Parts Manual User Manual

ManualsBrandsJLG ManualsSpecial machinery110HXER ANSI

Illustrated Parts Manual

Models

100HX

110HX

110HXER

100HX+6

3120637

July 29, 2011

Summary of content (354 pages)

PAGE 1
Illustrated Parts Manual Models 100HX 110HX 110HXER 100HX+6 3120637 July 29, 2011
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PAGE 3
REVISION LOG February 1989 - Original Issue Of Manual August 1989 - Revised (Added 100HX) February 1991 - Revised February 1997 - Revised (New Format) September 1997 - Change 1 October 1999 - Revised (Manual edited to 0010375 Revision 41) March 1, 2000 - Revised (Manual edited to 0010375 Revision 41) October 1, 2000 - Revised (Manual edited to 0010375 Revision 42) February 12, 2004 - Revised December 14, 2007 - Revised July 29, 2011 - Revised 3120637 A
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REVISION LOG B 3120637
PAGE 5
TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 STEERING AND AXLE/WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . .1-2 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 DRIVE BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. 2-29 2-30 2-31 2-32 2-33 2-34 2-35 2-36 2-37 2-38 2-39 TITLE PAGE NO. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT MARCH 1995 TO PRESENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 DUAL FUEL INSTALLATION - FORD ENGINE MACHINES . . . . . . . . . . . . . . . . . . . . . . 2-110 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 6 - HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 HYDRAULIC DIAGRAM - AXLE EXTENSION & STEER (WITHOUT TOW PACKAGE & WITH DUAL FRAME JACKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. iv TITLE PAGE NO.
PAGE 9
SECTION 1 FRAME S E C T I O N TABLE OF CONTENTS FIGURE 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 3120637 DESCRIPTION STEERING AND AXLE/WHEEL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE ASSEMBLY - AUSCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE ASSEMBLY - MICO . . . . . . . . .
PAGE 10
S E C T I O N SECTION 1 FRAME FIGURE 1-1.
PAGE 11
SECTION 1 FRAME FIGURE 1-1.
PAGE 12
S E C T I O N SECTION 1 FRAME FIGURE 1-1.
PAGE 13
SECTION 1 FRAME FIGURE 1-1.
PAGE 14
S E C T I O N SECTION 1 FRAME FIGURE 1-2.
PAGE 15
SECTION 1 FRAME FIGURE 1-2.
PAGE 16
S E C T I O N SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 43 44 45 7000283 Not Used 7000290 2900560 DESCRIPTION QTY. Spring 1 Coupling, Input —————————— Seal Kit (Includes Items 8, 10, 14 and 31) 1 REV.
PAGE 17
SECTION 1 FRAME FIGURE 1-2. DRIVE HUB ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 18
S E C T I O N SECTION 1 FRAME FIGURE 1-3.
PAGE 19
SECTION 1 FRAME FIGURE 1-3.
PAGE 20
S E C T I O N SECTION 1 FRAME FIGURE 1-4.
PAGE 21
SECTION 1 FRAME FIGURE 1-4.
PAGE 22
S E C T I O N SECTION 1 FRAME FIGURE 1-4.
PAGE 23
SECTION 1 FRAME FIGURE 1-4. DRIVE BRAKE ASSEMBLY - MICO (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 24
S E C T I O N SECTION 1 FRAME FIGURE 1-5.
PAGE 25
SECTION 1 FRAME FIGURE 1-5.
PAGE 26
S E C T I O N SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED) FIG & ITEM # PART NUMBER 2900659 DESCRIPTION —————————— Seal Kit (Includes 7,14,17,24,27,28 and 29) QTY. REV.
PAGE 27
SECTION 1 FRAME FIGURE 1-5. DRIVE MOTOR ASSEMBLY - VICKERS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 28
S E C T I O N SECTION 1 FRAME FIGURE 1-6.
PAGE 29
SECTION 1 FRAME FIGURE 1-6.
PAGE 30
S E C T I O N SECTION 1 FRAME FIGURE 1-7.
PAGE 31
SECTION 1 FRAME FIGURE 1-7.
PAGE 32
S E C T I O N SECTION 1 FRAME FIGURE 1-7.
PAGE 33
SECTION 1 FRAME FIGURE 1-7.
PAGE 34
S E C T I O N SECTION 1 FRAME FIGURE 1-8.
PAGE 35
SECTION 1 FRAME FIGURE 1-8.
PAGE 36
S E C T I O N SECTION 1 FRAME FIGURE 1-8. TOW PACKAGE INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 0252788 201 202 203 204 205 206 207 208 209 210 211 212 1 F R A M E 1-28 4844277 4844276 Not Used Not Used 3323002 0560605 3420620 Not Used 4761400 1260017 3311401 2160003 DESCRIPTION STEERING LINK ASSEMBLY QTY. REV. Ref.
PAGE 37
SECTION 2 TURNTABLE TABLE OF CONTENTS FIGURE 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27 2-28 2-29 2-30 2-31 2-32 2-33 2-34 2-35 2-36 2-37 2-38 2-39 3120637 DESCRIPTION PAGE TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620038 Turntable Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 38
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-1.
PAGE 39
SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620038 TURNTABLE MACHINES) FIG & ITEM # PART NUMBER 4620038 DESCRIPTION TURNTABLE Note: This Turntable used on machines with S/N 11300-11510, 11512-12248, 12250-12597, 1259912835 and 12837.
PAGE 40
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-1.
PAGE 41
SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620038 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 42
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-2.
PAGE 43
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 44
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-2.
PAGE 45
SECTION 2 TURNTABLE FIGURE 2-2. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620044 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM # PART NUMBER 407 408 409 410 411 412 413 to 450 451 2750527 2220063 4300031 4761400 3311401 1320040 Not Used 2750528 2751032 452 2750529 2750528 3120637 DESCRIPTION QTY. Hose Fitting Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Clamp, Insulated 2 3 1 1 1 1 Hose Options: 100HX & 110HX 110HX+10 & 110HXER Hose Options: 100HX & 110HX 110HX+10 & 110HXER 1 REV.
