Parts Manual Owner's manual

ManualsBrandsJLG ManualsSpecial machinery120HX

Illustrated Parts Manual

Model

120HX

P/N

3120820

August 31, 2011

Summary of content (216 pages)

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Illustrated Parts Manual Model 120HX P/N 3120820 August 31, 2011
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REVISION LOG May 1992 - Original Issue Of Manual May 1995 - Revised June 1997 - Revised May 1998 - Revised December 1998 - Revised November 12, 1999 - Revised (Manual edited to 0010448 Revision 32) March 2, 2000 - Revised (Manual edited to 0010448 Revision 32) October 1, 2000 - Revised (Manual edited to 0010448 Revision 33) February 24, 2004 - Revised January 4, 2008 - Revised August 31, 2011 - Revised 3120820 A
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REVISION LOG B 3120820
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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 FRAME, VALVES AND SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 STEERING AND AXLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO. SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 AXLE EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .
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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 3120820 DESCRIPTION FRAME, VALVES AND SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING AND AXLES INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . .
PAGE 8
S E C T I O N SECTION 1 FRAME FIGURE 1-1.
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SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION FRAME, VALVES AND SHIELDS INSTALLATION 1 2360353 2360369 0252709 0258677 101 102 103 4640260 Not Available 7009739 7007321 7007323 4640923 7012992 7012980 7012993 4640629 2900745 105 106 to 108 109 110 111 112 113 114 115 116 117 118 119 3120820 VALVES INSTALLATION - FRAME MOUNTED Prior To S/N 38697 S/N 38697 To Present REV. Ref. 1 1 Ref. Ref. Ref.
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S E C T I O N SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0252684 201 202 203 204 1 4060824 4300031 4751400 3300151 0100011 DESCRIPTION FRAME SHIELDS INSTALLATION Shield Stud (Welded on Part) Flatwasher 1/4" Nut, Acorn 1/4"-20NC —————————— Loctite #242 QTY. REV. Ref.
PAGE 11
SECTION 1 FRAME FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 12
S E C T I O N SECTION 1 FRAME FIGURE 1-2.
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SECTION 1 FRAME FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR FIG & ITEM # PART NUMBER 4640739 4641066 1 7012723 7012730 7012725 7012731 7017491 7021404 7021401 7021402 7021403 2 4640788 7012730 7012725 7017490 7021400 7021401 7021402 7021403 3 7012724 7012725 7012730 4 5 7017491 7021404 7021401 7021402 7021403 7012914 7012912 7012918 7012998 3120820 DESCRIPTION QTY. REV. VALVE ASSEMBLY - HYDRO AIR Prior To S/N 38697 S/N 38697 To Present Ref. Ref. Ref.
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S E C T I O N SECTION 1 FRAME FIGURE 1-3.
PAGE 15
SECTION 1 FRAME FIGURE 1-3.
PAGE 16
S E C T I O N SECTION 1 FRAME FIGURE 1-3.
PAGE 17
SECTION 1 FRAME FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 18
S E C T I O N SECTION 1 FRAME FIGURE 1-4.
PAGE 19
SECTION 1 FRAME FIGURE 1-4.
PAGE 20
S E C T I O N SECTION 1 FRAME FIGURE 1-5.
PAGE 21
SECTION 1 FRAME FIGURE 1-5.
PAGE 22
S E C T I O N SECTION 1 FRAME FIGURE 1-5.
PAGE 23
SECTION 1 FRAME FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 1 FRAME FIGURE 1-6.
PAGE 25
SECTION 1 FRAME FIGURE 1-6.
PAGE 26
S E C T I O N SECTION 1 FRAME FIGURE 1-6.
PAGE 27
SECTION 1 FRAME FIGURE 1-6. DRIVE BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 28
S E C T I O N SECTION 1 FRAME FIGURE 1-7.
PAGE 29
SECTION 1 FRAME FIGURE 1-7.
PAGE 30
S E C T I O N SECTION 1 FRAME FIGURE 1-8.
PAGE 31
SECTION 1 FRAME FIGURE 1-8. JACK CYLINDER INSTALLATION FIG & ITEM # PART NUMBER 0252607 1 2 3 4 5 6 7 8 1682511 0641812 4761800 3535906 0641816 4711800 3311805 3252185 9 4360314 10 4740397 11 0630448 12 13 14 15 16 4761400 Not Used 3340630 0641852 3311801 0100011 3120820 DESCRIPTION QTY. REV. JACK CYLINDER INSTALLATION Ref.
