JLG 120-SXJ Parts Manual
Illustrated Parts Manual
Models
100SX
110SX
110SXJ
120SXJ
P/N
3121106
January 2, 2012
REVISION LOG
June 1, 2000 - Original Issue Of Manual
August 2, 2000 - Revised (Manual edited to 0010569 Revision 3 Models 100SX/110SX/110SXJ & 0010570 Revision 2
Model 120SXJ)
November 9, 2000 - Revised (Manual edited to 0010569 Revision 5 Models 100SX/110SX/110SXJ & 0010570 Revision 5
Model 120SXJ)
June 18, 2001 - Revised (Manual edited to 0010569 Revision 9 Models 100SX/110SX/110SXJ & 0010570 Revision 9
Model 120SXJ)
August 22, 2002 - Revised (Manual edited to 0010569 Revision 17 Models 100SX/110SX/110SXJ & 0010570 Revision 14
Model 120SXJ)
September 30, 2003 - Revised (Manual edited to 0010569 Revision 18 Models 100SX/110SX/110SXJ & 0010570 Revision 15
Model 120SXJ)
November 15, 2006 - Revised (Manual edited to 0010569 Revision 18 Models 100SX/110SX/110SXJ & 0010570 Revision 15
Model 120SXJ)
January 2, 2012 - Revised Manual
3121106 A
REVISION LOG
B 3121106
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 1 - FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 FRAME, VALVES AND SHIELDS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-3 STEERING AND AXLES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-5 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-6 DRIVE MOTOR ASSEMBLY - REXROTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
1-7 JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
1-8 JACK VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 TURNTABLE, BOOM AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 VALVES INSTALLATION - TURNTABLE MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-3 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-4 ROTARY COUPLING AND COLLECTOR RING ASSEMBLY AND INSTALLATION . . . .2-14
2-5 SWING DRIVE AND BEARING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
2-6 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
2-7 SWING BRAKE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
2-8 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
2-9 LOAD MANAGEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
2-10 GROUND CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2-11 REMOTE DRIVE CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
2-12 DEUTZ F4L-912 ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
2-13 GENERATOR INSTALLATION- DEUTZ (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
2-14 FORD LRG-425EFI DUAL FUEL ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .2-46
2-15 DUAL FUEL INSTALLATIONS (FORD MACHINE OPTION) . . . . . . . . . . . . . . . . . . . . . .2-52
2-16 GENERATOR INSTALLATION - FORD (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
2-17 PUMP COUPLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
2-18 PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
2-19 PUMP ASSEMBLY - HYDRO-AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
2-20 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
2-21 HOOD INSTALLATION (PRIOR TO S/N 55762) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72
2-22 HOOD INSTALLATION (S/N 55762 TO PRESENT). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76
2-23 OIL COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-1 BOOM ASSEMBLY COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 CHAIN ADJUSTER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-3 JIB BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3-4 EXTEND-A-REACH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-5 BOOM LENGTH INDICATOR AND LIMIT SWITCHES INSTALLATION. . . . . . . . . . . . . .3-20
3-6 BOOM WIPERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
SECTION 4 - PLATFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-1 PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2 PLATFORM SUPPORT & ROTATOR INSTALLATION (100SX/110SX) . . . . . . . . . . . . . .4-6
4-3 PLATFORM SUPPORT & ROTATOR INSTALLATION (110SXJ/120SXJ) . . . . . . . . . . . .4-10
4-4 ROTATOR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-5 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-6 CONTROLLER ASSEMBLY (LIFT & SWING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
3121106 i
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
4-7 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4-8 CONTROLLER ASSEMBLY (SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
4-9 SOFT TOUCH SYSTEM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
SECTION 5 - CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 AXLE EXTENSION CYLINDER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-3 BOOM LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4 EXTEND-A-REACH LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-5 EXTEND-A-REACH LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-6 JACK CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 MASTER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-8 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-9 TIE ROD CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-10 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
