JLG Boom Lift 1030S 1100SJ Parts Catalog 3121756

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JLG Boom Lift 1030S 1100SJ Parts Catalog 3121756
Size: 38.47 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 1030S 1100SJ Boom Lift
Part Number: 3121756
Publication Date: 2025
Number of Pages: 528 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE INSTALLATION - 2WS​

FIGURE 1-2. AXLE INSTALLATION - 4WS​

FIGURE 1-3. STEER INSTALLATION - 2WS​

FIGURE 1-4. STEER INSTALLATION - 4WS​

FIGURE 1-5. WHEEL DRIVE INSTALLATION - 2WD​

FIGURE 1-6. WHEEL DRIVE INSTALLATION - 4WD​

FIGURE 1-7. DRIVE HUB ASSEMBLY - 2WD FRONT​

FIGURE 1-8. DRIVE HUB ASSEMBLY​

FIGURE 1-9. DRIVE MOTOR ASSEMBLY - 2WD​

FIGURE 1-10. DRIVE MOTOR ASSEMBLY - 4WD​

FIGURE 1-11. TIRE AND WHEEL INSTALLATION - FOAM-FILLED​

FIGURE 1-12. TIRE AND WHEEL INSTALLATION - SOLID​

FIGURE 1-13. VALVES INSTALLATION - FRAME (2WD) (SN B300001586 through B300001676)​

FIGURE 1-14. VALVES INSTALLATION - FRAME (WITH 2WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 1-15. VALVES INSTALLATION - FRAME (WITH 2WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 1-16. VALVES INSTALLATION - FRAME (4WD) (SN B300001586 through B300001676)​

FIGURE 1-17. VALVES INSTALLATION - FRAME (WITH 4WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 1-18. VALVES INSTALLATION - FRAME (WITH 4WD/4WS) (1030S)​

FIGURE 1-19. VALVES INSTALLATION - FRAME (WITH 4WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 1-20. VALVES INSTALLATION - FRAME (WITH 4WD/4WS) (1100SJ)​

FIGURE 1-21. TRACTION VALVE ASSEMBLY - 2WD​

FIGURE 1-22. TRACTION VALVE ASSEMBLY - 4WD​

FIGURE 1-23. AXLE EXTEND/STEER ASSEMBLY​

FIGURE 1-24. STEER VALVE ASSEMBLY​

FIGURE 1-25. FRAME COVER INSTALLATION - STANDARD MACHINES (2WS)​

FIGURE 1-26. FRAME COVER INSTALLATION - STANDARD MACHINES (4WS)​

FIGURE 1-27. FRAME COVER INSTALLATION - SHIPYARD MACHINES (2WS)​

FIGURE 1-28. FRAME COVER INSTALLATION - SHIPYARD MACHINES (4WS)​

SECTION 2 - TURNTABLE

FIGURE 2-1. VALVE INSTALLATION - TURNTABLE (1030S) (SN B300001586 through B300001676)​

FIGURE 2-2. VALVE INSTALLATION - TURNTABLE (WITH 2WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 2-3. VALVE INSTALLATION - TURNTABLE (WITH 4WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 2-4. VALVE INSTALLATION - TURNTABLE (WITH 4WD/4WS) (1030S)​

FIGURE 2-5. VALVE INSTALLATION - TURNTABLE (1100SJ) (SN B300001586 through B300001676)​

FIGURE 2-6. VALVE INSTALLATION - TURNTABLE (WITH 2WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 2-7. VALVE INSTALLATION - TURNTABLE (WITH 4WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 2-8. VALVE INSTALLATION - TURNTABLE (WITH 4WD/4WS) (1100SJ)​

