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 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 VIOLA-

TION.

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/OPERATOR.

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 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.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure

•KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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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

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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

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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

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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

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SUBJECT - SECTION, PARAGRAPH

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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

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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

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TABLE OF CONTENTS (Continued)

LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

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

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Mobil EAL Envirosyn H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-4 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

1-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-7 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

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

1-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

4-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-2 Boom Marking Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

5-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

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SECTION 1. SPECIFICATIONS

1.1CAPACITIES

Engine Crankcase

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

Fuel Tank

150 liters (40 gallons)

Hydraulic Tank

189 liters (50 gallons)

1.2COMPONENT 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)

High RPM - 14.2 lph (3.8 gph)

Horsepower - 70 @ 2400 RPM, no load

Torque Hub

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

1.3PERFORMANCE 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

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.)

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Wheelbase		Jib Range of Articulation
3.05 m (10 ft.)		3.35 m (11 ft.) 95 degrees (+15, -80)
Ground Clearance		Overall Width - Axles Retracted
32 cm (12.5 in.)		2.49 m (8 ft. 2 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/cm2 (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.)

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.)

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

1.4PERFORMANCE DATA - 120SXJ

Platform Height

36.58 m (120 ft.)

Horizontal Outreach

16.7 m (55 ft.)

Swing

360° Continuous

Platform Capacity

230 kg (500 lbs.)

Platform Rotator

180° Hydraulic

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)

Drive Speed

4.8 km/h (3 mph)

Gradeability

40%

Turning Radius (Inside)

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

Turning Radius (Outside)

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

Tire Size/Type

445/65R22.5 Foam Filled

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1.5TORQUE REQUIREMENTS

Table 1-1.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	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 fastener has loosened, refer to the Torque Chart to determine proper torque value.

1.6 LUBRICATION

Deutz F4L912 Engine

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

	When Outside Temp is Consistently	Use SAE Viscosity
		Number
	-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	Use SAE Viscosity
		Number
	-40° to +75° F(-40° to +24° C)	*5W-20
		(Synthetic)
	-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

Table 1-2.Hydraulic Oil

Hydraulic System Operating	SAE Viscosity
Temperature Range	Grade
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.

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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		-44°F (-44°C)
Flash Point, Min.		500°F (260°C)
Weight		7.64 lb. per gal.
		(0.9 kg per liter)
	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		-25°F (-32°C)
Flash Point, Min.		428°F (220°C)
Weight		7.64 lb. per gal.
		(0.9 kg per liter)
	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)

Table 1-5. Mobil DTE 13M Specs

Type		Petroleum Base
ISO Viscosity Grade		32
Specific Gravity		.877
Pour Point, Max		-40°F (-40°C)
Flash Point, Min.		330°F (166°C)
	Viscosity
at 104° F (40° C)		33 cSt
at 212° F (100° C)		6.5 cSt
Viscosity Index		140

Lubrication Specifications

	Table 1-6.Lubrication Specifications
KEY	SPECIFICATIONS
MPG	Multipurpose Grease having a minimum dripping point of 350
	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) meeting 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 procedures.

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Figure 1-1. Lubrication Point Location