SECTION 6 - HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 HYDRAULIC DIAGRAM - DRIVE (4WD / DEUTZ / FORD ENGINE) . . . . . . . . . . . . . . . .6-2
6-2 HYDRAULIC DIAGRAM - T/T & BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-3 HYDRAULIC DIAGRAM - STEER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-4 HYDRAULIC DIAGRAM - LIFTING JACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
6-5 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-2 ELECTRICAL SCHEMATIC - 100SX/110SX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-3 ELECTRICAL SCHEMATIC - 110SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-4 ELECTRICAL SCHEMATIC - 120SXJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7-5 HARNESS COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1 DECALS INSTALLATION - ANSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8-2 DECALS INSTALLATION - ANSI EXPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
ii 3121106
SECTION 1 FRAME
S
E
TABLE OF CONTENTS
FIGURE DESCRIPTION
1-1 FRAME, VALVES AND SHIELDS INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 STEERING AND AXLES INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4 WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-5 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-6 DRIVE MOTOR ASSEMBLY - REXROTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-7 JACK CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-8 JACK VALVE ASSEMBLY - HYDRO AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
C
T
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F
R
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3121106 1-1
S
108
116
116A
116B
116C
202
202
204
204
206
1
206
121
STEER
VALVE
SELECTOR
VALVE
BRAKE
VALVE
FLOW
DIVIDER
2WD
JUNCTION
MANIFOLD
FLOW
DIVIDER
4WD
106
121
121
114
115
108
105
105
112
104
119
121
121
117
127
125
119
124
117
128
104
119
203
203
201
201
205
205
113
113C
113B
113A
113A
AXLE
EXTENSION
VALVE
AXLE
EXTENSION
VALVE
SECTION 1 FRAME
E
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F
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FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION
1-2 3121106
SECTION 1 FRAME
S
FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
FRAME, VALVES AND SHIELDS INSTALLATION Ref.
1 2360535 Frame Weldment 1
0270353
0259923
101 to 103 Not Used
104 0641418 Bolt 1/4"-20NC x 2 1/4" 4
105 0641607 Bolt 3/8"-16NC x 7/8" 4
106 0641608 Bolt 3/8"-16NC x 1" 2
107 Not Used
108 0641628 Bolt 3/8"-16NC x 3 1/2" 4
109 to 111 Not Used
112 4641154 Valve Assembly - Hydro Air Selector 1
7012943 Coil 1
7017480 Cartridge 1
7012973 Seal Kit - 7017480 Cartridge 1
113 4641041 Valve Assembly - Flow Divider (2WD) 1
113A 7022397 Cartridge, Check Valves 2
7022399 Seal Kit - 7022397 Cartridge 2
113B 7022398 Cartridge, Load Shuttle 1
7023900 Seal Kit - 7022398 Cartridge 1
113C 7022396 Cartridge, Flow Divider 1
7021625 Seal Kit - 7022396 Cartridge 1
114 4641042 Valve Assembly - Flow Divider (4WD) 1
114A 7012978 Cartridge 2
7012980 Seal Kit 2
115 4641153 Valve Assembly - Solenoid 1
7012944 Coil, Solenoid
7012941 Cartridge
7010543 Seal Kit - 7012941 Cartridge
116 4641132 Valve Assembly - Steer 1
116A 7017490
7021400 Spool 1
7021401 Coil 2
7021402 Seal Kit 2
7021403 Cap, End 2
116B 7021407
7021408 Spool 1
7021401 Coil 2
7021402 Seal Kit 2
7021403 Cap, End 2
7021409 Spring, Centering 2
116C 7021644 Cartridge, Valve 2
7021645 Seal Kit - 7021644 Cartridge
VALVES INSTALLATION - FRAME MOUNTED
(100SX/110SX)
VALVES INSTALLATION - FRAME MOUNTED
(110SXJ/120SXJ)
Bosch Valve Section - Complete
(Directional Control)
Bosch Valve Section - Complete
(Directional Control)
Ref. B
Ref. E
1
1
E
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F
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3121106 1-3
S
SECTION 1 FRAME
E
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1
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FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
117 4641134
118 Not Used
119 4711400 Flatwasher 1/4” (Narrow) 7
120 Not Used
121 4751600 Flatwasher 3/8” (Wide) 10
122 to 123 Not Used
124 0641420 Bolt 1/4”-20NC x 2 1/2” 2
125 4641155 Valve, Junction Manifold 1
126 Not Used
127 4641165
128 4641166
0270200 2W/D Ref. B
0259925 4W/D Ref. B
201 0641404 Bolt 1/4”-20NC x 1/2” A/R
202 0641606 Bolt 3/8”-16NC x 3/4” 8
203 3572315 Plate, Cover A/R
204 4751600 Flatwasher 3/8" 8
205 4751400 Flatwasher 1/4" A/R
206 4846247 Shield 2
0100011 Loctite #242 A/R
Valve Assembly - Hydro Air (See Figure 1-2 for
Breakdown) (100SX & 110SX Only)
Valve Assembly - Hydro Air (See Figure 1-2 for
Breakdown) (110SXJ & 120SXJ Only)
Valve Assembly - Hydro Air (See Figure 1-2 for
Breakdown) (110SXJ & 120SXJ Only)
FRAME SHIELDS INSTALLATION OPTIONS: Ref.
