JLG 1100S Parts Manual

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Illustrated Parts Manual

Models

1100S

1100SJP

3121257

July 8, 2013

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 AXLE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 STEER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 TIRE AND WHEEL DRIVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-6 FRAME VALVES AND COVERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

1-7 TRACTION VALVE ASSEMBLY (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

1-8 TRACTION VALVE ASSEMBLY (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

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

2-1 VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS . . . . . . . . . . . . . . 2-2

2-2 MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 TURNTABLE SWING DRIVE AND BEARING INSTALLATION . . . . . . . . . . . . . . . . . . 2-10

2-4 SWING MOTOR/HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5 CATERPILLAR ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-6 DEUTZ ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-7 PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES) . . . . . . . . . . . . . . . . . . . . 2-34

2-8 PUMP ASSEMBLY (DEUTZ ENGINE MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-9 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL). . 2-46

2-10 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL) . . . . . . . . 2-50

2-11 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES. . 2-54

2-12 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES . . . . . . . . 2-60

2-13 TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-14 ROTARY COUPLING AND COLLECTOR RING INSTALLATION . . . . . . . . . . . . . . . . 2-70

2-15 HYDRAULIC OIL COOLER INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 2-72

2-16 GROUND CONTROLS INSTALLATION (PRIOR TO S/N 0300140836) . . . . . . . . . . . 2-74

2-17 GROUND CONTROLS INSTALLATION (S/N 0300140836 TO PRESENT) . . . . . . . . 2-78

2-18 ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82

2-19 HOOD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86

2-20 TURNTABLE BEARING SHIELD & GROUND CONTROL DOOR INSTALLATIONS . 2-90

SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 BOOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 ACTUATOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-4 POWER TRACK INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-5 BOOM SENSORS AND SWITCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-6 PLATFORM SUPPORT & CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . 3-26

3-7 HOSE/CABLE PROTECTION INSTALLATION (1100S ONLY) . . . . . . . . . . . . . . . . . . 3-30

SECTION 4 - PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 PLATFORM COMPONENTS INSTALLATION (1100S) . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 PLATFORM COMPONENTS INSTALLATION (1100SJP) . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3 PLATFORM CONSOLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-4 CONTROLLER ASSEMBLY (LIFT & SWING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-5 CONTROLLER ASSEMBLY (DRIVE & STEER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

3121257 1100S 1100SJP i

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 AXLE EXTENSION CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-3 PLATFORM LEVEL CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-5 JIB CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-6 STEER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-7 TELESCOPE CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-1 HYDRAULIC DIAGRAM - BOOM (1100S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-2 HYDRAULIC DIAGRAM - BOOM (1100SJP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 HYDRAULIC DIAGRAM - CHASSIS (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4 HYDRAULIC DIAGRAM - CHASSIS (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-5 HYDRAULIC DIAGRAM - OSCILLATING AXLE (1100SJP). . . . . . . . . . . . . . . . . . . . .6-10

6-6 HYDRAULIC DIAGRAM - STEER (1100S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-7 HYDRAULIC DIAGRAM - STEER (1100SJP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-8 HYDRAULIC DIAGRAM - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-9 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 ELECTRICAL SCHEMATIC (PRIOR TO S/N 0300140836) . . . . . . . . . . . . . . . . . . . . .7-4

7-3 ELECTRICAL SCHEMATIC (S/N 0300140836 TO PRESENT) . . . . . . . . . . . . . . . . . .7-10

7-4 HARNESS COMPONENTS INSTALLATION (PRIOR TO S/N 0300140836) . . . . . . .7-20

7-5 HARNESS COMPONENTS INSTALLATION (S/N 0300140836 TO PRESENT) . . . . .7-36

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

8-1 DECAL INSTALLATION (ANSI SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

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

47 13

115

105

254

144

145

483216

225

220

246

231

212

217

226

3329145126414247264142

7747

474141

4242262656

504343

212626

424741

475639

405525

234747

37 38

25253

FIGURE 1-1. AXLE INSTALLATIONS

1-2 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. AXLE INSTALLATIONS - COMMON PARTS 0271934 Ref. Fixed Axle J 0271521 Ref. Oscillating Axle J

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100081 A/R Adhesive #454 4 0363037 4 Bar, Stop 5Not Used 6 0641606 40 Bolt 3/8in-16NC x 3/4in 7 0641608 48 Bolt 3/8in-16NC x 1in 8 0641609 32 Bolt 3/8in-16NC x 1-1/8in

9 0641611 16 Bolt 3/8in-16NC x 1-3/8in 10 Not Used 11 0641613 8 Bolt 3/8in-16NC x 1-5/8in 12 Not Used 13 0641620 4 Bolt 3/8in-16NC x 2-1/2in 14 0641808 8 Bolt 1/2in-13NC x 1in 15 Not Used 16 0642214 1 Bolt 3/4in-10NC x 1-3/4in 17 0962033 2 Bushing 18 1180358 4 Carrier

7024365 A/R 24 in Section Repair Kit (Includes Inner & Outer Links, Joining

Bars & Rollers, and Assembling Hardware)

7024366 1 Mounting Bracket Kit (Includes Mounting Brackets for Both

Ends, 1 Roller Assembly and Assembling Hardware) 19 1320263 4 Clamp, Cable 20 1320298 4 Clamp, Hose 21 1684102 4 Axle Extension Cylinder Assembly (See Section 5 for Break-

down) 22 3310805 8 Locknut #8-32NC 23 3340881 8 Pad, Wear 24 3340907 2 Pad, Axle 25 3340946 8 Pad, Wear 26 3340932 32 Pad, Wear 27 3340939 8 Pad, Rubber 28 3422918 1 Pin 29 3422960 4 Pin 30 3573294 4 Plate 31 3573335 8 Plate 32 3841287 1 Keeper, Pin 33 3900270 4 Bolt, Shoulder 1/2in -13NC x 1-1/2in 34 3930820 8 Capscrew #8-32NC x 1-1/4in

35 to 36 Not Used

37 4071035 2 Shim #18 Gauge 38 4071036 4 Shim #11 Gauge 39 4071054 8 Shim #18 Gauge 40 4071055 12 Shim #11 Gauge 41 4071039 24 Shim #18 Gauge

3121257 1100S 1100SJP 1-3

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

42 4071040 36 Shim #11 Gauge 43 4071042 24 Shim #16 Gauge

44 to 45 Not Used

46 4360578 4 Switch, Limit 47 4711600 140 Flatwasher 3/8in Thin 48 4740461 1 Thrustwasher 49 4750800 8 Flatwasher #8 Regular 50 4846637 4 Extension, Axle 51 4846383 1 Box, Axle Pivot 52 0681813 12 Bolt 1/2in-13NC x 1-5/8in (Grade 8) 53 0681814 18 Bolt 1/2in-13NC x 1-3/4in (Grade 8) 54 0681815 12 Bolt 1/2in-13NC x 1-7/8in (Grade 8) 55 0681816 6 Bolt 1/2in-13NC x 2in (Grade 8) 56 4711800 48 Flatwasher 1/2in Thin 57 4460968 4 Connector, Strain Relief

Ref. AXLE INSTALLATION - OPTIONAL PARTS

0271934 Ref. Fixed Axle I

101 to 104 Not Used

105 0363076 2 Bar, Stop

106 to 114 Not Used

115 0641814 4 Bolt 1/2in-13NC x 1-3/4in

116 to 143 Not Used

144 4071049 6 Shim 11 Gauge 145 4071050 4 Shim 16 Gauge

0271521 Ref. Oscillating Axle J

201 to 211

212 0642020 4 Bolt 5/8in-11NC x 2-1/2in

213 to 216 Not Used

217 1684081 2 Oscillating Axle Cylinder Assembly (See Section 5 for

Breakdown)

218 to 219 Not Used

220 3312005 4 Locknut 5/8in-11NC

221 to 224 Not Used

225 3422833 2 Pin 226 3422915 2 Pin

227 to 230 Not Used

231 3841258 4 Keeper, Pin

232 to 245 Not Used

246 4712000 4 Flatwasher 5/8in Thin

247 to 253 Not Used

254 3520054 4 Plug

1-4 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-1. AXLE INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 1-5

SECTION 1 FRAME

223227262017394143

369333940

(2WS

REAR ONLY)

FIGURE 1-2. STEER INSTALLATION

1-6 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. STEER INSTALLATION

1001108809 Ref. 2WS (1100S) B

0271520 Ref. 4WS (1100SJP)

(Note: Qtys shown are for 2WS. Double qty for 4WS)

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100035 A/R Compound, Locking 4Not Used 5 0630464 2 Screw, Button Head #10-24NC x 1/2in 6 0641505 2 Bolt 5/16in-18NC x 5/8in 7 0641511 2 Bolt 5/16in-18NC x 1-3/8in 8Not Used

9 0641634 2 Bolt 3/8in-16NC x 4-1/4in 10 0642016 2 Bolt 5/8in-11NC x 2in 11 0962423 4 Bushing 12 2 Cover, Sensor Options:

1001109730 2WS (1100S)

1671040 4WS (1100SJP) 13 1684314 2 Steer Cylinder Assembly (See Section 5 for Breakdown) 14 3311505 2 Locknut 5/16in-18NC 15 3300464 2 Nut, Slotted 16 Not Used 17 3422917 2 Kingpin 18 3422940 2 Pin, Steer Cylinder (Outer) 19 3422941 2 Pin, Steer Cylinder (Inner) 20 3423256 2 Pin, Sensor 21 3451214 2 Pin, Cotter 3/8in x 3-1/2in 22 3760383 2 Ring, Retaining 23 3841258 2 Keeper, Pin 24 Not Used 25 3931020 4 Capscrew #10-24NC x 1-1/4in 26 3931412 8 Capscrew 1/4in-20NC x 3/4in 27 3932024 4 Capscrew 5/8in-11NC x 1-1/2in 28 1001099632 2 Spindle 29 4360505 2 Switch, Rotary Angle Sensor (Steer) 30 4460914 2 Terminal 31 4711500 6 Flatwasher 5/16in Thin 32 4711800 2 Flatwasher 1/2in Thin 33 4740181 2 Thrustwasher 34 4740229 2 Thrustwasher 35 4740505 4 Thrustwasher 36 4751600 2 Flatwasher 3/8in Regular 37 4755000 2 Flatwasher 2-1/2in Regular 38 0200833 2 Arm, Steer 39 0741606 4 Screw, Countersunk 3/8in-16NC x 3/4in 40 1120549 2 Cap, Seal (Outer) 41 1120550 2 Cap, Seal (Inner) 42 3960551 2 Seal (Outer)

3121257 1100S 1100SJP 1-7

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

43 3960552 2 Seal (Inner) 44 0080277 2 Adapter, Angle Sensor Pilot 45 4750800 4 Flatwasher M8 46 1001108788 2 Link (2WS Rear Only)

1-8 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-2. STEER INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 1-9

SECTION 1 FRAME

102

SPINDLE

REF.

101

304

303

302 LH

301 RH

201

102A

201B

102B

201A

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

1-10 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. WHEEL DRIVE INSTALLATION 1001108808 Ref. 2WD B 1001104324 Ref. 4WD A

1 0100019 A/R Compound, Locking 2 0701617 48 Bolt M16 x 45mm (12 Per Wheel) 3 4892000 48 Flatwasher 5/8in Hardened (12 Per Wheel)

1001108808 Ref. 2WD Wheel Drive B

101 1001112623 2 Hub Less Motor (Non-Drive Wheel) (See Figure 1-4 for

Breakdown)

102 1001109797 2 Hub with Motor (Drive Wheel) 102A 1001109796 2 Drive Hub Assembly (See Figure 1-4 for Breakdown) 102B 1001109236 2 Drive Motor Assembly (See Figure 1-5 for Breakdown)

1001104324 Ref. 4WD Wheel Drive A

201 1001104315 2 Hub with Motor 201A 1001104325 2 Drive Hub Assembly (See Figure 1-4 for Breakdown) 201B 3160339 2 Drive Motor Assembly (See Figure 1-5 for Breakdown)

Ref. TIRE AND WHEEL INSTALLATIONS (FOAM-FILLED)

0271852 Ref. 445/50D70 Foam Filled B

1001115961 Ref. 445/65-24 Solid A

Ref. 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.

301 2 Tire and Wheel Assembly (Right Side) Options:

0272055 445/50D710 Tire and Wheel Assembly (Foam-Filled) 4520261 445/50D710 Tire Only 4860236 Rim, Wheel (Use with 445/50D710 Tire)

1001112716 445/65-24 Tire and Wheel Assembly (Solid) (No Serviceable

Parts Available - Purchase Complete Assembly)

302 2 Tire and Wheel Assembly (Left Side) Options:

0272056 445/50D710 Tire and Wheel Assembly (Foam-Filled) 4520261 445/50D710 Tire Only 4860236 Rim, Wheel (Use with 445/50D710 Tire)

1001112669 445/65-24 Tire and Wheel Assembly (Solid) (No Serviceable

Parts Available - Purchase Complete Assembly) 303 0701619 64 Bolt M16 x 55mm (16 Per Wheel) 304 4892000 64 Flatwasher 5/8in Hardened (16 Per Wheel)

3121257 1100S 1100SJP 1-11

SECTION 1 FRAME

GENUINE PARTS

MOTOR SHOWN HERE

FOR CLARITY

43 42

38 37

101

109

107

105

110

103

104

106

102

108

11 10

9 8

52 53

FIGURE 1-4. DRIVE HUB ASSEMBLY

1-12 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE HUB ASSEMBLY LESS FITTINGS & HARDWARE 1001112623 Ref. 2WD Hub (Non-Drive Wheel) A 1001101550 Ref. 2WD Hub (Drive Wheel) C 1001101550 Ref. 4WD C

1 70002015 8 Bolt M8 x 25 2 1 Ring, Motor Support Options:

Use 70002681 1001112623 Hub

70002016 1001101550 Hub 3 Use 70002248 1 O-Ring 4 70002018 1 Snap Ring (1001101550 Hub Only) 5 70002019 1 Retainer, Spring (1001101550 Hub Only) 6 70002020 9 Spring (1001101550 Hub Only) 7 Use 70002249 1 Piston (1001101550 Hub Only) (was p/n 70002021) 8 See Note 1 Ring, Backup (1001101550 Hub) (Note: Use Item 51 or 53) 9 See Note 1 O-Ring (1001101550 Hub) (Note: Use Item 51 or 53)

