JLG 1100S 1100SJP Illustrated Parts Manual 3121257 – PDF DOWNLOAD

Illustrated Parts Manual

Models 1100S 1100SJP 3121257 July 8, 2013

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REVISION LOG June 15, 2009 - Original Issue of Manual (Edited to B/M 1001109343 Revision 7) October 23, 2009 - Revised Manual (Edited to B/M 1001109343 Revision 8) March 15, 2010 - Revised Manual (Edited to B/M 1001109343 Revision 13) March 17, 2011 - Revised Manual (Edited to B/M 1001109343 Revision 16) June 14, 2011 - Revised Manual (Edited to B/M 1001109343 Revision 17) September 21, 2011 - Revised Manual (Edited to B/M 1001109343 Revision 20) January 12, 2012 - Revised Manual (Edited to B/M 1001109343 Revision 20) June 16, 2012 - Revised Manual (Edited to B/M 1001109343 Revision B) August 10, 2012 - Revised Manual (Edited to B/M 1001109343 Revision B) November 30, 2012 - Revised Manual (Edited to B/M 1001109343 Revision B) April 4, 2013 - Revised Manual (Edited to B/M 1001109343 Revision B) July 8, 2013 - Revised Manual (Edited to B/M 1001109343 Revision B)

3121257

1100S 1100SJP

A

REVISION LOG

B

1100S 1100SJP

3121257

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

AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 TIRE AND WHEEL DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 TRACTION VALVE ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 TRACTION VALVE ASSEMBLY (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 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

VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . 2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 TURNTABLE SWING DRIVE AND BEARING INSTALLATION . . . . . . . . . . . . . . . . . . 2-10 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 DEUTZ ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES) . . . . . . . . . . . . . . . . . . . . 2-34 PUMP ASSEMBLY (DEUTZ ENGINE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL) . . 2-46 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-50 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES. . 2-54 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES . . . . . . . . 2-60 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . 2-70 HYDRAULIC OIL COOLER INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 2-72 GROUND CONTROLS INSTALLATION (PRIOR TO S/N 0300140836) . . . . . . . . . . . 2-74 GROUND CONTROLS INSTALLATION (S/N 0300140836 TO PRESENT) . . . . . . . . 2-78 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 HOOD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 TURNTABLE BEARING SHIELD & GROUND CONTROL DOOR INSTALLATIONS . 2-90

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7

BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ACTUATOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 POWER TRACK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . 3-26 HOSE/CABLE PROTECTION INSTALLATION (1100S ONLY) . . . . . . . . . . . . . . . . . . 3-30

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5

3121257

PLATFORM COMPONENTS INSTALLATION (1100S) . . . . . . . . . . . . . . . . . . . . . . . . 4-2 PLATFORM COMPONENTS INSTALLATION (1100SJP) . . . . . . . . . . . . . . . . . . . . . . 4-6 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 CONTROLLER ASSEMBLY (LIFT & SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

1100S 1100SJP

i

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5-1 5-2 5-3 5-4 5-5 5-6 5-7

AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 JIB CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9

HYDRAULIC DIAGRAM - BOOM (1100S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 HYDRAULIC DIAGRAM - BOOM (1100SJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 HYDRAULIC DIAGRAM - CHASSIS (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 HYDRAULIC DIAGRAM - CHASSIS (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 HYDRAULIC DIAGRAM - OSCILLATING AXLE (1100SJP) . . . . . . . . . . . . . . . . . . . . .6-10 HYDRAULIC DIAGRAM - STEER (1100S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 HYDRAULIC DIAGRAM - STEER (1100SJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 7-1 7-2 7-3 7-4 7-5

ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 ELECTRICAL SCHEMATIC (PRIOR TO S/N 0300140836) . . . . . . . . . . . . . . . . . . . . .7-4 ELECTRICAL SCHEMATIC (S/N 0300140836 TO PRESENT) . . . . . . . . . . . . . . . . . .7-10 HARNESS COMPONENTS INSTALLATION (PRIOR TO S/N 0300140836) . . . . . . .7-20 HARNESS COMPONENTS INSTALLATION (S/N 0300140836 TO PRESENT) . . . . .7-36

SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 8-1 8-2

DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2 DECAL INSTALLATION (ANSI EXPORT SPECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1 SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1 SECTION 11 - PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

ii

1100S 1100SJP

3121257

SECTION 1 FRAME

3121257

1100S 1100SJP

1-1

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS

19

30

47 6 1

115 254 105 144 145 46

18

47 1 6

57

22

3 27

47 20 13 1

29

1 6 47

49 46

28

34

220 217

17 48

246 231 212

1 11 37 38

2 53 54 55

24 1 9 47

26

23 47 1 8

26

2 16

1 33

4

29 2 14

47

56 39 40 25

51

41 42 47 1 8 41 42 47 1 8

26 41 42

47

1 7

47

1 7

26 41 42

47 1 8 43

21 31

1 7

43 47

1-2

32

50

225 220 246 231 212 226

41 42 1 9 47 41 42

18

1100S 1100SJP

50

39 40

2 52 53 56

1 7

47

41 42 26

47 41 42

26

25

3121257

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS ITEM #

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NUMBER

QTY.

0271934 0271521

Ref. Ref. Ref.

0100011 0100019 0100081 0363037 Not Used 0641606 0641608 0641609 0641611 Not Used 0641613 Not Used 0641620 0641808 Not Used 0642214 0962033 1180358 7024365 7024366

1

19 20 21

1320263 1320298 1684102

4 4 4

22 23 24 25 26 27 28 29 30 31 32 33 34 35 to 36 37 38 39 40 41

3310805 3340881 3340907 3340946 3340932 3340939 3422918 3422960 3573294 3573335 3841287 3900270 3930820 Not Used 4071035 4071036 4071054 4071055 4071039

3121257

DESCRIPTION AXLE INSTALLATIONS - COMMON PARTS Fixed Axle Oscillating Axle

A/R A/R A/R 4

Compound, Locking Compound, Locking Adhesive #454 Bar, Stop

40 48 32 16

Bolt 3/8in-16NC x 3/4in Bolt 3/8in-16NC x 1in Bolt 3/8in-16NC x 1-1/8in Bolt 3/8in-16NC x 1-3/8in

8

Bolt 3/8in-16NC x 1-5/8in

4 8

Bolt 3/8in-16NC x 2-1/2in Bolt 1/2in-13NC x 1in

1 2 4 A/R

8 8 2 8 32 8 1 4 4 8 1 4 8

Bolt 3/4in-10NC x 1-3/4in Bushing Carrier 24 in Section Repair Kit (Includes Inner & Outer Links, Joining Bars & Rollers, and Assembling Hardware) Mounting Bracket Kit (Includes Mounting Brackets for Both Ends, 1 Roller Assembly and Assembling Hardware) Clamp, Cable Clamp, Hose Axle Extension Cylinder Assembly (See Section 5 for Breakdown) Locknut #8-32NC Pad, Wear Pad, Axle Pad, Wear Pad, Wear Pad, Rubber Pin Pin Plate Plate Keeper, Pin Bolt, Shoulder 1/2in -13NC x 1-1/2in Capscrew #8-32NC x 1-1/4in

2 4 8 12 24

Shim #18 Gauge Shim #11 Gauge Shim #18 Gauge Shim #11 Gauge Shim #18 Gauge

1100S 1100SJP

REV. J J

1-3

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED) ITEM #

PART NUMBER

QTY.

42 43 44 to 45 46 47 48 49 50 51 52 53 54 55 56 57

4071040 4071042 Not Used 4360578 4711600 4740461 4750800 4846637 4846383 0681813 0681814 0681815 0681816 4711800 4460968

36 24

Shim #11 Gauge Shim #16 Gauge

4 140 1 8 4 1 12 18 12 6 48 4

Switch, Limit Flatwasher 3/8in Thin Thrustwasher Flatwasher #8 Regular Extension, Axle Box, Axle Pivot Bolt 1/2in-13NC x 1-5/8in (Grade 8) Bolt 1/2in-13NC x 1-3/4in (Grade 8) Bolt 1/2in-13NC x 1-7/8in (Grade 8) Bolt 1/2in-13NC x 2in (Grade 8) Flatwasher 1/2in Thin Connector, Strain Relief

Ref.

