JLG 100HX 110HX 110HXER 100HX+6 Illustrated Parts Manual 3120637 – PDF DOWNLOAD

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JLG 100HX 110HX 110HXER 100HX+6 Illustrated Parts Manual 3120637 – PDF DOWNLOAD

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JLG 100HX 110HX 110HXER 100HX+6 Illustrated Parts Manual 3120637 – PDF DOWNLOAD

Language : English
Pages : 354
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

JLG 100HX 110HX 110HXER 100HX+6 Illustrated Parts Manual 3120637 – 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 34
SECTION 2 TURNTABLE 37
FIGURE 2-1 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620038 TURNTABLE MACHINES) 38
FIGURE 2-2 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) 42
FIGURE 2-3 TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) 46
FIGURE 2-4 CONTROL VALVES AND TILT INDICATOR INSTALLATIONS 50
FIGURE 2-5 CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) 54
FIGURE 2-6 CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) 58
FIGURE 2-7 CONTROL VALVE ASSEMBLY – BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) 62
FIGURE 2-8 CONTROL VALVE ASSEMBLY – BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) 66
FIGURE 2-9 ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989) 70
FIGURE 2-10 ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT) 72
FIGURE 2-11 CONTROL VALVE ASSEMBLY – 1 SECTION BANG-BANG (100HX+10/110HXER MACHINES) 74
FIGURE 2-12 SWING DRIVE, BEARING AND LOCK INSTALLATIONS 76
FIGURE 2-13 SWING MOTOR ASSEMBLY – CHAR-LYNN (4620038 TURNTABLE MACHINES) 80
FIGURE 2-14 SWING MOTOR ASSEMBLY – NICHOLS (4620044 AND 4620078 TURNTABLE MACHINES) 82
FIGURE 2-15 SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) 84
FIGURE 2-16 SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT) 88
FIGURE 2-17 SWING HUB ASSEMBLY (4620038 TURNTABLE MACHINES) 92
FIGURE 2-18 SWING HUB ASSEMBLY (4620044 AND 4620078 TURNTABLE MACHINES) 94
FIGURE 2-19 ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION 96
FIGURE 2-20 DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) 100
FIGURE 2-21 DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) 108
FIGURE 2-22 ADECO THROTTLE COMPONENTS INSTALLATION – DEUTZ ENGINE MACHINES 114
FIGURE 2-23 GENERATOR INSTALLATIONS – DEUTZ ENGINE MACHINES 116
FIGURE 2-24 FORD LSG-423 ENGINE INSTALLATIONS (PRIOR TO MARCH 1995) 118
FIGURE 2-25 PRECISION GOVERNOR INSTALLATION – FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995 126
FIGURE 2-26 GENERATOR INSTALLATION – FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995 128
FIGURE 2-27 FORD LRG-423 ENGINE INSTALLATION – (MARCH 1995 TO S/N 35742) 130
FIGURE 2-28 FORD LRG-425 ENGINE INSTALLATION – (S/N 35742 TO PRESENT) 136
FIGURE 2-29 GENERATOR INSTALLATION – FORD ENGINE MACHINES BUILT MARCH 1995 TO PRESENT 142
FIGURE 2-30 DUAL FUEL INSTALLATION – FORD ENGINE MACHINES 146
FIGURE 2-31 PUMP COUPLING INSTALLATION 150
FIGURE 2-32 MAIN PUMP ASSEMBLY 154
FIGURE 2-33 TANKS INSTALLATION 156
FIGURE 2-34 GROUND CONTROLS INSTALLATION 160
FIGURE 2-35 LOAD MANAGEMENT INSTALLATION (4620038 TURNTABLE) 168
FIGURE 2-36 LOAD MANAGEMENT INSTALLATION (4620044 AND 4620078 TURNTABLES) 170
FIGURE 2-37 HOODS AND ALARM INSTALLATION (4620038 TURNTABLE) 172
FIGURE 2-38 HOODS AND ALARM INSTALLATION (FORD ENGINE MACHINES WITH 4620044 AND 4620078 TURNTABLE AND DEUTZ ENGINE MACHINES WITH 4620044 TURNTABLE) 176
FIGURE 2-39 HOODS AND ALARM INSTALLATION (DEUTZ ENGINE MACHINES WITH 4620078 TURNTABLE) 180
SECTION 3 BOOM 183
FIGURE 3-1 BOOM ASSEMBLY COMPONENTS INSTALLATION 184
FIGURE 3-1 BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 2 OF 2) 185
FIGURE 3-2 CHAIN ADJUSTER ASSEMBLIES 196
FIGURE 3-3 EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) 200
FIGURE 3-4 EXTEND-A-REACH INSTALLATIONS (MAY 1992 TO PRESENT) (100HX+10 & 110HXER ONLY) 204
FIGURE 3-5 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION 206
FIGURE 3-6 BOOM WIPERS INSTALLATION 208