PAGE 46
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-3.
PAGE 47
SECTION 2 TURNTABLE FIGURE 2-3. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) FIG & ITEM # 1 2 PART NUMBER DESCRIPTION QTY. 4620078 TURNTABLE Note: Used on machines built May 1992 to Present.
PAGE 48
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-3.
PAGE 49
SECTION 2 TURNTABLE FIGURE 2-3. TURNTABLE, BOOM AND CUTOUT SWITCH INSTALLATIONS (4620078 TURNTABLE MACHINES) (CONTINUED) FIG & ITEM # PART NUMBER 0239843 0239844 401 402 403 to 404 405 406 407 408 409 410 411 412 413 to 450 451 2160002 2220001 Not Used 2750807 2200261 2750527 2220063 4300031 4761400 3311401 1320040 Not Used 2750528 2751032 452 2750529 2750528 3120637 DESCRIPTION LUBE LINES INSTALLATION 100HX & 110HX 110HX+10 & 110HXER QTY. REV. Ref. Ref.
PAGE 50
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-4.
PAGE 51
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 52
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-4. CONTROL VALVES AND TILT INDICATOR INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER 17 18 19 20 21 22 23 24 4761500 0641616 4751600 4761600 3311601 0140001 0641418 4751700 4751600 1320041 0641408 4060808 Not Used 4300042 2 25 26 27 28 29 T U R N T A B L E 0239154 0239913 0254060 51 4640563 7000645 7017414 2900756 Not Required 52 Not Required 4640513 7003640 7004289 53 2-16 2900503 7000645 7012910 2900756 7022390 4640839 7012945 DESCRIPTION QTY.
PAGE 53
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 54
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 56
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) FIG & ITEM # PART NUMBER 45 46 Kit 7006761 7006761 7006761 7009369 7009368 7006777 Not Required 7006780 7006778 Kit 7009329 7006782 47 48 49 50 51 52 2 T U R N T A B L E 7009330 7009395 2-20 DESCRIPTION QTY.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-5. CONTROL VALVES ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 58
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-6.
PAGE 59
SECTION 2 TURNTABLE FIGURE 2-6.
PAGE 60
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-6.
PAGE 61
SECTION 2 TURNTABLE FIGURE 2-6. CONTROL VALVES ASSEMBLY (VICKERS) (OCTOBER 1994 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 62
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-7.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) FIG & ITEM # PART NUMBER 4640246 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 7002304 7004823 7002378 7002229 7004822 7004840 7002346 7004839 7004838 7004841 7002342 7002340 7002337 7004834 7002334 7004835 7000417 7004836 7002338 7002327 7004837 7002322 7004826 7002321 7002328 7002294 7002320 7004842 7002329 7002323 7000102 7002326 7002324 DESCRIPTION QTY. REV.
PAGE 64
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-7.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-7. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (PRIOR TO JUNE 1995) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 66
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-8.
PAGE 67
SECTION 2 TURNTABLE FIGURE 2-8. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) FIG & ITEM # PART NUMBER 4640941 1 2 3 4 7002447 7002448 7002449 7002450 7002451 7011118 7000448 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 7004859 7003825 7002348 7002305 7002345 Kit Kit 7002346 7002344 7000470 7002341 Kit 7002340 Kit 7002333 7002334 7002336 7000418 7002335 7002338 7002327 7002339 7000414 151 152 7002315 7002316 7011183 3120637 QTY. REV.
PAGE 68
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-8. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 69
SECTION 2 TURNTABLE FIGURE 2-8. CONTROL VALVE ASSEMBLY - BANG-BANG WITH DUMP SECTION (JUNE 1995 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 70
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-9.
PAGE 71
SECTION 2 TURNTABLE FIGURE 2-9. ACCESSORY VALVE ASSEMBLY (MILLER) (MACHINES BUILT THROUGH 1989) FIG & ITEM # PART NUMBER 4640535 1 2 3 4 5 6 7 8 9 10 11 12 13 14 3120637 7009755 7009759 7007760 3790015 7009761 3790014 7009756 3790118 3790211 3790016 7009762 7009757 7009758 QTY. REV. ACCESSORY VALVE ASSEMBLY (MILLER) Note: Not sold as a complete assembly. DESCRIPTION Ref.
PAGE 72
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-10.
PAGE 73
SECTION 2 TURNTABLE FIGURE 2-10. ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO PRESENT) FIG & ITEM # PART NUMBER 4640580 DESCRIPTION ACCESSORY VALVE ASSEMBLY (MACHINES BUILT 1990 TO SEPTEMBER 1991) QTY. REV. Ref. — Note: Not sold as a complete assembly.
PAGE 74
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-11.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 76
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-12.
PAGE 77
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 78
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-12.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-12. SWING DRIVE, BEARING AND LOCK INSTALLATIONS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 80
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-13.
PAGE 81
SECTION 2 TURNTABLE FIGURE 2-13. SWING MOTOR ASSEMBLY - CHAR-LYNN (4620038 TURNTABLE MACHINES) FIG & ITEM # PART NUMBER 3160138 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3120637 DESCRIPTION SWING MOTOR ASSEMBLY - CHAR-LYNN (4620038 TURNTABLE MACHINES) QTY. REV. Ref.
PAGE 82
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-14.
PAGE 83
SECTION 2 TURNTABLE FIGURE 2-14. SWING MOTOR ASSEMBLY - NICHOLS (4620044 AND 4620078 TURNTABLE MACHINES) FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 PART NUMBER DESCRIPTION QTY. REV. 3160127 SWING MOTOR ASSEMBLY - NICHOLS (4620044 AND 4620078 TURNTABLE MACHINES) Ref.
PAGE 84
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-15.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-15. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 0920032 0920032 SWING BRAKE ASSEMBLY - AUSCO (MODEL 28653) SWING BRAKE ASSEMBLY - AUSCO (MODEL 37265V) Ref. Ref. — C Note: Refer to Model Number stamped on the front of the Housing item 23.