10 See Note 1 O-Ring (1001101550 Hub) (Note: Use Item 51 or 53) 11 See Note 1 Ring, Backup(1001101550 Hub) (Note: Use Item 51 or 53) 12 70002026 5 Disc, Friction (1001101550 Hub Only) 13 70002027 6 Disc, Steel (1001101550 Hub Only) 14 Not Used 15 70002029 1 Spindle 16 70002030 4 Gear, Planetary (1001101550 Hub Only) 17 70002031 4 Bearing (1001101550 Hub Only) 18 70002032 5 Snap Ring (1001101550 Hub Only) 19 70002033 1 Gear, Brake/Input (1001101550 Hub Only) 20 70002034 1 Bearing (1001101550 Hub Only) 21 Not Used 22 70002035 1 Ring, Wear (1001101550 Hub Only) 23 70002036 1 Spring (1001101550 Hub Only) 24 70002037 1 Shaft, Engagement (1001101550 Hub Only) 25 Use 70002248 1 Seal 26 70002039 2 Bearing Assembly 27 70002040 1 Support, Hub 28 70002041 1 Nut, Retaining 29 Use 70002674 4 Flatwasher (was p/n 70002042) 30 Use 70002674 4 Screw, Flange (was p/n 70002043 Std Screw) 31 70002044 1 Gear, Planetary Sun (1001101550 Hub Only) 32 70002045 1 Reduction Assembly, Secondary (1001101550 Hub Only) 33 70002046 1 Snap Ring (1001101550 Hub Only) 34 70002047 1 Gear, Secondary Input Sun (1001101550 Hub Only) 35 70002048 1 Reduction Assembly, Primary (1001101550 Hub Only) 36 70002049 1 Snap Ring (1001101550 Hub Only) 37 70002050 1 Gear, Primary Input Sun (1001101550 Hub Only) 38 Use 70002248 1 O-Ring 39 1 Housing, Hub Options:

Use 70002681 1001112623 Hub

See Note 1001101550 Hub (Note: Not Available Purchase Complete

Hub Assembly)

3121257 1100S 1100SJP 1-13

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

40 70002052 2 Screw, Countersunk 41 See Note 1 O-Ring (Note: Use Item 51 or 52) 42 Use 70002247 1 Thrustwasher (1001101550 Hub Only) 43 See Note 1 O-Ring (1001101550 Hub Only) (Note: Use Item 51 or 52) 44 See Note 1 Cover, Hub (Note: Use Item 52) 45 70002057 3 Plug 46 See Note 1 Snap Ring (Note: Use Item 52) 47 Use 70002247 1 Pin, Engagement (1001101550 Hub Only) 48 See Note 1 Gasket (Note: Use Item 51 or 52) 49 See Note 1 Cover, Engagement (Note: Use Item 52) 50 See Note 2 Screw (Note: Use Item 52)

— — — — — — — — — — 51 70002248 1 Seal Kit (Includes Items 3, 8-11, 25, 38, 41, 43 & 48) 52 1 Cover Kit Options:

70002679 1001112623 Hub (Includes Items 41, 44-46 & 48-50) 70002247 1001101550 Hub (Includes Items 41-44 & 46-50)

53 1 Brake Kit Options:

Not Required 1001112623 Hub

70002249 1001101550 Hub (Includes Item 4-13)

54 1 Components Kit Options:

70002681 1001112623 Hub (Includes Items 1,2,15,27,39 & 40)

See Note 1001101550 Hub (Note: Not Available for Purchase)

Ref. DRIVE HUB ASSEMBLY WITH FITTINGS & HARDWARE 1001112623 Ref. 2WD Hub (Non-Drive Wheel) A 1001109796 Ref. 2WD Hub (Drive Wheel) C 1001104325 Ref. 4WD D

101 0761214 2 Bolt M12 x 30mm (10001109796 & 1001104325 Hubs Only) 102 2110404 1 Fitting, Straight (10001109796 & 1001104325 Hubs Only) 103 1 Fitting Options (10001109796 & 1001104325 Hubs Only):

2130808 Fitting, 90° 2110808 Fitting, Straight

104 1 Fitting Options (10001109796 & 1001104325 Hubs Only):

2151012 Fitting, 45°

2110812 Fitting, Straight 105 2130406 1 Fitting, 90° (10001109796 & 1001104325 Hubs Only) 106 1 Fitting, Options (10001109796 & 1001104325 Hubs Only):

2151012 Fitting, 45°

2130812 Fitting, 90° 107 5241200 2 Flatwasher 12mm Hardened (10001109796 & 1001104325

Hubs Only)

108 1 Hub Assembly (Includes Items 1-53)

1001112623 2WD Hub (Non-Drive Wheel) 1001101550 2WD Hub (Drive Wheel)

1001101550 4WD 109 0100011 A/R Compound, Locking 110 3790158 1 O-Ring

1-14 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-4. DRIVE HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

111 A/R Lubricant Options (Not Shown):

See Note 2WD (Note: Refer to Service Manual)

3020008 4WD (80W-90)

3121257 1100S 1100SJP 1-15

SECTION 1 FRAME

GENUINE PARTS

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

1-16 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DRIVE MOTOR ASSEMBLY

1001109236 Ref. 2WD A

3160339 Ref. 4WD B 1 7022368 4 Bolt 2 70000859 1 End Cap, Motor 3 70003628 2 Locating Pin 4 7021256 1 O-Ring 5 7007420 1 Plug (Includes Item 4) 6 7007446 1 Pin, Dowel 7 7021249 1 Bearing, Needle 8 70000854 1 Plate, Valve 9 7022311 1 Snap Ring (Part of Item 52)

10 7022314 1 Retainer, Spring (Part of Item 52) 11 7024867 1 Spring (Part of Item 52) 12 1 Washer Options (Part of Item 52):

7024868 Washer for 1001109236 Motor

Use 7024868 Washer for 3160339 Motor (was p/n 7022313) 13 70000855 1 Block, Cylinder (Part of Item 52) 14 7021275 3 Pin, Slipper (Part of Item 52) 15 70000856 1 Guide (Part of Item 52) 16 70000857 1 Retainer, Slipper (Part of Item 52) 17 7024865 9 Piston, Cylinder (Part of Item 52) 18 Use 70000862 1 Ring, Piston 19 Use 70000862 1 O-Ring 20 1 Piston, Servo Options (Includes Items 18 & 19):

70002310 Piston for 1001109236 Motor

70000860 Piston for 3160339 Motor 21 70000861 1 Spring 22 A/R Fastener Options:

See Note 1 Pin for 1001109236 Motor (Note: Not Available for

Purchase)

See Note 1 Ring, Retaining for 1001109236 Motor (Note: Not Available

for Purchase)

See Note 1 Pin for 3160339 Motor (Note: Not Available for Purchase) 23 70000853 1 Swashplate 24 70000852 1 Bearing Kit 25 Use 70000862 1 Gasket 26 70002133 1 Plug (includes Item 27) 27 7007207 1 O-Ring 28 7022321 1 Plug (Includes Item 29) 29 7022322 1 O-Ring 30 See Note 1 Housing (Note: Not Available - Purchase Complete Drive

Motor Assembly)

31 70000858 1 Shaft 32 7007437 1 Bearing 33 7007439 1 Snap Ring 34 7007438 2 Snap Ring 35 7007459 1 Seal, Lip 36 7022371 1 Washer, Seal Support

3121257 1100S 1100SJP 1-17

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

37 to 50 Not Used

51 70000862 1 Motor Seal Kit (Includes Items 4,18,19,25,27,29 & 35) 52 7027740 1 Cylinder Block Kit (Includes Items 9 - 17)

1-18 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-5. DRIVE MOTOR ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 1-19

SECTION 1 FRAME

2WDON

4WD/4WS

ONLY

104

107

110

104

105

104

109

4WD

ONLY

15B

109

123

104

10410

14B

14D

14C

14A

14F

14E

ALL

MACHINES

14A

14B

14C

14D

14F

118

116

119

122

120

103

121

114 112

102

114

101

104

111

FIGURE 1-6. FRAME VALVES AND COVERS INSTALLATION

1-20 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-6. FRAME VALVES AND COVERS INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME VALVES INSTALLATION 1001110164 Ref. 2WD/2WS D 1001116398 Ref. 4WD/2WS B

0271802 Ref. 4WD/4WS K

1 0100011 A/R Compound, Locking 2 0641504 A/R Bolt 5/16in-18NC x 1/2in

3 to 4 Not Used

5 0641608 12 Bolt 3/8in-16NC x 1in 6 0641808 4 Bolt 1/2in-13NC x 1in 7Not Used 8 3311605 4 Locknut 3/8in16NC

9 3841340 2 Loop, Hose 10 Not Used 11 4060808

12 to 13 Not Used

14 4641268 A/R Valve Assembly - Steer

14A 7026028 6 Cartridge (6 Per Valve)

7011346 6 Seal Kit - 7026028 Cartridge (1 Per Cartridge)

14B 7024927 2 Valve (2 Per Valve)

7012773 2 Seal Kit - 7024927 Cartridge (1 Per Cartridge) 7018991 4 Coil (2 Per Valve)

14C 7012770 1 Valve

7012773 1 Seal Kit - 7012770 Cartridge 7018991 2 Coil

70001939 1 Orifice 14D 2221086 6 Check, Pressure 14E 2110606 8 Fitting, Straight 14F 2130810 2 Fitting, 90°

15 1 Valve Assembly - Traction 15A 1001110060 2WD/2WS (See Figure 1-7 for Breakdown) 15B 4641454 4WD/2WS & 4WD/4WS (See Figure 1-8 for Breakdown)

16 4711500 A/R Flatwasher 5/16in Thin

17 4711600 A/R Flatwasher 3/8in Thin

18 4711800 4 Flatwasher 1/2in Thin

19 Not Used

20 0641424 2 Bolt 1/4in-20NC x 3in

21 3311405 2 Locknut 1/4in-20NC

22 4641155 1 Manifold, Junction (4WD Only)

23 4711400 8 Flatwasher 1/4in Thin

24 Not Used

25 0641509 4 Bolt 5/16in-18NC x1-1/8in

26 Not Used

27 Use 1001112758 1 Module (Chassis) (was p/n 1600331)

124in/3.2m

1 2WD/2WS & 4WD/2WS 2 4WD/4WS (Note: Qtys below for 1 valve. Double qtys for

Flex-Trim

4WD)

(Note: Control System must be recalibrated when Module is replaced)

3121257 1100S 1100SJP 1-21

SECTION 1 FRAME

FIGURE 1-6. FRAME VALVES AND COVERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

28 to 29 Not Used

30 3311505 4 Locknut 5/16in-18NC

1001110114 Ref. FRAME COVERS INSTALLATION C

101 0100011 A/R Compound, Locking 102 0641406 8 Bolt 1/4in-20NC x 3/4in 103 0641414 4 Bolt 1/4in-20NC x 1-3/4in 104 0791604 63 Screw 3/8in-16NC x 1/2in 105 1671045 4 Plate, Cover (Axle Side) 106 Not Used 107 1671046 4 Plate, Cover (Axle Corner) 108 1671047 1 Plate, Cover (Rear) 109 1671048 2 Plate, Cover (Frame Top) 110 1671049 3 Plate, Cover (Frame Side) 111 3300454 8 Nut 1/4in-20NC 112 3311405 4 Locknut 1/4in-20NC 113 Not Used 114 4711400 12 Flatwasher 1/4in Thin 115 Not Used 116 1001110108 1 Panel, Front Right 117 1001110109 1 Panel, Front Left 118 1001110110 1 Panel, Front 119 1001110111 1 Shield, Right Axle 120 1001110112 1 Shield, Left Axle 121 1001110113 2 Plate, Clamp 122 1001110513 51in/1.3m Seal 123 1001110877 1 Mount, Fire Extinguisher

1-22 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-6. FRAME VALVES AND COVERS INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 1-23

SECTION 1 FRAME

102

101

104

105

104

107

102

103

101

105

106 5 105

FIGURE 1-7. TRACTION VALVE ASSEMBLY (2WD)

1-24 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-7. TRACTION VALVE ASSEMBLY (2WD)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001113705 Ref. TRACTION VALVE ASSEMBLY LESS FITTINGS B

1 70002298 1 Cartridge, Valve (Relief)

7012998 1 Seal Kit - 70002298 Cartridge

2 7012941 1 Cartridge, Solenoid Valve (2 Speed Shift)

7010543 1 Seal Kit - 7012941 Cartridge 7012944 1 Coil 7017403 1 Water Proofing Kit for 7012944 Coil

3 7012941 1 Cartridge, Solenoid Valve (Brake Release)

7010543 1 Seal Kit - 7012941 Cartridge 7012944 1 Coil 7017403 1 Water Proofing Kit for 7012944 Coil

4 70000802 1 Cartridge, Valve (Pilot)

7012942 1 Seal Kit - 7026026 Cartridge 5 See Note 1 Orifice (Note: Not Available for Purchase) 6 70000804 1 Cartridge, Valve (Shuttle)

70000805 1 Seal Kit - Cartridge

1001110060 Ref. TRACTION VALVE ASSEMBLY F

101 2110406 2 Fitting, Straight 102 2110808 2 Fitting, Straight 103 2150808 1 Fitting, 45° 104 2151012 4 Fitting, 45° 105 2220238 2 Plug 106 2221086 1 Fitting, Diagnostic Test Port 107 1001113705 1 Valve Assembly less Fittings (Includes Item 1-6)

3121257 1100S 1100SJP 1-25

SECTION 1 FRAME

62883

FIGURE 1-8. TRACTION VALVE ASSEMBLY (4WD)

1-26 1100S 1100SJP 3121257

SECTION 1 FRAME

FIGURE 1-8. TRACTION VALVE ASSEMBLY (4WD)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641454 Ref. TRACTION VALVE ASSEMBLY E

1 7012941 3 Cartridge, Valve (2 Speed/Brake Release/Axle Lockout)

7010543 3 Seal Kit - 7012941 Cartridge

1A 7012944 2 Coil

2 70000801 1 Cartridge, Valve (Relief)

7012998 1 Seal Kit - 70000801 Cartridge 3 70000802 1 Cartridge, Valve (Pilot)

7012942 1 Seal Kit - 70000802 Cartridge 4 70000803 1 Switch, Pressure (Axle Lockout) 5 70000804 1 Cartridge, Valve (Shuttle)

70000805 1 Seal Kit - 70000804 Cartridge

6 70000806 2 Cartridge, Valve (Flow Divider)

7017405 2 Seal Kit - 70000806 Cartridge 7 7012955 4 Cartridge, Valve (Check)

7012967 4 Seal Kit - 7012955 Cartridge 8 2111012 2 Fitting, Straight 9 2151012 2 Fitting, 45°

10 2110810 13 Fitting, Straight 11 2110406 3 Fitting, Straight 12 2221086 1 Check, Pressure 13 2220883 1 Plug, #4 (Not Shown)

3121257 1100S 1100SJP 1-27

SECTION 1 FRAME

FIGURE 1-8. TRACTION VALVE ASSEMBLY (4WD) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1-28 1100S 1100SJP 3121257

