JLG 120-SXJ Service Manual

Service and Maintenance Manual

Models

100SX

110SX
110SXJ
120SXJ

P/N - 3121810

July 29, 2004

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

This section contains the general safety precautions which
must be observed during maintenance of the aerial plat­form. It is of utmost importance that maintenance person­nel pay strict attention to th ese warnings a nd precaut ions
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 pre cautions to be observ ed during mainte­nance are inserted at the appropriate point in the manual.
These precautions are, for the most part , those tha t app ly
when servicing hydrau lic and larger mach ine compon ent
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 t o 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 sup port is
provided.

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

B HYDRAULIC SYSTEM SAFETY

It should be noted that the mach ines hydrau lic systems
operate at extremely high potentially dangerous pressures.
Every effort should be made to relieve any system pres­sure prior to disconnecting or removing any port ion of the
system.

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

C MAINTENANCE

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 MANDA TORY. NEVER REFUEL DUR­ING ELECTRICAL STOR MS. ENSURE THAT FUEL
CAP IS CLOSED AND S ECURE 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 A NY OTHER M AINTENANC E, 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 t he engine stopped and ignition on , to
direct any line pressure back into the reservoir. Pressure

3121810 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - June 16, 2000
Revised - July 26, 2000
Revised - January 21, 2002
Revised - June 11, 2002
Revised - July 29, 2004

A-2 – JLG Lift – 3121810

TABLE OF CONTENTS

TABLE OF CONTENTS

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

3121810 – JLG Lift – i

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

ii – JLG Lift – 3121810

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

3121810 – JLG Lift – iii

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

iv – JLG Lift – 3121810

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

3121810 – JLG Lift – v

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

vi – JLG Lift – 3121810

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Engine Crankcase

Deutz F4L912 w/Filter - 12.5 liters (13.2 quarts)

Fuel Tank

150 liters (40 gallons)

Hydraulic Tank

189 liters (50 gallons)

1.2 COMPONENT DATA

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

10%.

Engine - Deutz F4L912

Fuel - Diesel

Oil Capacity (crankcase only) - 12 liters (12.7 quarts)

Low (Mid) RPM - 1800

High RPM - 2400

Alternator - 55 Amp

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

Fuel Consumption

Low RPM - 9.1 lph (2.4 gph)

1.3 PERFORMANCE DATA - 100SX, 110SX &
110SXJ

Platform Height

100SX - 30.5 m (100ft.)
110SX & 110SXJ - 33.5 m (110 ft.)

Horizontal Outreach

16.7 m (55 ft.)

Below Ground Reach (110SX only)

3.6 m (12 ft.)

Swing

360° Continuous

Platform Capacity - Restricted (100SX &
110SX - Australia Spec Only)

450 kg (1000 lbs.)

Platform Capacity - Unrestricted

230 kg (500 lbs.)

Platform Rotator

180° Hydraulic

High RPM - 14.2 lph (3.8 gph)

Horsepower - 70 @ 2400 RPM, no load

Tor q u e H u b

Input Torque - 157 Nm (116 ft. lbs.)

Input Speed - 2734 rpm

Output Torque - 13878 Nm (10236 ft. lbs.)

Output Speed - 31 rpm

Static Brake Torque - 200 Nm (147.5 ft. lbs.)

Release Pressure - 18 Bar (261 psi)

Max. Release Pressure - 50 Bar (725 psi)

Drive Motor

Max. Displacement - 45 cc (2.75 in3)

Min. Displacement - 15.2 cc (0.93 in3)

Output Speed at Max. Displacement - 3000 rpm

Output speed at Min. Displacement - 4000 rpm

Jib Range of Articulation - 110SXJ

3.05 m (10 ft.) 95 degrees (+15, -80)

Overall Width - Axles Retracted

2.49 m (8 ft. 2 in.)

Overall Width - Axles Extended

3.3 m (10 ft. 10 in.)