PAGE 86
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-15. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) (CONTINUED) FIG & ITEM # PART NUMBER 0920032 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 2 T U R N T A B L E SWING BRAKE ASSEMBLY - MICO QTY. REV. Ref.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-15. SWING BRAKE ASSEMBLY (PRIOR TO APRIL 1992) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 88
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-16.
PAGE 89
SECTION 2 TURNTABLE FIGURE 2-16.
PAGE 90
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-16.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-16. SWING BRAKE ASSEMBLY (APRIL 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 92
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-17.
PAGE 93
SECTION 2 TURNTABLE FIGURE 2-17. SWING HUB ASSEMBLY (4620038 TURNTABLE MACHINES) FIG & ITEM # PART NUMBER 2780055 1 2 3 4 5 6 7 8 9 7000209 7000217 7000214 4751500 7000242 Kit 7000208 7000253 7000207 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3120637 DESCRIPTION SWING HUB ASSEMBLY QTY. REV. Ref.
PAGE 94
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-18.
PAGE 95
SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 96
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-19.
PAGE 97
SECTION 2 TURNTABLE FIGURE 2-19. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 PART NUMBER Not Used 3530403 3951820 0641807 4761800 1440154 0641514 4761500 0100011 0100019 0238032 0251852 0254882 51 52 1660160 1660213 2200222 2200222 Not Required Not Required 101 0620058 Not Available 102 103 104 105 2760091 Not Available Kit 3760004 Kit 2901146 Use 1660213EX 3120637 DESCRIPTION QTY. ROTARY OIL COUPLING INSTALLATION (STANDARD PARTS) Ref.
PAGE 98
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-19.
PAGE 99
SECTION 2 TURNTABLE FIGURE 2-19. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 100
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-20.
PAGE 101
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 102
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-20.
PAGE 103
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 104
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-20.
PAGE 105
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 106
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-20.
PAGE 107
SECTION 2 TURNTABLE FIGURE 2-20. DEUTZ ENGINE INSTALLATION WITHOUT NOISE REDUCTION (BUILT PRIOR TO OCTOBER 1992) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 108
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-21.
PAGE 109
SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 110
SECTION 2 TURNTABLE S E C T I O N 2 T U R N T A B L E FIGURE 2-21.
PAGE 111
SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 112
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-21. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 0237627 201 202 203 204 205 206 207 208 209 210 211 2 T U R N T A B L E 3740059 3321001 3310801 3530425 3740080 3740067 3300220 0641405 4791400 3311401 4711400 0255152/0255568 0251683 0239119 0255274 301 2180360 4360065 4360037 4360037 4360065 4360179 2180730 2180749 DESCRIPTION QTY. REV. ELECTRICAL PANEL ASSEMBLY Ref.
PAGE 113
SECTION 2 TURNTABLE FIGURE 2-21. DEUTZ ENGINE INSTALLATION WITH NOISE REDUCTION (BUILT OCTOBER 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER 7000649 Use 7029274 Use 7029276 7000697 7000698 7000663 7000872 Use 7020413 7020420 7019607 7016330 Use 7019607 7026173 7016364 7020432 7020407 70001361 7020422 7020421 7020423 7016309 7020400 7020401 7020402 7020403 70001927 70001928 7000699 7026125 7020208 7020405 7020409 7020498 7027250 3120637 DESCRIPTION QTY.
PAGE 114
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-22.
PAGE 115
SECTION 2 TURNTABLE FIGURE 2-22.
PAGE 116
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-23.
PAGE 117
SECTION 2 TURNTABLE FIGURE 2-23.
PAGE 118
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-24.
PAGE 119
SECTION 2 TURNTABLE FIGURE 2-24. FORD LSG-423 ENGINE INSTALLATIONS (PRIOR TO MARCH 1995) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. Note: On machines with 4620038 turntable the engine faces the rear of the machine. On machines with 4620044 and 4620078 turntable the engine faces forward.
PAGE 120
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-24.
PAGE 121
SECTION 2 TURNTABLE FIGURE 2-24.
PAGE 122
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-24.
PAGE 123
SECTION 2 TURNTABLE FIGURE 2-24.
PAGE 124
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-24.
PAGE 125
SECTION 2 TURNTABLE FIGURE 2-24. FORD LSG-423 ENGINE INSTALLATIONS (PRIOR TO MARCH 1995) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 126
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-25.
PAGE 127
SECTION 2 TURNTABLE FIGURE 2-25. PRECISION GOVERNOR INSTALLATION - FORD ENGINE MACHINES BUILT PRIOR TO MARCH 1995 FIG & ITEM # 1 2 3 4 5 6 7 8 9 PART NUMBER DESCRIPTION QTY. REV. 0238044/0251678 PRECISION GOVERNOR INSTALLATION (STANDARD PARTS) Ref.
PAGE 128
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-26.
PAGE 129
SECTION 2 TURNTABLE FIGURE 2-26.
PAGE 130
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-27.
PAGE 131
SECTION 2 TURNTABLE FIGURE 2-27.
PAGE 132
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-27.
PAGE 133
SECTION 2 TURNTABLE FIGURE 2-27.
PAGE 134
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-27.
PAGE 135
SECTION 2 TURNTABLE FIGURE 2-27. FORD LRG-423 ENGINE INSTALLATION - (MARCH 1995 TO S/N 35742) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 136
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-28.
PAGE 137
SECTION 2 TURNTABLE FIGURE 2-28.
PAGE 138
SECTION 2 TURNTABLE S E C T I O N 2 T U R N T A B L E FIGURE 2-28.
PAGE 139
SECTION 2 TURNTABLE FIGURE 2-28.
PAGE 140
SECTION 2 TURNTABLE S E C T I O N 2 T U R N T A B L E FIGURE 2-28.
PAGE 141
SECTION 2 TURNTABLE FIGURE 2-28. FORD LRG-425 ENGINE INSTALLATION - (S/N 35742 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 142
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-29.