PAGE 32
S E C T I O N SECTION 1 FRAME FIGURE 1-8. JACK CYLINDER INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 33
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 3120820 DESCRIPTION TURNTABLE, BOOM AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE ASSEMBLY - HYDRO-AIR (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 34
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 35
SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 36
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-1.
PAGE 37
SECTION 2 TURNTABLE FIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0239844 401 402 403 404 405 406 407 408 409 410 411 412 3120820 2160002 2220001 2751032 2750528 2750807 2200261 2750527 2220063 4300031 4761400 3311401 1320040 DESCRIPTION LUBE LINES INSTALLATION Fitting, Grease Fitting Hose Hose Hose Fitting, Nipple Hose Fitting Stud (Welded on Part) Lockwasher 1/4" Nut 1/4"-20NC Clamp, Insulated QTY. REV. Ref.
PAGE 38
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 39
SECTION 2 TURNTABLE FIGURE 2-2.
PAGE 40
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-3.
PAGE 41
SECTION 2 TURNTABLE FIGURE 2-3.
PAGE 42
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 43
SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 44
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-4.
PAGE 45
SECTION 2 TURNTABLE FIGURE 2-4. VALVE ASSEMBLY - HYDRO AIR (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 46
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 47
SECTION 2 TURNTABLE FIGURE 2-5.
PAGE 48
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 212 213 214 215 216 217 218 4761400 1320040 3911012 4751000 4761000 3311001 4751400 2 DESCRIPTION Lockwasher 1/4" Clamp, Cable Screw, Machine Flatwasher #10 Lockwasher #10 Nut #10-24NC Flatwasher 1/4" QTY. REV.
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SECTION 2 TURNTABLE FIGURE 2-5. ROTARY COULPING AND COLLECTOR RING ASSEMBLY AND INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION.
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SECTION 2 TURNTABLE FIGURE 2-6. SWING DRIVE AND BEARING INSTALLATION.
PAGE 52
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-7.
PAGE 53
SECTION 2 TURNTABLE FIGURE 2-7. SWING MOTOR ASSEMBLY FIG & ITEM # PART NUMBER 3160184 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Kit Kit Kit 7004196 7004167 7004179 Kit Kit 7004171 7010780 Not Used 7010781 Not Used Not Used 7010782 Not Used 7004192 Not Used Not Used Not Used Kit 7010776 2900798 3120820 DESCRIPTION SWING MOTOR ASSEMBLY QTY. REV. Ref.
PAGE 54
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 55
SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY FIG & ITEM # PART NUMBER DESCRIPTION SWING BRAKE ASSEMBLY 1 2 3 4 to 10 11 12 13 14 15 16 17 18 19 20 21 22 to 25 26 27 Kit Kit 7007977 Not Used Kit Not Used 7011719 Not Used 7007987 Kit Kit Kit Kit Kit Kit Not Used Kit 7007934 2900766 2900768 0920083 0920083 0920109 51 7011718 7011720 52 7007979 7007980 Not Required 53 Not Required 7007970 7018602 54 7007981 7011713 7018605 55 7007985 7018607 3120820 QTY.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-8.
PAGE 57
SECTION 2 TURNTABLE FIGURE 2-8. SWING BRAKE ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-9.
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SECTION 2 TURNTABLE FIGURE 2-9.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-10.
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SECTION 2 TURNTABLE FIGURE 2-10.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 63
SECTION 2 TURNTABLE FIGURE 2-11.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-11.
PAGE 65
SECTION 2 TURNTABLE FIGURE 2-11.
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S E C T I O N SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0253378 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 2 T U R N T A B L E 2-34 3790012 4360202 4060229 3640930 4460299 3740019 4120028 4160112 3740086 4120029 3640555 3740090 4120030 4160112 Not Used 0720603 4760600 3310601 DESCRIPTION TUV MONITORING SYSTEM INSTALLATION QTY. REV. Ref.
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SECTION 2 TURNTABLE FIGURE 2-11. GROUND CONTROLS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 68
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 69
SECTION 2 TURNTABLE FIGURE 2-12.
PAGE 70
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-13.
PAGE 71
SECTION 2 TURNTABLE 1 S E C T I O N 1 2 FIGURE 2-13.