— — — — — — — — — —
2
1
1
1-4 3121106
SECTION 1 FRAME
S
FIGURE 1-1. FRAME, VALVES AND SHIELDS INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
E
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F
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3121106 1-5
S
124
5
105
104
103
101
102
202
201
203
3
AXLE EXTENSION VALVE
100SX & 110SX
P/N 4641134
REAR AXLE EXTENSION VALVE
110SXJ & 120SX
P/N 4641165
FRONT AXLE EXTENSION VALVE
110SXJ & 120SX
P/N 4641166
SECTION 1 FRAME
E
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1
F
R
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FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR
1-6 3121106
SECTION 1 FRAME
S
FIGURE 1-2. VALVE ASSEMBLY - HYDRO AIR
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4641134
1 7012913 Cartridge, Valve 2
7017496 Seal Kit - 7012913 Cartridge (1 Per Cartridge) 2
2 7021634 Cartridge, Valve 2
7010545 Seal Kit - 7021634 Cartridge (1 Per Cartridge) 2
3 7011336 Cartridge, Check Valve 4
4 7012995 Cartridge, Valve - Hydraforce 2
7012518 Seal Kit - 7012995 Cartridge (1 Per Cartridge) 2
7012943 Coil - 12V (1 Per Cartridge) 2
5 7021635 Cartridge, Valve - Hydraforce 1
7012942 Seal Kit - 7021635 Cartridge 1
7012943 Coil - 12V 1
4641165
101 7012913 Cartridge, Valve 2
7017496 Seal Kit - 7012913 Cartridge (1 Per Cartridge) 2
102 7021634 Cartridge, Valve 2
7010545 Seal Kit - 7021634 Cartridge (1 Per Cartridge) 2
103 7011336 Cartridge, Check Valve 2
2900770 Seal Kit - 7011336 Cartridge (1 Per Cartridge) 2
104 7012995 Cartridge, Valve - Hydraforce 2
7012518 Seal Kit - 7012995 Cartridge (1 Per Cartridge) 2
7012943 Coil - 12V (1 Per Cartridge) 2
105 7021635 Cartridge, Valve - Hydraforce 1
7012942 Seal Kit - 7021635 Cartridge 1
7023994 Coil - 12V 1
AXLE EXTENSION VALVE ASSEMBLY - HYDRO AIR
(100SX & 110SX)
FRONT AXLE EXTENSION VALVE ASSEMBLY HYDRO AIR (110SXJ & 120SXJ)
Ref. A
Ref. A
E
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F
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4641166
201 7012913 Cartridge, Valve 2
7017496 Seal Kit - 7012913 Cartridge (1 Per Cartridge) 2
202 7011336 Cartridge, Check Valve 2
2900770 Seal Kit - 7011336 Cartridge (1 Per Cartridge) 2
203 7012995 Cartridge, Valve - Hydraforce 2
7012518 Seal Kit - 7012995 Cartridge (1 Per Cartridge) 2
7012943 Coil - 12V (1 Per Cartridge) 2
3121106 1-7
REAR AXLE EXTENSION VALVE ASSEMBLY - HYDRO
AIR (110SXJ & 120SXJ)
Ref. A
S
129
110
127
137
140
113
120
134
126
118
118
143
143
104
107
127
140
137
137
108
117
140
107
116
125
105
115
110
148181017719152
146
145
1
47144
121
126118143140135120103
127
140
113
119
1
1
9
119
119
124
1
24128
111
111
123
12312
4
149
130
140
114
113
113
140
137
13212213913
6
1
5
1
123
124
142
141
13110
9
127
133
133
112
112
106
138
113
2
5
12
6
8
18
96122
212
0
1
3
3311111
5
5
9
6
19
12
2
21
20
14
16
22
4
3
3
11
11
15
SECTION 1 FRAME
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FIGURE 1-3. STEERING AND AXLES INSTALLATION
1-8 3121106
SECTION 1 FRAME
S
FIGURE 1-3. STEERING AND AXLES INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
STEERING INSTALLATIONS Ref.