PAGE 143
SECTION 2 TURNTABLE FIGURE 2-29.
PAGE 144
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-29. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT MARCH 1995 TO PRESENT FIG & ITEM # PART NUMBER 27 28 29 30 31 32 33 34 4920039 3251476 Not Used 2180360 4360037 4070585 4070586 4070587 DESCRIPTION Wire - Red Nameplate, Generator Fitting, Tee Switch, Oil Pressure Shim 5/8" x 1" x.010 Shim 5/8" x 1" x.005 Shim 5/8" x 1" x.002 QTY. REV. 12ft/3.
PAGE 145
SECTION 2 TURNTABLE FIGURE 2-29. GENERATOR INSTALLATION - FORD ENGINE MACHINES BUILT MARCH 1995 TO PRESENT FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 146
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-30.
PAGE 147
SECTION 2 TURNTABLE FIGURE 2-30.
PAGE 148
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-30. DUAL FUEL INSTALLATION - FORD ENGINE MACHINES (CONTINUED) FIG & ITEM # PART NUMBER 34 35 36 37 2200204 4100025 1320060 0701010 DESCRIPTION Plug, 3/4" Sock Clamp Bolt, Metric 10mm - 1.5 x 20mm QTY. REV. 1 2ft/0.
PAGE 149
SECTION 2 TURNTABLE FIGURE 2-30. DUAL FUEL INSTALLATION - FORD ENGINE MACHINES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 150
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-31.
PAGE 151
SECTION 2 TURNTABLE FIGURE 2-31.
PAGE 152
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-31. PUMP COUPLING INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0250599 0250600 201 1660183 202 0641607 0701010 2 203 T U R N T A B L E 204 4761600 4832000 0080163 0080164 205 0641610 0701015 206 4761600 4832000 3020021 1660218 301 7012656 DESCRIPTION HAYES COUPLING INSTALLATION (DESIGN C) Ford Engines Deutz Engines QTY. REV. Ref. Ref. Ref.
PAGE 153
SECTION 2 TURNTABLE FIGURE 2-31. PUMP COUPLING INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 154
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-32.
PAGE 155
SECTION 2 TURNTABLE FIGURE 2-32.
PAGE 156
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-33.
PAGE 157
SECTION 2 TURNTABLE FIGURE 2-33. TANKS INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION TANKS INSTALLATIONS NOTE: For Machines with Oversize Tanks see Section 10.
PAGE 158
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-33.
PAGE 159
SECTION 2 TURNTABLE FIGURE 2-33.
PAGE 160
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-34.
PAGE 161
SECTION 2 TURNTABLE FIGURE 2-34. GROUND CONTROLS INSTALLATION FIG & ITEM # PART NUMBER 0250055 0250054 0255196 0239358 0250077 0250083 0250081 0255192 0239557 0250078 0255195 0239545 0250082 0239359 0250079 0239558 0250080 3120637 DESCRIPTION QTY. GROUND CONTROLS INSTALLATION Note: For Cummins Engine Machines see Section 10.
PAGE 162
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-34. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM # DESCRIPTION QTY. REV. 0255197 GROUND CONTROLS INSTALLATION (110HXER AND 100HX+10 STANDARD MACHINE WITH FORD LRG-423 ENGINE/4620078 TURNTABLE) Ref.
PAGE 163
SECTION 2 TURNTABLE FIGURE 2-34.
PAGE 164
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-34. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 174 175 4070991 3910804 0860610 0860609 0860966 2 0239150 0860602 T U R N T A B L E 0239151 0860603 0860965 0239544 0860604 0239545 0860605 0860964 0239148 0860600 0239149 0860601 0860967 201 3251919 3252389 3252654 3251856 3252388 3252652 3251857 2-128 DESCRIPTION Shim,.
PAGE 165
SECTION 2 TURNTABLE FIGURE 2-34.
PAGE 166
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-34.
PAGE 167
SECTION 2 TURNTABLE FIGURE 2-34. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0251683 301 302 303 304 Not Used Not Used 4360037 2180360 DESCRIPTION ENGINE RUN LIGHT INSTALLATION Switch, Pressure Fitting, Tee QTY. REV. Ref.
PAGE 168
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-35.
PAGE 169
SECTION 2 TURNTABLE FIGURE 2-35.
PAGE 170
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-36.
PAGE 171
SECTION 2 TURNTABLE FIGURE 2-36.
PAGE 172
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-37.
PAGE 173
SECTION 2 TURNTABLE FIGURE 2-37.
PAGE 174
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-37.
PAGE 175
SECTION 2 TURNTABLE FIGURE 2-37. HOODS AND ALARM INSTALLATION (4620038 TURNTABLE) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 176
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-38.
PAGE 177
SECTION 2 TURNTABLE FIGURE 2-38. HOODS AND ALARM INSTALLATION (FORD ENGINE MACHINES WITH 4620044 AND 4620078 TURNTABLE AND DEUTZ ENGINE MACHINES WITH 4620044 TURNTABLE) FIG & ITEM # PART NUMBER DESCRIPTION QTY. HOODS AND ALARM INSTALLATIONS (FORD ENGINE MACHINES WITH 4620044 AND 4620078 TURNTABLE AND DEUTZ ENGINE MACHINES WITH 4620044 TURNTABLE) Note: See Section 10 for Cummins Engine Machines. Ref.
PAGE 178
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-38.
PAGE 179
SECTION 2 TURNTABLE FIGURE 2-38.
PAGE 180
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-39.
PAGE 181
SECTION 2 TURNTABLE FIGURE 2-39.
PAGE 182
SECTION 2 TURNTABLE S E C T I O N FIGURE 2-39.
PAGE 183
SECTION 3 BOOM TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 3-4 3-5 3-6 DESCRIPTION BOOM ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTEND-A-REACH INSTALLATIONS (Prior to May 1992) (100HX+10 & 110HXER Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 184
SECTION 3 BOOM FIGURE 3-1.
