Cylinder - Attach Pin

9

Platform Door Hinges

10

Platform Door Latch

11

Rotary Platform Control Stand

12

Platform Attach Pin and Rotary Worm

13

Gear

Drive Hubs

14

Swing Bearing Gear

15

Swing Bearing

16

Steer Spindles

17

Steer Cylinder - Rod End

18

Steer Cylinder - Barrel End

19

Tie Rod Ends

20

Extending Axle Beams

21

Wheel Bearings

22

Engine Crankcase

23

Engine Oil Filter

24

Door and Access Panel Hinges

25

Hydraulic Fluid

26

Hyd. Filter Element (Tank)

27

Hyd. Filter Element (Inline)

28

Telescope Cylinder Sheave

29

Extend Chain Sheave

30

Retract Chain Sheave

31

Number/Type

Lube Points

Lube & Method

Interval

Hours

Comments

1 Grease Fitting MPG - Pressure Gun 150 Remote Access

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150 Remote Access

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG- Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

N/A SAE10 - Oil Can 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting Each MPG - Pressure Gun 150

Fill Plug EPGL - SAE90 150/1200 Check every 150 hrs. /Change every 1200 hrs.

N/A M PG - Brush 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

N/A M PG - Brush 150

N/A MPG - Repack 1200

Fill Cap EO-SAE30 10/300 Check daily /Change every 300 hrs.

N/A Replaceable Cartridge 300

N/A SAE10 - Oil Can 150

Fill Cap HO 10/1200 Che ck daily/Change every 1200 hrs.

N/A N/A 50/300 Rep lace filter after first 50 hrs. of operation,

then every 300 hrs. thereafter

N/A N/A 50/300 Rep lace filter after first 50 hrs. of operation,

then every 300 hrs. thereafter

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

3120636 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Table 1-9.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Lift 9.0

(22.9)

43.375
(120.3)

4.0

(10.2)

Maser Level
(100HX, 110HX)

2.5

(6.4)

14.5

(36.8)

1.25
(3.2)

Master Level
(100HX+10)

2.5

(6.4)

15.1

(38.4)

1.25
(3.2)

Slave Level
(100HX, 110HX)

2.5

(6.4)

13.875
(35.2)

1.25
(3.2)

Slave Level
(100HX+10)

3.5

(8.9)

6.94

(17.6)

1.75
(4.4)

Steer 3

(7.6)

10.31
(26.2)

1.5

(3.8)

Telescope
(100HX, 100HX+10

5

(12.7)

247.81

(629.4)

3.5

(8.9)

Telescope
(110HX)

5

(12.7)

266

(675.6)

3.5

(8.9)

Axle Extension 2.5

(6.4)

28.19
(71.6)

1.25
(3.2)

Extend-a-Reach
(100HX+10)

3.5

(8.9

18.31
(46.5)

2.5

(6.4)

Table 1-8. Lubrication Chart

Components

Boom Chains

32

Turntable Pivot Pin

33

Extend-A-Reach Link Attach Pin

34

Extend-A-Reach Pivot Pin

35

NOTES:

1.6 PRESSURE SETTINGS

Proportional Valve

Drive - 3500 psi (241 bar)

Lift Up - 3000 psi (207 bar)

Lift Down - 1200 psi (83 bar)

Telescope In - 2500 psi (172 bar)

Number/Type

Lube Points

N/A Chain Lube/Hot Oil Dip 1200 Includes extend and retract chains

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

Lube & Method

Interval

Hours

Key to Lubricants:

EO
EPGL
HO
MPG t

Comments

Engine Oil
Extreme Pressure Gear Lube
Hydraulic Fluid (Mobil #424 or equivalent)
Multi-Purpose Grease

1.7 CYLINDER SPECIFICATIONS

NOTE: All cylinder dimensions are given in inches (in), with

the metric equivalent, centimeters (cm) in parenthe­ses.

Telescope Out - 1500 psi (103 bar)

Swing - 1200 psi (83 bar)

Accessory Valve

Main Relief - 3500 psi (241 bar)

Sequence Cartridge - 450 psi (31 bar)

Pressure Reducing Cartridge - 550 psi (38 bar)

Solenoid Valve

Main Relief - 2500 psi (172 bar)

Rotate - 2500 psi (172 bar)

Level - 2500 psi (172 bar)

Steer - 2000 psi (138 bar)

Extend-A-Reach Valve

Extend (Up) - 2500 psi (172 bar)

Retract (Down) - 700 psi (48 bar)

NOTE: Refer to Section 2 for pressure setting procedures.