Tailswing (Axles Extended)

86 cm (2 ft. 10 in.)

Stowed Height

3.0 m (9 ft. 10 in.)

Stowed Length

100SX - 11.55 m (37 ft. 10 in.)
110SX - 11.76 m (38 ft. 7 in.)
110SXJ - 13.46 m (44 ft. 2 in.)

3121810 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Wheelbase

3.05 m (10 ft.)

Ground Clearance

32 cm (12.5 in.)

Gross Weight

100SX - 17,136 kg (37,700 lbs.)
110SX - 19,006 kg (41,900 lbs.)
110SXJ - 18,779 kg (41,400 lbs.)

Max. Ground Bearing Pressure

100SX & 110SXJ - 6.3 kg/cm2 (90 psi)

110SX - 7.0 kg/cm

2

(100 psi)

Drive Speed

4.8 km/h (3 mph)

Gradeability

40%

Turning Radius (Inside)

Axles Retracted - 4.47 m (14 ft. 8 in.)
Axles Extended - 3.66 m (12 ft.)

Turning Radius (Outside)

Axles Retracted - 6.76 m (22 ft. 2 in.)
Axles Extended - 7.32 m (24 ft.)

Tire Size/Type

385/65R22.5 Foam Filled

Jib Range of Articulation

3.35 m (11 ft.) 95 degrees (+15, -80)

Overall Width - Axles Retracted

2.49 m (8 ft. 2 in.)

Overall Width - Axles Extended

3.3 m (10 ft. 10 in.)

Tailswing (Axles Extended)

86 cm (2 ft. 10 in.)

Stowed Height

3.05 m (10 ft.)

Stowed Length (Working)

15.95 m (52 ft. 4 in.)

Stowed Length (Transport)

10.95 m (35 ft. 11 in.)

Wheelbase

3.05 m (10 ft.)

Ground Clearance

37 cm (14.5 in.)

Gross Weight

19,732 kg (43,500 lbs.)

Max. Ground Bearing Pressure

6.3 kg/cm2 (90 psi)

1.4 PERFORMANCE DATA - 120SXJ
Drive Speed

Platform Height

36.58 m (120 ft.)

4.8 km/h (3 mph)

Gradeability

Horizontal Outreach

16.7 m (55 ft.)

40%

Turning Radius (Inside)

Swing

360° Continuous

Platform Capacity

230 kg (500 lbs.)

Axles Retracted - 3.91 m (12 ft. 10 in.)
Axles Extended - 3.23 m (10 ft. 7 in.)

Turn i ng Radi us (Out side)

Axles Retracted - 5.28 m (17 ft. 4 in.)
Axles Extended - 5.74 m (18 ft. 10 in.)

Platform Rotator

180° Hydraulic

1-2 – JLG Lift – 3121810

Tire Size/Type

445/65R22.5 Foam Filled

SECTION 1 - SPECIFICATIONS

1.5 TORQUE REQUIREMENTS

Ta b l e 1 - 1 . To r q u e R e q u ir e m e n t s

Description

Bearing to Chassis 220 298 50/600*

Bearing to Turntable 220 298 50/600*

Wheel Lugs 180 245 100

Turntable Springs 75 102 200

Boom Chains 59 80 500

Rotator Bottom Bolt 480 672 A/R

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

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.

Torque Value

Ft. Lbs. Nm

Interval

Hours

1.6 LUBRICATION

Ta b l e 1 - 2 . H y d r a u l i c Oi l

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 -7

degrees C. (20 degrees F), JLG Industries recom­mends the use of Mobil DTE13.

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

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

Use SAE Viscosity

Number

Use SAE Viscosity

Number

(Synthetic)

3121810 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Table 1-3. 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 1-4. 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 1-5. Mobil DTE 13M Specs

Type 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 1-6.Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350

degrees F. Excellent water resista nce and adhesive qualities;
and being of extreme pr essure type (Timken OK 40 pounds
minimum).