0259920 2WS Ref. D
0259919 4WS Ref. F
1Not Used
2 0641612 Bolt 3/8"-16NC x 1 1/2" 3
3 0641810 Bolt 1/2"-13NC x 1 1/4" 16
4 1683921 Cylinder, Tie-Rod (See Section 5 for Breakdown) 1
5
1683935 Steer Cylinder Assembly (2WS)
1683958 Steer Cylinder Assembly (4WS)
6 3311605 Locknut 3/8"-16NC 3
7 0641430 Bolt 1/4"-20NC x 3 3/4" 1
8 3422688 Pin (Steer Cylinder) 1
9 3422764 Pin (Steer Cylinder) 2
10 3422856 Pin, Weldment (Steer Cylinder) 1
11 Use 3422972 Kingpin (was p/n 3422849) 4
12 3841143 Keeper 3/8” 3
13 4130374 Spindle Weldment (LF, RR) A/R
14 4130375 Spindle Weldment (RF, LR) A/R
15 Washer, Thrust Options: 2
Use 4740517 Prior to S/N 67242 (was p/n 4740314 & 4740463)
4740517 S/N 67242 to Present
16 4846204 Weldment, Tie-Rod 1
17 3311405 Locknut 1/4"-20NC 1
18 3520181 Plug 2
19 Stop Options: 2
0561404 (2WS)
0561403 (4WS)
20 0641814 Bolt 1/2"-13NC x 1 3/4" 4
21 4711800 Flatwasher 1/2" (Narrow) 4
22 3313002 Nut, Jam 1 1/4”-7NC 1
0100011 Loctite #242 A/R
Steer Cylinder Assembly Options
(See Section 5 for Breakdown):
— — — — — — — — — —
2
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1
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EXTENDABLE AXLES INSTALLATION Ref.
0259922 4WD/2WS Ref. B
0259921 4WD/4WS Ref. C
101 Not Used
102 Not Used
103 0561391 Block, Axle Stop (Side) 2
104 0561392 Block, Axle Stop (Side) 2
105 0561394 Block, Axle Stop (Top) 2
106 0561400 Block, Axle Stop (Top) 2
107 0561401 Block, Axle Stop (Bottom) 4
108 0561402 Plate, Spacer 2
109 0641408 Bolt 1/4"-20NC x 1" 8
3121106 1-9
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SECTION 1 FRAME
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FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
110 0641436 Bolt 1/4"-20NC x 4 1/2" 4
111 0641607 Bolt 3/8"-16NC x 7/8" 16
112 0641612 Bolt 3/8"-16NC x 1 1/2" 4
113 0641808 Bolt 1/2"-13NC x 1" 26
114 0641812 Bolt 1/2"-13NC x 1 1/2" 6
115 0641816 Bolt 1/2"-13NC x 2" 6
116 0641820 Bolt 1/2"-13NC x 2 1/2" 6
117 0642014 Bolt 5/8"-11NC x 1 3/4" 4
118 0642010 Bolt 5/8"-11NC x 1 1/4" 18
119 0961950 Bearing 4
120 1120465 Cap 16
121 1683920
122 3310805 Locknut #8-32NC 8
123 3311405 Locknut 1/4”-20NC 12
124 3311605 Locknut 3/8"-16NC 28
125 3312002 Nut, Jam 5/8"-11NC 4
126 3312602 Nut, Jam 1"-8NC 16
127 3340888 Wear, Pad Assembly 8
128 3422689 Pin 2
129 3422818 Pin 2
130 3572340 Plate 2
131 3572346 Plate, Switch Mount 4
132 3572347 Angle, Switch Mount 4
133 3841143 Keeper, 3/8” 4
134 3900219 Set Screw 4
135 3900292 Set Screw 12
136 3930820 Bolt #8-32NC x 1 1/4” 8
137 4070772 Shim 12
138 4071001 Shim, Axle Stop 7
139 4360322 Switch, Limit 4
140 4711800 Flatwasher 1/2” (Narrow) 38
141 4751400 Flatwasher 1/4” (Wide) 8
142 4751600 Flatwasher 3/8” (Wide) 8
143 4752000 Flatwasher 5/8” (Wide) 18
144 4846176 Outer Axle Weldment A/R