1-8 – JLG Lift – 3120636

SECTION 1 - SPECIFICATIONS

Table 1-10.Major Component Weights

Component Lbs. KG.

Platform (36x48) w/o Control Box 150 68

Platform (36x60) w/o Control Box 165 75

Platform (36x72) w/o Control Box 180 82

Platform (36x96) w/o Control Box 220 100

Boom - 100HX (Incl. Lift Cylinder) 9920 4.500

Boom - 110HX (Incl. Lift Cylinder) 10960 4,971

Boom - 100HX+10 (Incl. Lift Cylinder) 10680 4,844

Turntable (w/Ford Engine, Less Cwt.) 10300 4,672

Turntable (w/Deutz Engine, Less Cwt.) 10620 4,817

Turntable (w/Cummins Engine, Less Cwt.) 10455 4,742

Frame Complete (incl. Wheels and Tires) 13620 6,178

Complete Machine - 100HX 37000 16,783

Complete Machine - 110HX 40500 18,371

Complete Machine - 100HX+10 38500 17,464

1.8 BOOM TAPE

With 4620038 Turntable

110HX Single Capacity

Blue - Not used

Yellow - Not used

Red - 119.5 in. (303.5 cm)

White - 154.5 in. (392.4 cm)

110HX Dual Capacity

Blue - Not used

Yellow - 82.5 in. (209.6 cm)

Red - 119.5 in. (303.5 cm)

White - 154.5 in. (392.4 cm)

100HX+10

Blue - 50 in. (127 cm)

Yellow - Not used

Red - 84 in. (213.4 cm)

White - 135.5 in. (344.2 cm)

100HX+10.

Blue - 53 in. (134.6 cm)

Yellow - Not used

Red - 87 in. (221.0 cm)

White - 138.5 in. (351.8 cm)

1.9 MAJOR COMPONENT WEIGHTS

With 4620044 or 4620078 Turntable

100HX Dual Capacity

Blue - Not used

Yellow - 62 in. (157.5 cm)

Red - 90 in. (228.6 cm)

White- 118 in. (299.7 cm)

110HX Single Capacity

Blue - Not used

Yellow - Not used

Red - 122.5 in. (311.2 cm)

White - 157.5 in. (400.1 cm)

110HX Dual Capacity

Blue - Not used

Yellow - 85.5 in. (217.2 cm)

Red - 122.5 in. (311.2 cm)

White - 160.5 in. (400.1 cm)







3120636 – JLG Lift – 1-9

1.10 SERIAL NUMBER LOCATIONS

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. In addition, the last
five digits of the serial number are stamped on top of the
fly end of the base boom section.













SECTION 1 - SPECIFICATIONS

Serial Number - Stamped

(Frame)

Serial Number Plate

(Frame)

Serial Number - Stamped

(Boom Sections)

Serial Number - Stamped

(Turntable - Far Side)

Figure 1-2. Serial Number Locations

Table 1-11.Critical Stability Weights

Component 100HX 110HX 100HX+10

Counterweight
(1.5:1)

6150 lbs.
(2790 kg)

10,350 lbs.

(4695 kg)

9,850 lbs.
(4468 kg)

Counterweight
(2:1)

N/A 10,350 lbs.

(4695 kg)

9,850 lbs.
(4468 kg)

Foam-Filled Tires
(each)

700 lbs.

(318 kg)

700 lbs.

(318 kg)

700 lbs.
(318 kg)

Ford Engine 525 lbs.

(238 kg)

525 lbs.
(238 kg)

525 lbs.
(238 kg)

Deutz Engine 837 lbs.

(380 kg)

837 lbs.
(380 kg)

837 lbs.
(380 kg)

Cummins Engine 680 lbs.

(308 kg)

680 lbs.
(308 kg)

680 lbs.
(308 kg)

36x48 Platform N/A N/A 150 lbs.

(68 kg)

36x60 Platform N/A N/A 165 lbs.