EPGL Extreme Pressure Gear Lube (oil) meeti ng API Service Classi-

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

HO Hydraulic Oil. API Serv ice 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 c lass, MIL-L-2104B/MIL-L-2104C.

Refer to Lubrication Chart for spe cific lubrica tion proce­dures.

1-4 – JLG Lift – 3121810

SECTION 1 - SPECIFICATIONS

Figure 1-1. Lubrication Point Location

3121810 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Table 1-7. Lubrication Chart

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 E nd

6

Slave Cylinder - Barrel End

7

Jib Cylinder - Rod End

8

Jib Cylinder - Attach Pin

9

Drive Hubs

10

Swing Bearing Gear

11

Swing Bearing

12

Steer Spindles

13

Extending Axle Beams

14

Engine Crankcase

15

Engine Oil Filter

16

Hydraulic Fluid

17

Hyd. Filter Element (Tank)

18

Hyd. Filter Element (I nline)

19

Telescope Cylinder Sheave

20

Extend Chain Sheave

21

Retract Chain Sheave

22

Boom Chains

23

Turntable Pivot Pin

24

Jib Link Attach Pin

25

Jib Pivot Pin

26

NOTES:

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

2 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG- Pressure Gun 1 50

2 Grease Fittings MPG - Pressure Gun 150

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

N/A MPG - Brush 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

N/A MPG - Brush 600 As neede d

Fill Cap EO-SAE30 10/300 Chec k daily/Change every 1000 hrs. or one

year, whichever come s first. Adjust fina l level
by mark on dipstick.

N/A Replaceable Cartridge 300

Fill Cap HO 10/1200 Ch eck daily/Change every 1200 hrs.

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

then every 300 hrs. thereafter

N/A N/A 50/300 Replace 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

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

Key to Lubricants:

EO
EPGL
HO
MPG t

Engine Oil
Extreme Pressure Gear Lube
Hydraulic F luid (Mobil #4 24 or equivalent )
Multi-Purpose Grease

1-6 – JLG Lift – 3121810

SECTION 1 - SPECIFICATIONS

1.7 PRESSURE SETTINGS

Main Valve

Main - 238 bar (3450 psi)

Lift Down - 103 bar (1500 psi)

Jib (Up) - 207 bar (3000 psi)

Jib (Down) - 97 bar (1400 psi)

Swing - 83 bar (1200 psi)

Platform Level Up - 152 bar (2200 psi)

Platform Level Down - 172 bar (2500 psi)

Drive - 310 bar (4500 psi)

Steer - 197 bar (2850 psi)

Platform Rotate - 172 bar (2500 psi)

Extendable Axles In - 172 bar (2500 psi)

Extendable Axles Out - 172 bar (2500 psi)

NOTE: Refer to Section 2 for pressure setting procedures.

1.8 FUNCTION SPEEDS (IN SECONDS)

100SX

Lift Up - 100-85

Lift Down - 100-75

110SXJ

Lift Up - 100-85

Lift Down - 100-75

Swing Right & Left - 200-140

Telescope Out - 93-74

Platform Rotate Right & Left - 24-36

Articulated Jib Up - 15-20

Articulated Jib Down - 45-55

Drive (61 m) - 56-46

Drive above Horizontal (15.2 m) - 89-96

120SXJ

Lift Up - 100-85

Lift Down - 100-75

Swing Right & Left - 200-140

Telescope Out - 100-80

Platform Rotate Right & Left - 24-36

Articulated Jib Up - 15-20

Articulated Jib Down - 45-55

Drive (61 m) - 56-46

Drive above Horizontal (15.2 m) - 89-96

Swing Right & Left - 200-140

Telescope Ou t - 9 3 - 7 4

Platform Rotate Right & Left - 20-10

Drive (61 m) - 57-47

Drive above Horizontal (15.2 m) - 89-96

110SX

Lift Up - 100-85

Lift Down - 100-75

Swing Right & Left - 200-140

Telescope Out - 100-80

Platform Rotate Right & Left - 20-10

Drive (61 m) - 57-47

Drive above Horizontal (15.2 m) - 89-96

3121810 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

1.9 CYLINDER SPECIFICATIONS

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

the metric equivalent, centimeters (cm) in parenthe­ses.