AXLE INSTALLATION - OPTIONAL PARTS

101 to 104 105 106 to 114 115 116 to 143 144 145

DESCRIPTION

0271934 Not Used 0363076 Not Used 0641814 Not Used 4071049 4071050

Ref.

Fixed Axle

2

Bar, Stop

4

Bolt 1/2in-13NC x 1-3/4in

6 4

Shim 11 Gauge Shim 16 Gauge Oscillating Axle

0271521

Ref.

201 to 211 212 213 to 216 217

0642020 Not Used 1684081

4

Bolt 5/8in-11NC x 2-1/2in

2

Oscillating Axle Cylinder Assembly (See Section 5 for Breakdown)

218 to 219 220 221 to 224 225 226 227 to 230 231 232 to 245 246 247 to 253 254

Not Used 3312005 Not Used 3422833 3422915 Not Used 3841258 Not Used 4712000 Not Used 3520054

4

Locknut 5/8in-11NC

2 2

Pin Pin

4

Keeper, Pin

4

Flatwasher 5/8in Thin

4

Plug

1-4

1100S 1100SJP

REV.

I

J

3121257

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED) ITEM #

3121257

PART NUMBER

QTY.

DESCRIPTION

1100S 1100SJP

REV.

1-5

SECTION 1 FRAME FIGURE 1-2. STEER INSTALLATION 12 7

3 25

31 31

45

14

29 44 1 6

38 30

31

3 5 22 1 26

2 27

32 20

1 39 41 43 19

17

35 11 36

28

1 39 40 42

1 9

33

18

OR 37 11

13

1 15

34

35 21

23

46 (2WS REAR ONLY)

2 10 1-6

1100S 1100SJP

3121257

SECTION 1 FRAME FIGURE 1-2. STEER INSTALLATION 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 35 36 37 38 39 40 41 42

3121257

PART NUMBER

QTY.

1001108809 0271520

Ref. Ref. Ref.

0100011 0100019 0100035 Not Used 0630464 0641505 0641511 Not Used 0641634 0642016 0962423 1001109730 1671040 1684314 3311505 3300464 Not Used 3422917 3422940 3422941 3423256 3451214 3760383 3841258 Not Used 3931020 3931412 3932024 1001099632 4360505 4460914 4711500 4711800 4740181 4740229 4740505 4751600 4755000 0200833 0741606 1120549 1120550 3960551

DESCRIPTION STEER INSTALLATION 2WS (1100S) 4WS (1100SJP) (Note: Qtys shown are for 2WS. Double qty for 4WS)

A/R A/R A/R

Compound, Locking Compound, Locking Compound, Locking

2 2 2

Screw, Button Head #10-24NC x 1/2in Bolt 5/16in-18NC x 5/8in Bolt 5/16in-18NC x 1-3/8in

2 2 4 2

2 2 2

Bolt 3/8in-16NC x 4-1/4in Bolt 5/8in-11NC x 2in Bushing Cover, Sensor Options: 2WS (1100S) 4WS (1100SJP) Steer Cylinder Assembly (See Section 5 for Breakdown) Locknut 5/16in-18NC Nut, Slotted

2 2 2 2 2 2 2

Kingpin Pin, Steer Cylinder (Outer) Pin, Steer Cylinder (Inner) Pin, Sensor Pin, Cotter 3/8in x 3-1/2in Ring, Retaining Keeper, Pin

4 8 4 2 2 2 6 2 2 2 4 2 2 2 4 2 2 2

Capscrew #10-24NC x 1-1/4in Capscrew 1/4in-20NC x 3/4in Capscrew 5/8in-11NC x 1-1/2in Spindle Switch, Rotary Angle Sensor (Steer) Terminal Flatwasher 5/16in Thin Flatwasher 1/2in Thin Thrustwasher Thrustwasher Thrustwasher Flatwasher 3/8in Regular Flatwasher 2-1/2in Regular Arm, Steer Screw, Countersunk 3/8in-16NC x 3/4in Cap, Seal (Outer) Cap, Seal (Inner) Seal (Outer)

1100S 1100SJP

REV. B H

1-7

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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