SECTION 2

TURNTABLE

3121257 1100S 1100SJP 2-1

SECTION 2 TURNTABLE

292423

1 5

102

109

117

115

112

116

114 104

101 103

113

116

110 105

1 5

111

116

108 101

1 3

201

202

115

106

115

107

109

117

115

FIGURE 2-1. VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS

2-2 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-1. VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRAME VALVES INSTALLATION 1001110164 Ref. 2WD/2WS D 1001116398 Ref. 4WD/2WS B

0271802 Ref. 4WD/4WS K

1 0100011 A/R Compound, Locking 2Not Used 3 0641506 4 Bolt 5/16in-18NC x 3/4in 4Not Used 5 0641608 8 Bolt 3/8in-16NC x 1in 6Not Used 7 0902755 1 Bracket, Valve Mounting

8 to12 Not Used

13 4641267 1 Main Valve Assembly (See Figure 2-2 for Breakdown)

14 to 15 Not Used

16 4711500 4 Flatwasher 5 /16in Thin 17 4711600 8 Flatwasher 3/8in Thin

18 to 22 Not Used

23 4711400 4 Flatwasher 1/4in Thin 24 0641406 4 Bolt 1/4in-20NC x 3/4in

25 Not Used

26 0902800 1 Bracket, Module Mounting 27 Not Used 28 Use 1001112757 1 Module, B.L.A.M. (was p/n 1600332)

(Note: Control System must be recalibrated when Module is replaced)

29 3300454 4 Nut, Special

1001110740 Ref. BATTERY, HORN & AUXILIARY PUMP INSTALLATION A

101 0100011 A/R Compound, Locking 102 0140001 1 Horn 103 0236768 4 Rod, Hold-down 104 0363062 2 Bar, Battery 105 0400020 1 Battery 106 0641408 1 Bolt 1/4in-20NC x 1in 107 0641412 1 Bolt 1/4in-20NC x 1-1/2in 108 0641606 2 Bolt 3/8in-16NC x 3/4in 109 3311405 3 Locknut 1/4in-20NC 110 3311601 4 Nut 3/8in-16NC 111 3600424 1 Auxiliary Pump Assembly (See Items 201-202 for Breakdown) 112 3740067 1 Relay 113 3980006 1 Seat, Battery 114 4420037 115 4711400 4 Flatwasher 1/4in 116 4711600 10 Flatwasher 3/8in 117 4791400 2 Starwasher 1/4in

17in/43cm

Tape, Insulation

3121257 1100S 1100SJP 2-3

SECTION 2 TURNTABLE

FIGURE 2-1. VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600424 AUXILIARY PUMP ASSEMBLY

201 70001056 1 Motor Kit

7011062 1 Bracket, Motor/Pump 7011016 1 Coupling 7029592 2 Setscrew

202 7029593 1 Pump Kit

7011016 1 Coupling 7011044 1 Gasket 7011048 4 Flatwasher 7011043 4 Screw

2-4 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-1. VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-5

SECTION 2 TURNTABLE

145

117

102

106

108

103

111

104

1053114

114

1142113

116

112

115

109

107

101

114

103

110

116

FIGURE 2-2. MAIN VALVE ASSEMBLY

2-6 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN VALVE ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

See Note Ref. MAIN VALVE ASSEMBLY LESS FITTINGS C

Ref. Note: Was p/n 4641222 - Use p/n 4641267 as Replacement

1 7024573 1 Cartridge, Solenoid Valve (Dump)

7024574 1 Seal Kit - 7024573 Valve 7011354 1 Coil

2 7021636 1 Cartridge, Solenoid Valve (Lift Flow)

7017495 1 Seal Kit - 7021636 Valve 7017451 1 Coil

3 7021636 1 Cartridge, Solenoid Valve (Tele Flow)

7017495 1 Seal Kit - 7021636 Valve 7017451 1 Coil

4 7024924 1 Control Valve Assembly (Swing)

7012773 1 Seal Kit - 7024924 Valve 7018991 2 Coil 7021375 2 Nut, Coil

5 7024925 1 Control Valve Assembly (Lift)

7012773 1 Seal Kit - 7024924 Valve 7018991 2 Coil 7021375 2 Nut, Coil

6Use 70001976 1 Control Valve Assembly (Tele) (was p/n 7012770)

7012773 1 Seal Kit - Valve 7018991 2 Coil 7021375 2 Nut, Coil

7 7026007 5 Cartridge, Relief Valve (Swing/Lift Up/Lift Down/Tele In/Tele Out)

7024574 1 Seal Kit - 7026007 Valve

8 to 11 Not Used

12 7026000 1 Cartridge, Check Valve

7011311 1 Seal Kit - 7026001 Valve

13 7026001 1 Cartridge, Check Valve

7011311 1 Seal Kit - 7026001 Valve

14 7026002 1 Cartridge, Shuttle Valve

2900770 1 Seal Kit - 7026000 Valve

15 7024570 1 Cartridge, Solenoid Valve (Aux Lift Down Select)

70001930 1 Seal Kit - 7024570 Valve (was p/n 2900770)

7024571 1 Coil

16 7026003 1 Cartridge, Pilot Valve

7026004 1 Seal Kit - 7026003 Valve

17 7026005 1 Cartridge, Solenoid Valve (Aux Lift Down)

7026006 1 Seal Kit - 7026005 Valve 7024571 1 Coil

18 7026008 1 Cartridge, Check Valve

7011346 1 Seal Kit - 7026004 Valve 19 7018942 12 Capscrew, Socket Head #10-24NC x 2in 20 7026016 1 Cartridge, Valve

7011346 1 Seal Kit - Valve

3121257 1100S 1100SJP 2-7

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN VALVE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

4641267 Ref. MAIN VALVE ASSEMBLY WITH FITTINGS B

101 2111216 1 Fitting, Straight 102 2130606 1 Fitting, 90° 103 2110606 3 Fitting, Straight 104 2110808 1 Fitting, Straight 105 2170316 1 Fitting, Tee 106 2131012 1 Fitting, 90° 107 2110406 1 Fitting, Straight 108 2110408 1 Fitting, Straight 109 2110810 2 Fitting, Straight 110 2111010 2 Fitting, Straight 111 2110608 1 Fitting, Straight 112 2220890 1 Plug 113 Use 70002760 1 Plug (was p/n 2220888) 114 2221086 6 Check, Pressure 115 Use 70002758 2 Fitting, Plug (was p/n 2220883) 116 88662193 7 Plug w/ O-Ring (was p/n 88662193 & 2220886) 117 See Note 1 Main Valve Assembly Less Fittings (Includes Items 1-20) (Was

p/n 4641222 - Use p/n 4641267 as Replacement)

2-8 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-2. MAIN VALVE ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-9

SECTION 2 TURNTABLE

107

106

105

109

204

202

206

205

201

203

110

104

102

103

110

101

1016412857311OR204

202

206

205

201

203

FIGURE 2-3. TURNTABLE SWING DRIVE AND BEARING INSTALLATION

2-10 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-3. TURNTABLE SWING DRIVE AND BEARING INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0271596 Ref. SWING DRIVE INSTALLATION D

1 0100019 A/R Compound, Locking 2 0682418 5 Bolt 7/8in- 9NC x 2-1/4in (Grade 8) 3 1 Swing Motor/Hub Assembly (See Figure 2-4 for Breakdown)

Use 1001134098 Prior to S/N 0300157749 (was p/n 3160302)

1001134098 S/N 0300157749 to Present 4 3312002 1 Nut, Jam 5/8in-11NC 5 3900223 1 Screw, Shoulder 6 3952020 1 Setscrew 5/8in-11NC x 2-1/2in 7 4071041 1 Shim 8 4892400 5 Flatwasher, 7/8in Hardened

0271512 Ref. TURNTABLE BEARING AND LUBE INSTALLATION B

101 0100019 A/R Compound, Locking 102 0440251 1 Bearing, Turntable 103 0682026 40 Bolt 5/8in-11NC x 3-1/4in (Grade 8) 104 0682040 40 Bolt 5/8in-11NC x 5in (Grade 8) 105 2180002 2 Fitting, Grease 106 2180344 2 Fitting, Bulkhead 107 2220063 2 Fitting, Adapter 108 Not Used 109 2750528 2 Hose 110 4892000 80 Flatwasher 5/8in Hardened

— — — — — — — — — —

2915072 1 Turntable Bearing Kit (Includes Items 102-104 & 110)

1001110186 Ref. TURNTABLE LOCK INSTALLATION C

201 0641524 1 Bolt 5/16in-18NC x 3in 202 1260017 9 in/23cm Chain - #3 203 3311505 1 Locknut 5/16in-18NC 204 3421563 1 Pin, Turntable Lock 205 3421565 1 Pin, Snap 206 3760170 2 Ring, Quick Release

3121257 1100S 1100SJP 2-11

SECTION 2 TURNTABLE

24 25

1515151616

1918172027

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

2-12 1100S 1100SJP 3121257

205

211

210

212

221

202

219

222

223

204

203

206

201

209

207

208

214

213

216

215

218

217

203

220

120

119

117

116

118

114

115

113

112

110

109

108

107

106

105

103

104

102

101

121

GENUINE PARTS

151 251

252 253 254 255

SECTION 2 TURNTABLE

3121257 1100S 1100SJP 2-13

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. SWING MOTOR/HUB ASSEMBLY OPTIONS:

3160302 Ref. Prior to S/N 0300157749 B

1001134098 Ref. S/N 0300157749 to Present B

Ref. Note: For Machines Prior to S/N 0300157749, Original

Equipment Assembly p/n 3160302 may have been replaced with p/n 1001134098 as Service Replacement Assembly. Identify P/N before ordering replacement components.

1 See Note 1 Housing/Shaft Assembly (Note: Not Available - Purchase

Complete Swing Motor/Hub Assembly)

1A 7024183 1 Shaft, Out put 1B 7000236 1 Seal, Lip 1C Use 1001091460 1 Cup, Bearing (was p/n 7000272 & p/n 90202500) 1D Use 1001091460 1 Cone, Bearing (was p/n 7000273 & p/n 90202501) 1E Use 1001091461 1 Cup, Bearing (was p/n 7000274

1F Use 1001091461 1 Cone, Bearing (was p/n 7000275 & p/n 90202503) 1G 7024184 1 Housing 1H 7000239 1 Thrustwasher

1I 7000240 1 Ring, Retaining

1J 7017072 1 Plug, Pipe

2 7001917 1 Gear, Internal

3 7001918 1 Carrier Assembly 3A 7001900 1 Carrier 3B 7007645 6 Washer, Tanged 3C 7001902 84 Bearing, Needle 3D 7007646 3 Thrustwasher 3E 7001904 3 Shaft, Planet

3F 7001927 3 Gear, Cluster 3G 7001906 3 Rollpin 3H 7007648 6 Washer

4 7010467 1 Gear, Ring 5 7000224 2 O-Ring 6 7001920 1 Cover, Input 7 Not Used 8 7001922 1 Thrustwasher 9 Not Used

10 7024188 1 Motor Assembly (See Items 101-121 for Breakdown)

11 to 12 Not Used

13 7001921 1 Gear, Sun

14 Not Used

15 7000287 4 Thrustwasher

16 7000288 2 Bearing, Thrust

17 7001923 8 Bolt 3/8in-16NC x 3in (Grade 8)

18 7001924 4 Bolt, Shoulder 3/8in-16NC x 2-3/4in (Grade 8)

19 7001929 4 Lockwasher (Used with Item 18 Only)

20 7001928 1 Plug, Pipe

21 7001926 2 Plug, Pipe

22 7017082 1 Plug, Pipe

23 Not Used

24 See Note 1 Plate, ID (Note: Not Available For Purchase)

2-14 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

25 7000281 2 Screw, Drive 26 1 Brake Assembly Options (See Items 201-223 for Breakdown):

7024182 Prior to S/N 0300151138

70003524 S/N 0300151138 to Present 27 7024763 1 O-Ring 28 See Note 2 Lug, Lifting (Note: Not Available For Purchase) 29 7024185 2 Bolt 1/2in-13NC x 5in (Grade 8) 30 Not Used 31 7000731 1 Gasket 32 A/R Valve Options:

Used With Swing Motor/Hub Assembly p/n 3160302

Use 4640741 1 Valve (was p/n 7024187)

7011320 2 Cartridge 2900770 2 Seal Kit - 7011320 Cartridge (1 Per Cartridge)

Used With Swing Motor/Hub Assembly p/n 1001134098

70003523 1 Valve

70003629 2 Cartridge

2900770 2 Seal Kit - 70003629 Cartridge (1 Per Cartridge) 33 See Note 4 Lockwasher (Note: Not Available For Purchase) 34 7024135 4 Bolt 5/16in-18NC x 2-1/2in (Grade 8) 35 7024186 1 Tube 36 7017085 2 Elbow

7024188 Ref. MOTOR ASSEMBLY

101 7024391 5 Bolt 102 7004035 1 Cover, End 103 Use 7024389 1 Seal, Commutator 104 Use 7024389 5 Seal, Ring 105 Use 7024453 1 Commutator and Ring Assembly (was p/n 7004037) 106 Use 7004453 1 Ring (was p/n 7004037) 107 7024379 Manifold 108 7024392 1 Rotor Set 109 7024380 1 Plate, Wear 110 7024393 1 Link, Drive 111 Not Used 112 7024395 1 Shaft, Coupling 113 7024381 1 Bushing, Bronze 114 7004043 1 Thrustwasher 115 7004044 1 Bearing, Thrust 116 Use 7024389 Seal, Inner 117 Use 7024389 1 Washer, Back-up 118 7024394 1 Housing 119 7024390 1 Bearing 120 Use 7024389 1 Seal 121 7010795 1 Plug, O-Ring

122 to 150 Not Used

— — — — — — — — — —

151 Use 7024389 1 Seal Kit - 7024188 Motor (Includes Items 103, 104, 116,117 &

120) (was p/n 7024396)

3121257 1100S 1100SJP 2-15

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. BRAKE ASSEMBLIES

7024182 Ref. Prior to S/N 0300151138

70003524 Ref. S/N 0300151138 to Present

201 7024189 1 Shaft 202 Use 7024182 1 Housing (Note: Not Available For Purchase) 203 Use 7024193 2 Plate, Friction 204 Use 7024193 1 Plate, Pressure 205 7000731 1 Gasket 206 Use 7024193 2 Plate, Outer 207See Note 1Gasket (Note: Use Item 251, 254 or 255.) 208 7024191 1 Cylinder 209 7024192 1 Piston 210 Use 7024197 1 Bearing, Ball 211 Use 7024197 1 Ring, Retaining 212 Use 7024197 1 Seal, Shaft 213 See Note 6 Capscrew (Note: Not Available For Purchase) 214 See Note 6 Lockwasher (Note: Not Available For Purchase) 215 Use 7024194 1 O-Ring 216 Use 7024194 1 Ring, Back-up 217 Use 7024194 1 O-Ring 218 Use 7024194 1 Ring, Back-up 219 7024190 2 Pin, Dowel 220 See Note 1 Plug (Note: Not Available For Purchase) 221 See Note 1 Plug (Note: Not Available For Purchase) 222 Use 7024196 A/R Spring (Natural) 223 Use 7024196 A/R Spring, (Blue)

224 to 250 Not Used

— — — — — — — — — — 251 7024194 1 Seal Kit - Brake (Includes Items 205, 207 & 215-218) 252 Use 7024196 1 Spring Kit - Brake (Includes 12 Natural Colored Springs)

(was p/n 7024195)

Note: Spring Kit p/n 7024195 no Longer Available,

Purchase p/n 7024196 for Replacement.

