JLG 100Hx 110Hx 100HX+10 Parts Manual (3120801) – PDF DOWNLOAD En

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JLG 100Hx 110Hx 100HX+10 Parts Manual (3120801) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 100Hx 110Hx 100HX+10 Parts Manual (3120801) – PDF DOWNLOAD 

SECTION 1 FRAME.............................................................................................  9
	FIGURE 1-1. STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS................................................. 10
	FIGURE 1-2. DRIVE HUB ASSEMBLY.......................................................................... 14
	FIGURE 1-3. DRIVE BRAKE ASSEMBLY - AUSCO................................................................ 18
	FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO................................................................. 20
	FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS.............................................................. 24
	FIGURE 1-6. DRIVE MOTOR ASSEMBLY - SAUER-DANFOSS........................................................ 28
	FIGURE 1-7. VALVES AND SWITCHES INSTALLATIONS (FRAME MOUNTED)........................................... 30
	FIGURE 1-8. TOW PACKAGE INSTALLATIONS................................................................... 36
SECTION 2 TURNTABLE......................................................................................... 39
	FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES)................ 40
	FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES)................ 44
	FIGURE 2-3. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS............................................. 48
	FIGURE 2-4. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994)................................... 52
	FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT)................................. 56
	FIGURE 2-6. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995)................... 60
	FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT)................. 64
	FIGURE 2-8. ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989)............................. 68
	FIGURE 2-9. ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT)................................... 70
	FIGURE 2-10. CONTROL VALVE ASSEMBLY - 1 SECTION BANG-BANG (100HX+10/110HXER MACHINES)................... 72
	FIGURE 2-11. SWING DRIVE, BEARING AND LOCK INSTALLATIONS................................................ 74
	FIGURE 2-12. SWING MOTOR ASSEMBLY - NICHOLS............................................................. 76
	FIGURE 2-13. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992)................................................. 78
	FIGURE 2-14. SWING BRAKE ASSEMBLY (APRIL 1992 to PRESENT)............................................... 82
	FIGURE 2-15. SWING HUB ASSEMBLY......................................................................... 86
	FIGURE 2-16. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION............................... 88
	FIGURE 2-17. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992)............ 92
	FIGURE 2-18. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT)............. 98
	FIGURE 2-19. ADECO THROTTLE COMPONENTS INSTALLATION - DEUTZ ENGINE MACHINES.............................106
	FIGURE 2-20. GENERATOR INSTALLATIONS - DEUTZ ENGINE MACHINES............................................108
	FIGURE 2-21. PUMP COUPLING INSTALLATION.................................................................110
	FIGURE 2-22. MAIN PUMP ASSEMBLY.........................................................................112
	FIGURE 2-23. TANKS INSTALLATION.........................................................................114
	FIGURE 2-24. GROUND CONTROLS INSTALLATION...............................................................118
	FIGURE 2-25. LOAD MANAGEMENT INSTALLATION...............................................................124
	FIGURE 2-26. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620044 TURNTABLE).............................126
	FIGURE 2-27. HOODS AND ALARM INSTALLATION (MACHINES WITH 4620078 TURNTABLE).............................130
SECTION 3 BOOM..............................................................................................133
	FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION.......................................................134
	FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 2 OF 2)........................................135
	FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES...................................................................146
	FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY)..................150
	FIGURE 3-4. EXTEND-A-REACH INSTALLATIONS (MAY 1992 TO PRESENT) (100HX+10 & 110HXER ONLY)................154
	FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION.......................................156
	FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN SPECS BUILT PRIOR TO S/N 28224).....160
	FIGURE 3-7. BOOM WIPERS INSTALLATION....................................................................162
SECTION 4 PLATFORMS.........................................................................................165
	FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX..............................................166
	FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992).....................170
	FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT)...................174
	FIGURE 4-4. ROTATOR MOTOR ASSEMBLY......................................................................178
	FIGURE 4-5. CONSOLE BOX ASSEMBLY (PRIOR TO SEPTEMBER 1991)..............................................180
	FIGURE 4-6. CONSOLE BOX ASSEMBLY (SEPTEMBER 1991 TO PRESENT)............................................184
	FIGURE 4-7. CONTROLLER ASSEMBLIES - OEM.................................................................190
	FIGURE 4-8. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS.................................................192
SECTION 5 CYLINDER..........................................................................................197
	FIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY............................................................198
	FIGURE 5-2. AXLE LIFT CYLINDER ASSEMBLY.................................................................200
	FIGURE 5-3. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992)....................202
	FIGURE 5-4. LEVEL CYLINDER ASSEMBLY (100HX & 110HX).....................................................204
	FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992)...............206
	FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER).......................................208
	FIGURE 5-7. LIFT CYLINDER ASSEMBLY - BOOM (PRIOR TO MAY 1992)...........................................210
	FIGURE 5-8. LIFT CYLINDER ASSEMBLY - BOOM (MAY 1992 TO PRESENT).........................................212
	FIGURE 5-9. LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE)............................................214
	FIGURE 5-10. LIFT CYLINDER ASSEMBLY - EXTEND-A-REACH (100HX+10 & 110HXER ONLY)..........................216
	FIGURE 5-11. MASTER CYLINDER ASSEMBLY...................................................................218
	FIGURE 5-12. STEER CYLINDER ASSEMBLY....................................................................220
	FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES..............................................................222
	FIGURE 5-14. CYLINDER BELLOWS INSTALLATION..............................................................226
SECTION 6 HYDRAULICS........................................................................................229
	FIGURE 6-1. HYDRAULIC DIAGRAM LIST......................................................................230
	FIGURE 6-2. HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS)....232
	FIGURE 6-3. HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKES).......234
	FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE...................................................................236
	FIGURE 6-5. HYDRAULIC DIAGRAM - EXTEND-A-REACH (100HX+10 AND 110HXER)...................................240
	FIGURE 6-6. HYDRAULIC DIAGRAM - LEVEL...................................................................242
	FIGURE 6-7. HYDRAULIC DIAGRAM - LIFT....................................................................244
	FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP....................................................................246
	FIGURE 6-9. HYDRAULIC DIAGRAM - ROTATE..................................................................250
	FIGURE 6-10. HYDRAULIC DIAGRAM - SEQUENCE LINE..........................................................252
	FIGURE 6-11. HYDRAULIC DIAGRAM - SWING..................................................................254
	FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE..............................................................256
SECTION 7 ELECTRICAL........................................................................................259
	FIGURE 7-1. ELECTRICAL DIAGRAM LIST.....................................................................260
	FIGURE 7-2. WIRING SCHEMATIC - PLATFORM (SHEET 1 OF 2)..................................................266
	FIGURE 7-2. WIRING SCHEMATIC - PLATFORM (SHEET 2 OF 2)..................................................267
	FIGURE 7-3. WIRING SCHEMATIC - STANDARD (SHEET 1 OF 2)..................................................268
	FIGURE 7-3. WIRING SCHEMATIC - STANDARD (SHEET 2 OF 2)..................................................269
SECTION 8 DECALS............................................................................................271
	FIGURE 8-1. DECALS INSTALLATION - BROWN DECALS..........................................................272
	FIGURE 8-2. DECALS INSTALLATION - BLACK DECALS..........................................................278
SECTION 9 RECOMMENDED SERVICE PARTS STOCK...................................................................285
SECTION 10 SPECIAL OPTIONS..................................................................................287

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