JLG 100Hx 110Hx 110Hxer 100HX+6 Parts Manual (3120637) – PDF DOWNLOAD

Description

JLG 100Hx 110Hx 110Hxer 100HX+6 Parts Manual (3120637) – PDF DOWNLOAD

TABLE OF CONTENTS:

JLG 100Hx 110Hx 110Hxer 100HX+6 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

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.M