Jlg 110SX Parts Manual User Manual

Illustrated Parts ManualModels100SX110SX110SXJ120SXJP/N3121811January 2, 2012

1-4 3121811SECTION 1 FRAMESECTION1FRAME117 4641134Valve Assembly - Hydro Air (See Figure 1-2 for Breakdown) (100SX & 110SX Only)2118 Not Used119 4

3-6 3121811SECTION 3 BOOMSECTION3 BOOM35 0238945Adjustable Clevis Assembly - Outer Mid and Fly Retract Chain (See Figure 3-2 for Breakdown)236 Not Us

3121811 3-7SECTION3 BOOMSECTION 3 BOOM80 0239607 Sheave Assembly - Outer Mid Extend Chain 10961370 Bushing, Bronze 181 0901700 Bracket, Wear Pad 182

3-8 3121811SECTION 3 BOOMSECTION3 BOOM105 Cable, Electrical - 10/4 + 18/16 Options: 14922403 100SX4922401 110SX/110SXJ - With Inverted Power Track492

3121811 3-9SECTION3 BOOMSECTION 3 BOOM116 4060684 Shield, Hose and Cable (Right Side) 1117 Support, Hydraulic Line Options: 41320279 100SX/110SX/110S

3-10 3121811SECTION 3 BOOMSECTION3 BOOM156 Not Required157 Not Used158 0741608 Screw, Countersunk 3/8"-16NC x 1" 1159 Not Used160 4740304 W

3121811 3-11SECTION3 BOOMSECTION 3 BOOMFIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. RE

3-12 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES

3121811 3-13SECTION3 BOOMSECTION 3 BOOMFIGURE 3-2. CHAIN ADJUSTER ASSEMBLIESFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CHAIN ADJUSTER ASSEMBL

3-14 3121811SECTION 3 BOOMSECTION3 BOOM— — — — — — — — — —0100003 Loctite #277 A/R0238900CHAIN ADJUSTER ASSEMBLY (OUTER MID RETRACT)Ref. B401 1360207

3121811 3-15SECTION3 BOOMSECTION 3 BOOMFIGURE 3-2. CHAIN ADJUSTER ASSEMBLIES (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 1-5SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. R

3-16 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-3. JIB BOOM INSTALLATION

3121811 3-17SECTION3 BOOMSECTION 3 BOOMFIGURE 3-3. JIB BOOM INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0258414 JIB BOOM INSTALLAT

3-18 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-4. EXTEND-A-REACH INSTALLATION

3121811 3-19SECTION3 BOOMSECTION 3 BOOMFIGURE 3-4. EXTEND-A-REACH INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.EXTEND-A-REACH INSTA

3-20 3121811SECTION 3 BOOMSECTION3 BOOM21 3535978 Plate 222 Cover, Hose and Cable Options: 11670642 110SXJ1670634 120SXJ23 4300076 Stud (Welded on Pa

3121811 3-21SECTION3 BOOMSECTION 3 BOOMFIGURE 3-4. EXTEND-A-REACH INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3-22 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION

3121811 3-23SECTION3 BOOMSECTION 3 BOOMFIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY

3-24 3121811SECTION 3 BOOMSECTION3 BOOM316 to 318 Not Used0270824BOOM LENGTH LIMIT SWITCHES INSTALLATIONS (120SXJ ONLY)Ref. 1401 4360277 Switch, Limi

3121811 3-25SECTION3 BOOMSECTION 3 BOOMFIGURE 3-5. BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DES

1-6 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR12451051041031011022022012033AXLE EXTENSION VALVE100SX & 110SXP/N 464

3-26 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-6. BOOM WIPERS INSTALLATION

3121811 3-27SECTION3 BOOMSECTION 3 BOOMFIGURE 3-6. BOOM WIPERS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0253303 BOOM WIPERS INS

3-28 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-6. BOOM WIPERS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 4-1SECTION4PLATFORMSSECTION 4 PLATFORMSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . .

4-2 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION

3121811 4-3SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-1. PLATFORM COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.PLATFORM

4-4 3121811SECTION 4 PLATFORMSSECTION4PLATFORMS105 4845426 Gate Weldment 1106 3900207 Fastener A/R(Note: P/N 3900207 Fastener may be replaced with P/

3121811 4-5SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-1. PLATFORM COMPONENTS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY.

