JLG 1100S Parts Manual

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

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