253 7024196 1 Spring Kit - Brake (Includes 12 Natural & 2 Blue Colored

Springs) 254 7024193 1 Friction Disc Kit - Brake (Includes Items 203, 204, 206 & 207) 255 7024197 1 Bearing Kit - Brake (Includes Items 207 & 210-212)

2-16 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-17

GENERAT

OVE

R SHIEL

(

TEM

17)

HOW

N HER

EFO

R C

LARIT

109

131

145

105

129

115

102

145

160

182

183

161

175

190

102

111

102

145

153

192

148

133

112

147

157

142

102

340

342

316

341

152

134

119

102

116

151

113

147

173

192

171

148

133

1451451311238109102139118

163

177

168

177

402

401

177

156

164

120

110

146

132

771551771231041071021441401651241

3114514

916

130

149

178149106167106

10214917912

158

113

147

151

116

102

154 170

154

169

186

121

176

185

144

187

188

191

151

102

189

101

162

135

409

323

326

159

7371710

180

114

102

145

185

144

187

595355632436626061436

172

141

102

144

117

102

203

196

102

200

197

102

195

102

200

195

102

202

198

199

204

131

145

194

201

2108109145131

145

193

102

145

136

174

205

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

2-18 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

243236

301

310

319

301

307

314

301

311

313

330

336

337

301

311

312

313

301

318

301

309

320

329

301

305

314

324

301

306

314

324

137

143

130

106

138

143

130

106

50D

179

122

301

303

315

302

327

301

308

317

301

304

316

322

36245

36244

102

107

407

328

404

301

321

319

315

303

334

402

332

325

338

103

406

333

335

242

926

150

40929

403

50B

50A

BATTE

REF

.50E50C50A50A50FI

TEM (50

) INCLUDES50A THR

U 5

F 3

181

3121257 1100S 1100SJP 2-19

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001120529 Ref. CATERPILLAR DIESEL ENGINE INSTALLATION C

1 0100011 A/R Compound, Locking 2 0100079 A/R Sealant, Pipe 3 0641606 4 Bolt 3/8in-16NC x 3/4in 4 0641506 A/R Bolt 5/16in-18NC x 3/4in 5 0641509 A/R Bolt 5/16in-18NC x 1-1/8in 6 0641511 13 Bolt 5/16in-18NC x 1-3/8in 7 0641605 3 Bolt 3/8in-16NC x 5/8in 8 0641608 A/R Bolt 3/8in-16NC x 1in

9 0641610 1 Bolt 3/8in-16NC x 1-1/4in 10 0641611 2 Bolt 3/8in-16NC x 1-3/8in 11 0641808 1 Bolt 1/2in-13NC x 1in 12 0642010 1 Bolt 5/8in-11NC x 1-1/4in 13 0700808 1 Bolt M8 x 16mm

0761210 1 Bolt M12 x 20mm 14 1320022 5 Clamp 15 1320187 1 Clamp, Twin 16 1320190 1 Cover, Clamp 17 1671121 1 Cover, Generator 18 2180348 1 Fitting, Barbed 19 2200222 1 Plug, Pipe (Used in Bottom of Fuel Tank) (Not Shown) 20 2220313 1 Fitting, 90° Barbed 21 2221176 1 Fitting, 90° Elbow 22 2750532 55in/1.4m Hose 23 2820170 1 Insulation, Sound Absorbing 24 3311505 A/R Locknut 5/16in-18NC 25 3311605 A/R Locknut 3/8in-16NC 26 1001128899 1 Panel, Rubber 27 3422446 1 Pin 28 3573644 1 Plate, Tray Clamp 29 1001128898 1 Plate, Clamp 30 3573728 1 Plate, Tray Clamp 31 3841143 1 Keeper, Pin 32 3900272 4 Screw, Button 5/16in-18NC x 1-3/4in 33 4240018 A/R Strap, Tie (Not Shown) 34 4240033 A/R Strap, Tie 35 Not Used 36 4711500 A/R Flatwasher 5/16in Thin 37 4711600 16 Flatwasher 3/8in Thin 38 4752000 1 Flatwasher 5/8in Regular 39 4811900 1 Flatwasher M8

4812100 1 Flatwasher M12 40 1001108617 Pressure Filter

70002231 1 Element, Filter 41 1001111132 1 Panel, Rubber 42 1001112878 1 Plate, Top Clamp 43 1001112879 1 Plate, Bottom Clamp 44 1001112880 1 Plate, Tray Clamp

2-20 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

45 Not Used 46 1001116112 1 Engine, Caterpillar C3.4 Turbo (See Items 401 to 411 for Individu-

ally Serviced Components) 47 1001116792 3 Clamp 48 1001119995 1 Harness, Engine (Not Shown - See Section 7 for Breakdown) 49 1001120492 2 Fitting, Straight 50 1001120743 1 Battery Cable Kit B

50A 7027034 1 Cable, Red (To Aux Pump Relay, Battery Positive

Terminal, Glow Plug Solenoid & Starter)

50B 7024581 1 Cable, Black (To Aux Pump, Battery Negative

Terminal & Ground at Tray Pivot) 50C 7027035 1 Cable, Red (Aux Pump Relay to Aux Pump) 50D 7027039 1 Cable, Black (Tray Pivot to Engine Block) 50E See Note 4 Boot, Terminal (Red) (Note: Not Available For Purchase) 50F See Note 1 Boot, Square Terminal (Red) (Note: Not Available For

Purchase)

51 1001121236 1 Bracket, Fuel Pump Mounting 52 3311005 1 Locknut 10-24NC 53 3311405 6 Locknut 1/4in-20NC 54 4711000 2 Flatwasher #10 55 4711400 12 Flatwasher 1/4in 56 0641612 2 Bolt 3/8in-16NC x 1-1/2in 57 0721006 1 Screw #10-24NC x 3/4in 58 2200221 1 Plug 59 1001128765 1 Support, Baffle 60 1001128789 1 Panel, Rubber 61 1001128797 1 Plate, Clamp 62 1001130774 1 Seal 63 0641406 6 Bolt 1/4in-20NC x 3/4in

1001116111 Ref. CATERPILLAR DIESEL ENGINE ASSEMBLY D

101 0080181 1 Plate, Pump Mounting Adapter 102 0100011 A/R Compound, Locking 103 0100020 A/R Sealant, Pipe (Not Shown) 104 0340003 2 Band, Air Cleaner 105 0340051 2 Band, Muffler 106 0641406 9 Bolt 1/4in-20NC x 3/4in 107 0641506 6 Bolt 5/16in-18NC x 3/4in 108 0641605 2 Bolt 3/8in-16NC x 5/8in 109 0641608 19 Bolt 3/8in-16NC x 1in 110 0641808 1 Bolt 1/2in-13NC x 1in 111 0641812 2 Bolt 1/2in-13NC x 1-1/2in 112 0642028 2 Bolt 5/8in-11NC x 3-1/2in 113 0642030 2 Bolt 5/8in-11NC x 3-3/4in 114 0701012 4 Bolt M10 x 25mm 115 0701015 2 Bolt M10 x 35mm 116 0711214 8 Bolt M12 x 30mm 117 0760810 4 Bolt M8 x 20mm 118 0940070 1 Bumper

3121257 1100S 1100SJP 2-21

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

119 0961986 2 Bushing, Flanged 120 1001131542 1 Lanyard 121 1320017 2 Clamp 122 1320022 4 Clamp 123 1340065 1 Air Cleaner Assembly

7003655 1 Element, Air Cleaner 7015013 1 Baffle, Rubber 7015014 1 Clamp, Cap 7015015 1 Cup

7015003 1 Wingnut 124 1703162 2 Decal - Fan Blade 125 2060025 1 Fan 126 2300004 127 3020016 128 3020037 A/R Lube, Coupling Grease (Not Shown) 129 3220126 1 Muffler

70003555 1 Clamp 130 3311405 7 Locknut 1/4in-20NC 131 3311605 A/R Locknut 3/8in-16NC 132 3311805 1 Locknut 1/2in-13NC 133 3312005 4 Locknut 5/8in-11NC 134 3422532 1 Pin, Hitch 135 3520054 3 Plug 136 3573412 1 Gusset 137 3740067 1 Relay 138 3740080 1 Relay 139 3960543 1 Seal 140 3960544 1 Seal 141 4031911 4 Capscrew M8 x 35mm 142 4032008 8 Capscrew M10 x 20mm 143 4711400 6 Flatwasher 1/4in Thin 144 4711500 A/R Flatwasher 5/16in Thin 145 4711600 A/R Flatwasher 3/8in Thin 146 4711800 2 Flatwasher 1/2in Thin 147 4712000 4 Flatwasher 5/8in Thin 148 4740242 4 Washer, Snubbing 149 4751400 10 Flatwasher 1/4in Regular 150 4751500 2 Flatwasher 5/16in Regular 151 4812100 10 Flatwasher 12mm 152 4832000 8 Lockwasher 10mm 153 4891800 2 Flatwasher 1/2in Hardened 154 8405104 4 Clamp, Gear 155 91083128 1 Elbow, 90° 156 91403244 1 Rubber, Straight Hump 157 1001129023 1 Plate, Engine Mounting (Rear) 158 1001129304 1 Mount, Motor (Front) 159 1001116153 1 Tray, Engine 160 1001116186 1 Tube, Exhaust 161 1001116201 1 Plate, Muffler Mounting

2.95gl/11.17Li

2.64gl/9.99Li

Anti-Freeze (Not Shown) Oil, Motor 15W-40 (Not Shown)

2-22 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

162 1001116278 1 Coupling, Pump 163 1001116313 1 Tube, Air Intake 164 1001116324 1 Tube, Air Intake 165 1001116348 1 Plate, Radiator Mounting 166 1001116354 1 Radiator

7027412 1 Cap, Radiator 167 1001116367 1 Support, Tank Mounting 168 1001116413 1 Hose, Air Intake Reducer 169 1001116436 1 Hose, Radiator (Top) 170 1001116437 1 Hose, Radiator (Bottom) 171 1001116525 2 Mount, Engine 172 1001116591 1 Spacer, Fan 173 1001117546 1 Mount, Generator 174 1001117874 1 Engine, Caterpillar C3.4 Turbo W/E Controls (See Items 301 to

339 for Individually Serviced Components)

175 1001118368 1 Pump Assembly (Machines with Rexroth Pump Only) (See

Figure 2-7 for Breakdown) 176 1001116836 A/R Hose, Air Intake 177 1320058 1 Clamp 178 1580011 1 Container, Coolant Overflow 179 2720058 31.66ft Hose 180 4060805 181 4640750 1 Valve, Oil Drain 182 4812000 3 Flatwasher 10mm 183 1001121004 3 Nut M10 x 1.25 184 Not Used 185 0641508 3 Bolt 5/16in-18NC x 1in 186 1320130 1 Clamp 187 3311505 3 Locknut 5/16in-18NC 188 1001125891 1 Bracket, Valve 189 0761212 2 Bolt M12 x 25mm 190 0701016 6 Bolt M10 x 40mm 191 1001130161 1 Bracket, Muffler Mounting 192 1001130171 2 Mount, Engine 193 0641610 4 Bolt 3/8in-16NC x 1-1/4in 194 0641614 3 Bolt, Hex Head 3/8in-16NC x 1-3/4in 195 0700822 5 Bolt M8 x 70mm 196 0700823 2 Bolt M8 x 75mm 197 0700824 1 Bolt M8 x 80mm 198 3580321 1 Pulley, Engine 199 4568735 3 Tube, Spacer 200 4811900 8 Flatwasher M8 201 4891600 3 Flatwasher 3/8in Hardened 202 1001117500 1 Spacer, Pulley 203 1001117577 1 Support, Generator Pulleys 204 1001129995 3 Pulley, Idler Grooved 205 4831900 4 Lockwasher 8mm

5in/12.7cm

Flex-Trim 1/4in

3121257 1100S 1100SJP 2-23

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001117874 Ref. CATERPILLAR DIESEL ENGINE W/E CONTROLS B

301 0100011 A/R Compound, Locking 302 0100020 A/R Sealant, Pipe 303 0700808 3 Bolt M8 x 16mm 304 0701010 2 Bolt M10 x 20mm 305 0760606 2 Bolt M6 x 12mm 306 0760610 2 Bolt M6 x 20mm 307 0760612 3 Bolt M6 x 25mm 308 0761210 2 Bolt M12 x 20mm 309 1320224 1 Clamp 310 1320263 1 Clamp 311 3290501 3 Nut M5 312 4031607 2 Capscrew M5 x 16mm 313 4811600 3 Flatwasher M5 314 4811700 8 Flatwasher M6 315 4811900 3 Flatwasher M8 316 4812000 3 Flatwasher M10 317 4812100 2 Flatwasher M12 318 5250608 2 Bolt M6 x 16mm 319 5250808 4 Bolt M8 x 16mm 320 8303541 1 Bolt M6 x 1 x 35mm 321 8406101 2 Tube, Clip 322 8406105 2 Tube, Clip 323 1001097553 1 Washer, Coolant Sensor 324 1001112059 5 Bumper 325 1001112068 1 Sensor, Speed 326 1001112069 1 Sensor, Temperature 327 1001112070 1 Switch, Oil Pressure 328 1001112073 1 Actuator 329 1001112570 1 Spacer, Nylon 330 1001112592 1 Bearing 231 Not Used 332 1001120769 1 Bracket, ECM/Fuse Box 333 1001120771 1 Bracket, Actuator 334 1001120772 1 Bracket, Actuator 335 1001120773 1 Link, Spacer 336 1001120774 1 Bolt, M5 337 1001120775 1 Bracket, Actuator 338 1001120810 1 Controller 339 1001120776 1 Engine Harness (Not Shown - See Section 7 for Breakdown) 340 1001129361 1 Tube, Dipstick 341 0761007 1 Bolt M10 x 14mm 342 1001129360 1 Dipstick, Oil

2-24 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001116112 Ref. CATERPILLAR ENGINE COMPONENTS A

401 70002831 1 TurboCharger

70002829 1 Gasket, TurboCharger Drain Pipe

70002830 1 Gasket, TurboCharger 402 70002832 1 Hose 403 7026839 1 Pump, Fuel

70002833 1 Ring, Retaining

70002834 1 Bowl, Water Collect

7026830 1 Element, Fuel/Water

70002835 1 Kit Seal 404 70002837 4 Plug, Glow 405 7026802 1 Flywheel W/Gear (Not Shown)

7026803 1 Gear

406 7026811 1 Filter, Oil

7026812 1 O-Ring (Between Center Bolt & Oil Filter Bracket) 7026813 1 O-Ring (Between Oil Filter Bracket & Engine)

407 7026822 1 Thermostat

7026820 1 Gasket, Thermostat (Between Housing & Cylinder Head)

7026821 1 Gasket (Between Housing & Thermostat Cover) 408 7026829 1 Gasket, Intake Manifold (Not Shown) 409 7026833 1 Starter 410 7026804 1 Gasket (Not Shown - Located Between Bell Housing & Engine

Block)

411 7026805 1 Seal, Rear Main (Not Shown)

3121257 1100S 1100SJP 2-25

10910

170

12110

1461462

1170170

112

103

76153162133132102

135

208

17010

10210

216

16313

169

10716

10810411282201691

18313

13016

143

174

146146104017017011111

173102106

154

15117

158

123

LOCATED ON T/T

(SHOWN HERE

FOR CLARITY)

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

2-26 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

TANK REF.