4-6 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-2. PLATFORM SUPPORT & ROTATOR INSTALLATION (100SX/110SX)

3121811 4-7SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-2. PLATFORM SUPPORT & ROTATOR INSTALLATION (100SX/110SX)FIG & ITEM # PART NUMBER DESC

3121811 1-7SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-2. VALVE ASSEMBLY - HYDRO AIRFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.4641134AXLE EXTENSION

4-8 3121811SECTION 4 PLATFORMSSECTION4PLATFORMS41 0641820 Bolt 3/8”-16NC x 2 1/2” 20235238 ROTATOR ASSEMBLY Ref. E101 3160083Rotator Motor Assembly (S

3121811 4-9SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-2. PLATFORM SUPPORT & ROTATOR INSTALLATION (100SX/110SX) (CONTINUED)FIG & ITEM # PART

4-10 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-3. PLATFORM SUPPORT & ROTATOR INSTALLATION (110SXJ/120SXJ)PIVOTATTACHREF.1D38871010997766

3121811 4-11SECTION4PLATFORMSSECTION 4 PLATFORMS FIGURE 4-3. PLATFORM SUPPORT & ROTATOR INSTALLATION (110SXJ/120SXJ)FIG & ITEM # PART NUMBER

4-12 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-4. ROTATOR MOTOR ASSEMBLY

3121811 4-13SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-4. ROTATOR MOTOR ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3160083 ROTATOR M

4-14 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-5. PLATFORM CONSOLE ASSEMBLY52123016830240340722202011922131717A22192022382377762036618591922

3121811 4-15SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-5. PLATFORM CONSOLE ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.CONSOLE BOX AS

4-16 3121811SECTION 4 PLATFORMSSECTION4PLATFORMS36 4460234 Mount, Wire Strap 637 3740123 Relay 238 3740124 Spring, Relay A/R39 4360232 Breaker, Circui

3121811 4-17SECTION4PLATFORMSSECTION 4 PLATFORMSCONSOLE BOX ASSEMBLIES: Ref.Use 0861640 Production (was p/n 0861353) Ref. 1/A0861640 Post Production A

1-8 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-3. STEERING AND AXLES INSTALLATION12911012713714011312013412611811814314310410712714013713710811714010

4-18 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-6. CONTROLLER ASSEMBLY (LIFT & SWING)3232313130272857916151101418171913262521223324202326

3121811 4-19SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-6. CONTROLLER ASSEMBLY (LIFT & SWING)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1

4-20 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER)CONNECTTO PLUG2023211182123 72625242277A12201920104

3121811 4-21SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

4-22 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSHANDLE ASSEMBLY Ref.201 7019160 Cast Housing Assembly 1202 7019155 Shaft 8mm 1203 7019111 Bearing 2204

3121811 4-23SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-7. CONTROLLER ASSEMBLY (DRIVE & STEER) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTI

4-24 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-8. CONTROLLER ASSEMBLY (SPEED)91234551010A12667811

3121811 4-25SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-8. CONTROLLER ASSEMBLY (SPEED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1600272 CONT

4-26 3121811SECTION 4 PLATFORMSSECTION4PLATFORMSFIGURE 4-9. SOFT TOUCH SYSTEM INSTALLATION

3121811 4-27SECTION4PLATFORMSSECTION 4 PLATFORMSFIGURE 4-9. SOFT TOUCH SYSTEM INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.SOFT TOUC

3121811 1-9SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-3. STEERING AND AXLES INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.STEERING INSTALL

4-28 3121811SECTION 4 PLATFORMSSECTION4PLATFORMS34 1320040 Clamp 435 0641406 Bolt 1/4”-20NC x 3/4” 436 4711400 Flatwasher 1/4” 837 3311405 Locknut 1/4

3121811 5-1SECTION5CYLINDERSSECTION 5 CYLINDERSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE5-1 AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . .

