Jlg 120-SXJ Service Manual Bedienungsanleitung

Service and Maintenance ManualModels100SX110SX110SXJ120SXJP/N - 3121810July 29, 2004

vi – JLG Lift – 3121810TABLE OF CONTENTS (Continued) LIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Torque Requirements . . . . . . . . . . . . . . .

SECTION 6 - SCHEMATICS6-18 – JLG Lift – 3121810Figure 6-17. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 3 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-19Figure 6-18. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 4 of 62792406 B

SECTION 6 - SCHEMATICS6-20 – JLG Lift – 3121810Figure 6-19. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 5 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-21Figure 6-20. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 6 of 62792406 B

SECTION 6 - SCHEMATICS6-22 – JLG Lift – 3121810Figure 6-21. 120SXJ Hydraulic Schematic - Sheet 1 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-23Figure 6-22. 120SXJ Hydraulic Schematic - Sheet 2 of 62792407 B

SECTION 6 - SCHEMATICS6-24 – JLG Lift – 3121810Figure 6-23. 120SXJ Hydraulic Schematic - Sheet 3 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-25Figure 6-24. 120SXJ Hydraulic Schematic - Sheet 4 of 62792407 B

SECTION 6 - SCHEMATICS6-26 – JLG Lift – 3121810Figure 6-25. 120SXJ Hydraulic Schematic - Sheet 5 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-27Figure 6-26. 120SXJ Hydraulic Schematic - Sheet 6 of 62792407 B

SECTION 1 - SPECIFICATIONS3121810 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESEngine CrankcaseDeutz F4L912 w/Filter - 12.5 liters (13.2 qu

SECTION 6 - SCHEMATICS6-28 – JLG Lift – 3121810This page left blank intentionally.

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Ind

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121810Wheelbase3.05 m (10 ft.)Ground Clearance32 cm (12.5 in.)Gross Weight100SX - 17,136 kg (37,700 lbs.)1

SECTION 1 - SPECIFICATIONS3121810 – JLG Lift – 1-31.5 TORQUE REQUIREMENTSNOTE: See Procedure Section for tightening sequence ofturntable bearing bolts

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121810Lubrication SpecificationsRefer to Lubrication Chart for specific lubrication proce-dures.Table 1-3.

SECTION 1 - SPECIFICATIONS3121810 – JLG Lift – 1-5Figure 1-1. Lubrication Point Location

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3121810Table 1-7. Lubrication Chart ComponentsNumber/TypeLube PointsLube & MethodIntervalHoursComments1

SECTION 1 - SPECIFICATIONS3121810 – JLG Lift – 1-71.7 PRESSURE SETTINGSMain ValveMain - 238 bar (3450 psi)Lift Down - 103 bar (1500 psi)Jib (Up) - 207

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31218101.9 CYLINDER SPECIFICATIONSNOTE: All cylinder dimensions are given in inches (in), withthe metric eq

SECTION 1 - SPECIFICATIONS3121810 – JLG Lift – 1-91.10 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the left

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121810SIZE412126677891212121416181820202424202432324010111213141618283236404861-1/21-1/23.81003.49254.013

SECTION 2 - GENERAL3121810 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31218102.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121810 – JLG Lift – 2-3Components Removal and Installation1. Use adjustable lifting devices, whenever possible, ifmechanical assis

SECTION 2 - GENERAL2-4 – JLG Lift – 31218102.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121810 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

SECTION 2 - GENERAL2-6 – JLG Lift – 3121810Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3121810 – JLG Lift – 2-7Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop Switches (Ground &am

SECTION 2 - GENERAL2-8 – JLG Lift – 3121810Annual Machine Inspection Due 21No Unauthorized Modifications or Additions 21 21All Relevant Safety Publica

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 SWING BEARINGTurntable Bearing Mounting Bolt Conditi

INTRODUCTION3121810 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3121810MEASURING POINTMEASURING POINTFORWARDa. BOOM FULLY ELEVATEDAND FULLY RETRACTEDb. BOOM AT HO

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-35. If bearing inspection shows no defects, reassemblebearing and return to service.THE SWIN

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121810g. Carefully lower the turntable onto the swingbearing, ensuring that the turntable and bea

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-5Swing Bearing Torque Values1. Outer Race - 325 Nm (240 ft.lbs.) Loctite, 230 Nm(170 ft.lbs.