(75 kg)

36x72 Platform N/A N/A 180 lb.

(82 kg)

36x96 Platform (100 kg) (100 kg) (1 00 kg)

1.11 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS THE
COUNTERWEIGHT OR FOAM-FILLED TIRES, WITH ITEMS OF DIF­FERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN
ANY WAY TO AFFECT STABILITY.



1-10 – JLG Lift – 3120636

SIZE

4

12

12

6

6

7

7

8

9

12

12

12

14

16

18

18

20

20

24

24

20

24

32

32

40

10

11

12

13

14

16

18

28

32

36

40

48

6

1-1/2

1-1/2

3.8100

3.4925

4.0132

39781

2983

2224

3118

4827

4712

4068

3559

2983

2712

2136

1898

1492

3200

2766

2413

2034

1844

1464

4284

3688

3227

2712

2468

1953

1736

1356

983

895

631

570

359

326

258

224

183

1003

922

678

624

434

380

244

231

176

149

895

814

570

515

326

298

231

204

163

149

21

18

16

12

95

68

61

34

34

8

7

5

5

3

3

2

2

5

4

4

2

2

1

1

142200

57380

53570

47174

43818

38554

34927

31162

27080

23360

20775

18870

15241

13653

10433

9231

8278

7539

6532

5783

4854

4332

3583

3175

2821

2141

1488

1297

817

717

599

572

417

372

272

245

1708

2373

1247

1762

895

1254

719

997

475

705

298

448

176

258

1980

2746

1492

2068

1139

1593

814

1139

651

915

434

644

271

387

149

224

122

183

88

136

109

163

75

115

48

75

31

48

18

26

10

16

4

9

12

4

3

2

1

3

2

1

68

81

34

54

19

29

2278

2630

1980

1519

1681

1193

949

1085

868

583

353

637

407

231

163

204

149

122

75

102

68

41

23

11

5

4

2

1

14

6

4

2

1

48

26

33113

35381

29076

24404

19187

17509

13336

9662

6532

5262

4105

3085

3425

2540

1678

2241

1515

1052

583

426

277

191

916

508

408

263

172

27035

21546

19142

14697

10796

7394

5874

4854

3.3401

3.5687

2.9337

2.4613

1.9380

1.5392

1.1735

0.8484

0.5740

0.4623

0.3604

0.2700

0.1969

0.1331

0.0925

0.0508

0.0808

0.0445

0.0356

0.0232

0.0153

0.0374

0.0258

0.0168

2.7254

2.1742

1.6840

1.2929

0.9474

0.6502

0.5156

0.4061

0.3015

0.2230

0.1473

3.1750

2.8575

2.5400

2.2225

1.9050

1.5875

1.4288

1.2700

1.1112

0.9525

0.7938

0.6350

0.4826

0.4166

0.3505

0.2845

1-1/4

1-1/8

1

7/8

3/4

5/8

9/16

1/2

7/16

5/16

3/8

1/4

10

8

THD

SAE GRADE 5 BOLTS & GRADE 2 NUTS

SAE GRADE 5

SAE GRADE 8

SAE GRADE 8 BOLTS & GRADE 8 NUTS

UNBRAKO 1960 SERIES

SOCKET HEAD CAP SCREW

WITH LOC-WEL PATCH

BOLT

DIA.

(CM)

CLAMP

LOAD

(KG)

CLAMP

LOAD

(KG)

CLAMP LOAD

(KG)

TORQUE

TORQUE

(DRY OR

LOC. 263)

(DRY OR

LOC. 263)

(LOCTITE

262)

(LOCTITE

262)

(LOCTITE

)

242 OR 271

(LOCTITE

)

242 OR 271

TORQUE

(as received)

(LUB.)

(LUB.)

NM

NM

NM

NM

NM

NM

NM

NM

NM

Note: These torque values do not apply to cadium plated fasteners.