PAGE 72
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 73
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 74
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 75
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 76
S E C T I O N 2 T U R N T A B L E SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 77
SECTION 2 TURNTABLE FIGURE 2-14. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 0252694 401 402 403 404 405 406 407 408 409 410 411 412 413 414 451 452 453 454 455 456 457 458 459 460 461 462 463 464 3220080 0340041 0641406 4751400 4761400 3311401 4565269 Not Used 4565663 4844169 4565267 4565664 1320011 4100025 EXHAUST INSTALLATION (PRIOR TO OCTOBER 1992) QTY. REV. Ref.
PAGE 78
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 79
SECTION 2 TURNTABLE FIGURE 2-14.
PAGE 80
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 81
SECTION 2 TURNTABLE FIGURE 2-15.
PAGE 82
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (CONTINUED) FIG & ITEM # PART NUMBER 27 28 29 2180730 4761600 4751600 DESCRIPTION Fitting, Adapter (Not Shown - Located on Engine) Lockwasher 3/8" Flatwasher 3/8" QTY. REV.
PAGE 83
SECTION 2 TURNTABLE FIGURE 2-15. GENERATOR INSTALLATION- DEUTZ (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 84
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-16.
PAGE 85
SECTION 2 TURNTABLE FIGURE 2-16. PUMP COUPLING INSTALLATION FIG & ITEM # PART NUMBER DESCRIPTION PUMP COUPLING INSTALLATIONS 0239954 1 2 3 4 1660170 1660174 1660175 0701014 4832000 0080164 0250600 0256849 101 102 103 104 105 1660183 1660233 0701014 4832000 0080164 0701010 3020021 3120820 PUMP COUPLING INSTALLATION - LOVEJOY (STANDARD PARTS WHEN EQUIPPED) Note: Used with 13 tooth pump.
PAGE 86
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-17.
PAGE 87
SECTION 2 TURNTABLE FIGURE 2-17.
PAGE 88
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-17.
PAGE 89
SECTION 2 TURNTABLE FIGURE 2-17. PUMP ASSEMBLY - SUNSTRAND (CONTINUED) FIG & ITEM # PART NUMBER 86 87 88 89 7007475 7007477 7007476 7010120 2900752 7007412 2900826 2900827 3120820 DESCRIPTION Plug, Orifice/Screen -.156 Plug, Orifice -.
PAGE 90
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-18.
PAGE 91
SECTION 2 TURNTABLE FIGURE 2-18. PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697) FIG & ITEM # PART NUMBER 3600205 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7010955 Kit 7010956 Kit Kit 7010957 Kit 7010996 7010959 Not Used 7010997 7010998 7010960 7010961 7010953 3120820 DESCRIPTION PUMP ASSEMBLY - BARNES (OCTOBER 1992 TO S/N 38697) QTY. REV. Ref.
PAGE 92
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-19.
PAGE 93
SECTION 2 TURNTABLE FIGURE 2-19. PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT) FIG & ITEM # PART NUMBER 3600286 1 2 3 4 5 6 7 8 9 10 11 12 13 7010105 Not Serviced Not Serviced 7010103 7010126 7010125 Kit Kit 7010124 7010104 7010127 Kit Kit 7007489 3120820 DESCRIPTION PUMP ASSEMBLY - HYDRO-AIR (S/N 38697 TO PRESENT) QTY. REV. Ref.
PAGE 94
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 95
SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 96
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-20.
PAGE 97
SECTION 2 TURNTABLE FIGURE 2-20. TANKS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 98
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 99
SECTION 2 TURNTABLE FIGURE 2-21.
PAGE 100
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-21. HOOD INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 0641512 0940036 0901197 Not Used 0641508 4761500 3200222 2940042 Not Used Not Used 4300032 3536414 3536415 3535951 3820018 2820059 2820058 53 2820053 54 2820057 2 T U R N T A B L E 0100011 0252652 101 102 103 104 3960418 3960389 3960429 3960433 0251543 201 202 203 204 2-68 0140032 0641406 4751400 3311405 DESCRIPTION QTY.
PAGE 101
SECTION 2 TURNTABLE FIGURE 2-21. HOOD INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 102
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-22.
PAGE 103
SECTION 2 TURNTABLE FIGURE 2-22.