BATTE

REF

23F23F23A23C23B

23B

23A23

ITE

M (

23) INCLUDE

S23

HRU 23G 214

134

20420620320

221

205

213213

23D

23E

21021

2305243

16131

342438

113739

624384243

825207201

3121257 1100S 1100SJP 2-27

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DEUTZ DIESEL ENGINE INSTALLATION OPTIONS: 1001111054 Ref. Without Skypower (2500W Generator Prep) D 1001111352 Ref. With Skypower (7500W Generator Prep) D

1 0100011 A/R Compound, Locking 2 0100079 A/R Sealant, Pipe 3 0641410 4 Bolt 1/4in-20NC x 1-1/4in 4 0641506 1 Bolt 5/16in-18NC x 3/4in 5 0641509 7 Bolt 5/16in-18NC x 1-1/8in 6 0641511 13 Bolt 5/16in-18NC x 1-3/8in 7 0641605 3 Bolt 3/8in-16NC x 5/8in 8 0641610 1 Bolt 3/8in-16NC x 1-1/4in

9 0641808 1 Bolt 1/2in-13NC x 1in 10 0642010 1 Bolt 5/8in-11NC x 1-1/4in 11 A/R Bolt Options:

0641406 2 Bolt 1/4in-20NC x 3/4in

0641606 4 Bolt 3/8in-16NC x 3/4in 12 1320022 3 Clamp 13 1320187 1 Clamp 14 1320190 1 Clamp, Cover Plate 15 1671121 1 Cover, Generator 16 1001108617 1 Filter, Hydraulic (Note: Filter Head uses either 2-Bolt or

4-Bolt Mounting Pattern.)

70002231 1 Element, Filter 17 2180348 1 Fitting, Straight Barbed 18 2200222 1 Plug (Not Shown - Located in Bottom of Fuel Tank) 19 2220313 1 Fitting, 90° Barbed 20 2221176 1 Fitting, 90° Barbed 21 2750532 89in/2.3m Hose 22 1 Insulation Options:

2820148 Prior to S/N 0300138360 2820170 S/N 0300138360 to Present

23 2902099 1 Battery Cable Kit C

23A 7024580 1 Cable, Red (To Aux Pump Relay, Battery Positive Terminal &

Start Relay)

23B 7024581 1 Cable, Black (To Aux Pump, Battery Negative Terminal &

Ground at Tray Pivot) 23C 7024582 1 Cable, Red (Aux Pump Relay to Aux Pump) 23D 7024583 1 Cable, Black (Tray Pivot to Engine Mount)

23E 7024584 1 Cable, Red (Start Relay to Starter) 23F See Note 6 Boot, Terminal (Red) (Note: Not Available for Purchase)

23G See Note 1 Boot, Square Terminal (Red) (Note: Not Available for

Purchase)

24 3311505 24 Locknut 5/16in-18NC 25 3380473 1 Panel, Rubber 26 3422446 1 Pin 27 3573644 1 Plate, Tray Clamp 28 1001112878 1 Plate, Top Clamp 29 1001112879 1 Plate, Bottom Clamp 30 3573669 1 Plate, Clamp

2-28 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

31 1001112880 1 Plate, Tray Clamp 32 3573728 1 Plate, Tray Clamp 33 3841143 1 Keeper, Pin 34 3900272 4 Screw, Buttonhead 5/16in-18NC x 1-3/4in 35 4240018 2 Tie-Strap (Not Shown) 36 4240099 A/R Tie-Strap 37 4711400 A/R Flatwasher 1/4in Thin 38 4711500 44 Flatwasher 5/16in Thin 39 4711600 A/R Flatwasher 3/8in Thin 40 4752000 1 Flatwasher 5/8in Regular 41 Not Used 42 1001111132 1 Panel, Rubber

Ref. DEUTZ DIESEL ENGINE ASSEMBLY OPTIONS: 1001098513 Ref. Without Skypower (2500W Generator Prep) E 1001098530 Ref. With Skypower (7500W Generator Prep) E

101 1 Spacer, Fan Options: 101A 0080237 Without Skypower (2500W Generator Prep) 101B 0080244 With Skypower (7500W Generator Prep)

102 0100011 A/R Compound, Locking

103 0272060 1 Box, Air Intake

104 0340003 2 Band, Air Cleaner

105 0340051 2 Band, Muffler

106 0641406 15 Bolt 1/4in-20NC x 3/4in

107 0641506 5 Bolt 5/16in-18NC x 3/4in

108 0641507 4 Bolt 5/16in-18NC x 7/8in

109 0641605 4 Bolt 3/8in-16NC x 5/8in

110 0641608 25 Bolt 3/8in-16NC x 1in

111 0641609 2 Bolt 3/8in-16NC x 1-1/8in

112 0641610 4 Bolt 3/8in-16NC x 1-1/4in

113 0641808 1 Bolt 1/2in-13NC x 1in

114 0641812 2 Bolt 1/2in-13NC x 1-1/2in

115 0641818 2 Bolt 1/2in-13NC x 2-1/4in

116 0641826 2 Bolt 1/2in-13NC x 3-1/4in

117 0711214 2 Bolt M12 x 30mm

118 0771414 6 Bolt M14 x 30mm

119 4 Bolt M14 x 45mm

0771414 Without Skypower (2500W Generator Prep)

0711417 With Skypower (7500W Generator Prep) 120 1001112766 1 Bracket, Muffler 121 0940070 1 Bumper 122 0961986 2 Bushing, Flanged 123 1 Lanyard Options:

1060637 16in/40.6cm Length

1001131542 13in/33cm Length 124 1320022 2 Clamp 125 1320058 2 Clamp 126 1320060 1 Clamp

3121257 1100S 1100SJP 2-29

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

127 1320223 1 J-Clip 128 1340065 1 Air Cleaner Assembly

7003655 1 Element, Air Cleaner 129 1671023 1 Shroud, Fan 130 1703162 2 Decal - Fan Blade 131 2060025 1 Fan 132 2220451 1 Fitting, Straight 133 2220498 1 Fitting, 45° 134 2720058 135 2720500 1 Hose, Oil Cooler (Top) 136 2720501 1 Hose, Oil Cooler (Bottom) 137 2750532 9in/23cm Hose 138 2902065 1 Pump Coupling Kit F

138A Use 2902065 1 Plate, Pump Mounting 138B 70000793 1 Coupling, Flex 138C See Note 20 Capscrew M10 (Grade 10.9) (Note: Not Available Purchase

139 3020016 3.25 gal Oil, Engine 15W-40 140 3200362 2 Mount, Motor (Front) 141 3200401 2 Mount, Motor (Rear) 142 1 Muffler Options:

3220126 Standard Spark Arresting Muffler

3220130 Optional Catalytic Muffler

70001017 1 Clamp 143 3300454 10 Nut 144 3311405 5 Locknut 1/4in-20NC 145 3311505 5 Locknut 5/16in-18NC 146 3311605 30 Locknut 3/8in-16NC 147 3311805 5 Locknut 1/2in-13NC 148 3422532 1 Pin, Hitch 149 3520054 2 Plug, Hole 150 3537416 1 Plate, Mounting (Front RIght) 151 3539971 1 Bracket, Engine Mounting (Front) 152 3573142 1 Bracket, Engine Mounting (Rear) 153 3573411 2 Plate, Clamp 154 3573412 1 Plate, Gusset 155 3573529 1 Plate, Mounting (Front Left) 156 1 Pulley Options:

156A 3580158 Without Skypower (2500W Generator Prep) 156B 3580320 With Skypower (7500W Generator Prep)

157 3600339 1 Pump Assembly (See Figure 2-8 for Breakdown) 158 Use 1001145382 1 Cooler, Engine Oil (was p/n 3620041) 159 3740067 2 Relay 160 3740080 2 Relay 161 3960543 1 Seal 162 3960544 1 Seal 163 4032022 4 Capscrew M10 x 90mm 164 4060804 165 4060805 8in/20cm Flex-Trim 166 4240099 A/R Tie, Wire (Not Shown)

34ft/10.3m

12in/30cm

Hose

Locally)

Flex-Trim

2-30 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

167 4568293 1 Pipe, Exhaust 168 4640751 1 Valve, Oil Drain 169 4711500 13 Flatwasher 5/16in Thin 170 4711600 68 Flatwasher 3/8in Thin 171 4711800 7 Flatwasher 1/2in Thin 172 4740274 4 Washer, Snubbing 173 4740518 10 Washer, Nylon 174 4751400 20 Flatwasher 1/4in Regular 175 4791400 4 Starwasher 1/4in 176 4846552 1 Plate, Oil Cooler Mounting 177 A/R Mount, Generator Options:

Not Required 0 Without Skypower (2500W Generator Prep)

4846945 1 With Skypower (7500W Generator Prep) 178 4846946 1 Tray 179 4891800 2 Flatwasher, 1/2in Hardened 180 4923468 1 Harness, Glow Plugs 181 4923592 A/R Cable, Jumper 182 1001092856 1 Hose, Turbo 183 1001098601 1 Engine, Deutz BF4M2011 (See Items 201 to 222 for Serviced

Components)

184 8410013 1 Clamp, Gear

1001098601 Ref. DEUTZ ENGINE COMPONENTS A

201 7027235 1 Dipstick 202 7020465 1 Cap, Filler 203 70001850 1 Pump, Oil Lube

7020468 1 Seal Between Oil Pump & Engine Block (Not Shown) 204 7016331 1 Filter, Oil 205 4 Injector Pump Options:

Ref. Note: Series Letter is shown on label at base of Injector

Pump.

70001128 A/R “A” Series 70001129 A/R “B” Series 70001130 A/R “C” Series

70001131 A/R “D” Series 206 7016328 1 Filter, Fuel 207 70000916 1 Pump Fuel Supply

70001435 1 Repair Kit

70000917 1 O-Seal Between Fuel Pump & Engine Block (Not Shown) 208 7020414 1 V-Belt 209 7020471 4 Gasket, Exhaust Manifold to Cylinder Head (Not Shown)

7020486 1 Gasket, Exhaust Manifold to Exhaust Pipe (Not Shown)

210 70001867 1 Alternator Options:

70001868 Regulator, Voltage (Not Shown) 211 7020479 1 Starter (Not Shown - Located on Right Side of Engine)

7026608 1 Solenoid 212 7027791 1 Sender, Coolant Temperature 213 7027790 1 Sensor, Oil Pressure 214 7024565 1 Sensor, Speed

3121257 1100S 1100SJP 2-31

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

215 7027792 1 Actuator, Throttle

7027276 2 Spring 216 7020459 1 Thermostat 217 7024579 1 Gear, Ring (Not Shown) 218 7027236 1 Sensor, Temperature (Not Shown) 219 7027239 1 Solenoid, Start (Not Shown) 220 7027240 1 Turbocharger 221 1600443 1 Module, EMR2 Controller 222 70002718 1 Seal, Rear Main (Not Shown)

2-32 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-6. DEUTZ ENGINE INSTALLATION (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-33

FRONT

DRIVE

PUMP

MIDDLE

DRIVE PUMP

REAR

FUNCTION

PUMP

124

201

125

120

115

134

110

103

102

122

109

133

131

108

105

107 117

101

112

116

121

106

127

COMPLETE REAR PUMP

VIEW

B - B

444

405

404

403

402

401

SECTION 2 TURNTABLE

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES)

2-34 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

PORT PLATE

SECTION

FRONT & MID PUMPS

(DETAIL OF ITEM 303)

COMPLETE FRONT & MID PUMPS

ROTARY GROUP FRONT & MID

PUMPS (DETAIL OF ITEM 301)

304A

304F

304B

304E

304C

304J

304D

304H

304K

304G

304L

304G

310

331

322

302

328

305

313

324

301

314

341

303

304

321

320

327

301L

301G

301F

301B

301E

301

301A

301J

301D

301H

301C

301K

301M

302C

302B

302A

302E

302D

HYD. CONTROL FRONT & MID

PUMPS (DETAIL OF ITEM 302)

303C 303L

303D

303E

303F 303H

303J

303B

303A

303K

303G

CONTROL MODULE FRONT & MID

PUMPS (DETAIL OF ITEM 305)

VIEW

A-A

305C

305K

305B

305M

305P

305A

305D

305L

305J

305E

305F

305H

305G

305N

305Q

3121257 1100S 1100SJP 2-35

SECTION 2 TURNTABLE

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001118368 Ref. PUMP ASSEMBLY C

1 70003163 1 Front Drive Pump Assembly (Includes Items 301- 341) 2 70003164 1 Middle Drive Pump Assembly (Includes Items 301- 341) 3 7024044 1 Rear Function Pump Assembly (Includes Items 101-201 4 See Note 1 Hydraulic Kit (Includes all Rexroth Supplied Hydraulic Fittings,

Hoses & Tubes) (Note: Not Available for Purchase)

7024044 Ref. REAR FUNCTION PUMP ASSEMBLY

101 70003173 1 Rotary Section 102 See Note 1 Piston, Control (Note: Not Available for Purchase) 103 See Note 1 Rod, Piston (Note: Not Available for Purchase) 104 Not Used 105 See Note 1 Housing, Pump (Note: Not Available - Purchase Complete

Pump Assembly)

106 See Note 1 Plate, Port (Note: Not Available for Purchase) 107 70003174 1 Plate, Swash 108 70003175 1 Driveshaft 109 See Note 1 Plug (Note: Not Available for Purchase) 110 See Note 1 Spring (Note: Not Available for Purchase) 111 Not Used 112 7012709 1 Shim

113 to 114 Not Used

115 7024038 1 Bearing, Roller 116 7012706 1 Bearing, Roller 117 7024917 2 Shell, Cradle

118 to 119 Not Used

120 7024918 1 Seal, Shaft 121 70003176 1 O-Ring 122 7024920 1 O-Ring 123 Not Used 124 7024950 1 Seal 125 70003177 1 Ring, Retaining 126 Not Used 127 See Note 4 Capscrew M12 x 45-10.9 (Note: Not Available for Purchase)

128 to 130 Not Used

131 See Note 1 Plug (Note: Not Available for Purchase) 132 Not Used 133 See Note 1 Pin, Dowel (Note: Not Available for Purchase) 134 See Note 1 Plug (Note: Not Available for Purchase)

201 7024913 Ref. Pilot Valve Assembly

Ref. Note: Two mounting designs of p/n 7024913 pilot valve exist.