145 4846177 Inner Axle Weldment A/R
146 4846219
147 4846220
148 4846226 Hose Carrier Weldment (LF, RR) 2
149 4846227 Hose Carrier Weldment (RF, LR) 2
150 Not Used
151 4460428
152 3951804 Set Screw, Knurled Cup Point 1/2” x 1/2” 2
0100011 Loctite #242 A/R
0100079 Sealant, Pipe A/R
Axle Extension Cylinder Assembly
(See Section 5 for Breakdown)
Inner Axle Weldment (100SX/110SX/110SXJ
4WD/2WS Rear Only)
Outer Axle Weldment (100SX/110SX/110SXJ
4WD/2WS Rear Only)
Connector, Strain Relief (100SX/110SX/110SXJ
4WD/2WS Only)
— — — — — — — — — —
2
1
1
4
1-10 3121106
SECTION 1 FRAME
S
FIGURE 1-3. STEERING AND AXLES INSTALLATION (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
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3121106 1-11
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3
102
SPINDLE
REF.
101
204
203
202 LH
201 RH
4
SECTION 1 FRAME
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FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS
1-12 3121106
SECTION 1 FRAME
S
FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
TIRE AND WHEEL DRIVE INSTALLATIONS Ref.
0259895 WHEEL DRIVE INSTALLATION Ref. B
1Not Used
2Not Used
3 0701617 Bolt (Metric)16mm x 45mm (12 Per Wheel) 48
4 4892000 Washer Hardened 5/8” (12 Per Wheel) 48
— — — — — — — — — —
0100019 Loctite #271 A/R
0259878 HUB AND MOTOR ASSEMBLY Ref. C
101 2780248 Drive Hub Assembly (See Figure 1-5 for Breakdown) 4
102 3160248
0259909 100SX/110SX & 110SXJ Ref. A
0259906 120SXJ Ref. A
Drive Motor Assembly
(See Figure 1-6 for Breakdown)
TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED) Ref.
4
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201 Tire and Wheel Assembly (Foam-Filled) Options: 2
0259907 Right Side (100SX/110SX & 110SXJ)
0259904 Right Side (120SXJ)
202 Tire and Wheel Assembly (Foam-Filled) Options: 2
0259908 Left Side (100SX/110SX & 110SXJ)
0259905 Left Side (120SXJ)
4520215 Tire 385/65 x 22.5
4640113 Valve
Note: Assemblies may require ballast/foam filling to manufacturer’s specifications prior to
installing on a machine. Refer to Operation &
Safety or Service & Maintenance Manuals. Purchase individual tire and/or rim only if able to
foam fill tire & wheel assembly, otherwise, purchase complete assembly.
203 0701619 Bolt (Metric)16mm x 55mm (16 Per Wheel) 64
204 4892000 Washer Hardened 5/8” (16 Per Wheel) 64
3121106 1-13
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SECTION 1 FRAME
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FIGURE 1-5. DRIVE HUB ASSEMBLY
1-14 3121106
SECTION 1 FRAME
S
FIGURE 1-5. DRIVE HUB ASSEMBLY
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
2780248 DRIVE HUB ASSEMBLY Ref. C
Note: Unless there is capability to torque shaft
(item 4) to 626 ft./lbs. (850Nm) Repair beyond this
level is NOT advised.