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121810Figure 3-5. Swing Torque Hub

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-75. Inspect o-ring grooves in hub (24) and cover (1) forburrs or sharp edges. Dress applicab

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121810i. Align roll pin holes in both shaft (15) and carrier(10) with chamfered portion of shaft

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-91. Capscrew2. End Cover3. Bleeder Screw4. Case Seal5. O-ring6. Back-Up Ring7. Piston8. O-ri

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31218103. Remove piston (7) from end cover (2).4. Remove o-ring (5), back-up ring (6), o-ring (8)

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-113.4 TILT ALARM SWITCH LEVELINGNOTE: Each machine is equipped with a tilt alarm switch,fact

INTRODUCTIONA-2 – JLG Lift – 3121810REVISON LOGOriginal Issue - June 16, 2000Revised - July 26, 2000Revised - January 21, 2002Revised - June 11, 2002R

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121810flange nuts have been tightened too far. Loosen the“X” nut and repeat steps 3 through 7.Vo

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-13This circuit card operates as follows:A calibrated dc voltage representing the boom angle

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121810Immediately beyond this point of balance the turntable ispermitted to pivot a maximum vert

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-153.6 LOAD MANAGEMENT SYSTEM ADJUSTMENT1. With boom retracted, limit switch and proximityswi

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121810Current Regulated OutputThis controller output is also current regulated. This con-troller

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-17Telescope, Level, Rotate, & Jib1. Connect Amp Meter inline between the function cardpl

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121810Dual RangeThis Rotary Selector Controller is capable of providingtwo, independently adjust

SECTION 3 - CHASSIS & TURNTABLE3121810 – JLG Lift – 3-19ACTUATOR CABLEADECO ACTUATORLOW ENGINEHIGH ENGINE LIMIT SWITCHSLIDE PIN (2)SLIDE PIN (1)LI

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121810This page left blank intentionally.

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval1. Shut down machine systems.NOTE: Bo

3121810 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 312181017145121616166Figure 4-1. Boom Assembly - Sheet 1 of 2

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-371818432189151510111. Boom Base2. Inner Mid Boom3. Outer Mid Boom4. Fly Boom5. Telescope Cylind

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121810NOTE: Note and record the number and thickness of anywear pad shims during wear pad removal.13.

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-538. Remove bolts and lockwashers which attach topwear pad at front of inner mid section and rem

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121810AssemblyNOTE: When installing fly section wear pads, install samenumber and thickness of shims

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-721. Install sheave pins and if necessary, tap pins intoplace using a soft headed mallet. Secure

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31218105. Using all applicable safety precautions, operate lift-ing equipment in order to position boo

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-9Inspection ProcedureBOOM CHAINS TO BE INSPECTED AT TIME OF NEXT BOOMOVERHAUL AND WHEN DEEMED NE

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121810Figure 4-4. Boom Chain Adjustments

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-11d. Fatigue Cracks: Fatigue is a phenomenon thataffects most metals, and is the most commoncaus

ii – JLG Lift – 3121810TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.Turning Radius (Outside)

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121810h. Chain Anchors and Sheaves: An inspection ofthe chain must include a close examination ofcha

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-134.3 WEAR PADSShim up wear pads to within 1.6 mm (1/16 in.) tolerancebetween wear pad and adjac

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31218104.5 BOOM MARKING TAPE INSTALLATIONBoom marking tape installation for Models 100SX, 110SXand 11

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-15Table 4-2.Boom Marking Tape Installationw/o Boom WipersModel Dim. A Dim. B Dim.C100SX Single C

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31218104.6 BOOM LOAD RADIUS SETUP PROCEDURES - 100SXNOTE: The boom length and angle sensor adjustment

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-175. Telescope the boom until the leading edge of the redmarking tape is exposed from the mid bo

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3121810Boom Angle Sensor Adjustment1. With the platform level, the boom fully retracted andat 45 (+/-

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-194.8 BOOM LOAD RADIUS SETUP PROCEDURES - 110SXNOTE: The boom length and angle sensor adjustment

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121810(critical length) where the lift down speed limiter isturned on.4.9 BOOM LOAD RADIUS SETUP PRO

SECTION 4 - BOOM & PLATFORM3121810 – JLG Lift – 4-21Boom Angle Sensor Adjustment1. With the platform level, the boom fully retracted andat 45 (+/-

3121810 – JLG Lift – iii TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.Bearing Replacement . . . .