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SECTION 1 - SPECIFICATIONS

Table 1-7. Lubrication Chart

	Components	Number/Type	Lube & Method		Interval	Comments
		Lube Points			Hours
1	Master Cylinder - Barrel End	1 Grease Fitting	MPG - Pressure Gun		150	Remote Access
2	Master Cylinder - Rod End	1 Grease Fitting	MPG - Pressure Gun		150
3	Boom Pivot Bushings	2 Grease Fittings	MPG - Pressure Gun		150
4	Lift Cylinder - Rod End	1 Grease Fitting	MPG - Pressure Gun		150
5	Lift Cylinder - Barrel End	1 Grease Fitting	MPG - Pressure Gun		150	Remote Access
6	Slave Cylinder - Rod End	1 Grease Fitting	MPG - Pressure Gun		150
7	Slave Cylinder - Barrel End	2 Grease Fitting	MPG - Pressure Gun		150
8	Jib Cylinder - Rod End	1 Grease Fitting	MPGPressure Gun		150
9	Jib Cylinder - Attach Pin	2 Grease Fittings	MPG - Pressure Gun		150
10	Drive Hubs	Fill Plug	EPGL - SAE90		150/1200	Check every 150 hrs. /Change every 1200 hrs.
11	Swing Bearing Gear	N/A	MPG - Brush		150
12	Swing Bearing	1 Grease Fitting	MPG - Pressure Gun		150
13	Steer Spindles	2 Grease Fittings	MPG - Pressure Gun		150
14	Extending Axle Beams	N/A	MPG - Brush		600	As needed
15	Engine Crankcase	Fill Cap	EO-SAE30		10/300	Check daily/Change every 1000 hrs. or one
						year, whichever comes first. Adjust final level
						by mark on dipstick.
16	Engine Oil Filter	N/A	Replaceable Cartridge		300
17	Hydraulic Fluid	Fill Cap	HO		10/1200	Check daily/Change every 1200 hrs.
18	Hyd. Filter Element (Tank)	N/A	N/A		50/300	Replace filter after first 50 hrs. of operation,
						then every 300 hrs. thereafter
19	Hyd. Filter Element (Inline)	N/A	N/A		50/300	Replace filter after first 50 hrs. of operation,
						then every 300 hrs. thereafter
20	Telescope Cylinder Sheave	1 Grease Fitting	MPG - Pressure Gun		150
21	Extend Chain Sheave	1 Grease Fitting	MPG - Pressure Gun		150
22	Retract Chain Sheave	1 Grease Fitting	MPG - Pressure Gun		150
23	Boom Chains	N/A	Chain Lube/Hot Oil Dip		1200	Includes extend and retract chains
24	Turntable Pivot Pin	2 Grease Fittings	MPG - Pressure Gun		150
25	Jib Link Attach Pin	1 Grease Fitting	MPG - Pressure Gun		150
26	Jib Pivot Pin	2 Grease Fittings	MPG - Pressure Gun		150
NOTES:				Key to Lubricants:
				EO		Engine Oil
				EPGL		Extreme Pressure Gear Lube
				HO		Hydraulic Fluid (Mobil #424 or equivalent)
				MPG t		Multi-Purpose Grease

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1.7PRESSURE 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.

1.8FUNCTION SPEEDS (IN SECONDS)

100SX

Lift Up - 100-85

Lift Down - 100-75

Swing Right & Left - 200-140

Telescope Out - 93-74

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

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

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1.9CYLINDER 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	43.375	4.0
	(22.9)	(120.3)	(10.2)
Master Level	2.5	14.5	1.25
(100SX, 110SX)	(6.4)	(36.8)	(3.2)
Master Level	2.5	15.1	1.25
(110SXJ)	(6.4)	(38.4)	(3.2)
Slave Level	2.5	13.875	1.25
(100SX, 110SX)	(6.4)	(35.2)	(3.2)
Slave Level	3.5	6.94	1.75
(110SXJ)	(8.9)	(17.6)	(4.4)
Steer	3	10.31	1.5
	(7.6)	(26.2)	(3.8)
Telescope	5	247.81	3.5
(100SX, 110SXJ	(12.7)	(629.4)	(8.9)
Telescope	5	266	3.5
(110SX)	(12.7)	(675.6)	(8.9)
Axle Extension	2.5	28.19	1.25
	(6.4)	(71.6)	(3.2)
Jib	3.5	18.31	2.5
(110SXJ)	(8.9	(46.5)	(6.4)

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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 DIF-