Table 1-8.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Lift 9.0

(22.9)

Master Level
(100SX, 110SX)

Master Level
(110SXJ)

Slave Level
(100SX, 110SX)

Slave Level
(110SXJ)

Steer 3

Telescope
(100SX, 110SXJ

Telescope
(110SX)

Axle Extension 2.5

Jib
(110SXJ)

2.5

(6.4)

2.5

(6.4)

2.5

(6.4)

3.5

(8.9)

(7.6)

(12.7)

(12.7)

(6.4)

3.5

(8.9

5

5

43.375
(120.3)

14.5

(36.8)

15.1

(38.4)

13.875
(35.2)

6.94

(17.6)

10.31
(26.2)

247.81

(629.4)

266

(675.6)

28.19
(71.6)

18.31
(46.5)

4.0

(10.2)

1.25
(3.2)

1.25
(3.2)

1.25
(3.2)

1.75
(4.4)

1.5

(3.8)

3.5

(8.9)

3.5

(8.9)

1.25
(3.2)

2.5

(6.4)

1-8 – JLG Lift – 3121810

SECTION 1 - SPECIFICATIONS

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.

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.

Table 1-9.Critical Stability Weights

Component 100SX 110SX 110SXJ 120SXJ

Counterweight
(1.5:1)

Foam-Filled Tires
(each)

Deutz Engine 837 lbs.

36x72 Platform 20 5 lbs.

36x96 Platform 23 8 lbs.

6150 lbs.
(2790 kg)

700 lbs.
(318 kg)

(380 kg)

93 kg

(108 kg)

10,350 lbs.

(4695 kg)

700 lbs.

(318 kg)

837 lbs.

(380 kg)

205 lbs.

93 kg

238 lbs.

(108 kg)

9,850 lbs.
(4468 kg)

700 lbs.

(318 kg)

837 lbs.

(380 kg)

205 lbs.

93 kg

238 lbs.

(108 kg)

9,050 lbs.
(4,105 kg)

932 lbs.
(423 kg)

837 lbs.
(380 kg)

205 lbs.

238 lbs.
(108 kg)

93 kg

Figure 1-2. Serial Number Locations

3121810 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

NM

TORQUE

(as received)

UNPLATED

CAP SCREWS

UNBRAKO 1960 SERIES

WITH LOC-WEL PATCH

SOCKET HEAD CAP SCREW

CLAMP LOAD

)

(LOCTITE

242 OR 271

262)

(LOCTITE

(LUB.)

TORQUE

(KG)

M
N

M
N

M
N

5

4

4

2

2

1

1

6

19

18

1651

1442

21

18

14

12

37

34

2631

2377

41

41

34

30

27

25

68

61

3983

3493

75

68

61

54

48

48

95

102

5384

4822

109

122

95

85

81

75

156

149

7253

6437

163

183

146

130

109

122

224

210

9208

8256

258

224

209

188

176

149

298

285

11612

10251

359

326

277

244

244

231

542

495

16919

15150

631

570

456

408

434

380

861

793

23088

20956

983

895

724

658

678

624

1241

1173

30074

27488

1492

1342

931

1079

922

1003

1871

1681

38828

34610

2136

1898

1566

1396

1302

1464

2549

2373

48671

43954

2983

2712

2183

1970

2034

1844

3308

3145

59648

52391

4068

3559

2586

2935

2766

2413

4433

4122

71669

63731

4712

5322

3856

3430

3200

3607

SAE GRADE 8

SAE GRADE 5

VALUES FOR ZINC PLATED BOLTS ONLY

(DRYOR

SAE GRADE 8 BOLTS & GRADE 8 NUTS

CLAMP

(LOCTITE

(LOCTITE

TORQUE

(DRYOR

SAE GRADE 5 BOLTS & GRADE 2 NUTS

CLAMP

AREA

STRESS

THREAD

DIA.