Early design uses qty. 3 o-rings. Late design uses qty. 1 sealing plate. Seal designs cannot be interchanged. Verify seal design before ordering.

7024922 3 O-Ring (Seals between Pilot Valve & Rear Pump)

70021867 1 Plate, Sealing (Seals between Pilot Valve & Rear Pump)

2-36 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRONT DRIVE PUMP ASSEMBLIES 70003163 Ref. Front Drive Pump Assembly 70003164 Ref. Middle Drive Pump Assembly

301 7024064 1 Rotary Group 301A See Note 1 Cradle (Note: Not Available - Purchase p/n 7024064) 301B See Note 1 Ring, Slide (Note: Not Available - Purchase p/n 7024064) 301C See Note 1 Driveshaft (Note: Not Available - Purchase p/n 7024064) 301D See Note 1 Wire (Note: Not Available - Purchase p/n 7024064) 301E See Note 1 Pin, Joint (Note: Not Available - Purchase p/n 7024064)

301F See Note 1 Wire (Note: Not Available - Purchase p/n 7024064)

301G See Note 1 Pair Liner, Bearing (Note: Not Available - Purchase

p/n 7024064)

301H See Note 1 Bearing, Roller (Note: Not Available - Purchase

p/n 7024064)

301J See Note 1 Set Cradle Bearing Assembly (Note: Not Available for

Purchase)

301K See Note 1 Ring, Retaining (Note: Not Available for Purchase)

301L 70001968 2 Ring, Retaining

301M Use 70003167 1 Seal, Shaft Ring

302 7024065 1 Control Group - Hydraulic 302A See Note 1 Piston, Positioning - Complete (Note: Not Available -

Purchase p/n 7024065) Note: Sold only in Kit Except Outer Seal O-Ring & Stem O-Ring.

7024071 1 O-Ring, Outer Seal

7024072 1 O-Ring, Stem 302B Use 70003168 4 Capscrew M6 x 12-8.8 302C See Note 1 Nut (Note: Not Available - Purchase p/n 7024065) 302D Use 70003168 2 Ring, Guide 302E Use 70003168 2 Seal, O-Ring

303 1 Port Plate Group Options:

7024905 Front Drive Pump

7024911 Middle Drive Pump 303A 7024073 2 Cartridge, Relief Valve (High Pressure)

Note: Sold as an Assembly Except Outer Seals.

7024075 1 O-Ring

7024076 1 Ring, Back-up 303B 1 Cartridge Options:

7024907 1 Front Pump Cartridge (Lock Valve With Orifice)

Note: Sold as an Assembly Except Outer Seal.

7024909 1 Screw, Locking

7024075 1 O-Ring

70020329 1 Middle Pump Cartridge (Pressure Relief Valve)

Note: Sold as an Assembly Except Outer Seal.

70003172 1 Ring, Sealing (Steel)

7024077 1 O-Ring 303C See Note 1 Plate, Port (Note: Not Available - Purchase p/n 7024905

or 7024911)

303D See Note 1 Bushing, Bearing (Note: Not Available - Purchase p/n

7024905 or 7024911)

3121257 1100S 1100SJP 2-37

SECTION 2 TURNTABLE

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

303E See Note 4 Screw, Socket Head M12 x 70-10.9 (Note: Not Available -

Purchase p/n 7024911)

303F Use 70003169 2 Pin, Dowel 303G Use 70003169 1 Pin, Break-Off 303H Use 70003169 1 Screw, Locking M10 x 1

303J 7024908 2 O-Ring 303K Use 70003169 2 Screw, Locking 7/16in-20NF

303L See Note 1 Bearing, Roller (Note: Not Available - Purchase

p/n 7024905 or 7024911)

304 7024906 1 Internal Gear Pump Options:

304A See Note 1 Flange, Intermediate (Note: Not Available - Purchase

p/n 7024906)

304B See Note 1 Internal Gear Pump Housing (Note: Not Available -

Purchase p/n 7024906)

304C See Note 1 Coupling, Driveshaft Through (Note: Not Available -

Purchase p/n 7024906)

304D 7024079 1 Key, Driveshaft 304E 80934174 1 Ring, Retaining

304F See Note 4 Capscrew M10 x 20-8.8 (Note: Not Available - Purchase

p/n 7024906)

304G 7024080 2 Seal 304H 7024081 1 O-Ring

304J See Note 1 Ring, Retaining (Note: Not Available - Purchase

p/n 7024906)

304K 7024910 1 O-Ring

304L See Note 1 Pin, Cylinder (Note: Not Available - Purchase p/n 7024906)

305 70003165 1 Control Module 305A See Note 1 Valve Body, Lever & Internal Components 305B 70003170 2 Coil, Solenoid 305C See Note 2 Spacer, Coil (Note: Not Available - Purchase p/n

70003165)

305D Use 70020336 1 Gasket 305E See Note 1 Cover W/Filter (Note: Not Available - Purchase

p/n 70003165)

305F See Note 1 Spring, Draw (Note: Not Available - Purchase

p/n 70003165)

305G Use 70020336 1 Gasket 305H Use 70020336 4 Capscrew M6 x 65-8.8

305J Use 70020336 1 Capscrew M6 x 45-8.8

305K See Note 8 Capscrew M5 x 10-8.8 (Note: Not Available for Purchase)

305L Use 70020336 1 O-Ring 305M See Note 2 O-Ring (Note: Not Available for Purchase) 305N See Note 2 Cup, Spring (Note: Not Available for Purchase) 305P Use 70020336 2 Pin, Cylinder 305Q See Note 2 Nut, Coil (Note: Not Available for Purchase)

306 to 309 Not Used

310 See Note 1 Housing (Note: Not Available - Purchase Complete Pump

Assembly)

311 to 312 Not Used

313See Note 2Pin, Dowel (Note: Not Available for Purchase) 314 See Note 1 Pin, Cylinder (Note: Not Available for Purchase)

2-38 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

315 to 319 Not Used

320 Use 70003166 1 Screw 7/8-14NF (Front Drive Pump Only) 321 Use 70003166 1 Screw 9/16-18NF 322 Use 70003166 1 Screw 7/16-20NF 323 Not Used 324 Use 70003166 1 Screw M10 x 1

325 to 326 Not Used

327 Use 70003166 1 Pin, Double Break-Off 328 Use 70003166 2 Orifice

329 to 330 Not Used

331 Use 70003166 2 Pin, Clamping

333 to 340 Not Used

341 Use 70003166 1 O-Ring

Seal Kit Options: 401 70003167 1 Seal Kit - Drive Shaft (Includes Items 301L & 301M) 402 70003168 1 Seal Kit - Control Group - Hydraulic (Includes Items 302B,

302D & 302E) 403 70003169 1 Seal Kit - Port Plate Group (Includes Items 303F-303K) 404 70020336 1 Seal Kit - Control Module (Includes Items 305D, 305G-305J,

305L & 305P) 405 70003166 1 Seal Kit - Front Pump (Includes Items 320-322, 324, 327,

328, 331 & 341)

3121257 1100S 1100SJP 2-39

SECTION 2 TURNTABLE

FRONT

DRIVE

PUMP

MIDDLE

DRIVE

PUMP

REAR

FUNCTION

PUMP

124

201

125

120

115

134

110

103

102

122

109

133

131

108

105

107 117

101

112

116

121

106

127

COMPLETE REAR PUMP

VIEW

B - B

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES)

2-40 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

PORT PLATE

SECTION

FRONT & MID PUMPS

(DETAIL OF ITEM 303)

COMPLETE FRONT & MID PUMPS

ROTARY GROUP FRONT & MID

PUMPS (DETAIL OF ITEM 301)

304A

304H

304B

304G

304C

304D

304L

304F

304E

304N

304K

304M

304J

304P

304J

310

331

322

302

328

305

313

324

301

314

341

303

304

321

320

333

327

301L

301G

301F

301B

301E

301

301A

301J

301D

301H

301C

301K

301M

302C

302B

302A

302E

302D

HYD. CONTROL FRONT & MID

PUMPS (DETAIL OF ITEM 302)

303C 303L

303D

303E

303F 303H

303J

303B

303A

303K

303G

CONTROL MODULE FRONT & MID

PUMPS (DETAIL OF ITEM 305)

VIEW

A-A

305C

305K

305B

305M

305P

305A

305D

305L

305J

305E

305F

305H

305G

305N

3121257 1100S 1100SJP 2-41

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3600339 Ref. PUMP ASSEMBLY D 1 7024042 1 Front Drive Pump Assembly (Includes Items 301- 341) 2 7024043 1 Middle Drive Pump Assembly (Includes Items 301- 341) 3 7024044 1 Rear Function Pump Assembly (Includes Items 101-201 4 70001952 1 Hydraulic Kit (Includes all Rexroth Supplied Hydraulic Fittings,

Hoses & Tubes)

7024044 Ref. REAR FUNCTION PUMP ASSEMBLY

101 7024914 1 Rotary Section 102 See Note 1 Piston, Control (Note: Not Available for Purchase) 103 See Note 1 Rod, Piston (Note: Not Available for Purchase) 104 Not Used 105 See Note 1 Housing, Pump (Note: Not Available - Purchase Complete

Pump Assembly)

106 See Note 1 Plate, Port (Note: Not Available for Purchase) 107 7024915 1 Plate, Swash 108 7024916 1 Driveshaft 109 See Note 1 Plug (Note: Not Available for Purchase) 110 See Note 1 Spring (Note: Not Available for Purchase) 111 Not Used 112 7012709 1 Shim

113 to 114 Not Used

115 7024038 1 Bearing, Roller 116 7012706 1 Bearing, Roller 117 7024917 2 Shell, Cradle

118 to 119 Not Used

120 7024918 1 Seal, Shaft 121 7024919 1 O-Ring 122 7024920 1 O-Ring 123 Not Used 124 7024921 1 Seal 125 7012715 1 V-Ring 126 Not Used 127 See Note 4 Capscrew M12 x 45-10.9 (Note: Not Available for Purchase)

128 to 130 Not Used

131 See Note 1 Plug 132 Not Used 133 See Note 1 Pin, Dowel (Note: Not Available for Purchase) 134 See Note 1 Plug (Note: Not Available for Purchase)

201 7024913 Ref. Pilot Valve Assembly

Ref. Note: Two mounting designs of p/n 7024913 pilot valve exist.

Early design uses qty. 3 o-rings. Late design uses qty. 1 sealing plate. Seal designs cannot be interchanged. Verify seal design before ordering.

7024922 3 O-Ring (Seals between Pilot Valve & Rear Pump)

70021867 1 Plate, Sealing (Seals between Pilot Valve & Rear Pump)

2-42 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. FRONT DRIVE PUMP ASSEMBLIES 7024042 Ref. Front Drive Pump Assembly 7024043 Ref. Middle Drive Pump Assembly

301F See Note 1 Wire (Note: Not Available - Purchase p/n 7024064)

301G See Note 1 Pair Liner, Bearing (Note: Not Available - Purchase

p/n 7024064)

301H See Note 1 Bearing, Roller

(Note: Not Available - Purchase p/n 7024064)

301J See Note 1 Set Cradle Bearing Assembly

(Note: Not Available for Purchase)

301K See Note 1 Ring, Retaining (Note: Not Available for Purchase)

301L 70001968 2 Ring, Retaining

301M 7024070 1 Seal, Shaft Ring

302 7024065 1 Control Group - Hydraulic 302A See Note 1 Piston, Positioning - Complete (Note: Not Available -

Purchase p/n 7024065) Note: Sold only in Kit Except Outer Seal O-Ring & Stem O-Ring.

7024071 1 O-Ring, Outer Seal

7024072 1 O-Ring, Stem 302B See Note 4 Capscrew M6 x 12-8.8 302C See Note 1 Nut (Note: Not Available - Purchase p/n 7024065) 302D See Note 2 Ring, Guide (Note: Not Available - Purchase p/n 7024065) 302E See Note 2 Seal, O-Ring (Note: Not Available - Purchase p/n 7024065)

303 7024911 1 Port Plate Group

303A 7024073 2 Cartridge, Relief Valve (High Pressure)

Note: Sold as an Assembly Except Outer Seals.

7024075 1 O-Ring

7024076 1 Ring, Back-up 303B 1 Cartridge Options:

7024097 1 Front Pump Cartridge (Lock Valve With Orifice)

Note: Sold as an Assembly Except Outer Seal.

7024075 1 O-Ring

7023881 1 Middle Pump Cartridge (Pressure Relief Valve)

Note: Sold as an Assembly Except Outer Seal.

