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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