FERENT 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			6150 lbs.		10,350 lbs.	9,850 lbs.	9,050 lbs.
(1.5:1)			(2790 kg)		(4695 kg)	(4468 kg)	(4,105 kg)
Foam-Filled Tires			700 lbs.		700 lbs.	700 lbs.	932 lbs.
(each)			(318 kg)		(318 kg)	(318 kg)	(423 kg)
Deutz Engine			837 lbs.		837 lbs.	837 lbs.	837 lbs.
			(380 kg)		(380 kg)	(380 kg)	(380 kg)
36x72 Platform			205 lbs.		205 lbs.	205 lbs.	205 lbs.
			93 kg		93 kg	93 kg	93 kg
36x96 Platform			238 lbs.		238 lbs.	238 lbs.	238 lbs.
			(108 kg)		(108 kg)	(108 kg)	(108 kg)

Figure 1-2. Serial Number Locations

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1-9

SECTION 1 - SPECIFICATIONS

UNPLATED CAP SCREWS

VALUES FOR ZINC PLATED BOLTS ONLY

UNBRAKO1960SERIES SOCKETHEADCAPSCREW	WITHLOC-WELPATCH	TORQUE	(asreceived)	NM
		CLAMPLOAD (KG)
8NUTS	TORQUE	(LOCTITE	)242OR271	NM
BOLTS8&GRADE		ORY(DR	263).LOC	MNMN NM
		(LOCTITE	262)
		(LUB.)
SAEGRADE
	CLAMP	LOAD (KG)
2NUTS	TORQUE	(LOCTITE	)242OR271	NM
BOLTS5&GRADE		ORY(DR	263).LOC	MNMN NM
		(LOCTITE	262)
		(LUB.)
SAEGRADE
	CLAMP	LOAD (KG)
THREAD	STRESS AREA		(SQ.CM)
BOLT DIA. (CM)
	THD
	SIZE

1 1
2 2
245	272

1 1
1 1
172	191
0.0153	0.0168
0.2845
40	48
4

2 2 4 4
3 3 5 5
372	417	572	599

2	2 3			3
2	2 4			4
263	277	408		426
0.0232	0.0258	0.0356		0.0374
0.3505		0.4166
32	40	32		36
6		8

5 6
7 8
717	817

4 4
5 6
508		583
0.0445		0.0508
0.4826
24		32
10

18	19
1442	1651
18	21

12	14
16	19
1297	1488
12	16

9		10
11		14
916		1052
0.0808		0.0925
0.6350
20		28
1/4

34	37	61	68	95	102	149	156	210	224
2377	2631	3493	3983	4822	5384	6437	7253	8256	9208
41	41	68	75	109	122	163	183	224	258
30	34	54	61	85	95	130	146	188	209
25	27	48	48	75	81	109	122	149	176
34	34	61	68	95	109	149	163	204	231
2141	2821	3175	3583	4332	4854	5783	6532	7539	8278
26	29	48	54	75	81	115	136	163	183
22	23	38	43	61	68	92	108	133	148
18	19	31	34	48	68	75	88	109	122
23	26	41	48	68	75	102	122	149	163
1515	1678	2241	2540	3085	3425	4105	4854	5262	5874
0.1331	0.1473	0.1969	0.2230	0.2700	0.3015	0.3604	0.4061	0.4623	0.5156
0.7938		0.9525		1.1112		1.2700		1.4288
18	24	16	24	14	20	13	20	12	18
5/16		3/8		7/16		1/2		9/16

285	298
10251	11612
326	359
244	277
231	244
298	326
9231	10433
224	258
183	207
149	176
204	231
6532	7394
0.5740	0.6502
1.5875
11	18
5/8

495	542	793	861
15150	16919	20956	23088
570	631	895	983
408	456	658	724
380	434	624	678
515	570	814	895
13653	15241	18870	20775
387	448	644	705
325	363	523	576
271	298	434	475
353	407	583	637
9662	10796	13336	14697
0.8484	0.9474	1.1735	1.2929
1.9050		2.2225
10	16	9	14
3/4		7/8

1173	1241
27488	30074
1342	1492
931	1079
922	1003
1220	1356
23360	27080
915	997
785	858
651	719
868	949
17509	19142
1.5392	1.6840
2.5400
8
	12
1