PAGE 185
SECTION 3 BOOM FIGURE 3-1.
PAGE 186
SECTION 3 BOOM FIGURE 3-1.
PAGE 187
SECTION 3 BOOM FIGURE 3-1.
PAGE 188
SECTION 3 BOOM FIGURE 3-1.
PAGE 189
SECTION 3 BOOM FIGURE 3-1.
PAGE 190
SECTION 3 BOOM FIGURE 3-1.
PAGE 191
SECTION 3 BOOM FIGURE 3-1.
PAGE 192
SECTION 3 BOOM FIGURE 3-1.
PAGE 193
SECTION 3 BOOM FIGURE 3-1.
PAGE 194
SECTION 3 BOOM FIGURE 3-1.
PAGE 195
SECTION 3 BOOM FIGURE 3-1.
PAGE 196
SECTION 3 BOOM FIGURE 3-2.
PAGE 197
SECTION 3 BOOM FIGURE 3-2.
PAGE 198
SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM # S E C T I O N 3 B O O M PART NUMBER QTY. REV. B 0239267 CHAIN ADJUSTER AND ROD ASSEMBLY - 100HX, 100HX+10 AND 110HXER (OUTER MID EXTEND) Ref. 301 302 303 3840955 1360208 0238900 Rod Clevis, Rod Chain Adjuster Assembly (See Items 401-407 for Breakdown) 1 1 1 304 0100003 Loctite #277 (Not Shown) A/R 0239268 CHAIN ADJUSTER AND ROD ASSEMBLY - 110HX (OUTER MID EXTEND) Ref.
PAGE 199
SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 200
SECTION 3 BOOM FIGURE 3-3.
PAGE 201
SECTION 3 BOOM FIGURE 3-3.
PAGE 202
SECTION 3 BOOM FIGURE 3-3.
PAGE 203
SECTION 3 BOOM FIGURE 3-3. EXTEND-A-REACH INSTALLATIONS (PRIOR TO MAY 1992) (100HX+10 & 110HXER ONLY) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 204
SECTION 3 BOOM FIGURE 3-4.
PAGE 205
SECTION 3 BOOM FIGURE 3-4.
PAGE 206
SECTION 3 BOOM FIGURE 3-5.
PAGE 207
SECTION 3 BOOM FIGURE 3-5.
PAGE 208
SECTION 3 BOOM FIGURE 3-6.
PAGE 209
SECTION 3 BOOM FIGURE 3-6. BOOM WIPERS INSTALLATION FIG & ITEM # PART NUMBER 0239257 0253303 1 to 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 to 50 51 Not Used 0540074 Not Used 0540078 0540075 0540077 0540079 2660067 Not Used 2660071 2660068 2660070 2660072 3820001 1670491 0641404 4761400 4711600 Not Used 3200286 3200344 52 3200288 3200346 53 3200290 3200348 54 3200287 3200345 55 3200289 3200347 56 3200291 3200349 57 0540076 0540089 58 2660069 2660085 3120637 QTY. REV.
PAGE 210
SECTION 3 BOOM FIGURE 3-6. BOOM WIPERS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 211
SECTION 4 PLATFORMS TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 4-6 4-7 DESCRIPTION PLATFORM COMPONENTS INSTALLATION - 100HX/110HX . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (Prior to May 1992) . . . . PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (May 1992 to Present). . ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONSOLE BOX ASSEMBLY - OEM CONTROLLERS . . . . .
PAGE 212
SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 213
SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 214
SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 215
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION - 100HX/110HX (CONTINUED) FIG & ITEM # PART NUMBER 3510303 DESCRIPTION Not Required 2600095 3311805 2160006 1780252 2940006 2560010 0237963 401 3120637 0641408 3311405 4740362 4360031 7000625 4460071 REV. Platform (Japanese) PLATFORM ASSEMBLY COMPONENTS 301 302 303 304 305 306 307 QTY.
PAGE 216
SECTION 4 PLATFORMS FIGURE 4-2.
PAGE 217
SECTION 4 PLATFORMS FIGURE 4-2.
PAGE 218
SECTION 4 PLATFORMS FIGURE 4-2.
PAGE 219
SECTION 4 PLATFORMS FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (PRIOR TO MAY 1992) (CONTINUED) FIG & ITEM # PART NUMBER 3510320 3510300 DESCRIPTION Not Required 2600095 3311805 2160006 1780252 2940006 2560010 0237963 401 3120637 0641408 3311405 4740362 4360031 7000625 4460071 REV. Platform with Welded-on Bumpers Platform (Japanese Spec) PLATFORM ASSEMBLY COMPONENTS 301 302 303 304 305 306 307 QTY.
PAGE 220
SECTION 4 PLATFORMS FIGURE 4-3.
PAGE 221
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1 3510363 3510393 3510365 DESCRIPTION PLATFORM ASSEMBLY OPTIONS: 3’ x 6’ (91.
PAGE 222
SECTION 4 PLATFORMS FIGURE 4-3.
PAGE 223
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION - 100HX+10/110HXER (MAY 1992 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 224
SECTION 4 PLATFORMS FIGURE 4-4.
PAGE 225
SECTION 4 PLATFORMS FIGURE 4-4. ROTATOR MOTOR ASSEMBLY FIG & ITEM # PART NUMBER 3160083 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 DESCRIPTION ROTATOR MOTOR ASSEMBLY QTY. REV. Ref.
PAGE 226
SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 227
SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 228
SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 229
SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 230
SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 231
SECTION 4 PLATFORMS FIGURE 4-5. CONSOLE BOX ASSEMBLY - OEM CONTROLLERS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 232
SECTION 4 PLATFORMS FIGURE 4-6.
PAGE 233
SECTION 4 PLATFORMS FIGURE 4-6.
PAGE 234
SECTION 4 PLATFORMS FIGURE 4-7.