BOLT

M
N

LOC. 263)

(KG)

LOAD

)

M
N

242 OR 271

M

262)

N

M
N

(LUB.)

M
N

LOC. 263)

(KG)

LOAD

(SQ. CM)

(CM)

2

2

272

245

1

1

1

1

172

191

0.0168

0.0153

0.2845

3

3

417

372

2

2

2

2

263

277

0.0258

0.0232

0.3505

5

5

599

572

3

3

4

4

408

426

0.0374

0.0356

0.4166

8

7

817

717

4

4

6

5

508

583

0.0445

0.0508

0.4826

19

16

1488

1297

12

16

9

10

11

14

916

1052

0.0808

0.0925

0.6350

34

34

2821

2141

29

26

23

22

19

18

26

23

1515

1678

0.1473

0.1331

0.7938

61

68

3583

3175

54

48

43

38

34

31

48

41

2241

2540

0.2230

0.1969

0.9525

95

109

4332

4854

81

75

61

68

68

48

68

75

3425

3085

0.3015

0.2700

1.1112

163

149

6532

5783

115

136

92

108

75

88

102

122

4105

4854

0.4061

0.3604

1.2700

231

204

8278

7539

163

183

133

148

109

122

149

163

5874

5262

0.5156

0.4623

1.4288

326

298

9231

10433

224

258

207

183

149

176

204

231

7394

6532

0.6502

0.5740

1.5875

570

515

15241

13653

387

448

363

325

271

298

407

353

9662

10796

0.9474

0.8484

1.9050

895

814

20775

18870

644

705

576

523

434

475

637

583

14697

13336

1.2929

1.1735

2.2225

1220

1356

27080

23360

915

997

785

858

651

719

868

949

19142

17509

1.6840

1.5392

2.5400

1953

1736

34927

31162

1139

1254

968

1087

814

895

1085

1193

21546

19187

2.1742

1.9380

2.8575

2712

2468

43818

38554

1593

1762

1516

1368

1139

1247

1681

1519

27035

24404

2.7254

2.4613

3.1750

3688

3227

53570

47174

2068

2373

2042

1792

1492

1708

1980

2278

29076

33113

2.9337

3.3401

3.4925

4827

4284

57380

142200

3118

2746

2676

2379

2224

1980

2983

2630

39781

35381

4.0132

3.5687

3.8100

Figure 1-3. Torque Chart

9

8

7

7

6

THD

SIZE

40

18

16

14

13

12

11

48

40

36

32

28

24

24

20

7/16

1/2

20

9/16

32

32

24

20

6

4

8

10

1/4

5/16

3/8

18

5/8

18

10

3/4

16

7/8

14

12

12

1

1-1/8

1-1/4

12

12

1-1/2

6

1-1/2

12

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

1-10 – JLG Lift – 3121810

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION,
AND MAINTENANCE

General

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehen­sive inspection and preventive maintenance program. The
following table outlines the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for fur­ther requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to per­form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera­tor’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per­forming the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent
Inspection

The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recog­nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.

The Pre-Delivery Inspection and Frequent Inspection pro­cedures are performed in the same manner, but at differ­ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser­vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the perfor­mance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance proce­dures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a
Factory-Certified Service Technician on an annual basis,
no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. rec­ognizes a Factory-Certified Service Technician as a per­son who has successfully completed the JLG Service
Training School for the subject JLG product model. Refer­ence the machine Service and Maintenance Manual and
appropriate JLG inspection form for performance of this
inspection.

Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man­ual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, mainte­nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train­ing, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.

Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.

3121810 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative

Maintenance

In service for 3 mo nths or 150 hours, which-

Prior to use each day ; or

At each Operator change .