FIGURE 2-9. MAIN VALVE ASSEMBLY (SN B300001586 through B300001676)​

FIGURE 2-10. MAIN VALVE ASSEMBLY (SN B300001677 through B300005767)​

FIGURE 2-11. SWING DRIVE INSTALLATION (SN B300001586 through B300003673)​

FIGURE 2-12. SWING DRIVE INSTALLATION (SN B300003674 through B300005767)​

FIGURE 2-13. SWING MOTOR/HUB ASSEMBLY (SN B300001586 through B300003673)​

FIGURE 2-14. SWING MOTOR/HUB ASSEMBLY (SN B300003674 through B300005767)​

FIGURE 2-15. PINION SHIELD INSTALLATION (OPTIONAL)​

FIGURE 2-16. TURNTABLE BEARING AND LUBE INSTALLATION​

FIGURE 2-17. BEARING AND TURNTABLE SHIELDS INSTALLATION​

FIGURE 2-18. TURNTABLE LOCK INSTALLATION​

FIGURE 2-19. ROTARY COUPLING AND COLLECTOR RING INSTALLATION​

FIGURE 2-20. BATTERY TRAY AND AUXILIARY PUMP INSTALLATION​

FIGURE 2-21. TANKS INSTALLATION​

FIGURE 2-22. FUEL TANK ASSEMBLY​

FIGURE 2-23. HYDRAULIC TANK ASSEMBLY​

FIGURE 2-24. ELECTRICAL COMPONENTS INSTALLATION (1030S)​

FIGURE 2-25. ELECTRICAL COMPONENTS INSTALLATION (1100SJ)​

FIGURE 2-26. GROUND CONTROL PANEL ASSEMBLY (1030S)​

FIGURE 2-27. GROUND CONTROL PANEL ASSEMBLY (1100SJ)​

FIGURE 2-28. KEYSWITCH INSTALLATION​

FIGURE 2-29. ELECTRICAL ASSEMBLY​

FIGURE 2-30. STROBE LIGHT INSTALLATION - AMBER (OPTIONAL)​

FIGURE 2-31. STROBE LIGHT INSTALLATION - BLUE (OPTIONAL) (SN B300000100 through B300004464)​

FIGURE 2-32. ALARM AND TURNTABLE COVERS INSTALLATION​

FIGURE 2-33. HOOD INSTALLATION - DEUTZ TD2011 ENGINE​

FIGURE 2-34. HOOD INSTALLATION - DEUTZ TD2.9L4 ENGINE​

FIGURE 2-35. HOOD ASSEMBLY - ENGINE SIDE (DEUTZ TD2011 ENGINE)​

FIGURE 2-36. HOOD ASSEMBLY - ENGINE SIDE (DEUTZ TD2.9L4 ENGINE)​

FIGURE 2-37. HOOD ASSEMBLY - TANK SIDE​

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ TD2011 ENGINE INSTALLATION​

FIGURE 3-2. DEUTZ TD2011 ENGINE AND PUMPS SUB-ASSEMBLY​

FIGURE 3-3. DEUTZ TD2011 ENGINE ASSEMBLY​

FIGURE 3-4. DEUTZ TD2011 ENGINE COMPONENTS​

FIGURE 3-5. DEUTZ TD2.9L4 T4F ENGINE INSTALLATION​

FIGURE 3-6. DEUTZ TD2.9L4 T4F ENGINE AND PUMPS SUB-ASSEMBLY​

FIGURE 3-7. DEUTZ TD2.9L4 T4F ENGINE ASSEMBLY​

FIGURE 3-8. DEUTZ TD2.9L4 T4F ENGINE COMPONENTS​

FIGURE 3-9. DEUTZ TD2.9L4 T4I ENGINE INSTALLATION​

FIGURE 3-10. DEUTZ TD2.9L4 T4I ENGINE AND PUMPS SUB-ASSEMBLY​

FIGURE 3-11. DEUTZ TD2.9L4 T4I ENGINE ASSEMBLY​

FIGURE 3-12. DEUTZ TD2.9L4 T4I ENGINE COMPONENTS​

FIGURE 3-13. PUMP COUPLING KIT​

FIGURE 3-14. TANDEM PUMP ASSEMBLY​

FIGURE 3-15. PISTON PUMP ASSEMBLY​

FIGURE 3-16. GEAR PUMP ASSEMBLY​

FIGURE 3-17. AIR CLEANER ASSEMBLY​

FIGURE 3-18. FUEL FILTER INSTALLATION – DEUTZ TD2011 ENGINE (OPTIONAL)​

FIGURE 3-19. FUEL FILTER ASSEMBLY (DEUTZ DT2.9L4 T4F)​

FIGURE 3-20. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ/240V (DEUTZ TD2.9L4 T4F ENGINES) (OPTIONAL)​

SECTION 4 - BOOM

FIGURE 4-1. BOOM INSTALLATION (1030S)​

FIGURE 4-2. BOOM INSTALLATION (1100SJ)​

FIGURE 4-3. BOOM ASSEMBLY​

FIGURE 4-4. TELESCOPE VALVE ASSEMBLY (SN B300001681 through B300005767)​

FIGURE 4-5. JIB ASSEMBLY (1100SJ)​

FIGURE 4-6. PLATFORM ROTATOR ASSEMBLY (1030S) (SN B300001586 through B300001726)​

FIGURE 4-7. PLATFORM ROTATOR ASSEMBLY (1030S) (SN B300001727 through B300005767)​

FIGURE 4-8. PLATFORM ROTATOR ASSEMBLY (1100SJ)​

FIGURE 4-9. POWER TRACK INSTALLATION​

FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - WITHOUT LSS (1030S)​

FIGURE 4-11. PLATFORM SUPPORT INSTALLATION - WITHOUT LSS (1100SJ)​

FIGURE 4-12. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (1030S)​

FIGURE 4-13. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS (1030S)​

FIGURE 4-14. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS (1100SJ)​

FIGURE 4-15. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS (1100SJ)​

FIGURE 4-16. VALVE INSTALLATION - BOOM (1030S) (SN B300001586 through B300001676)​

FIGURE 4-17. VALVE INSTALLATION - BOOM (WITH 2WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 4-18. VALVE INSTALLATION - BOOM (WITH 4WD/2WS) (1030S) (SN B300001677 through B300005767)​