PAGE 235
SECTION 4 PLATFORMS FIGURE 4-7. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS FIG & ITEM # PART NUMBER 0239259 0252054/0231203 1 2 3 4 1670482 1670607 1670526 Not Used Not Used Not Used QTY. REV. CONSOLE BOX COVER INSTALLATIONS PRIOR TO SEPTEMBER 1990 SEPTEMBER 1990 TO PRESENT Note: See Section 10 for Metal Console Covers. DESCRIPTION Ref. Ref. Ref.
PAGE 236
SECTION 4 PLATFORMS FIGURE 4-7. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 1281083 PLATFORM BUMPERS INSTALLATION (WELDED-ON TYPE) Ref. I Ref. Ref. Ref.
PAGE 237
SECTION 4 PLATFORMS FIGURE 4-7. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM # 254 255 PART NUMBER DESCRIPTION QTY.
PAGE 238
SECTION 4 PLATFORMS FIGURE 4-7. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 239
SECTION 5 CYLINDER TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 DESCRIPTION AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM LEVEL CYLINDER ASSEMBLY (Model 100HX & 110HX Built Prior To May 1992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 240
SECTION 5 CYLINDER FIGURE 5-1.
PAGE 241
SECTION 5 CYLINDER FIGURE 5-1.
PAGE 242
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 243
SECTION 5 CYLINDER FIGURE 5-2.
PAGE 244
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 245
SECTION 5 CYLINDER FIGURE 5-3.
PAGE 246
SECTION 5 CYLINDER FIGURE 5-4.
PAGE 247
SECTION 5 CYLINDER FIGURE 5-4. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX & 110HX BUILT MAY 1992 TO PRESENT) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 1682590 1683536 PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: May 1992 To S/N 33111 S/N 33111 To Present Ref. Ref. Ref.
PAGE 248
SECTION 5 CYLINDER FIGURE 5-5.
PAGE 249
SECTION 5 CYLINDER FIGURE 5-5. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT PRIOR TO MAY 1992) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 1681791 1682459 PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: Prior To February 1991 February 1991 To May 1992 Ref. Ref. Ref.
PAGE 250
SECTION 5 CYLINDER FIGURE 5-6.
PAGE 251
SECTION 5 CYLINDER FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (100HX+10 & 110HXER BUILT MAY 1992 TO PRESENT) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV. 1682753 1683493 1683493 1683530 PLATFORM LEVEL CYLINDER ASSEMBLY OPTIONS: May 1992 To S/N 29913 S/N 29913 to Present CSA - Prior To S/N 33111 CSA - S/N 33111 To Present Ref. Ref. Ref. Ref. Ref.
PAGE 252
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 253
SECTION 5 CYLINDER FIGURE 5-7.
PAGE 254
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 255
SECTION 5 CYLINDER FIGURE 5-8.
PAGE 256
SECTION 5 CYLINDER FIGURE 5-9.
PAGE 257
SECTION 5 CYLINDER FIGURE 5-9. LIFT CYLINDER ASSEMBLY - BOOM (TUV STYLE) (MAY 1992 TO PRESENT) FIG & ITEM # PART NUMBER 1682587 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1682588 0961082 1681835 0961082 1120238 1681298 4565603 3480104 3300297 4640731 4640495 2900770 3900171 2160002 Kit Kit Kit Not Used Kit Kit Kit Kit 3900141 0100011 0100038 0100035 2900338 3120637 DESCRIPTION LIFT CYLINDER ASSEMBLY - BOOM (GERMAN TUV STYLE) QTY. REV. Ref.
PAGE 258
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 259
SECTION 5 CYLINDER FIGURE 5-10.
PAGE 260
SECTION 5 CYLINDER FIGURE 5-11.
PAGE 261
SECTION 5 CYLINDER FIGURE 5-11. MASTER CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1681978 1681978 1681580 1 Not Used 1681979 1681979 1681490 2 Not Used 1681974 1681974 1681488 2A 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0960097 1120179 1680892 3480120 3300101 3300272 Kit Kit Kit Kit Kit Kit Kit Kit 3900170 Not Used 4564057 4564057 4563031 17 18 2160002 2200201 0100011 0100038 0100035 2900381 3120637 DESCRIPTION MASTER CYLINDER ASSEMBLY Note: Refer to P/N stamped on Barrel for identification.
PAGE 262
SECTION 5 CYLINDER FIGURE 5-12.
PAGE 263
SECTION 5 CYLINDER FIGURE 5-12.
PAGE 264
SECTION 5 CYLINDER FIGURE 5-13.
PAGE 265
SECTION 5 CYLINDER FIGURE 5-13.
PAGE 266
SECTION 5 CYLINDER FIGURE 5-13.
PAGE 267
SECTION 5 CYLINDER FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 268
SECTION 5 CYLINDER FIGURE 5-14.
PAGE 269
SECTION 5 CYLINDER FIGURE 5-14.
PAGE 270
SECTION 5 CYLINDER FIGURE 5-14. CYLINDER BELLOWS INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 271
SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 DESCRIPTION HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - AXLE EXTENSION AND STEER (WITHOUT TWO PACKAGE AND WITH DUAL FRAME JACKS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - BRAKE WITH PRESSURE REDUCING VALVE (USED WITH AUSCO DRIVE BRAKE) . .
PAGE 272
SECTION 6 HYDRAULICS FIGURE 6-1 - HYDRAULIC DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in the following pages. Information on diagrams not shown are available from the JLG Service/ Parts Department.
PAGE 273
SECTION 6 HYDRAULICS FIGURE 6-1 - HYDRAULIC DIAGRAM LIST (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION Steer Hydraulic Diagrams (See Axle Extension Hydraulic Diagrams) 2791426* 2791427* Swing Hydraulic Diagram Telescope Hydraulic Diagram Tow Hydraulic Diagram (See Axle Extension Hydraulic Diagrams) S E C T I O N 6 H Y D R A U L I C S 3120637 6-3
PAGE 274
SECTION 6 HYDRAULICS FIGURE 6-1 - HYDRAULIC DIAGRAM LIST (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION S E C T I O N 6 H Y D R A U L I C S 6-4 3120637
PAGE 275
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 276
SECTION 6 HYDRAULICS FIGURE 6-2.