THREAD

STRESS

AREA

(SQ. CM)

1220

109

75

41

41

109

81

75

48

48

27

25

109

14

6

3607

1302

122

19

163

68

5322

1342

122

VALUES FOR ZINC PLATED BOLTS ONLY

UNPLATED

CAP SCREWS

22

23

38

43

68

92

108

133

61

148

183

207

325

363

523

576

785

858

968

1087

1368

1516

1792

2042

2379

2676

18

19

34

37

61

68

95

102

149

156

210

224

285

298

495

542

793

861

1173

1241

1681

1871

2373

2549

3145

3308

4122

4433

71669

63731

59648

52391

48671

43954

38828

34610

30074

27488

23088

20956

16919

15150

11612

10251

9208

8256

7253

6437

5384

4822

3983

3493

2631

2377

1651

1442

1079

931

724

658

456

408

277

244

209

188

146

130

95

85

61

54

34

30

1396

1566

1970

2183

2586

2935

3430

3856

Figure 1-3. Torque Chart

SECTION 1 - SPECIFICATIONS

3120636 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

This page left blank intentionally

1-12 – JLG Lift – 3120636

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

NOTE: The JLG Models 100HX, 110HX and 100HX+10

have been built with two different turntable configura­tions. Turntable number 4620044 is used on
machines with serial numbers 11511, 12249, 12598,
12836, 12838 and higher through March, 1992.
Turntable number 4620078 is used on machines
since March, 1992. Where differences between
specifications on maintenance procedures exist, the
turntable number will be specified. Refer to the JLG
Illustrated Parts Manual for turntable illustrations.

This section provides information necessary to perform
maintenance on the aerial platform. Descriptions, tech­niques and specific procedures are designed to provide
the safest and most efficient maintenance for use by per­sonnel responsible for ensuring the correct installation
and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES
CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE
NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND
TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK
IS RESUMED.

The maintenance procedures included consist of servic­ing and component removal and installation, disassembly
and assembly, inspection, lubrication and cleaning. Infor­mation on any special tools or test equipment is also pro­vided where applicable.

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

The following information is provided to assist you in the
use and application of servicing and maintenance proce­dures contained in this chapter.

Safety and Workmanship

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.

Cleanliness

1. The most important single item in preserving the
long service life of a machine is to keep dirt and for­eign materials out of the vital components. Precau­tions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.

2. At any time when air, fuel, or oil lines are discon­nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo­nent is disconnected, cap or cover all openings to
prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or main­tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain­ers until they are ready to be used.

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.

2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eye­bolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90 degrees.

3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc.,have been
removed and that no adjacent parts are interfering.

Component Disassembly and Reassembly

When disassembling or reassembling a component, com­plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an “anti-seize” or
molybdenum disulfide base compound to lubricate the
mating surface.

3120636 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

Bearings

1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.

4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear­ing is to be installed on a shaft, apply pressure to the
inner race.

Gaskets

Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.

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.

2. Unless specific torque requirements are given within
the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accor­dance with recommended shop practices. See the
Torque Chart in Section 1 - Specifications.

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.

Hydraulic System

1. Keep the system clean. If evidence of metal or rub­ber particles are found in the hydraulic system, drain
and flush the entire system.

2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable

cleaning solvent. Lubricate components, as
required, to aid assembly.

Lubrication

Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti-corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.

2.3 LUBRICATION INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contam­ination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suc­tion) lines.

2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
components and generally results in faulty opera­tion. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci­fied intervals required in Section 1. Always examine
filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or cor­rosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is oper­ating, are recommended for use.

2-2 – JLG Lift – 3120636

SECTION 2 - PROCEDURES

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

1. Refer to Table 1-1 for recommendations for viscosity
ranges.

2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F (-26 degrees C) is not recom­mended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a mini­mum temperature of -15 degrees F (-26 degrees C).

3. The only exception to the above is to drain and fill
the system with Mobil DTE 11 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
11 oil should not be operated at temperatures above
200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this man­ual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assis­tance in selecting the proper equivalent. Avoid mix­ing petroleum and synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.

2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contami­nants from the service container. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.

Lubrication Specifications

Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise regarding the use of greases in
maintenance stock, consult your local supplier for evalua­tion. Refer to Table 1-2 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

2.4 CYLINDERS - THEORY OF OPERATION

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. Directing oil (by actuating the corre­sponding control valve to the piston side of the cylin­der) forces the piston to travel toward the rod end of
the barrel, extending the cylinder rod (piston
attached to rod). When the oil flow is stopped,
movement of the rod will stop. By directing oil to the
rod side of the cylinder, the piston will be forced in
the opposite direction and the cylinder rod will
retract.

