JLG 1100SB Illustrated Parts Manual 3121266 – PDF DOWNLOAD

Illustrated Parts Manual

Model 1100SB 3121266 January 14, 2014

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REVISION LOG June 30, 2010 - Original Issue of Manual (Edited to B/M 0010582 Revision 82) March 11, 2011 - Revised Manual (Edited to B/M 0010582 Revision 85) June 8, 2011 - Revised Manual (Edited to B/M 0010582 Revision 91) September 20, 2011 - Revised Manual (Edited to B/M 0010582 Revision 96) January 20, 2012 - Revised Manual (Edited to B/M 0010582 Revision C) June 20, 2012 - Revised Manual (Edited to B/M 0010582 Revision C) August 15, 2012 - Revised Manual (Edited to B/M 0010582 Revision C) December 15, 2012 - Revised Manual (Edited to B/M 0010582 Revision C) April 10, 2013 - Revised Manual (Edited to B/M 0010582 Revision C) July 10, 2013 - Revised Manual (Edited to B/M 0010582 Revision C) October 7, 2013 - Revised Manual (Edited to B/M 0010582 Revision C) January 14, 2014 - Revised Manual (Edited to B/M 0010582 Revision AF & 1001160100 Revision D)

3121266

1100SB

A

REVISION LOG

B

1100SB

3121266

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 DRIVE HUB ASSEMBLY - BONFIGLIOLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 DRIVE HUB ASSEMBLY - REGGIANA RIDUTTORI . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 TRACTION VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

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 2-21 2-22

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 DEUTZ TD2011 TIER III ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 DEUTZ TD2011 TIER IVi-FLEX ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 2-26 DEUTZ TCD2.9L4 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 PUMP ASSEMBLY (REXROTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 PUMP ASSEMBLY (SAUER TANDEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 PUMP ASSEMBLY (SAUER PISTON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 PUMP ASSEMBLY (SAUER GEAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . . 2-64 HYDRAULIC OIL COOLER INSTALLATION - TD2011 ENGINES (OPTIONAL) . . . . . . 2-66 HYDRAULIC OIL COOLER INSTALLATION - DEUTZ TCD2.9L4 ENGINES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 GROUND CONTROLS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 ENGINE TRAY JACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 HOOD INSTALLATION (ABS) (SN 0300073745 ONLY) . . . . . . . . . . . . . . . . . . . . . . . 2-84 HOOD INSTALLATION (STEEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90 7500W SKYPOWER GENERATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96 CLEARSKY TELEMATICS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . 2-102

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

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

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-1 4-2 4-3 4-4 4-5 4-6

3121266

PLATFORM COMPONENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM). . . . . . . . . 4-6 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CONTROLLER ASSEMBLY (LIFT & SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

1100SB

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

HYDRAULIC DIAGRAM - DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HYDRAULIC DIAGRAM - OSCILLATING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 HYDRAULIC DIAGRAM - STEER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 HYDRAULIC DIAGRAM - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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

ELECTRICAL DIAGRAM LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 HARNESS COMPONENTS INSTALLATION (TD2011 Engines) . . . . . . . . . . . . . . . . . . 7-4 HARNESS COMPONENTS INSTALLATION (TCD2.9L4 Engines) . . . . . . . . . . . . . . . . 7-20

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

DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

ii

1100SB

3121266

SECTION 1 FRAME

3121266

1100SB

1-1

SECTION 1 FRAME FIGURE 1-1. AXLE INSTALLATIONS 47 13 3 20 1 27

19

30

18

47 1 6

22

47 6 1 46

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

1100SB

50

39 40

2 52 53 56

1 7

47

41 42 26

47 41 42

26

25

3121266

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.

0271521

Ref Ref

DESCRIPTION AXLE INSTALLATIONS - COMMON PARTS Oscillating Axle

0100011 0100019 0100081 0363037 Not Used 0641606 0641608 0641609 0641611 Not Used 0641613 Not Used 0641624 0641808 Not Used 0642214 0962033 1180358 7024365

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

1 2 4 AR

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 42

3310805 3340881 Use 1001161401 Use 1001161402 Use 1001161403 3340939 3422918 3422960 3573294 3573335 3841287 3900270 3930820 Not Used 4071035 4071036 4071054 4071055 4071039 4071040

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 CYLINDER SECTION for Breakdown) Locknut #8-32NC Pad, Wear Pad, Axle (was p/n 3340907) Pad, Wear (was p/n 3340946) Pad, Wear (was p/n 3340932) 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 36

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

3121266

1100SB

REV. K

1-3

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

PART NUMBER

QTY.

43 44 to 45 46

4071042 Not Used 4360578

24

Shim #16 Gauge

4

47 48 49 50 51 52 53 54 55 56 57 58 to 200

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

140 1 8 4 1 12 18 12 6 48 4

Switch, Limit (Note: P/N 4360578 does not include #57 Connector - Purchase Separately) 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 (Not Shown)

0271521 201 to 211 212 213 to 216 217

0642020 Not Used 1684081

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

1-4

Ref Ref

DESCRIPTION

REV.

AXLE INSTALLATION - OPTIONAL PARTS Oscillating Axle

K

4

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

2

Oscillating Axle Cylinder Assembly (See CYLINDER SECTION for Breakdown)

4

Locknut 5/8in-11NC

2 2

Pin Pin

4

Keeper, Pin

4

Flatwasher 5/8in Thin

4

Plug (Not Shown)

1100SB

3121266

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

3121266

PART NUMBER

QTY.

DESCRIPTION

1100SB

REV.

1-5

SECTION 1 FRAME FIGURE 1-2. STEER INSTALLATION

1-6

1100SB

3121266

SECTION 1 FRAME FIGURE 1-2. STEER INSTALLATION ITEM #

PART NUMBER

QTY.

0271520

Ref

STEER INSTALLATION

1 2 3 4 5 6 7 8 9 10 11 12 13

0100011 0100019 0100035 Not Used 0630464 0641505 0641511 Not Used 0641634 0642016 0962423 1671040 1684314

AR AR AR

Compound, Locking Compound, Locking Compound, Locking

4 4 4

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

4 4 8 4 4

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 43 44 45

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 3960552 0080277 4750800

4 4

Bolt 3/8in-16NC x 4-1/4in Bolt 5/8in-11NC x 2in Bushing Cover, Sensor Steer Cylinder Assembly (See CYLINDER SECTION for Breakdown) Locknut 5/16in-18NC Nut, Slotted

4 4 4 4 4 4 4

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

8 16 8 4 4 4 12 4 4 4 8 4 4 4 8 4 4 4 4 4 8

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) Seal (Inner) Adapter, Angle Sensor Pilot Flatwasher M8

3121266

DESCRIPTION

1100SB

REV. J

1-7

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