PAGE 277
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 278
SECTION 6 HYDRAULICS FIGURE 6-3.
PAGE 279
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 280
SECTION 6 HYDRAULICS FIGURE 6-4.
PAGE 281
SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (CONTINUED) FIG & ITEM # PART NUMBER 48 49 50 51 Not Used 2220822 2220909 2220811 DESCRIPTION Fitting Fitting Fitting, Reducer QTY. REV.
PAGE 282
SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - DRIVE (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 283
SECTION 6 HYDRAULICS FIGURE 6-5.
PAGE 284
SECTION 6 HYDRAULICS FIGURE 6-5.
PAGE 285
SECTION 6 HYDRAULICS FIGURE 6-6.
PAGE 286
SECTION 6 HYDRAULICS FIGURE 6-6.
PAGE 287
SECTION 6 HYDRAULICS FIGURE 6-7.
PAGE 288
SECTION 6 HYDRAULICS FIGURE 6-7. HYDRAULIC DIAGRAM - LIFT FIG & ITEM # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 S E C T I O N 6 PART NUMBER QTY. REV. 2791599 HYDRAULIC DIAGRAM - LIFT DESCRIPTION Ref.
PAGE 289
SECTION 6 HYDRAULICS FIGURE 6-8.
PAGE 290
SECTION 6 HYDRAULICS FIGURE 6-8.
PAGE 291
SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP (CONTINUED) FIG & ITEM # PART NUMBER 43 44 45 46 47 2750968 2220596 2220237 2220582 2750777 2750792 Not Used 2750977 2750757 Not Used Not Used 2751015 2220435 Not Used 2180491 2750872 Not Used Not Used 2750777 2751484 2220385 2751021 2751014 Not Used 2751353 2750129 2750137 2220072 2220414 2220605 2720280 2720239 2720347 2750889 2220472 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 3120637 DESCRIPTION QTY.
PAGE 292
SECTION 6 HYDRAULICS FIGURE 6-8. HYDRAULIC DIAGRAM - PUMP (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 293
SECTION 6 HYDRAULICS FIGURE 6-9.
PAGE 294
SECTION 6 HYDRAULICS FIGURE 6-9.
PAGE 295
SECTION 6 HYDRAULICS FIGURE 6-10.
PAGE 296
SECTION 6 HYDRAULICS FIGURE 6-10. HYDRAULIC DIAGRAM - SEQUENCE LINE FIG & ITEM # PART NUMBER 2791703 1 2 3 4 5 6 7 8 S E C T I O N 2220582 2220605 Not Used 2220909 Not Used 2751015 2220684 2220250 DESCRIPTION HYDRAULIC DIAGRAM - SEQUENCE LINE QTY. REV. Ref. A Fitting, Straight Fitting, Tee 1 1 Orifice (.
PAGE 297
SECTION 6 HYDRAULICS FIGURE 6-11.
PAGE 298
SECTION 6 HYDRAULICS FIGURE 6-11. HYDRAULIC DIAGRAM - SWING FIG & ITEM # PART NUMBER 2791426 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 S E C T I O N 2220577 0100020 4640013 Not Used 2220635 2180377 2180270 0100011 2220609 2750900 2220416 2220414 2220466 2220415 2751014 2750999 DESCRIPTION HYDRAULIC DIAGRAM - SWING QTY. REV. Ref. 3 Fitting, Straight Sealant, Pipe (Not Shown) Valve, Shuttle 2 A/R 1 Fitting, Tee Fitting, Modified Orifice (.
PAGE 299
SECTION 6 HYDRAULICS FIGURE 6-12.
PAGE 300
SECTION 6 HYDRAULICS FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE FIG & ITEM # PART NUMBER 2791427 1 2 3 4 5 6 7 8 9 10 S E C T I O N 2220577 0100020 Not Used 2220492 2220221 2220758 4640216 2220343 2752163 2220396 DESCRIPTION HYDRAULIC DIAGRAM - TELESCOPE Fitting, Straight Sealant, Pipe (Not Shown) Fitting, Straight Fitting, Reducer Fitting, Straight Valve, Color Flow Fitting, Straight Hose Fitting, Straight QTY. REV. Ref.
PAGE 301
SECTION 6 HYDRAULICS FIGURE 6-12. HYDRAULIC DIAGRAM - TELESCOPE FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 302
SECTION 6 HYDRAULICS S E C T I O N 6 H Y D R A U L I C S 6-32 3120637
PAGE 303
SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 DESCRIPTION ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - BOOM INDICATOR PENDULUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - DUAL FUEL (Ford Engine Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM - GENERATOR (Deutz Engine). . . . . . . . . . . . . . .
PAGE 304
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST FIG & ITEM # PART NUMBER 4931947/1281985 4931947/1281985 4932595/1281985 4931947/1281985 0253077 4931947/1281985 S E C T I O N 0610091 3740049 3990010 0140026 1540002 4932637/1282091 4932637/1282091 4932639/1282091 4932637/1282091 0253077 7 4932637/1282091 0610104 3740049 3990010 1060641 0140026 1540002 E L E C T R I C A L 4932877 1060042 3990010 3740049 4921877 4932029 1281671 4932029 1282370 7-2 DESCRIPTION QTY.
PAGE 305
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED) FIG & ITEM # PART NUMBER 1060515 1060516 Boom Cables Cable, Electrical - 12/4 Cable, Electrical - 16/30 QTY. REV. A/R 131ft/40m 131ft/40m Boom Indicator Pendulum Wiring Diagrams: 1st Generation (1st Eight Machines) 2nd Generation (Nineth Machines to Mid 1989) 3rd/4th/5th Generations (Mid 1989 to Present) Resistor - 100 Ohms Resistor, Variable - 500 Ohms (2nd Generation Only) Ref. Ref. Ref. Ref. 1 Ref.