2. Holding valves are used in the Lift, Slave Level, Tele­scope, and Extend-A-Reach circuits to prevent
retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and
its related control valve.

2.5 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid
valves of the sliding spool design. When a circuit is acti­vated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to per­mit oil flow to the component in the selected circuit, with
the opposite work port opening to reservoir. Once the cir­cuit is deactivated (control returned to neutral), the valve
spool returns to neutral (center) and oil flow is then
directed through the valve body and returns to reservoir.

3. While the unit is shut down, a good preventive main­tenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.

3120636 – JLG Lift – 2-3

SECTION 2 - PROCEDURES

A typical control valve consists of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring­loaded to center position, therefore when the control is
released, the spool automatically returns to neutral, pro­hibiting any flow through the circuit.

Manual Hydraulic Control Valves

The manual hydraulic control valves consist of four-way,
multi-position valve sections, each section incorporating a
sliding spool, spring-loaded to neutral or off. Each spool is
attached to a control lever which provides for proportional
control of the selected system function. This proportional
control enables metering of oil flow in accordance with
spool position, affording variable and smooth speed con­trol capability. Spool movement causes work ports within
the valve to align in a predetermined way, permitting flow
to the selected function, with the opposing work ports
positioned to allow return flow to the hydraulic reservoir.

Proportional Control Valves - Vickers

The Vickers proportional valves provide a power output
matching that required by the load. A small line connected
to a load sensing port feeds load pressure back to a
sequence valve. The sequence valve senses the differ­ence between the load and pump outlet pressure, and
varies the pump displacement to keep the difference con­stant. This differential pressure is applied across the
valve’s meter-in spool, with the effect that pump flow is
determined by the degree of spool opening, independent
of load pressure. Return lines are connected together,
simplifying routing of return flow and to help reduce cavi­tation.

Load sensing lines connect through shuttle valves to feed
the highest load signal back to the sequence valve. Inte­gral actuator port relief valves, anti-cavitation check
valves, and load check valves are standard.

Relief Valves

Main relief valves are installed at various points with the
hydraulic system to protect associated systems and com­ponents against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of
travel and the flow of pressurized fluid continues from the
system control. The relief valve provides an alternate path
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir­cuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than

the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pres­sure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actu­ator requires an operating pressure lower than that sup­plied to the system. When the circuit is activated and the
required pressure at the actuator is developed, the cross­over relief diverts excess pump flow to the reservoir. Indi­vidual, integral reliefs are provided for each side of the
circuit.

2.6 BOOM CHAINS

Adjusting Procedures

ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE.

1. Position boom fully retracted at +5 degrees horizon­tal, no load in platform.

2. Torque outer mid section extend chain adjuster to 59
ft. lb. (80 Nm).

3. Torque outer mid section retract chain adjuster to 59
ft. lb. (80 Nm).

4. Torque fly section extend chain adjuster to 59 ft. lb.
(80 Nm).

5. Torque fly section retract chain adjuster to 59 ft. lb.
(80 Nm).

6. Cycle boom (extend at least 6 feet [2 meters], then
retract fully).

7. Recheck outer mid section extend chain.

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 instructions outlined in Boom Maintenance in this
section, every two years. All boom chains and related
components (i.e., sheaves, pins, sprockets, wear pads,
etc.) must also be inspected and replaced (as necessary)
during this disassembly.

2-4 – JLG Lift – 3120636

SECTION 2 - PROCEDURES

Meter-Out Poppet

Adjustable Relief

Actuator Port "A"

Actuator Port "B"

Load Drop Check

Pilot Relief

"A" Solenoid

Pilot Supply Passages

Gasket

Valve Inlet Port

Meter-In Chambers

Load Sensing Check Valves

Electro-Hydraulic
Reducing Valve Spool

Meter-In Spool

"B" Solenoid

Vent

Return Port

Figure 2-1. Proportional Control Valve

3120636 – JLG Lift – 2-5

SECTION 2 - PROCEDURES

FLY EXTEND

FLY RETRACT

OUTER MID RETRACT

OUTER MID EXTEND

Figure 2-2. Boom Chain Adjustments

2-6 – JLG Lift – 3120636