1681	1871	2373	2549	3145	3308	4122	4433
34610	38828	43954	48671	52391	59648	63731	71669
1898	2136	2712	2983	3559	4068	4712	5322
1396	1566	1970	2183	2586	2935	3430	3856
1302	1464	1844	2034	2413	2766	3200	3607
1736	1953	2468	2712	3227	3688	4284	4827
31162	34927	38554	43818	47174	53570	57380	142200
1139	1254	1593	1762	2068	2373	2746	3118
968	1087	1368	1516	1792	2042	2379	2676
814	895	1139	1247	1492	1708	1980	2224
1085	1193	1519	1681	1980	2278	2630	2983
19187	21546	24404	27035	29076	33113	35381	39781
1.9380	2.1742	2.4613	2.7254	2.9337	3.3401	3.5687	4.0132
2.8575		3.1750		3.4925		3.8100
7	12	7	12	6	12	6	12
1-1/8		1-1/4		1-1/2		1-1/2

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

SAE GRADE 5 SAE GRADE 8

Figure 1-3. Torque Chart

1-10

– JLG Lift –

3121810

SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1MACHINE 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.

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2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start Inspec-	Prior to use each day; or	User or Operator	User or Operator	Operator and Safety Manual
	tion	At each Operator change.
	Pre-Delivery	Prior to each sale, lease, or	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	Inspection	rental delivery.		Mechanic	Manual and applicable JLG
					inspection form.
	Frequent Inspec-	In service for 3 months or 150 hours, which-	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	tion	ever comes first; or		Mechanic	Manual and applicable JLG
		Out of service for a period of more than 3			inspection form.
		months; or
		Purchased used.
	Annual Machine	Annually, no later than 13 months from the	Owner, Dealer, or User	Factory-Certified	Service and Maintenance
	Inspection	date of the prior inspection.		Service Technician	Manual and applicable JLG
					inspection form.
	Preventative	At intervals as specified in the Service and	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	Maintenance	Maintenance Manual.		Mechanic	Manual

2.2SERVICE 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.

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 MAINTE-

NANCE TOOL.

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.

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.

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.

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 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.

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.

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 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.

2-4

– JLG Lift –

3121810

SECTION 2 - GENERAL

2.4CYLINDER 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	Max. Acceptable Drift
		in 10 Minutes

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 cylinder leakage.

2.5PINS 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 housing.

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

Table 2-3. Inspection and Preventive Maintenance Schedule

				INTERVAL
	AREA	Pre-Start1	Weekly	Monthly	Pre-Delivery2	Annual4	Every 2
			Preventive	Preventive	or Frequent3	(Yearly)
		Inspection					Years
			Maintenance	Maintenance	Inspection	Inspection
	Boom Assembly	9
	Boom Weldments				1,2,4	1,2,4
	Hose/Cable Carrier Installations				1,2,9,12	1,2,9,12
	Pivot Pins and Pin Retainers				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 or Cable Systems				1,2,3	1,2,3
	Platform Assembly	9
	Platform	1,2				1,2
	Railing	1,2			1	1,2
	Gate			5	1	1,5
	Floor	1,2			1	1,2
	Rotator		9,5
	Lanyard Anchorage Point	2			1,2,10	1,2,10
	Turntable Assembly	9
	Swing Bearing or Worm Gear				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 Latches				5	1,2,5
	Chassis Assembly	9
	Tires	1	16,17		16,17,18	16,17,18
	Wheel Nuts/Bolts	1	15		15	15
	Wheel Bearings						14,24
	Oscillating Axle/Lockout Cylinder Systems					5,8
	Outrigger or Extendable Axle Systems				5,8	5,8
	Steer Components
	Drive Motors
	Torque Hubs				11	11
	Functions/Controls	9
	Platform Controls	5	5		6	6
	Ground Controls	5	5		6	6