PAGE 306
SECTION 7 ELECTRICAL FIGURE 7-1. ELECTRICAL DIAGRAM LIST (CONTINUED) FIG & ITEM # PART NUMBER 4931858* 3990001 4931859 3990001 E L E C T R I C A L Ref. 1 A Ref. A 2 0252928 0256595 Heaters Wiring Diagram Deutz Ford Ref. Ref. Ref. F — 4932635 Japanese Modification Wiring Diagram Ref. D Ref. E Ref.
PAGE 307
SECTION 7 ELECTRICAL FIGURE 7-1.
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SECTION 7 ELECTRICAL FIGURE 7-1.
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SECTION 7 ELECTRICAL FIGURE 7-1.
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SECTION 7 ELECTRICAL FIGURE 7-2. WIRING DIAGRAM - BOOM INDICATOR PENDULUM.
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SECTION 7 ELECTRICAL FIGURE 7-3. WIRING DIAGRAM - DUAL FUEL (FORD ENGINE OPTION).
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SECTION 7 ELECTRICAL FIGURE 7-4. WIRING DIAGRAM - GENERATOR (DUETZ).
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SECTION 7 ELECTRICAL FIGURE 7-5. WIRING DIAGRAM - GENERATOR (FORD).
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SECTION 7 ELECTRICAL FIGURE 7-6. WIRING DIAGRAM - PLATFORM (100HX &110HX).
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SECTION 7 ELECTRICAL FIGURE 7-7. WIRING DIAGRAM - PLATFORM (100HX+10 & 110HXER).
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SECTION 7 ELECTRICAL FIGURE 7-8. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 1 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-8. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 2 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-8. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH DEUTZ ENGINE) (SHEET 3 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-9. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 1 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-9. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 2 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-9. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH DEUTZ ENGINE) (SHEET 3 OF 3).
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SECTION 7 ELECTRICAL FIGURE 7-10. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 1 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-10. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 2 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-10. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 3 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-10. WIRING DIAGRAM - STANDARD (100HX & 110HX WITH FORD ENGINE) (SHEET 4 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-11. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 1 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-11. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 2 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-11. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 3 OF 4).
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SECTION 7 ELECTRICAL FIGURE 7-11. WIRING DIAGRAM - STANDARD (100HX+10 & 110HXER WITH FORD ENGINE) (SHEET 4 OF 4).
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SECTION 7 ELECTRICAL S E C T I O N THIS PAGE INTENTIONALLY LEFT BLANK 7 E L E C T R I C A L 7-28 3120637
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SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 8-2 8-3 8-4 DESCRIPTION DECALS INSTALLATION - STANDARD BROWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DECALS INSTALLATION - COUNTRY SPEC BROWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DECALS INSTALLATION - STANDARD BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DECALS INSTALLATION - COUNTRY SPEC BLACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 8 DECALS FIGURE 8-1.
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SECTION 8 DECALS FIGURE 8-1.
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SECTION 8 DECALS FIGURE 8-1.
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SECTION 8 DECALS FIGURE 8-1.
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SECTION 8 DECALS FIGURE 8-2.
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SECTION 8 DECALS FIGURE 8-2.
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SECTION 8 DECALS FIGURE 8-2.
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SECTION 8 DECALS FIGURE 8-2.
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SECTION 8 DECALS FIGURE 8-3.
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SECTION 8 DECALS FIGURE 8-3.
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SECTION 8 DECALS FIGURE 8-3.
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SECTION 8 DECALS FIGURE 8-3.
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SECTION 8 DECALS FIGURE 8-4.
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SECTION 8 DECALS FIGURE 8-4.
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SECTION 8 DECALS FIGURE 8-4. DECALS INSTALLATION - COUNTRY SPEC BLACK (CONTINUED) FIG & ITEM # PART NUMBER 42 43 44 45 46 to50 51 52 1701499 Not Available 1702731 1702730 Not Required 4420052 4420051 Not Available DESCRIPTION Decal - Lift Here Decal - Bar Code Decal - Black Stripe Decal - JLG Lift 2 1 A/R 1 Tape, Safety Tape, Safety (100HX Only) —————————— Decal Kit - Black A/R A/R DECALS INSTALLATION (OPTIONAL PARTS) 71 1700197 72 S E C T I O N 73 74 1700194 1700196 3252356 1700818 1702720 QTY.
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SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 100HX/110HX+10/110HX The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
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S E C T I O N SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS 100HX/110HX+10/110HX/110HXER The following list will service fleets of machines (built to current production per date on the front cover) with emergency repair parts which can be installed in the field. Parts from the list should be replaced when inventory is depleted to keep service parts stock supplied. For further information, contact your JLG dealer or the JLG Industries Parts Department.
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SECTION 10 SPECIAL OPTIONS Note: This list is to accommodate machines ordered with special equipment. Options may not be applicable to all models. For more specific parts information contact JLG Parts Department. FIG & ITEM # PART NUMBER DESCRIPTION MISCELLANEOUS SPECIAL OPTIONS Air Cleaner Service Indicator Installation Ref. 1281002 0239261 0239262 Airline to Platform Installations 1/2" Airline Installation 3/4" Airline Installation Ref. Ref. Ref.
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SECTION 10 SPECIAL OPTIONS S E C T I O N FIG & ITEM # PART NUMBER 0252560/1281004 0860770/1281150 0252561/1281004 0860769/1281150 O P T I O N Ref. Hood Installation - Cummins Engine Machines Ref. 0239998 0239257 0239258 Hostile Environment Package Installation Boom Wipers Installation Cylinder Bellows Installation Ref. Ref. Ref. 4360295 Ignition Switch with Individual Coded Keys Ref.
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SECTION 10 SPECIAL OPTIONS FIG & ITEM # PART NUMBER DESCRIPTION QTY. 0251140 Receptacle at Ground Controls Installation (GFI) Ref. 0255937 4400389 Tank Installations - Fuel and Oil (Special) 52 Gallon Tank Fuel Installation Tank - 52 Gallon Ref. Ref.
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SECTION 10 SPECIAL OPTIONS S E C T I O N FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3120637 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.