PAGE 104
S E C T I O N SECTION 2 TURNTABLE FIGURE 2-22. OIL COOLER INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 105
SECTION 3 BOOM TABLE OF CONTENTS FIGURE 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3120820 DESCRIPTION BOOM ASSEMBLY COMPONENTS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JIB BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTEND-A-REACH INSTALLATION . . . . . . . . . . . . . . . . . . . . .
PAGE 106
S E C T I O N SECTION 3 BOOM FIGURE 3-1.
PAGE 107
SECTION 3 BOOM FIGURE 3-1.
PAGE 108
S E C T I O N SECTION 3 BOOM FIGURE 3-1.
PAGE 109
SECTION 3 BOOM FIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY.
PAGE 110
S E C T I O N SECTION 3 BOOM FIGURE 3-1.
PAGE 111
SECTION 3 BOOM FIGURE 3-1.
PAGE 112
S E C T I O N SECTION 3 BOOM FIGURE 3-1.
PAGE 113
SECTION 3 BOOM FIGURE 3-1.
PAGE 114
S E C T I O N SECTION 3 BOOM FIGURE 3-2.
PAGE 115
SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES FIG & ITEM # PART NUMBER 0238945 1 2 3 4 5 6 7 8 4843026 3532466 1360175 3420552 0630197 4740156 4740270 3450504 0238919 101 102 103 104 105 106 107 0630410 1360209 3532425 3421535 3421534 3450506 4740111 0238901 201 202 203 204 205 206 207 0630409 1360206 3532410 3421535 3421534 3450506 4740111 0239268 301 302 3840945 1360208 303 0238900 0100003 0238900 401 402 3120820 1360207 1360206 DESCRIPTION QTY. CHAIN ADJUSTER ASSEMBLIES Ref.
PAGE 116
S E C T I O N SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER 403 404 405 406 407 3532410 3421535 3421534 3450506 3534436 DESCRIPTION Plate, Chain Adjuster (Top) Pin, Adjuster Plate Pin, Clevis Pin, Cotter 3/32" x 1 1/2" Plate, Chain Adjuster Plate (Bottom) QTY. REV.
PAGE 117
SECTION 3 BOOM FIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 118
S E C T I O N SECTION 3 BOOM FIGURE 3-3.
PAGE 119
SECTION 3 BOOM 1 S E C T I O N 1 3 FIGURE 3-3.
PAGE 120
S E C T I O N SECTION 3 BOOM FIGURE 3-4.
PAGE 121
SECTION 3 BOOM FIGURE 3-4. EXTEND-A-REACH INSTALLATION FIG & ITEM # PART NUMBER 0252610 1 2 3 4 4844092 0960565 4844093 0961654 0960565 4844094 0961654 4844095 1320051 5 1682635 1683725 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1682642 1682753 1683493 3422087 3422077 3422079 3422081 3422083 3422037 Not Used 2160002 0641608 4761600 0641610 3311605 3422085 1320184 3535978 1670634 4300076 3311602 4751600 0100011 3120820 DESCRIPTION EXTEND-A-REACH INSTALLATION QTY. REV. Ref.
PAGE 122
S E C T I O N SECTION 3 BOOM FIGURE 3-5.
PAGE 123
SECTION 3 BOOM FIGURE 3-5.
PAGE 124
S E C T I O N SECTION 3 BOOM FIGURE 3-5.
PAGE 125
SECTION 3 BOOM FIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 126
S E C T I O N SECTION 3 BOOM FIGURE 3-6.
PAGE 127
SECTION 3 BOOM FIGURE 3-6. BROKEN CHAIN LIMIT SWITCH INSTALLATION (GERMAN/AUSTRIAN EN280 SPECS & ALL CE SPECS) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 128
S E C T I O N SECTION 3 BOOM FIGURE 3-7.
PAGE 129
SECTION 3 BOOM FIGURE 3-7.
PAGE 130
S E C T I O N SECTION 3 BOOM FIGURE 3-7. BOOM WIPERS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
PAGE 131
SECTION 4 PLATFORMS TABLE OF CONTENTS FIGURE 4-1 4-2 4-3 4-4 4-5 DESCRIPTION PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLY (Prior to S/N 25609) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM CONSOLE ASSEMBLY (S/N 25609 to Present). . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 132
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 133
SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 134
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-1.