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121810This page left blank intentionally.

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDERS - THEORY OF OPERATION1. Cylinders are of the double acting type. Sys

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121810port is leaking, the counterbalance valve is defectiveand must be replaced.5. If no repairs are necessar

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-315. Remove the three (3) bolts, washers and lockwash-ers attaching the chain adjust bracket to the aft e

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121810Lift Cylinder Removal1. Place the machine on a flat and level surface. Startthe engine and place the boo

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-55.4 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 312181010. Remove the piston rings.11. Remove and discard the piston o-rings, seal rings,and backup rings.12. R

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-73. Carefully slide the piston spacer on the rod. If appli-cable, align the oil holes in the rod and the

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3121810IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ONTHE MACHINE, EXTREME CARE SHOULD BE USED TO INSU

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-9* Adjustable on SXJ Models Only1. Ma in P ress ur e Adj us tmen t2. Swing Flow Control 3.

iv – JLG Lift – 3121810TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.4.8 BOOM LOAD RADIUS SETU

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31218102. Lift Down Relief.a. Monitor pressure gauge at quick-connect (Gport) on main valve.b. Bottom out Lift

SECTION 5 - HYDRAULICS3121810 – JLG Lift – 5-11a. Steer Select Switch should be in crab or com-pound steer.b. Operate steer switch right or left to se

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121810This page left blank intentionally.

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-1SECTION 6. SCHEMATICS6.1 GENERALThis section contains troubleshooting information to beused for locatin

SECTION 6 - SCHEMATICS6-2 – JLG Lift – 3121810Figure 6-1. Electrical Components Installation - Sheet 1

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-3Figure 6-2. Electrical Components Installation - Sheet 2

SECTION 6 - SCHEMATICS6-4 – JLG Lift – 3121810.Figure 6-3. 100SX, 110SX Electrical Schematic - Platform - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-5Figure 6-4. 100SX, 110SX Electrical Schematic - Platform - Sheet 2 of 21870125 C

SECTION 6 - SCHEMATICS6-6 – JLG Lift – 3121810Figure 6-5. 100SX, 110SX Electrical Schematic - Boom, Turntable, Chassis - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-7Figure 6-6. 100SX, 110SX Electrical Schematic - Boom, Turntable, Chassis - Sheet 2 of 21870125 C

3121810 – JLG Lift – v TABLE OF CONTENTSLIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Lubrication Point Location . . . . . . . . . . . .

SECTION 6 - SCHEMATICS6-8 – JLG Lift – 3121810Figure 6-7. 110SXJ Electrical Schematic - Platform - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-9Figure 6-8. 110SXJ Electrical Schematic - Platform - Sheet 2 of 21870124 C

SECTION 6 - SCHEMATICS6-10 – JLG Lift – 3121810Figure 6-9. 110SXJ Electrical Schematic - Boom, Turntable, Chassis - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-11Figure 6-10. 110SXJ Electrical Schematic - Boom, Turntable, Chassis - Sheet 2 of 21870124 C

SECTION 6 - SCHEMATICS6-12 – JLG Lift – 3121810Figure 6-11. 120SXJ Electrical Schematic - Platform - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-13Figure 6-12. 120SXJ Electrical Schematic - Platform - Sheet 2 of 21870123 C

SECTION 6 - SCHEMATICS6-14 – JLG Lift – 3121810Figure 6-13. 120SXJ Electrical Schematic - Boom, Turntable, Chassis - Sheet 1 of 2

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-15Figure 6-14. 120SXJ Electrical Schematic - Boom, Turntable, Chassis - Sheet 2 of 21870123 C

SECTION 6 - SCHEMATICS6-16 – JLG Lift – 3121810Figure 6-15. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 1 of 6

SECTION 6 - SCHEMATICS3121810 – JLG Lift – 6-17Figure 6-16. 100SX, 110SX, 110SXJ Hydraulic Schematic - Sheet 2 of 62792406 B