1 Kit 1 Gear, Planet 1
2 Kit 2 Gear, Planet 1
3 7022535 Gear, Sun 1
4 Kit 3 Nut, Shaft 1
5 7021388 Pin, Planet 3
6Not Used
7 7022537 Carrier, Planet 1
8 7022538 Cover 1
9 7024967 Button, Thrust 1
10 Kit 2 Bearing, Roller 3
11 7022541 Bearing, Roller 4
12 Kit 3 Bearing, Ball 1
13 7022543 Bolt, Hex 12
14 Kit 2 Ring, Retaining 3
15 Kit 1 Ring, Retaining 4
16 7022546 Ring, Retaining 1
17 Kit 2 Ring, Stay 3
18 Not Used
19 7024966 O-Ring 1
20 7024968 Seal, Face 1
21 7022550 Plug 2
22 Kit 4 Seal, Ring 2
23 Kit 3 Bolt 2
24 Not Available Ball 2
25 to 26 Not Used
27 Not Available Bolt 2
28 7025555 Washer 2
29 Not Used
30 7022556 Gear, Ring 1
31 to 32 Not Used
33 Kit 4 O-Ring 1
34 to 40 Not Used
41 7022559 Carrier
42 7022560
43 Kit 4 Gear, Sun 1
44 Kit 4 Shaft, Input 1
45 7011326 Pin, Planet 3
46 Not Used
47 7022564 Ring, Retaining 1
48 to 50 Not Used
51 7022567 Cover 1
52 7022568 Washer Thrust 1
53 Kit 3 Bolt 2
54 Kit 4 O-Ring 1
Ref.
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3121106 1-15
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SECTION 1 FRAME
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FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
55 Kit 4 Spring, Pressure 1
56 to 59 Not Used
60 7022572 Spindle 1
61 7022573 Piston 1
62 7022574 Coupler 1
63 7022575 Ring, Locator 1
64 7021354 Plate, Back-up 1
65 7022576 Plate, Back-up 1
66 7022577 Ring, Retaining 1
67 7022578 Ring, Retaining 1
68 7022509 Ring, Retaining 1
69 7022579 Bolt 2
70 to 71 Not Used
72 Kit 5 Disc, Brake 4
73 Kit 5 Disc, Brake 5
74 Kit 5 Spring A/R
75 Kit 6 Ring, Back-up 2
76 Kit 6 Seal 1
77 Kit 6 Ring, Back-up 2
78 Kit 6 Seal 1
79 to 84 Not Used
85 7024031 O-Ring 1
86 Not Used
87 7024032 O-Ring 1
88 to 119 Not Used
120 3160248 Motor, Hydraulic 1
— — — — — — — — — —
7024028 Kit 1 - Planet Bearing Kit (Includes Items 1, 11 & 15) 1
7024029 Kit 2 - Planet Bearing Kit
(Includes Items 2, 10, 14 & 17)
7022536 Kit 3 - Bearing Kit (Includes Items 4, 12, 23, & 53) 1
7022540 Kit 4 - Mechanical Disconnect Kit
(Includes Items 13, 22, 33, 43, 44, 54 & 55)
7022580 Kit 5 - Brake Disc Kit (Includes Items 72-74) 1
7022581 Kit 6 - Brake Seal Kit (Includes Items 75-78) 1
7024030 Kit 7 - Planet Gear Kit
(Includes Items 40, 46, 48 & 50)
1
1
1
1-16 3121106
SECTION 1 FRAME
S
FIGURE 1-5. DRIVE HUB ASSEMBLY (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
E
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1
F
R
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3121106 1-17
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SECTION 1 FRAME
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FIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTH
1-18 3121106
SECTION 1 FRAME
S
FIGURE 1-6. DRIVE MOTOR ASSEMBLY - REXROTH
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
3160248 DRIVE MOTOR ASSEMBLY Ref. D
1 7012716 Rotary Group Assembly 1
2 Not Available Piston, Control 1
3 Not Available Rod, Piston 1
4Not Used
5 Not Available Housing 1
6 Not Available Plate, Port 1
7 7024036 Plate, Swash 1
8 7024037 Driveshaft 1
9 Not Available Plug, Screw 1
10 to 11 Not Used
12 7012709 Shim 1