2-6

– JLG Lift –

3121810

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

				INTERVAL
	AREA	Pre-Start1	Weekly	Monthly	Pre-Delivery2	Annual4	Every 2
			Preventive	Preventive	or Frequent3	(Yearly)
		Inspection					Years
			Maintenance	Maintenance	Inspection	Inspection
	Function Control Locks, Guards, or Detents	1,5	1,5		5	5
	Footswitch	1,5			5	5
	Emergency Stop Switches (Ground & Platform)	5			5	5
	Function Limit or Cutout Switch Systems				5	5
	Capacity Indicator					5
	Drive Brakes				5
	Swing Brakes				5
	Boom Synchronization/Sequencing Systems					5
	Manual Descent or Auxiliary Power				5	5
	Power System	9
	Engine Idle, Throttle, and RPM				3	3
	Engine Fluids (Oil, Coolant, Fuel)	11	9,11		11	11
	Air/Fuel Filter		1,7		7	7
	Exhaust System			1,9	9	9
	Batteries	5	1,9			19
	Battery Fluid		11		11	11
	Battery Charger		5			5
	Fuel Reservoir, Cap, and Breather	11,9		2	1,5	1,5
	Hydraulic/Electric System	9
	Hydraulic Pumps		1,9		1,2,9
	Hydraulic Cylinders		1,9,7	2	1,2,9	1,2,9
	Cylinder Attachment Pins and Pin Retainers		1,9		1,2	1,2
	Hydraulic Hoses, Lines, 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		1		20	20
	Instruments, Gauges, Switches, Lights, Horn		1			5,23
	General
	Operators and Safety Manuals in Storage Box	21			21	21
	ANSI and EMI Manuals/Handbooks Installed					21
	Capacity Decals Installed, Secure, Legible	21			21	21
	All Decals/Placards Installed, Secure, Legible	21			21	21
	Walk-Around Inspection Performed	21

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– JLG Lift –

2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

				INTERVAL
	AREA	Pre-Start1	Weekly	Monthly	Pre-Delivery2	Annual4	Every 2
			Preventive	Preventive	or Frequent3	(Yearly)
		Inspection					Years
			Maintenance	Maintenance	Inspection	Inspection
	Annual Machine Inspection Due				21
	No Unauthorized Modifications or Additions				21	21
	All Relevant Safety Publications Incorporated				21	21
	General Structural Condition and Welds				2,4	2,4
	All Fasteners, Pins, Shields, and Covers				1,2	1,2
	Grease and Lubricate to Specifications				22	22
	Function Test of All Systems	21			21	21, 22
	Paint and Appearance				7	7
	Stamp Inspection Date on Frame					22
	Notify JLG of Machine Ownership					22

Footnotes:

1Prior to use each day; or at each Operator change

2Prior to each sale, lease, or delivery

3In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used

4Annually, no later than 13 months from the date of the prior inspection

Performance Codes:

1 - Check for proper and secure installation

2 - Visual inspection for damage, cracks, distortion or excessive wear 3 - Check for proper adjustment

4 - Check for cracked or broken welds

5 - Operates Properly

6 - Returns to neutral or "off" position when released 7 - Clean and free of debris

8 - Interlocks function properly

9 - Check for signs of leakage

10 - Decals installed and legible

11 - Check for proper fluid level

12 - Check for chafing and proper routing

13 - Check for proper tolerances

14 - Properly lubricated

15 - Torqued to proper specification

16 - No gouges, excessive wear, or cords showing

17 - Properly inflated and seated around rim

18 - Proper and authorized components

19 - Fully charged

20 - No loose connections, corrosion, or abrasions

21 - Verify

22 - Perform

23 - Sealed Properly

24 - Drain, Clean, Refill

2-8

– JLG Lift –

3121810

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1SWING BEARING

Turntable Bearing Mounting Bolt Condition

Check

NOTE: This check is designed to replace the existing bearing 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 recheck 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

FORWARD

MEASURING POINT
	MEASURING POINT
a. BOOM FULLY ELEVATED	b. BOOM AT HORIZONTAL
AND FULLY RETRACTED	AND FULLY EXTENDED

Figure 3-2. Swing Bearing Tolerance Boom Placement

TURNTABLE REF.

SWING BEARING

FRAME REF.

MEASURING POINT

Figure 3-3. Swing Bearing Tolerance Measuring Point

3-2

– JLG Lift –

3121810