PAGE 135
SECTION 4 PLATFORMS FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (LOW MOUNT) (CONTINUED) FIG & ITEM # PART NUMBER 506 507 508 509 510 511 512 1100066 4460049 4761600 0641608 3440418 4360307 2540016 DESCRIPTION Cam, Interlock Connector, Strain Relief Lockwasher 3/8” Bolt 3/8”-16NC x 1” Roll Pin 1/8” x 1 1/8” Head, Switch Grommet (Not Shown) QTY. REV.
PAGE 136
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-2.
PAGE 137
SECTION 4 PLATFORMS FIGURE 4-2.
PAGE 138
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-3.
PAGE 139
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) FIG & ITEM # 1 PART NUMBER DESCRIPTION QTY. REV. 0860773 PLATFORM CONSOLE ASSEMBLY (MACHINES BUILT PRIOR TO S/N 25609) Ref.
PAGE 140
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-3.
PAGE 141
SECTION 4 PLATFORMS FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 25609) (CONTINUED) FIG & ITEM # PART NUMBER 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 3300047 0960239 Not Used 4460414 4460412 4460411 4460451 4460452 0720803 4750800 4760800 4360327 4460308 1600153 3910616 4460415 4460413 3300352 92 93 94 95 96 97 98 2560115 2560136 2920104 4460442 2920108 0140019 0140026 4420008 3520033 3520034 0100001 3120820 DESCRIPTION QTY.
PAGE 142
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-4.
PAGE 143
SECTION 4 PLATFORMS FIGURE 4-4.
PAGE 144
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-4.
PAGE 145
SECTION 4 PLATFORMS FIGURE 4-4.
PAGE 146
S E C T I O N SECTION 4 PLATFORMS FIGURE 4-5.
PAGE 147
SECTION 4 PLATFORMS FIGURE 4-5. OPTIONAL PLATFORM MOUNTED COMPONENTS FIG & ITEM # PART NUMBER 0251203 0252054 1 1670526 1670607 3900022 3901406 4751400 0253077 2 3 to 7 0140026 Not Used 0253987 0254748 8 2920111 3536089 0250143 9 10 to 14 4160028 0900232 0901056 4220007 Not Used 1282197 0255695 0259365 15 16 17 0630440 3010088 1260136 4360057 0200048 0940038 1670663 1670715 1670665 1670666 1670716 1670717 3120820 DESCRIPTION QTY. OPTIONAL PLATFORM MOUNTED COMPONENTS Ref.
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S E C T I O N SECTION 4 PLATFORMS FIGURE 4-5. OPTIONAL PLATFORM MOUNTED COMPONENTS (CONTINUED) FIG & ITEM # PART NUMBER 17 (cont’d) 1670718 1670719 4360274 3252238 18 DESCRIPTION Cover (RH Mid Rail) Cover (Bumper Rail) Switch, Push Button Decal - Soft Touch System QTY. REV.
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SECTION 5 CYLINDERS TABLE OF CONTENTS FIGURE 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 3120820 DESCRIPTION AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXTEND-A-REACH LIFT CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . .
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-1.
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SECTION 5 CYLINDERS FIGURE 5-1.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-2.
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SECTION 5 CYLINDERS FIGURE 5-2.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-3.
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SECTION 5 CYLINDERS FIGURE 5-3.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-4.
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SECTION 5 CYLINDERS FIGURE 5-4.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-5.
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SECTION 5 CYLINDERS FIGURE 5-5.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-6.
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SECTION 5 CYLINDERS FIGURE 5-6. MASTER CYLINDER ASSEMBLY FIG & ITEM # PART NUMBER 1681580 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1681490 1681488 0960097 1120179 1680892 3480120 3300272 Kit Kit Kit Kit Kit Kit Kit Kit Not Used 4563031 2160002 2200201 Not Used Not Used 3900170 0100011 0100038 0100035 2900381 3120820 DESCRIPTION QTY. REV. MASTER CYLINDER ASSEMBLY Ref.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-7.
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SECTION 5 CYLINDERS FIGURE 5-7.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-8.
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SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY FIG & ITEM # 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 26 27 28 29 30 31 32 33 34 to 35 36 3120820 PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER 0100020 0100011 0100035 0100038 2901109 2901234 5 DESCRIPTION Sealant, Pipe Loctite #242 Loctite #222 Primer, Locking ————————— Seal Kit Options (Includes Items 13-20) : Prior to November 1992 November 1992 to Present QTY. REV.
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SECTION 5 CYLINDERS FIGURE 5-8. TELESCOPE CYLINDER ASSEMBLY (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-9.