13 Not Available Stop Screw 1
14 Not Used
15 7024038 Bearing 1
16 7012706 Bearing 1
17 7024039 Shell, Cradle 2
18 to 19 Not Used
20 Kit Seal, Shaft 1
21 Kit O-Ring 1
22 Kit O-Ring 1
23 Kit O-Ring 2
24 Kit Seal 1
25 7012715 V-Ring 1
26 Not Used
27 7024040 Screw, Socket head M12 x 60 4
28 Not Used
29 Not Available Ring, Stop 1
30 Not Available Plug 1
31 to 32 Not Used
33 Not Available Pin, Dowel 1
34 Not Used
35 Not Available Nut M10 1
36 Not Available Nut, Cap M10 1
37 Kit Plug 1
38 7024041 Orifice 1
39 Kit O-Ring 1
— — — — — — — — — — —
7024034 Seal Kit (Includes Items 20-24, 37 & 39) 1
E
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1
F
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3121106 1-19
S
2
15 15
17
JUNCTION
BOX REF.
20
20
14
11
14
14
13
11
11
18
5
7
9
7
7
3
8
3
10 10
SECTION 1 FRAME
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FIGURE 1-7. JACK CYLINDER INSTALLATION
1-20 3121106
SECTION 1 FRAME
S
FIGURE 1-7. JACK CYLINDER INSTALLATION
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
JACK CYLINDER INSTALLATIONS Ref.
0259936 ANSI Ref. D
0270268 ANSI EXPORT Ref. C
1Not Used
2 0641812 Bolt 1/2"-13NC X 1 1/2" (4 Per Cylinder) 8
3 0641816 Bolt 1/2"-13NC x 2" (4 Per Cylinder) 8
4 0641852 Bolt 1/2" -13 NC x 6 1/2" 4
5 1683965
6Not Used
7 3311805 Locknut 1/2"-13NC (4 Per Cylinder) 12
8 3340630 Jack Pad Weldment 2
9 3535906 Plate, Mounting (1 Per Cylinder) 2
10 4711800 Flatwasher 1/2" Narrow (4 Per Cylinder) 8
11 0641609 Bolt 3/8"-16NC X 1 1/8" 4
12 1704544 Decal- Lifting Instructions (Not Shown) 1
13 4641133 Valve, Jack (See Figure 1-8 For Breakdown) 1
14 4751600 Flatwasher 3/8” (Wide) 4
15 4751800 Flatwasher 1/2” (Wide) 8
16 Not Used
17 0641404 Bolt 1/4"-20NC X 1/2" 1
18 0641412 Bolt 1/4"-20NC X 1 1/2" 1
19 Not Used
20 4751400 Flatwasher 1/4” (Wide) 2
0100011 Loctite A/R
Jack Cylinder Assembly
(See Section 5 for Breakdown)
— — — — — — — — — —
2
E
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N
1
F
R
A
M
E
3121106 1-21
S
2
3
4
4
3
5
5
1
1
SECTION 1 FRAME
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FIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIR
1-22 3121106
SECTION 1 FRAME
S
FIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIR
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
4641133 VALVE ASSEMBLY - HYDRO AIR Ref. A
1 7011336 Cartridge, Check Valve 2
2 7012955 Cartridge, Valve 2
7012967 Seal Kit - 7012955 Cartridge (1 Per Cartridge) 2
3 7021631 Cartridge, Valve 4
7021632 Seal Kit - 7021631 Cartridge (1 Per Cartridge) 4
4 7012995 Cartridge, Valve - Hydraforce 5
7012518 Seal Kit - 7012995 Cartridge (1 Per Cartridge) 5
7012943 Coil - 12V (1 Per Cartridge) 5
5 7021633 Orifice 4
E
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1
F
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A
M
E
3121106 1-23
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SECTION 1 FRAME
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FIGURE 1-8. JACK VALVE ASSEMBLY - HYDRO AIR (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
1-24 3121106
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