Prior to each sa le, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as sp ecified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Certified

Owner, Dealer, or User Qualified JLG

The jacks (if equipped) provided for extending and retract­ing the axles are not to be used as a maintenance tool.
When performing maintenance on the machine which
requires lifting, use adequate hydraulic jacks for lifting the
machine, not the axle jacks.

Service

Qualification

Mechanic

Mechanic

Service Technician

Mechanic

Reference

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual

Cleanliness

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.

MAKE SURE THAT PERSONNEL ARE CLEAR OF CHASSIS AT
ALL TIMES WHEN JACKS ARE EXTENDED.

JACKS RETRACT AUTOMATICALLY, LOWERING THE CHASSIS.

THE JACKS ARE TO BE USED FOR EXTENDING AND RETRACT­ING THE AXLES. THEY ARE NOT TO BE USED AS A MAINTE­NANCE TOOL.

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.

2-2 – JLG Lift – 3121810

SECTION 2 - GENERAL

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.

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.

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
Torque Chart Section 1.)

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.

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.

3121810 – JLG Lift – 2-3

SECTION 2 - GENERAL

2.3 LUBRICATION AND 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 the Lubrication Chart 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.

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 Section 1 for recommendations for viscosity
ranges.

3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 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
13 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.

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.

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 Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

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).

2-4 – JLG Lift – 3121810

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured
using the following methods.

Platform Drift

Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, upper boom fully
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
If the machine does not pass this test, proceed with the
following.

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temper­ature and temperature stabilized.

The cylinder must have the normal load, which is the nor­mal platform load applied.

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING
REPAIR GUIDELINES

Filament wound bearings.

1. Pinned joints should be disassembled and
inspected if the following occurs:

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any
of the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):

a. Detectable wear in the bearing area.

b. Flaking, pealing, scoring, or scratches on the pin

surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound
bearings.

a. Housing should be blown out to remove all dirt

and debris...bearings and bearing housings
must be free of all contamination.

b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubri­cated.

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would dam­age the bearing during installation and opera­tion.

3121810 – JLG Lift – 2-5

SECTION 2 - GENERAL

AREA

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

Boom Assembly

Boom Weldmen ts 1,2,4 1,2,4

Hose/Cable Carrie r Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retai ners 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

Extend/Retract Chain o r Cable Systems 1,2,3 1,2,3

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5

Lanyard Anchorage Point 2 1,2,10 1,2,10

Turntable Assembly

Swing Bearing or Worm Gea r 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System

Turntable Lock 1,2,5 1,2,5

Hood, Hood Props, Hood L atches 5 1,2,5

Chassis Assembly

Tires 1 16,17 16,17,18 16,17,18

Wheel Nuts/Bolts 115 1515

Wheel Bearings 14,24

Oscillating Axle/L ockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

To r qu e H ub s 11 11

Functions/Controls

Platform Cont rols 55 66

Ground Controls 55 66

9

9

9

9

9

2-6 – JLG Lift – 3121810

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Function Control Locks, Guards, or Detents 1,5 1,5 5 5

Footswitch 1,5 5 5

Emergency Stop Swit ches (Ground & Platform) 555

Function Limit or C utout Switch Systems 55

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/ Sequencing Systems 5

Manual Descent or Aux iliary Power 55

Power System

9

Engine Idle, Throttl e, and RPM 33

Engine Fluids (Oil, Cool ant, Fuel) 11 9,11 11 11

Air/Fuel Filter 1,7 7 7

Exhaust Syste m 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5

Hydraulic/Electric System

9

Hydraulic Pumps 1,9 1,2,9

Hydraulic Cyli nders 1,9,7 2 1,2,9 1,2,9

Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2

Hydraulic Hoses, Li nes, and Fittings 1,9 12 1,2,9,12 1,2,9,12

Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

Instruments, Gauges, S witches, Lights, Horn 15,23

General

Operators and Safety Manuals in Stora ge Box 21 21 21

ANSI and EMI Manuals/Handbooks Install ed 21

Capacity Decals Ins talled, Secure, Legible 21 21 21

All Decals/Placards Installed, Secure, Legible 21 21 21

Walk-Around Inspection Perform ed 21

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

3121810 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Annual Machine Inspecti on Due 21