FIGURE 4-19. VALVE INSTALLATION - BOOM (WITH 4WD/4WS) (1030S)​

FIGURE 4-20. VALVE INSTALLATION - BOOM (1100SJ) (SN B300001586 through B300001676)​

FIGURE 4-21. VALVE INSTALLATION - BOOM (WITH 2WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 4-22. VALVE INSTALLATION - BOOM (WITH 4WD/2WS) (1100SJ) (SN B300001677 through B300005767)​

FIGURE 4-23. VALVE INSTALLATION - BOOM (WITH 4WD/4WS) (1100SJ)​

FIGURE 4-24. PLATFORM ROTATE VALVE ASSEMBLY (1030S)​

FIGURE 4-25. JIB AND PLATFORM ROTATE VALVE ASSEMBLY (1100SJ)​

FIGURE 4-26. BOOM SENSORS INSTALLATION​

FIGURE 4-27. BOOM SENSORS INSTALLATION (WITH VERTICAL/HORIZONTAL CONTROLS)​

FIGURE 4-28. BOOM SHIELDS INSTALLATION​

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY - STANDARD MACHINES (SN B300001586 through B300001680)​

FIGURE 5-2. PLATFORM ASSEMBLY - STANDARD MACHINES (SN B300001681 through B300005767)​

FIGURE 5-3. PLATFORM ASSEMBLY - SHIPYARD MACHINES​

FIGURE 5-4. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH LANGUAGE)​

FIGURE 5-5. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/CHINESE LANGUAGE)​

FIGURE 5-6. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/JAPANESE LANGUAGE)​

FIGURE 5-7. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/KOREAN LANGUAGE)​

FIGURE 5-8. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH LANGUAGE)​

FIGURE 5-9. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/CHINESE LANGUAGE)​

FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/JAPANESE LANGUAGE)​

FIGURE 5-11. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/KOREAN LANGUAGE)​

FIGURE 5-12. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/CHINESE LANGUAGE)​

FIGURE 5-13. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/JAPANESE LANGUAGE)​

FIGURE 5-14. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/KOREAN LANGUAGE)​