5-2 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLY219232322812241817455191920202525710131615146

3121811 5-3SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-1. AXLE EXTENSION CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1683920

5-4 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-2. PLATFORM LEVEL CYLINDER ASSEMBLY

3121811 5-5SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-2. PLATFORM LEVEL CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.PLATFORM

5-6 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-3. BOOM LIFT CYLINDER ASSEMBLY

3121811 5-7SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-3. BOOM LIFT CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.BOOM LIFT CYL

5-8 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-4. EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY

3121811 5-9SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-4. EXTEND-A-REACH LEVEL CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.16

1-10 3121811SECTION 1 FRAMESECTION1FRAME110 0641436 Bolt 1/4"-20NC x 4 1/2" 4111 0641607 Bolt 3/8"-16NC x 7/8" 16112 0641612 Bolt

5-10 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-5. EXTEND-A-REACH LIFT CYLINDER ASSEMBLY

3121811 5-11SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-5. EXTEND-A-REACH LIFT CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.EX

5-12 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-6. JACK CYLINDER ASSEMBLY

3121811 5-13SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-6. JACK CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1683965 JACK CYLI

5-14 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-7. MASTER CYLINDER ASSEMBLY

3121811 5-15SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-7. MASTER CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.MASTER CYLINDER

5-16 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-8. STEER CYLINDER ASSEMBLY

3121811 5-17SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-8. STEER CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.STEER CYLINDER A

5-18 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-9. TIE ROD CYLINDER ASSEMBLY

3121811 5-19SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-9. TIE ROD CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.1683921 TIE RO

3121811 1-11SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

5-20 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-10. TELESCOPE CYLINDER ASSEMBLY

3121811 5-21SECTION5CYLINDERSSECTION 5 CYLINDERSFIGURE 5-10. TELESCOPE CYLINDER ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.TELESCOPE C

5-22 3121811SECTION 5 CYLINDERSSECTION5CYLINDERSFIGURE 5-10. TELESCOPE CYLINDER ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

3121811 6-1SECTION6HYDRAULICSSECTION 6 HYDRAULICSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE6-1 HYDRAULIC DIAGRAM - DRIVE (4WD - DEUTZ ENGINE) . . . . .

6-2 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICSFIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD/DEUTZ ENGINE) 30114112714142827112640444443202213134241312

3121811 6-3SECTION6HYDRAULICSSECTION 6 HYDRAULICSFIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD/DEUTZ ENGINE)FIG & ITEM # PART NUMBER DESCRIPTION QTY

6-4 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICS41 2753035 Hose 142 2752446 Hose 143 4100059 Hose, Protection 16ft/4.9m44 2220407 Fitting, 90° 1FIGUR

3121811 6-5SECTION6HYDRAULICSSECTION 6 HYDRAULICSFIGURE 6-1. HYDRAULIC DIAGRAM - DRIVE (4WD/DEUTZ ENGINE) (CONTINUED)FIG & ITEM # PART NUMBER DES

6-6 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICSFIGURE 6-2. HYDRAULIC DIAGRAM - T/T & BOOM1555525736205849525351525427531650401653215552275117187

3121811 6-7SECTION6HYDRAULICSSECTION 6 HYDRAULICSFIGURE 6-2. HYDRAULIC DIAGRAM - T/T & BOOMFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HYDR

1-12 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS3102SPINDLEREF.101204203202 LH201 RH4

6-8 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICS39 2750889 Hose A/R40 2750785 Hose 541 2750771 Hose 242 2751617 Hose 143 2751466 Hose 244 2750763 Hos

3121811 6-9SECTION6HYDRAULICSSECTION 6 HYDRAULICS76 Plug Options: A/R2220237 100SX/110SX 2Not Required 110SXJ/120SXJ 0FIGURE 6-2. HYDRAULIC DIAGRAM -

6-10 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICSFIGURE 6-3. HYDRAULIC DIAGRAM - STEER121011111181119934561111211312825112”12”71112”12”

3121811 6-11SECTION6HYDRAULICSSECTION 6 HYDRAULICSFIGURE 6-3. HYDRAULIC DIAGRAM - STEERFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HYDRAULIC DI

6-12 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICSFIGURE 6-4. HYDRAULIC DIAGRAM - LIFTING JACKS129888101016111212221120143121336111111145101528547

3121811 6-13SECTION6HYDRAULICSSECTION 6 HYDRAULICSFIGURE 6-4. HYDRAULIC DIAGRAM - LIFTING JACKSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.2792

6-14 3121811SECTION 6 HYDRAULICSSECTION6HYDRAULICSFIGURE 6-5. HYDRAULIC DIAGRAM LISTFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HYDRAULIC DIAGRA

3121811 7-1SECTION7ELECTRICALSECTION 7 ELECTRICALTABLE OF CONTENTSFIGURE DESCRIPTION PAGE7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . .

7-2 3121811SECTION 7 ELECTRICALSECTION7ELECTRICAL FIGURE 7-1.ELECTRICAL DIAGRAM LISTFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.Note: Diagrams

3121811 7-3SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-1.ELECTRICAL DIAGRAM LIST (Continued)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 1-13SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONSFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.TIRE AND WHE

7-4 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-2.ELECTRICAL SCHEMATIC - 100SX/110SX

3121811 7-5SECTION 7 ELECTRICALSECTION7ELECTRICAL1870125_D

7-6 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFigure 7-2. ELECTRICAL SCHEMATIC - 100SX/110SX

3121811 7-7SECTION 7 ELECTRICALSECTION7ELECTRICAL1870125_D

7-8 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-3.ELECTRICAL SCHEMATIC - 110SXJ

3121811 7-9SECTION 7 ELECTRICALSECTION7ELECTRICAL1870124_D

7-10 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFigure 7-3. ELECTRICAL SCHEMATIC - 110SXJ

3121811 7-11SECTION 7 ELECTRICALSECTION7ELECTRICAL1870124_D

7-12 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-4.ELECTRICAL SCHEMATIC - 120SXJ

3121811 7-13SECTION 7 ELECTRICALSECTION7ELECTRICAL

1-14 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-5. DRIVE HUB ASSEMBLY

7-14 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFigure 7-4. ELECTRICAL SCHEMATIC - 120SXJ

3121811 7-15SECTION 7 ELECTRICALSECTION7ELECTRICAL1870123_D

7-16 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-5. HARNESS COMPONENTS INSTALLATION TO CONSOLEBOXSTROBELIGHT655655ALOADMANAGEMENTLIMIT

3121811 7-17SECTION 7 ELECTRICALSECTION7ELECTRICAL2-SPEED VALVEBRAKEBROKEN FAN BELTRELAYHORIZONTALBOOM LIMIT SWITCHBEFORE 10’BOOM LIMIT SWITCHAXLELIMI

7-18 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-5. HARNESS COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.HARNES

3121811 7-19SECTION 7 ELECTRICALSECTION7ELECTRICAL205 4460473 Clamp, Cable 1BOOM HARNESS INSTALLATION - 10/4-18/164922403 100SXJ Ref. 24922401 110SX/1

7-20 3121811SECTION 7 ELECTRICALSECTION7ELECTRICAL302 4922451 Harness - Relay 1 1/A302A 4460741 Plug - 5 Position 16302B 4460420 Terminal 50303 492238

3121811 7-21SECTION 7 ELECTRICALSECTION7ELECTRICAL558 4460499 Connector, DIN with Diode 11559 to 563 Not Used564 4460225 Connector - 6 Position 1565 4

7-22 3121811SECTION 7 ELECTRICALSECTION7ELECTRICAL658 Not Available Alarm Harness (Travel, Descend & Motion) A/R1060341 Cable, Electrical - 16/211

3121811 7-23SECTION 7 ELECTRICALSECTION7ELECTRICAL708A 4460741 Plug - 5 Position 1708B 4460420 Terminal 3708C 1060016 Cable, Electrical - 16/352ft/15.

3121811 1-15SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-5. DRIVE HUB ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.2780248 DRIVE HUB ASSEMBLY R

7-24 3121811SECTION 7 ELECTRICALSECTION7ELECTRICALFIGURE 7-5. HARNESS COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 8-1SECTION8DECALSSECTION 8 DECALSTABLE OF CONTENTSFIGURE DESCRIPTION PAGE8-1 DECALS INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

8-2 3121811SECTION 8 DECALSSECTION8DECALSFIGURE 8-1.DECALS INSTALLATION 4432252616 471718364232262035413273118387572611372424621542123293028195555

3121811 8-3SECTION 8 DECALSSECTION8DECALSFIGURE 8-1. DECALS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.STANDARD DECAL INSTALLATION