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SECTION 5 CYLINDERS FIGURE 5-9. CYLINDER BELLOWS INSTALLATION (OPTIONAL) FIG & ITEM # PART NUMBER 0252829 1 2 3 4 5 6 7 0460089 0460088 0460087 0460086 0460071 1320037 1320059 DESCRIPTION CYLINDER BELLOWS INSTALLATION (OPTIONAL) Bellow (Steer) Bellow (Extend-A-Reach Level) Bellow (Extend-A-Reach Lift) Bellow (Boom Lift) Bellow (Master) Clamp Clamp QTY. REV. Ref.
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S E C T I O N SECTION 5 CYLINDERS FIGURE 5-9. CYLINDER BELLOWS INSTALLATION (OPTIONAL) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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SECTION 6 HYDRAULICS TABLE OF CONTENTS FIGURE 6-1 6-2 6-3 6-4 6-5 6-6 DESCRIPTION HYDRAULIC DIAGRAM - DRIVE (4WD - Deutz Engine) (Prior to S/N 38697) . . . . . . . . . . . . . HYDRAULIC DIAGRAM - DRIVE (4WD - Deutz Engine) (S/N 38697 to Present) . . . . . . . . . . . HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS) . . . . . . . . . . HYDRAULIC DIAGRAM - STANDARD (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DIAGRAM - STANDARD (S/N 38697 to Present) . .
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-1.
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SECTION 6 HYDRAULICS FIGURE 6-1.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-1.
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SECTION 6 HYDRAULICS FIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (PRIOR TO S/N 38697) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-2.
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SECTION 6 HYDRAULICS FIGURE 6-2.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-2.
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SECTION 6 HYDRAULICS FIGURE 6-2. HYDRAULIC DIAGRAM - DRIVE (4WD AND DEUTZ ENGINE) (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-3.
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SECTION 6 HYDRAULICS FIGURE 6-3. HYDRAULIC DIAGRAM - MANUAL DESCENT (FRENCH AND ITALIAN SPECS) FIG & ITEM # PART NUMBER 0253649 1 2 3 4 5 6 7 8 9 10 11 12 13 3120820 4640543 2220468 2750900 2220605 Not Used 2751396 4640731 2220415 4300051 3311405 4751400 Not Used 1701746 DESCRIPTION HYDRAULIC DIAGRAM - MANUAL DESCENT QTY. REV. Ref.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-4.
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SECTION 6 HYDRAULICS FIGURE 6-4.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-4.
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SECTION 6 HYDRAULICS FIGURE 6-4. HYDRAULIC DIAGRAM - STANDARD (PRIOR TO S/N 38697) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-5.
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SECTION 6 HYDRAULICS FIGURE 6-5.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-5.
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SECTION 6 HYDRAULICS FIGURE 6-5. HYDRAULIC DIAGRAM - STANDARD (S/N 38697 TO PRESENT) (CONTINUED) FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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S E C T I O N SECTION 6 HYDRAULICS FIGURE 6-6. HYDRAULIC DIAGRAM LIST FIG & ITEM # PART NUMBER DESCRIPTION HYDRAULIC DIAGRAM LIST Note: Diagrams with asterisk (*) are shown in preceding pages. Information on Diagrams not shown are available from JLG Service/Parts Departments. 2791925* 6 2792376* H Y D R A U L I C S Ref. Ref. Hydraulic Diagram - Manual Descent (Prior to October 1992) Ref. 0253649* Hydraulic Diagram - Manual Descent (October 1992 to Present) Ref.
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SECTION 7 ELECTRICAL TABLE OF CONTENTS FIGURE 7-1 7-2 7-3 DESCRIPTION PAGE ELECTRICAL SCHEMATIC (Prior to S/N 38697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 ELECTRICAL SCHEMATIC (S/N 38697 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 ELECTRICAL COMPONENTS AND DIAGRAM CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-1.
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SECTION 7 ELECTRICAL S E C T I O N FIGURE 7-1.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-1.
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SECTION 7 ELECTRICAL S E C T I O N FIGURE 7-1.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-2.
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SECTION 7 ELECTRICAL FIGURE 7-2.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-2.