SECTION 4 PLATFORMS 211
FIGURE 4-1 PLATFORM COMPONENTS INSTALLATION – 100HX/110HX 212
FIGURE 4-2 PLATFORM COMPONENTS INSTALLATION – 100HX+10/110HXER (PRIOR TO MAY 1992) 216
FIGURE 4-3 PLATFORM COMPONENTS INSTALLATION – 100HX+10/110HXER (MAY 1992 TO PRESENT) 220
FIGURE 4-4 ROTATOR MOTOR ASSEMBLY 224
FIGURE 4-5 CONSOLE BOX ASSEMBLY – OEM CONTROLLERS 226
FIGURE 4-6 CONTROLLER ASSEMBLIES – OEM 232
FIGURE 4-7 OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS 234
SECTION 5 CYLINDER 239
FIGURE 5-1 AXLE EXTENSION CYLINDER ASSEMBLY 240
FIGURE 5-2 AXLE LIFT CYLINDER ASSEMBLY 242
FIGURE 5-3 PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT PRIOR TO MAY 1992) 244
FIGURE 5-4 PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT MAY 1992 TO PRESENT) 246
FIGURE 5-5 PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992) 248
FIGURE 5-6 PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT MAY 1992 TO PRESENT) 250
FIGURE 5-7 LIFT CYLINDER ASSEMBLY – BOOM (PRIOR TO MAY 1992) 252
FIGURE 5-8 LIFT CYLINDER ASSEMBLY – BOOM (MAY 1992 TO PRESENT) 254
FIGURE 5-9 LIFT CYLINDER ASSEMBLY – BOOM (TUV STYLE) (MAY 1992 TO PRESENT) 256
FIGURE 5-10 LIFT CYLINDER ASSEMBLY – EXTEND-A-REACH (100HX+10 & 110HXER ONLY) 258
FIGURE 5-11 MASTER CYLINDER ASSEMBLY 260
FIGURE 5-12 STEER CYLINDER ASSEMBLY 262
FIGURE 5-13 TELESCOPE CYLINDER ASSEMBLIES 264
FIGURE 5-14 CYLINDER BELLOWS INSTALLATION 268
SECTION 6 HYDRAULICS 271
FIGURE 6-2 HYDRAULIC DIAGRAM – AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS) 275
FIGURE 6-3 HYDRAULIC DIAGRAM – BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCODRIVE BRAKES) 277
FIGURE 6-4 HYDRAULIC DIAGRAM – DRIVE 279
FIGURE 6-5 HYDRAULIC DIAGRAM – EXTEND-A-REACH (100HX+10 AND 110HXER) 283
FIGURE 6-6 HYDRAULIC DIAGRAM – LEVEL 285
FIGURE 6-7 HYDRAULIC DIAGRAM – LIFT 287
FIGURE 6-8 HYDRAULIC DIAGRAM – PUMP 289
FIGURE 6-9 HYDRAULIC DIAGRAM – ROTATE 293
FIGURE 6-10 HYDRAULIC DIAGRAM – SEQUENCE LINE 295
FIGURE 6-11 HYDRAULIC DIAGRAM – SWING 297
FIGURE 6-12 HYDRAULIC DIAGRAM – TELESCOPE 299
SECTION 7 ELECTRICAL 303
FIGURE 7-2 WIRING DIAGRAM – BOOM INDICATOR PENDULUM 310
FIGURE 7-3 WIRING DIAGRAM – DUAL FUEL (FORD ENGINE OPTION) 311
FIGURE 7-4 WIRING DIAGRAM – GENERATOR (DUETZ) 312
FIGURE 7-5 WIRING DIAGRAM – GENERATOR (FORD) 313
FIGURE 7-6 WIRING DIAGRAM – PLATFORM (100HX &110HX) 314
FIGURE 7-7 WIRING DIAGRAM – PLATFORM (100HX+10 & 110HXER) 315
FIGURE 7-8 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 1 OF 3) 316
FIGURE 7-8 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 2 OF 3) 317
FIGURE 7-8 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 3 OF 3) 318
FIGURE 7-9 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 1 OF 3) 319
FIGURE 7-9 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 2 OF 3) 320
FIGURE 7-9 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 3 OF 3) 321
FIGURE 7-10 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 1 OF 4) 322
FIGURE 7-10 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 2 OF 4) 323
FIGURE 7-10 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 3 OF 4) 324
FIGURE 7-10 WIRING DIAGRAM – STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 4 OF 4) 325
FIGURE 7-11 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 1 OF 4) 326
FIGURE 7-11 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 2 OF 4) 327
FIGURE 7-11 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 3 OF 4) 328
FIGURE 7-11 WIRING DIAGRAM – STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 4 OF 4) 329
SECTION 8 DECALS 331
FIGURE 8-1 DECALS INSTALLATION – STANDARD BROWN 332
FIGURE 8-2 DECALS INSTALLATION – COUNTRY SPEC BROWN 336
FIGURE 8-3 DECALS INSTALLATION – STANDARD BLACK 340
FIGURE 8-4 DECALS INSTALLATION – COUNTRY SPEC BLACK 344
SECTION 9 RECOMMENDED SERVICE PARTS STOCK 347
SECTION 10 SPECIAL OPTIONS 349

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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