8-4 3121811SECTION 8 DECALSSECTION8DECALS12 Decal - Attach Lanyard Here Options: 41704277 Australian Spec1704277 Dutch/French/German/Italian/Spanish/U

3121811 8-5SECTION 8 DECALSSECTION8DECALS41 Not Used42 Decal Options: 21704600 Decal - 4 x 41704581 Decal - 4 x 4 x 4 All Wheel Steer43 1702861 Decal

8-6 3121811SECTION 8 DECALSSECTION8DECALS52 (cont’d) Use 1705397 100SX/110SX - French Spec (Was P/N 3252701) (Prior to S/N 67976)Use 1705396 110SXJ -

3121811 8-7SECTION 8 DECALSSECTION8DECALS57 0961127 Bushing, Snap 158 1701543 Decal, LPG (Not Shown) 259 1700818 Decal, Liquid Withdrawal System (Not

8-8 3121811SECTION 8 DECALSSECTION8DECALSFIGURE 8-1. DECALS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 9-1SECTION9RECOMMENDEDSERVICEPARTSSTOCKSECTION 9 RECOMMENDED SERVICE PARTS STOCKMODELS 100SX/110SX/110SXJ/120SXJThe following list will servic

1-16 3121811SECTION 1 FRAMESECTION1FRAME55 Kit 4 Spring, Pressure 156 to 59 Not Used60 7022572 Spindle 161 7022573 Piston 162 7022574 Coupler 163 7022

9-2 3121811SECTION 9 RECOMMENDED SERVICE PARTS STOCKSECTION9RECOMMENDEDSERVICEPARTSSTOCKMODELS 100SX/110SX/110SXJ/120SXJThe following list will servic

3121811 10-1SECTION10SPECIALOPTIONSSECTION 10 SPECIAL OPTIONSNote: This list is to accommodate machines ordered with special equipment. Options may no

10-2 3121811SECTION 10 SPECIAL OPTIONSSECTION10SPECIALOPTIONS0270511 Rail Extension (36”x 72”) (0.9m X 1.83m) Ref.0271771 Rail Extension (36”x 96”) (

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

3121811 1-17SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

1-18 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTH

3121811 1-19SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTHFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3160248 DRIVE MO

1-20 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-7. JACK CYLINDER INSTALLATION215 1517JUNCTIONBOX REF.2020141114141311111857977384310 10

3121811 1-21SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-7. JACK CYLINDER INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0270268 JACK CYLINDE

1-22 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIR234435511

3121811 1-23SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIRFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.4641133 VALVE A

REVISION LOG3121811 AJune 16, 2000 - Original Issue Of ManualAugust 2, 2000 - Revised (Manual edited to 0010569 Revision 3 Models 100SX/110SX/110SXJ &

1-24 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIR (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 2-1SECTION2TURNTABLESECTION 2 TURNTABLETABLE OF CONTENTSFIGURE DESCRIPTION PAGE2-1 TURNTABLE, BOOM AND SWITCHES INSTALLATION . . . . . . . . .

2-2 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATION

3121811 2-3SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-1. TURNTABLE, BOOM AND SWITCHES INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV

2-4 3121811SECTION 2 TURNTABLESECTION2TURNTABLE118 4751600 Flatwasher 3/8" A/R119 4761600 Lockwasher 3/8" A/R120 3311601 Nut 3/8"-16NC

3121811 2-5SECTION2TURNTABLESECTION 2 TURNTABLE304 Hose Options: 12750529 100SX/110SX2750528 110SXJ/120SXJ305 2750807 Hose 1306 2200261 Fitting, Nippl

2-6 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED

3121811 2-7SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTEDFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.V

2-8 3121811SECTION 2 TURNTABLESECTION2TURNTABLE112 4922448 Harness, Plug Assembly (Not Shown) 10252926 TILT INDICATOR INSTALLATION Ref. 3201 4360363 S

3121811 2-9SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-2. VALVES INSTALLATION - TURNTABLE MOUNTED (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTIO

REVISION LOGB 3121811

2-10 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-3. VALVES ASSEMBLY - HYDRO AIR

3121811 2-11SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-3. VALVES ASSEMBLY - HYDRO AIRFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.VALVE ASSEMB

2-12 3121811SECTION 2 TURNTABLESECTION2TURNTABLE18 7017452 Cartridge, Solenoid Valve (Without Coil) (Telescope) 17017402 Seal Kit - 7017452 Cartridge

3121811 2-13SECTION2TURNTABLESECTION 2 TURNTABLE33 7024826 Screw A/RFIGURE 2-3. VALVES ASSEMBLY - HYDRO AIR (CONTINUED)FIG & ITEM # PART NUMBER D

2-14 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-4. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION

3121811 2-15SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-4. ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATIONFIG & ITEM # PART NUMBER

2-16 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-5. SWING DRIVE AND BEARING INSTALLATION.