7024077 1 O-Ring 303C See Note 1 Plate, Port (Note: Not Available - Purchase p/n 7024911) 303D See Note 1 Bushing, Bearing

(Note: Not Available - Purchase p/n 7024911)

303E See Note 4 Screw, Socket Head M12 x 70-10.9

(Note: Not Available - Purchase p/n 7024911)

303F See Note 2 Pin, Dowel (Note: Not Available - Purchase p/n 7024911)

303G See Note 1 Pin, Break-Off (Note: Not Available - Purchase

p/n 7024911)

3121257 1100S 1100SJP 2-43

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

303H See Note 1 Screw, Locking M10 x 1

(Note: Not Available - Purchase p/n 7024911)

303J 7024908 2 O-Ring

303K See Note 2 Screw, Locking 7/16in-20NF

303L See Note 1 Bearing, Roller

(Note: Not Available - Purchase p/n 7024911)

304 7024906 1 Internal Gear Pump

304A See Note 1 Flange, Intermediate

(Note: Not Available - Purchase p/n 7024906)

304B See Note 1 IZP-Housing (Note: Not Available - Purchase p/n 7024906) 304C See Note 1 Bushing, Bearing

(Note: Not Available - Purchase p/n 7024906)

304D See Note 1 Coupling, Driveshaft Through

(Note: Not Available - Purchase p/n 7024906)

304E 7024078 1 Gear Set

304F 7024079 1 Key, Driveshaft

304G See Note 1 Ring, Retaining

(Note: Not Available - Purchase p/n 7024906)

304H See Note 4 Capscrew M10 x 20-8.8

(Note: Not Available - Purchase p/n 7024906)

304J 7024080 2 Seal

304K 7024081 1 O-Ring

304L See Note 1 Ring, Retaining

(Note: Not Available - Purchase p/n 7024906)

304M 7024910 1 O-Ring 304N 7024005 1 Plate, Wear 304P See Note 1 Pin, Cylinder (Note: Not Available - Purchase p/n 7024906)

305 7024068 1 Control Module 305A 7024084 1 Valve Body, Lever & Internal Components 305B 7024083 2 Coil, Solenoid

70002569 2 Nut, Coil 305C See Note 2 Spacer, Coil (Note: Not Available - Purchase p/n 7024068) 305D 7024085 1 Gasket 305E See Note 1 Cover (Note: Not Available - Purchase p/n 7024068)

305F See Note 1 Spring, Draw (Note: Not Available - Purchase p/n 7024068) 305G 7024086 1 Gasket 305H See Note 4 Capscrew M6 x 65-8.8 (Note: Not Available For Purchase)

305J See Note 1 Capscrew M6 x 45-8.8 (Note: Not Available For Purchase) 305K See Note 8 Capscrew M5 x 10-8.8 (Note: Not Available For Purchase)

305L 7024087 1 O-Ring 305M 7024088 2 O-Ring 305N 7024089 2 Cup, Spring 305P See Note 2 Pin, Cylinder (Note: Not Available - Purchase p/n 7024068)

306 to 309 Not Used

310 See Note 1 Housing (Note: Not Available - Purchase Complete Pump

Assembly)

311 to 312 Not Used

313 See Note 2 Pin, Dowel (Note: Not Available For Purchase) 314 See Note 1 Pin, Cylinder (Note: Not Available For Purchase)

315 to 319 Not Used

2-44 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES) (CONTINUED)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

320 See Note 1 Screw 7/8-14NF (Front Drive Pump Only)

(Note: Not Available For Purchase)

321 See Note 1 Screw 9/16-18NF (Note: Not Available For Purchase) 322 See Note 1 Screw 7/16-20NF (Note: Not Available For Purchase) 323 Not Used 324 See Note 1 Screw M10 x 1 (Note: Not Available For Purchase)

325 to 326 Not Used

327 See Note 1 Pin, Double Break-Off (Note: Not Available For Purchase) 328 7018936 2 Orifice

329 to 330 Not Used

331 See Note 2 Pin, Clamping (Note: Not Available For Purchase) 323 Not Used 333 See Note 1 Screw, Locking (Note: Not Available For Purchase)

334 to 340 Not Used

341 7024069 1 O-Ring

3121257 1100S 1100SJP 2-45

SECTION 2 TURNTABLE

PLATFORM REF.

2061112

24119425

162321

7D1514

USE EXISTING

HARDWARE

109

107

102

103

104

105

110

111

112

113

106

OPTIONAL HOURMETER

101

2111377A

FIGURE 2-9. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

2-46 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-9. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. 2500W GENERATOR INSTALLATION

1001117509 Ref. 110Volt - 60Hz (ANSI & ANSI Export Specs Only) B

1 0100011 A/R Compound, Locking 2 0200530 1 Arm, Adjusting 3 0641508 1 Bolt 5/16in-18NC x 1in 4 0641608 3 Bolt 3/8in-16NC x 1in 5 0641718 2 Bolt 7/16in-14NC x 2-1/4in 6 0700816 4 Bolt M8 x 40mm 7 2460055 1 Generator and Control Box Assembly

7A 7012558 1 Generator - 110V/60Hz

Ref. Note: Replacement generators come standard with

p/n 3580134 pulley. This pulley maynot be correct for all applications. Refer to pulley options below for correct pulley.

7012513 4 Cap, Brush Holder 7020108 4 Brush 7020109 4 Holder, Brush 7012514 1 Fan 7020190 2 Bearing 7020110 1 End Bell, Front 7020111 1 End Bell, Rear

7B 7019680 1 Box, Control - 110V/60Hz

4360542 1 Breaker, Circuit 4460190 A/R Receptacle, Double (110V)

4460027 A/R Receptacle, Double Twist Lock (110V) 7C 2420203 A/R Voltmeter - 110V/60Hz 7D 3580276 1 Pulley

7027887 1 Key, Woodruff

8 2820031 A/R Heatshrink

9 3251102 1 Nameplate - Generator 10 3311005 2 Locknut #10-24NC 11 3580322 1 Pulley 12 3740080 1 Relay 13 3900322 2 Screw, Socket Head Shoulder 14 4060802 1 Guard, Switch 15 4360336 1 Switch, Toggle 16 4711700 2 Flatwasher 7/16in Thin 17 4751000 2 Flatwasher #10 Regular 18 4751500 1 Flatwasher 5/16in Regular 19 4751600 3 Flatwasher 3/8in Regular 20 4811900 4 Flatwasher, M8 21 4892000 2 Flatwasher 5/8in Hardened 22 Not Used 23 1001117641 1 Bar, Adjusting 24 1001118180 1 Support, Adjusting 25 0480122 1 Belt

3121257 1100S 1100SJP 2-47

SECTION 2 TURNTABLE

FIGURE 2-9. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

1001103286 Ref. HOURMETER INSTALLATION (OPTIONAL) A

101 0720808 1 Screw #8-32 x 1in 102 2420165 1 Hourmeter 103 3310601 2 Nut #6-32 104 3310805 1 Locknut #8-32 105 3910608 2 Screw #6-32 x 1/2in 106 4240032 3 Strap, Tie 107 4420060 3in/7cm Tape, Double-Sided 108 4460018 1 Connector, Butt Splice (Not Shown) 109 4460234 2 Mount, Tie Strap 110 4750800 1 Flatwasher #8 Regular 111 4760600 2 Lockwasher #6 112 1001094375 1 Bracket, Hourmeter 113 1001094509 1 Harness, Hourmeter

2-48 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-9. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-49

SECTION 2 TURNTABLE

152221

PLATFORM REF.

13B

13C

13A

13D

123251123

11111

109

107

102

101

103

104

105

110

111

112

113

106

OPTIONAL HOURMETER

(Located on Opposite Side

of Turntable)

FIGURE 2-10. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

2-50 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-10. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. GENERATOR INSTALLATION - DEUTZ

0274083 Ref. 110V/60Hz (ANSI & ANSI Export Specs) (Prior to

S/N 03000140836)

1001125425 Ref. 110V/60Hz (ANSI & ANSI Export Specs) (S/N 0300140836 to

Present)

1 0100011 A/R Compound, Locking

2 0200742 1 Arm, Adjusting

3 0363081 1 Bar, Mounting

4 0363082 1 Bar, Adjusting

5 0480127 1 Belt

6 0641406 1 Bolt 1/4in-20NC x 3/4in

7 0641508 1 Bolt 5/16in-18NC x 1in

8 0641608 4 Bolt 3/8in-16NC x 1in

9 0641610 2 Bolt 3/8in-16NC x 1-1/4in 10 0641718 2 Bolt 7/16in-14NC x 2-1/4in 11 0701418 2 Bolt M14 x 50mm 12 0902813 1 Bracket, Arm Mounting 13 1 Generator and Control Box Assembly

2460055 110V/60Hz Assembly (ANSI & ANSI Export Specs)

13A 7012558 1 Replacement Generator 110V/60Hz

Ref. Note: Replacement generators come standard with

p/n 3580134 pulley. This pulley maynot be correct for all applications. Refer to pulley options below for correct pulley.

7012513 4 Cap, Brush Holder 7020108 4 Brush 7020109 4 Holder, Brush 7012514 1 Fan 7020190 2 Bearing 7020110 1 End Bell, Front 7020111 1 End Bell, Rear

13B 7019680 1 Box, Control 110V/60Hz

4360542 1 Breaker, Circuit 4460190 A/R Receptacle, Double (110V)

4460027 A/R Receptacle, Double Twist Lock (110V) 13C 2420203 1 Voltmeter 13D 3580276 1 Pulley 110V/60Hz

7027887 1 Key, Woodruff

14 2820031 A/R Heatshrink 15 3251102 1 Nameplate - Generator 16 3311005 2 Locknut #10-24NC 17 3311405 1 Locknut 1/4in-20NC 18 3311605 1 Locknut 3/8in-16NC 19 3740080 1 Relay 20 3900322 2 Screw, Socket Head Shoulder 21 4060802 1 Guard, Switch 22 4360336 1 Switch, Toggle 23 4711600 7 Flatwasher 3/8in Thin 24 4711700 2 Flatwasher 7/16in Thin

3121257 1100S 1100SJP 2-51

SECTION 2 TURNTABLE

FIGURE 2-10. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

25 4711900 2 Flatwasher 9/16in Thin 26 4740397 1 Spacer 27 4751000 6 Flatwasher #10 Regular 28 4751400 2 Flatwasher 1/4in Regular 29 4891500 2 Flatwasher 5/16in Hardened 30 4892000 2 Flatwasher 5/8in Hardened 31 Not Used

1001103286 Ref. HOURMETER INSTALLATION (OPTIONAL) A

2-52 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-10. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-53

204

301

201

513

509

506

507

502

501

503

504

505

510

511

512

303

102

103

107

116

117

125 126

101

204

104

116

117

101

105

110

121

109

122

121

407

106

410

401

402 403

404 405

407

408

406

409

128

SEE

SECTION 7

SEE

SECTION 7

435452

34224148

534811

301

204

53B

53A

53C

53D

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

2-54 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. 7500W SKYPOWER GENERATOR INSTALLATION

1001117508 Ref. 60Hz Spec D

Ref. Note: SkyPower Generator is Standard On ANSI & CSA

Specs. Optional on All Other Specs.

Ref. Note: See Section 7 for Boom Cable Installation.

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100020 A/R Sealant, Pipe (Not Shown) 4 0100048 A/R Grease, Dielectric 5 0641404 A/R Bolt 1/4in-20NC x 1/2in 6 0641508 4 Bolt 5/16in-18NC x 1in 7 0641516 3 Bolt, 5/16in-18NC x 2in

8 to 9 Not Used

10 0641618 1 Bolt 3/8in-16NC x 2-1/4in 11 0641810 2 Bolt 1/2in-13NC x 1 -/4in 12 0700822 5 Bolt M8 x 70mm 13 0700823 5 Bolt M8 x 75mm 14 0700824 5 Bolt M8 x 80mm 15 0860038 2 Box, Switch-Weatherhead 16 0861538 A/R Box, Generator Control

7024488 1 Card, Circuit - Generator Power (Not Shown)

See Note 1 Fuse (Note: Not Available - Purchase Locally)

7024489 1 Card, Circuit - Control (Not Shown)

Ref. Note: When replacing card, rocker switch on card must

be set for required application.

70000619 1 Harness, Circuit Card 17 0861542 1 Junction Box Assembly (See Items 101-128 for Breakdown) 18 0902888 1 Bracket, Generator Junction Box 19 0962520 1 Bushing, Taper 20 2820031 A/R Insulator, Heat Shrink 21 3251102 1 Nameplate, Generator 22 3311508 3 Nut, 5/16in-18NC Serrated Flange 23 Not Used 24 3311801 2 Nut, 1/2in-13NC

25 to 26 Not Used

27 3580317 1 Pulley, Belt Tensioner 28 3580318 1 Pulley, Generator 29 Not Used 30 3910606 A/R Screw, Round Head 6-32NC x 3/8in 31 3960422 2 Gasket, AC Receptacle Options: 32 4060802 1 Guard, Switch 33 4240018 A/R Strap, Tie (Not Shown) 34 4300157 2 Stud 35 4360336 1 Switch, Toggle 36 4460051 1 Connector, Strain Relief 37 4460071 1 Connector, Strain Relief 38 4460315 4 Terminal, Spade (Not Shown - Use 2 each with items 39 & 40) 39 4460346 1 Terminal, Receptacle

3121257 1100S 1100SJP 2-55

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

40 4460958 1 Receptacle 41 Not Used 42 4711400 A/R Flatwasher 1/4in Thin 43 4711600 1 Flatwasher 3/8in Thin 44 4751500 7 Flatwasher 5/16in Regular 45 4791400 2 Starwasher 1/4in

46 to 47 Not Used

48 4891800 4 Flatwasher 1/2in Hardened 49 4922972 1 Harness, Generator Cable A

4460225 1 Plug, Male 6 Position (Plugs into Generator) 4460226 6 Socket, Female (Use with 4460225) 4460807 1 Seal, Plug (Use with 4460225) 4460808 1 Seal, Interface (Use with 4460225)

See Note 1 Connector, Female 6 Position (Plugs into Control Box)

(Note: Not Available For Purchase)

See Note 6 Pin, Male (Note: Not Available For Purchase)

50 to 51 Not Used

52 1001118599 1 Shield, Pulley (Prior to S/N 0300172839) 53 1001119250 1 Generator, 7500W

Use 70003631 1 Brushholder Assembly (Not Shown) (was p/n 7024484)

70001966 1 Bearing, Ball Radial (Located in Belt Tensioner Endbell - Not

Shown)

7027799 1 Block, Connector 6 Position (Not Shown)

70002460 1 Nut, Brass (Attaches p/n 7027799 to Cover) (Not Shown)

7024485 1 Breaker, Circuit 30Amp (Not Shown) 70001696 1 Boot, Breaker (Not Shown) 70002297 A/R Stud 1/4in-20NC x 12-7/8in (Not Shown)

7026188 1 Clamp, Cable (Not Shown)

7026597 1 Connector with Leads (Not Shown) 70001100 1 Rotor/Armature (Not Shown) 70001384 1 Bearing, Ball Radial (Not Shown) 70003451 1 Stator (Not Shown)

Use 70004170 1 Plate, End Panel (Not Shown) (was p/n 70001972)

70000863 1 Fan (Not Shown) 70001974 1 Decal - Terminal Connections (Not Shown)

53A Use 70004171 1 Key (was p/n 7024561) 53B Use 70004170 1 Endbell, Rear (Brush Block End) (was p/n 70001385)

Use 70004170 1 Shroud, Endbell (was p/n 70002290)

70003452 1 Shroud, Endbell Panel

53C 70003450 1 Endbell, Front (Tensioner End) 53D 70001973 1 Decal - Warning Moving Parts

54 1001119966 1 Belt, Generator 55 1001110872 1 Cover, Receptacle 56 1001110873 1 Shield, Receptacle Cover