PAGE 199
SECTION 7 ELECTRICAL FIGURE 7-2.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART FIG & ITEM # 7 PART NUMBER Ref. REV. 3740049 3990010 1060341 0253077 0140026 1540002 4932635 Australian Spec Wiring Diagram Ref. D 1281819 1060394 Boom Electric Components Cable, Electrical - 10/4 Options: Prior to S/N 37026 S/N 37026 to Present Cable, Electrical - 16/36 Options: Prior to S/N 37026 S/N 37026 to Present Ref. H 0610091 3740049 4932639/1282091 4932638/1282091 1060392 — 2/C 2/C 5 140 ft.
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SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM # PART NUMBER 0255152 4360179 4360065 4932892 4921886 3740080 Engine Distress Electrical Diagram Switch, Temperature Switch, Oil Pressure Engine Shutdown Electrical Diagram (Broken Fan Belt) Harness Relay, Bosch QTY. REV. Ref. 1 1 3 Ref. — 1 1 3300047 0960239 4932484 4921417 Frame Electrical Diagram Harness Assembly Ref.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM # PART NUMBER 0255273 3740049 3990010 0255272 2920113 0901928 4360089 7 E L E C T R I C A L Stop Lights Components Relay Diode 6 Amp Turn Signal Components Taillight Bracket Switch, Flasher QTY. REV. Ref. 4 5 Ref.
PAGE 203
SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM # PART NUMBER QTY. 4360057 4360274 3252238 3740049 1060341 Platform Bumpers Electrical Diagrams Prior to S/N 43389 S/N 43389 to Present Switch, Limit Switch, Push Button Decal - Softtouch Relay Cable, Electrical - 16/2 12 ft./3.7m 4932621 1060300 Platform Gate Interlock Electrical Diagram Cable, Electrical 15 ft./4.
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S E C T I O N SECTION 7 ELECTRICAL FIGURE 7-3. ELECTRICAL COMPONENTS AND DIAGRAM CHART (Continued) FIG & ITEM # PART NUMBER 1060302 4921415 4921416 4921418 1540003 3730095 3730115 7 E L E C T R I C A L 7-14 DESCRIPTION Cable, Electrical - 16/5 (GCB to Boom Length Measuring Device) Harness (Engine Terminal Strip to GCB) Harness (Valves to GCB) Harness (GCB to Collector Ring) Capacitor Resistor - 7.5 Ohm Resistor Adjustable - 7.5 Ohm QTY. REV. 15 ft./4.
PAGE 205
SECTION 8 DECALS TABLE OF CONTENTS FIGURE 8-1 DESCRIPTION PAGE DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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S E C T I O N SECTION 8 DECALS FIGURE 8-1.
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SECTION 8 DECALS FIGURE 8-1.
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S E C T I O N SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM # 101 102 103 8 PART NUMBER DESCRIPTION QTY. 0010448 DECAL INSTALLATION - FUEL (VARIABLE PARTS) Ref.
PAGE 209
SECTION 8 DECALS FIGURE 8-1.
PAGE 210
S E C T I O N SECTION 8 DECALS FIGURE 8-1. DECALS INSTALLATION (CONTINUED) FIG & ITEM # PART NUMBER 213 Not Required Not Required 1703663* 214 Not Required Not Required 1703664* 8 215 Not Required Not Required 1702612* D E C A L S Not Available 2900998 0257223 301 302 8-6 1703481 1702928 DESCRIPTION QTY.
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SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS EURO 120HX 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.
PAGE 212
S E C T I O N SECTION 9 RECOMMENDED SERVICE PARTS STOCK MODELS EURO 120HX 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.
PAGE 213
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. FIGURE 10-1. MISCELLANEOUS SPECIAL OPTIONS FIG & ITEM # PART NUMBER DESCRIPTION MISCELLANEOUS SPECIAL OPTIONS Airline Installation - 1/2" Ref. 2910105 Axle Hose Retract Springs Kit Ref.
PAGE 214
S E C T I O N SECTION 10 SPECIAL OPTIONS FIGURE 10-1. MISCELLANEOUS SPECIAL OPTIONS (CONTINUED) FIG & ITEM # PART NUMBER 7016654 7002822 7004275 7004276 7002828 7014676 9900443 0257728 Tube Rack Installation Ref. 0253050 Turntable Pinion Shield Installation Ref. 0258918 Utility Rack Installation Ref. 0255061 Weld Leads Installation Ref. 7002823 S P E C I A L QTY. Tools for Service: Crimper, Wire Fastener Kit - U.S.
PAGE 215
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3120820 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.