FIGURE 5-15. CONSOLE BOX ASSEMBLY​

FIGURE 5-16. CONTROLLER ASSEMBLY (LIFT AND SWING)​

FIGURE 5-17. CONTROLLER ASSEMBLY (DRIVE AND STEER)​

FIGURE 5-18. JIB SWITCH INSTALLATION (1100SJ)​

FIGURE 5-19. SKYEYE INSTALLATION​

FIGURE 5-20. SKYGUARD INSTALLATION​

FIGURE 5-21. SKYLINE INSTALLATION​

FIGURE 5-22. OVERHEAD PROTECTION INSTALLATION - WITHOUT LSS (KOREAN/CHINA SPECS)​

FIGURE 5-23. OVERHEAD PROTECTION INSTALLATION - WITH LSS (KOREAN/CHINA SPECS)​

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE EXTEND CYLINDER ASSEMBLY​

FIGURE 6-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE​

FIGURE 6-3. LIFT CYLINDER ASSEMBLY - BOOM​

FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB​

FIGURE 6-5. MASTER CYLINDER ASSEMBLY​

FIGURE 6-6. STEER CYLINDER ASSEMBLY​

FIGURE 6-7. TELESCOPE CYLINDER​

FIGURE 6-8. TELESCOPE CYLINDER (SN B300002340 through B300005767)​

SECTION 7 - HYDRAULIC

FIGURE 7-1. BOOM HYDRAULIC DIAGRAM (1030S)​

FIGURE 7-2. BOOM HYDRAULIC DIAGRAM (1100SJ,1100SJ,1100SJ)​

FIGURE 7-3. CHASSIS HYDRAULIC DIAGRAM - 2WD/2WS​

FIGURE 7-4. CHASSIS HYDRAULIC DIAGRAM - 4WD/2WS​

FIGURE 7-5. CHASSIS HYDRAULIC DIAGRAM - 4WD/4WS​

FIGURE 7-6. TURNTABLE HYDRAULIC DIAGRAM​

FIGURE 7-7. HYDRAULIC DIAGRAM LIST​

SECTION 8 - ELECTRICAL

FIGURE 8-1. ELECTRICAL DIAGRAM LIST​

FIGURE 8-2. AXLE POWER TRACK HARNESS​

FIGURE 8-3. BATTERY CABLE KIT - DEUTZ TD2011​

FIGURE 8-4. BATTERY CABLE KIT - DEUTZ TD2.9L4​

FIGURE 8-5. BLAM HARNESS​

FIGURE 8-6. BOOM CABLES INSTALLATION - WITHOUT POWER AT PLATFORM (1030S)​

FIGURE 8-7. BOOM CABLES INSTALLATION - WITH AC POWER AT PLATFORM (1030S)​

FIGURE 8-8. BOOM CABLES INSTALLATION - WITH SKYPOWER (1030S)​

FIGURE 8-9. BOOM CABLES INSTALLATION - WITHOUT POWER AT PLATFORM (1100SJ)​

FIGURE 8-10. BOOM CABLES INSTALLATION - WITH AC POWER AT PLATFORM (1100SJ)​

FIGURE 8-11. BOOM CABLES INSTALLATION - WITH SKYPOWER (1100SJ)​

FIGURE 8-12. BOOM CABLE - MAIN​

FIGURE 8-13. BOOM CABLE - MAIN​

FIGURE 8-14. CHASSIS AND TURNTABLE HARNESS INSTALLATION​

FIGURE 8-15. CHASSIS HARNESS​

FIGURE 8-16. ENGINE HARNESS - DEUTZ TD2011 ENGINES​

FIGURE 8-17. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES​

FIGURE 8-18. FUEL FILTER HARNESS - DEUTZ TD2.9L4 T4I​

FIGURE 8-19. FUEL PUMP HARNESS - DEUTZ TD2.9L4​

FIGURE 8-20. GENERATOR HARNESS - 7500W SKYPOWER (60HZ/240V) (DEUTZ TD2.9L4 T4F ENGINES) (OPTIONAL)​

FIGURE 8-21. GENERATOR CABLE HARNESS - 7500W SKYPOWER (60HZ/240V) (DEUTZ TD2.9L4 T4F ENGINES)​

FIGURE 8-22. GROUND CONTROL PANEL HARNESS​

FIGURE 8-23. LOAD SENSING PIN HARNESS​

FIGURE 8-24. MAIN VALVE HARNESS​

FIGURE 8-25. OVERHEAD SOFT TOUCH HARNESS​

FIGURE 8-26. PLATFORM CONSOLE BOX HARNESS​

FIGURE 8-27. PLATFORM VALVE HARNESS (1030S)​

FIGURE 8-28. PLATFORM VALVE HARNESS (1100SJ) (SN B300001586 through B300002339)​

FIGURE 8-29. PLATFORM VALVE HARNESS (1100SJ) (SN B300002340 through B300005767)​

FIGURE 8-30. SKYEYE EMITTER HARNESS​

FIGURE 8-31. SKYEYE RECEIVER HARNESS​

FIGURE 8-32. SKYEYE INTERMEDIATE HARNESS​

FIGURE 8-33. SKYGUARD SENSOR HARNESS​

FIGURE 8-34. SKYLINE HARNESS​

FIGURE 8-35. STROBE LIGHT CONTROL HARNESS (BLUE LIGHT)​

FIGURE 8-36. SWING DRIVE HARNESS​

FIGURE 8-37. TURNTABLE HARNESS​

SECTION 9 - DECALS

FIGURE 9-1. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH LANGUAGE) (1030S)​

FIGURE 9-2. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH LANGUAGE) (1030S)​

FIGURE 9-3. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/CHINESE LANGUAGE) (1030S)​

FIGURE 9-4. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/CHINESE LANGUAGE) (1030S)​

FIGURE 9-5. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/JAPANESE LANGUAGE) (1030S)​

FIGURE 9-6. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/JAPANESE LANGUAGE) (1030S)​

FIGURE 9-7. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/KOREAN LANGUAGE) (1030S)​

FIGURE 9-8. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/KOREAN LANGUAGE) (1030S)​

FIGURE 9-9. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH LANGUAGE) (1100SJ)​

FIGURE 9-10. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH LANGUAGE) (1100SJ)​

FIGURE 9-11. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/CHINESE LANGUAGE) (1100SJ)​

FIGURE 9-12. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/CHINESE LANGUAGE) (1100SJ)​

FIGURE 9-13. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/JAPANESE LANGUAGE) (1100SJ)​

FIGURE 9-14. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/JAPANESE LANGUAGE) (1100SJ)​

FIGURE 9-15. DECAL INSTALLATION - WITH STANDARD PLATFORM (ENGLISH/KOREAN LANGUAGE) (1100SJ)​

FIGURE 9-16. DECAL INSTALLATION - WITH SHIPYARD PLATFORM (ENGLISH/KOREAN LANGUAGE) (1100SJ)​

FIGURE 9-17. DECAL INSTALLATIONS - OPTIONS​

SECTION 10 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 11 - SPECIAL OPTIONS

FIGURE 11-1. SPECIAL OPTIONS​

PART NUMBER INDEX