3121811 2-17SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-5. SWING DRIVE AND BEARING INSTALLATION.FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.SW

2-18 3121811SECTION 2 TURNTABLESECTION2TURNTABLE0239842 TURNTABLE LOCK INSTALLATION Ref. B201 4843318 Bushing Weldment 1202 3421565 Pin, Snap 1203 126

3121811 2-19SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-5. SWING DRIVE AND BEARING INSTALLATION. (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION

3121811 iFIGURE NO. TITLE PAGE NO.TABLE OF CONTENTSSECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-6. SWING MOTOR ASSEMBLY1101211212102310312112151158108225105122810841066107710666106810817117

3121811 2-21SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-6. SWING MOTOR ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3160184 SWING MOTOR

2-22 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-7. SWING BRAKE ASSEMBLY141881916661777111210141392222231552120

3121811 2-23SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-7. SWING BRAKE ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0920109 SWING BRAKE

2-24 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-8. SWING HUB ASSEMBLY

3121811 2-25SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-8. SWING HUB ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.2780116 SWING HUB ASS

2-26 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-9. LOAD MANAGEMENT INSTALLATION

3121811 2-27SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-9. LOAD MANAGEMENT INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0239868 LOA

2-28 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-10. GROUND CONTROLS INSTALLATION1371021011111551571121041321461091101051062031272021711781771

3121811 2-29SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-10. GROUND CONTROLS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.GROUND CON

ii 3121811TABLE OF CONTENTS FIGURE NO. TITLE PAGE NO.SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-30 3121811SECTION 2 TURNTABLESECTION2TURNTABLE116 4460442 Stop, Terminal 1117 4460387 Block, Terminal 36118 4460388 Barrier, Terminal 5119 4460307 S

3121811 2-31SECTION2TURNTABLESECTION 2 TURNTABLE162 2420172 Hourmeter 1163 3740112 Relay, Ignition 1164 4070991 Shim .125 1165 4070987 Shim .015 1166

2-32 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-11. REMOTE DRIVE CONTROL BOX ASSEMBLY

3121811 2-33SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-11. REMOTE DRIVE CONTROL BOX ASSEMBLYFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.02700

2-34 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-12. DEUTZ F4L-912 ENGINE INSTALLATION

3121811 2-35SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-12. DEUTZ F4L-912 ENGINE INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.02702

2-36 3121811SECTION 2 TURNTABLESECTION2TURNTABLE43 4565269 Adapter, Exhaust 144 4751700 Flatwasher 7/16” 145 0700810 Bolt, Metric 8-1.25mm x 20mm 146

3121811 2-37SECTION2TURNTABLESECTION 2 TURNTABLE86 2220063 Fitting, 90° 287 2220720 Fitting, Barbed 288 0641414 Bolt 1/4"-20NC x 1 3/4" 1389

2-38 3121811SECTION 2 TURNTABLESECTION2TURNTABLE310 3290801 Nut, Metric 8mm - 1.25 2311 1320041 Clamp 1312 4761400 Lockwasher 1/4" 3313 4751600 F

3121811 2-39SECTION2TURNTABLESECTION 2 TURNTABLE70001112 Shaft, Idler70001065 Pin, Drive70000976 Bearing, Needle7010911 Pin, Dowel70001085 GasketUse I

3121811 1-1SECTION1FRAMESECTION 1 FRAMETABLE OF CONTENTSFIGURE DESCRIPTION1-1 FRAME, VALVES AND SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . .

2-40 3121811SECTION 2 TURNTABLESECTION2TURNTABLE7020400 Washer/Fuel Line 17020401 Washer 17020402 Washer/Fuel Line 17020403 Washer/Fuel Line 17020405

3121811 2-41SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-12. DEUTZ F4L-912 ENGINE INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QT

2-42 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-13. PUMP COUPLING INSTALLATION

3121811 2-43SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-13. PUMP COUPLING INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0256849 PUMP

2-44 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-14. PUMP ASSEMBLY - SUNSTRAND

3121811 2-45SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-14. PUMP ASSEMBLY - SUNSTRANDFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3600260 PISTO

2-46 3121811SECTION 2 TURNTABLESECTION2TURNTABLE48 7007208 Plug 149 7007454 Cover, Front 150 Kit Block, Cylinder 151 7007456 Screw - 12 Point Head 652

3121811 2-47SECTION2TURNTABLESECTION 2 TURNTABLE2900752Seal Kit - Complete (Includes Items 3,6,14,15,37,41,42, 44,45,55,56,63,76,78,84 and 85)17007412

2-48 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-15. PUMP ASSEMBLY - HYDRO-AIR

3121811 2-49SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-15. PUMP ASSEMBLY - HYDRO-AIRFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.3600286 PUMP

1-2 3121811SECTION 1 FRAMESECTION1FRAMEFIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION108116116A116B116C2022022042042061206121STEERVAL VESELECTORVA

2-50 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-16. TANKS INSTALLATION

3121811 2-51SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-16. TANKS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0252524 TANKS INSTAL

2-52 3121811SECTION 2 TURNTABLESECTION2TURNTABLE213 3311401 Nut 1/4"-20NC 14214 4761400 Lockwasher 1/4" 14215 0100020 Sealant, Thread (Not S

3121811 2-53SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-16. TANKS INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-54 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-17. HOOD INSTALLATION (PRIOR TO S/N 55762)

3121811 2-55SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-17. HOOD INSTALLATION (PRIOR TO S/N 55762)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

2-56 3121811SECTION 2 TURNTABLESECTION2TURNTABLE46 4300032 Stud (Welded on Part) 547 3536414 Plate, Seal 148 3536415 Plate, Seal 149 3535951 Plate, Hi

3121811 2-57SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-17. HOOD INSTALLATION (PRIOR TO S/N 55762) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTI

2-58 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-18. HOOD INSTALLATION (S/N 55762 TO PRESENT)

3121811 2-59SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-18. HOOD INSTALLATION (S/N 55762 TO PRESENT)FIG & ITEM # PART NUMBER DESCRIPTION QTY. RE

3121811 1-3SECTION1 FRAMESECTION 1 FRAMEFIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.FRAME, VA

2-60 3121811SECTION 2 TURNTABLESECTION2TURNTABLE46 4300032 Stud (Welded on Part) 547 3536414 Plate, Seal 148 3536415 Plate, Seal 149 3535951 Plate, Hi

3121811 2-61SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-18. HOOD INSTALLATION (S/N 55762 TO PRESENT) (CONTINUED)FIG & ITEM # PART NUMBER DESCRIP

2-62 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-19. OIL COOLER INSTALLATION

3121811 2-63SECTION2TURNTABLESECTION 2 TURNTABLEFIGURE 2-19. OIL COOLER INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.0252906 OIL COO

2-64 3121811SECTION 2 TURNTABLESECTION2TURNTABLEFIGURE 2-19. OIL COOLER INSTALLATION (CONTINUED)FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

3121811 3-1SECTION3 BOOMSECTION 3 BOOMTABLE OF CONTENTSFIGURE DESCRIPTION PAGE3-1 BOOM ASSEMBLY COMPONENTS . . . . . . . . . . . . . . . . . . . . .

3-2 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION(SHEET 1 OF 2)

3121811 3-3SECTION3 BOOMSECTION 3 BOOMFIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATION (SHEET 2 OF 2)

3-4 3121811SECTION 3 BOOMSECTION3 BOOMFIGURE 3-1. BOOM ASSEMBLY COMPONENTS INSTALLATIONFIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.BOOM ASSEMB

3121811 3-5SECTION3 BOOMSECTION 3 BOOM6 Chain, Extend - Outer Mid BL866 Options: 1 set1260239 100SX/110SXJ1260235 110SX/120SXJ1260235 110SX/110SXJ -