2-56 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

0861542 Ref. JUNCTION BOX ASSEMBLY D

101 0861541 1 Box, Junction 102 1060494 103 1060708 104 1705376 1 Decal - Wiring Schematic 105 3300396 1 Cover, Fuse 106 3310601 2 Nut #6-32NC 107 1060343 108 Not Used 109 3910610 2 Bolt #6-32NC x 5/8in 110 4360070 1 Circuit Breaker - 15 Amp

111 to 115 Not Used

116 4460425 2 Strain Relief, Terminal 117 4460426 2 Connector, Strain Relief

118 to 120 Not Used

121 4750600 4 Flatwasher, #6 Regular 122 4760600 2 Lockwasher #6

123 to 124 Not Used

125 1671092 1 Cover 126 4460963 1 Connector 127 Not Used 128 1001121340 1 Terminal Block Assembly (See Items 401-410 for Breakdown)

0272435 Ref. DECAL INSTALLATION B

2ft/.6m

2.5ft/.76m

1.5ft/.46m

Cable, Electrical 12/3 Cable, Electrical 10/3

Cable, Electrical 10/4

201 1705460 2 Decal - SkyPower™ 202 1705374 1 Decal - 240V - 60Hz 203 1705375 1 Decal - 240V - 3 Phase 204 1705387 3 Decal, Hazardous Voltage

1001122528 Ref. ELECTRICAL DIAGRAM COMPONENTS A

301 1001119968 1 Generator Harness B

301A 4460967 1 Plug, Male - 3 Position (Not Shown)

4460465 6 Socket, Female

301B 1001117078 1 Fuseholder w/Fuse (Not Shown)

302 Not Used 303 4922641 1 Switch Harness

1001121340 Ref. TERMINAL BLOCK ASSEMBLY A

401 70002818 2 Marker Strip #1 402 70002819 4 Marker Strip #2 403 70002820 2 Marker Strip #3 404 70002821 2 Marker Strip #4 405 70002822 4 Marker Strip #5 406 70002823 1 Terminal, End Barrier 407 70002824 2 Terminal, End Block

3121257 1100S 1100SJP 2-57

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

408 70002825 7 Terminal, Block 409 70002826 2 Terminal, Cross Connector Jumper

1001103286 Ref. HOURMETER INSTALLATION (OPTIONAL) A

501 0720808 1 Screw #8-32 x 1in 502 2420165 1 Hourmeter 503 3310601 2 Nut #6-32 504 3310805 1 Locknut #8-32 505 3910608 2 Screw #6-32 x 1/2in 506 4240032 3 Strap, Tie 507 4420060 3in/7cm Tape, Double-Sided 508 4460018 1 Connector, Butt Splice (Not Shown) 509 4460234 2 Mount, Tie Strap 510 4750800 1 Flatwasher #8 Regular 511 4760600 2 Lockwasher #6 512 1001094375 1 Bracket, Hourmeter 513 1001094509 1 Harness, Hourmeter

2-58 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

3121257 1100S 1100SJP 2-59

SECTION 2 TURNTABLE

410

406

407

408

14C

14B

121

304

102

103

109

122

401

402

403

404

405

106

125 126

104

116

117

101

2231202

301

301A

201

3215

127

8237

105

110

SEE

SECTION 7

SEE

SECTION 7

507

502

503

504

505

510

511

512

501

513

509

506

OPTIONAL HOURMETER

(Located on Opposite

Side of Turntable)

14D

14A

23A

23B

25B

25A

204

107

128

409

301

302

301B

302A

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

2-60 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. 7500W SKYPOWER GENERATOR INSTALLATION

0273455 Ref. 60Hz Spec (Prior to S/N 0300140836) H

1001125427 Ref. 60Hz Spec (S/N 0300140836 to Present) A

0273456 Ref. 50Hz Spec (Prior to S/N 0300140836) F

1001125428 Ref. 50Hz Spec (S/N 0300140836 to Present) A

Ref. Note: SkyPower Generator is Standard On ANSI & CSA

Specs. Optional on All Other Specs.

Ref. Note: See Section 7 for Boom Cable Installation.

1 0100011 A/R Compound, Locking 2 0100019 A/R Compound, Locking 3 0100048 A/R Grease, Dielectric 4 1 Belt, Generator Options:

0480128 60Hz Spec

0480129 50Hz Spec 5 0641404 5 Bolt 1/4in-20NC x 1/2in 6 0641508 4 Bolt 5/16in-18NC x 1in 7 0641516 3 Bolt, 5/16-18NC x 2in 8 0641810 4 Bolt, 1/2in-13NC x 1-1/4in 9 2 Box, Switch-Weatherhead Options:

0860038 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

10 A/R Box, Generator Control Options:

0861538 1 60Hz Spec

0861572 1 50Hz Spec

7024488 1 Card, Circuit - Generator Power

See Note 1 Fuse (Note: Not Available - Purchase Locally)

7024489 1 Card, Circuit - Control

Ref. Note: Same Circuit Card (P/N 7024489) is used for both

60Hz & 50Hz. When replacing card, rocker switch on card must be set for required application.

70000619 1 Harness, Circuit Card

11 1 Junction Box Assembly Options (See Items 101-128 for

Breakdown): 0861542 1 60Hz Spec 0861567 1 50Hz Spec

12 0902888 1 Bracket, Generator Junction Box 13 0962520 1 Bushing, Taper 14 2460048 1 Generator, 7500W

Use 70003631 1 Brushholder Assembly (Not Shown) (was p/n 7024484)

7024485 1 Breaker, Circuit 30Amp (Not Shown)

70001696 1 Boot, Breaker (was p/n 7024486) (Not Shown) 70001966 1 Bearing, Ball Radial (Located in Belt Tensioner Endbell - Not

Shown)

7027799 1 Block, Connector 6 Position (Not Shown)

70002460 1 Nut, Brass (Attaches p/n 7027799 to Cover) (Not Shown) 70002297 A/R Stud 1/4in-20NC x 12-7/8in (Not Shown)

7026188 1 Clamp, Cable (Not Shown) 7026597 1 Connector with Leads (Not Shown)

3121257 1100S 1100SJP 2-61

SECTION 2 TURNTABLE

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

14 (cont’d) 70001100 1 Rotor/Armature (Not Shown)

70001384 1 Bearing, Ball Radial (Not Shown) 70002088 1 Stator (Not Shown)

Use 70004169 1 Plate, End Panel (Not Shown) (was p/n 70002255)

70000863 1 Fan (Not Shown)

70001974 1 Decal - Terminal Connections (Not Shown) 14A Use 70004171 1 Key (was p/n 7024561) 14B Use 70004169 1 Endbell, Rear (Brush Block End) (was p/n 70001385)

Use 70004169 1 Shroud, Endbell (was p/n 70002290) 14C 70001953 1 Endbell, Front (Tensioner End) 14D 70001973 1 Decal - Warning Moving Parts

15 2820031 A/R Insulator, Heat Shrink 16 3251102 1 Nameplate, Generator 17 3311508 3 Nut, 5/16in-18NC Serrated Flange 18 3580317 1 Pulley, Belt Tensioner 19 1 Pulley, Generator Options:

3580318 1 60Hz Spec

3580319 1 50Hz Spec 20 3910606 A/R Screw, Round Head #6-32NC x 3/8in 21 0641618 1 Bolt 3/8in-16NC x 2in 22 1 Gasket, AC Receptacle Options:

3960422 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

23 1 Shield, Receptacle Cover Options:

See Note 50Hz Spec (Note: Not Available - Purchase Locally) 23A 4060700 60Hz Spec (Side Hinged) 23B 1001110873 60Hz Spec (Top Hinged)

24 4060802 1 Guard, Switch 25 1 Cover, Receptacle Options:

See Note 50Hz Spec (Note: Not Available - Purchase Locally) 25A 4061043 60Hz Spec (Side Hinged) 25B 1001110872 60Hz Spec (Top Hinged)

26 4240018 A/R Strap, Tie (Not Shown) 27 4360336 1 Switch, Toggle 28 1 Connector, Strain Relief Options:

4460051 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

29 4460315 4 Terminal, Spade (Not Shown - Use 2 each with items 30 & 31) 30 1 Terminal, Receptacle Options:

4460346 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

31 1 Receptacle Options:

4460958 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

32 4711400 4 Flatwasher 1/4in Thin 33 4740397 1 Spacer, Washer 34 4751500 A/R Flatwasher 5/16in Regular 35 4791400 2 Starwasher 1/4in 36 4891800 4 Flatwasher 1/2in Hardened

2-62 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

37 4922972 1 Harness, Generator Cable A

4460225 1 Plug, Male 6 Position (Plugs into Generator) 4460226 6 Socket, Female (Use with 4460225) 4460807 1 Seal, Plug (Use with 4460225) 4460808 1 Seal, Interface (Use with 4460225)

See Note 1 Connector, Female 6 Position (Plugs into Control Box)

(Note: Not Available For Purchase)

See Note 6 Pin, Male (Note: Not Available For Purchase) 38 4711600 1 Flatwasher 3/8in Thin 39 0100020 A/R Sealant, Pipe (Not Shown) 40 1 Connector, Strain Relief Options:

4460071 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

Ref. JUNCTION BOX ASSEMBLY 0861542 1 60Hz Spec D 0861567 1 50Hz Spec B

101 0861541 1 Box, Junction 102

1060494 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally)

103

1060708 60Hz Spec

See Note 50Hz Spec (Note: Not Available - Purchase Locally) 104 1705376 1 Decal - Wiring Schematic 105 3300396 1 Cover, Fuse 106 3310601 2 Nut 6-32NC 107 1060343 108 Not Used 109 3910610 2 Bolt #6-32NC x 5/8in 110 4360070 1 Circuit Breaker - 15 Amp

111 to 115 Not Used

116 4460425 2 Strain Relief, Terminal 117 4460426 2 Connector, Strain Relief

118 to 120 Not Used

121 4750600 4 Flatwasher, #6 Regular 122 4760600 2 Lockwasher #6

123 to 124 Not Used

125 1671092 1 Cover (60Hz Spec Only) 126 4460963 1 Connector (60Hz Spec Only) 127 3520189 1 Plug (50Hz Spec Only) 128 1 Terminal Block Assembly Options (See Items 401-410 for

NPN Gray Terminal Block Assembly

1001121340 Tan Terminal Block Assembly

2ft/.6m

2.5ft/.76m

1.5ft/.46m

Cable, Electrical 12/3

Cable, Electrical 10/3

Cable, Electrical 10/4 (60Hz Spec Only)

Breakdown):

3121257 1100S 1100SJP 2-63

SECTION 2 TURNTABLE

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

Ref. DECAL INSTALLATION 0272435 1 60Hz Spec B 0272589 1 50Hz Spec A

201 1705460 2 Decal - SkyPower™ 202 1705374 1 Decal - 240V - 60Hz (60Hz Spec Only) 203 1 Decal - 240V - 3 Phase Options:

1705375 60Hz Spec 1705461 50Hz Spec

204 3 Decal, Hazardous Voltage Options:

1705387 60Hz Spec 1705489 50Hz Spec

4933264 Ref. ELECTRICAL DIAGRAM COMPONENTS C

301 4922757 1 Generator Harness 3/C

301A 4460374 2 Plug, Sealed Relay

4460375 7 Terminal

301B 4460967 1 Plug, Male - 3 Position

4460465 3 Socket, Female

301C 2400060 1 Fuseholder (Not Shown)

2400064 1 Fuse- 5 Amp (Not Shown)

302 to303 Not Used

304 4922641 1 Switch Harness

Ref. TERMINAL BLOCK ASSEMBLY

NPN Ref. Gray Terminal Block Assembly (Complete Assembly Not

Available - Purchase Individual Components)

1001121340 Ref. Tan Terminal Block Assembly A

401 2 Marker Strip #1 Options:

4460411 Gray Terminal Block Assembly

70002818 Tan Terminal Block Assembly

402 4 Marker Strip #2 Options:

4460412 Gray Terminal Block Assembly

70002819 Tan Terminal Block Assembly

403 2 Marker Strip #3 Options:

4460413 Gray Terminal Block Assembly

70002820 Tan Terminal Block Assembly

404 2 Marker Strip #4 Options:

4460414 Gray Terminal Block Assembly

70002821 Tan Terminal Block Assembly

405 4 Marker Strip #5 Options:

4460415 Gray Terminal Block Assembly

70002822 Tan Terminal Block Assembly

406 1 Terminal, End Barrier Options:

4460956 Gray Terminal Block Assembly

70002823 Tan Terminal Block Assembly

2-64 1100S 1100SJP 3121257

SECTION 2 TURNTABLE

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

ITEM # PART NUMBER QTY. DESCRIPTION REV.

407 2 Terminal, End Block Options:

4460607 Gray Terminal Block Assembly

70002824 Tan Terminal Block Assembly

408 7 Terminal, Block Options:

4460957 Gray Terminal Block Assembly

70002825 Tan Terminal Block Assembly

409 2 Terminal, Cross Connector Jumper Options:

4461001 Gray Terminal Block Assembly

70002826 Tan Terminal Block Assembly

410 3641533 1 Rail, Relay

1001103286 Ref. HOURMETER INSTALLATION (OPTIONAL) A

3121257 1100S 1100SJP 2-65

SECTION 2 TURNTABLE

19141

14128

210

311

FIGURE 2-13. TANK INSTALLATION

2-66 1100S 1100SJP 3121257

JLG 1100S Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FIGURE 1-1. AXLE INSTALLATIONS

FIGURE 1-2. STEER INSTALLATION

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATION

FIGURE 1-4. DRIVE HUB ASSEMBLY

FIGURE 1-5. DRIVE MOTOR ASSEMBLY

FIGURE 1-6. FRAME VALVES AND COVERS INSTALLATION

FIGURE 1-7. TRACTION VALVE ASSEMBLY (2WD)

FIGURE 1-8. TRACTION VALVE ASSEMBLY (4WD)

FIGURE 2-1. VALVE, BATTERY, HORN & AUXILIARY PUMP INSTALLATIONS

FIGURE 2-2. MAIN VALVE ASSEMBLY

FIGURE 2-3. TURNTABLE SWING DRIVE AND BEARING INSTALLATION

FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY

FIGURE 2-5. CATERPILLAR ENGINE INSTALLATION

FIGURE 2-6. DEUTZ ENGINE INSTALLATION

FIGURE 2-7. PUMP ASSEMBLY (CATERPILLAR ENGINE MACHINES)

FIGURE 2-8. PUMP ASSEMBLY (DEUTZ ENGINE MACHINES)

FIGURE 2-9. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)

FIGURE 2-10. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)

FIGURE 2-11. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR MACHINES

FIGURE 2-12. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ MACHINES

FIGURE 2-13. TANK INSTALLATION