No Unauthorized Modificatio ns or Additions 21 21

All Relevant Safety Publ ications Incorporated 21 21

General Structural C ondition and Welds 2,4 2,4

All Fasteners, Pins , Shields, and Covers 1,2 1,2

Grease and Lubricate to Specificat ions 22 22

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownershi p 22

Footnotes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

In service for 3 m onths or 150 Hours; or Out of service for 3 months or more; or Purchased use d

4

Annually, no later than 13 months from the date of the prior inspection

Performance Codes:
1 - Check for pro per and secure installation
2 - Visual inspection for d amage, cracks, distortion or exces sive wear
3 - Check for proper adjustment
4 - Check for crack ed or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of de bris
8 - Interlocks funct ion properly
9 - Check for signs of leakage
10 - Decals inst alled and legible
11 - Check for proper fluid level
12 - Check for cha fing and proper routing
13 - Check for proper tolerances
14 - Properly lubri cated
15 - Torqued to proper spec ification
16 - No gouges, excess ive wear, or cords showing
17 - Properly inflate d and seated around rim
18 - Proper and authoriz ed components
19 - Fully charged
20 - No loose connecti ons, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Ref ill

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

2-8 – JLG Lift – 3121810

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 SWING BEARING

Turntable Bearing Mounting Bolt Condition
Check

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts rech eck all existing bolts for
looseness.

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full
elevation).

2. At the positions indicated on Figure 3-1., Swing
Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and
hardened washer at the arrow indicated position.

3. Assure that the 0.0015" feeler gauge will not pene­trate under the bolt head to the bolt shank.

4. Swing the turntable 90 degrees, and check some
selected bolts at the new position.

5. Continue rotating the turntable at 90 degrees inter­vals until a sampling of bolts have been checked in
all quadrants.

Check the turntable to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full
elevation).

2. At the positions indicated on Figure 3-1., Swing
Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and
hardened washer at the arrow indicated position.

3. Lower the boom to horizontal and fully extend the
boom.

4. At the position indicated on Figure 3-1., Swing Bear­ing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and
hardened washer at the arrow indicated position.

.0015" Feeler Gauge

Figure 3-1. Swing Bearing Bolt Feeler Gauge Check

Bearing Wear Tolerance

1. From the underside of the machine, at rear center,
with the boom fully elevated and fully retracted (Fig­ure 3-2., Swing Bearing Tolerance Boom Place­ment), measure and record the distance between
the swing bearing and the frame using a magnetic
base dial indicator. (Figure 3-2., Swing Bearing Tol­erance Boom Placement)

2. At the same point, with the boom at horizontal and
extended until red marking band on mid section is
exposed, measure and record the distance between
the swing bearing and frame using a magnetic base
dial indicator. (Figure 3-2., Swing Bearing Tolerance
Boom Placement)

3. If a difference greater than 1.625 mm (0.064 in.) is
determined, the swing bearing should be replaced.

4. If a difference less than 1.625 mm (0.064 in.) is
determined, and any of the following conditions
exist, the bearing should be removed, disassem­bled, and inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

c. Noise.

d. Rough rotation.

3121810 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

MEASURING POINT

FORWARD

MEASURING POINT

a. BOOM FULLY ELEVATED

AND FULLY RETRACTED

Figure 3-2. Swing Bearing Tolerance Boom Placement

b. BOOM AT HORIZONTAL

AND FULLY EXTENDED

TURNTABLE REF.

SWING BEARING

FRAME REF.

MEASURING POINT

Figure 3-3. Swing Bearing Tolerance Measuring Point

3-2 – JLG Lift – 3121810