Oshkosh Corporation JLG 1030S Setup guide

3121756 1030S, 1100SJ 3

4 1030S, 1100SJ 3121756

3121756 1030S, 1100SJ 5

TABLE OF CONTENTS
3121756 1030S, 1100SJ 7
SECTION 1 - FRAME......................................................................................................................................................................... 11
FIGURE 1-1. AXLE INSTALLATION - 2WS ................................................................................................................................... 12
FIGURE 1-2. AXLE INSTALLATION - 4WS ................................................................................................................................... 14
FIGURE 1-3. STEER INSTALLATION - 2WS................................................................................................................................. 16
FIGURE 1-4. STEER INSTALLATION - 4WS................................................................................................................................. 18
FIGURE 1-5. WHEEL DRIVE INSTALLATION - 2WD.................................................................................................................... 22
FIGURE 1-6. WHEEL DRIVE INSTALLATION - 4WD.................................................................................................................... 24
FIGURE 1-7. DRIVE HUB ASSEMBLY - 2WD FRONT.................................................................................................................. 26
FIGURE 1-8. DRIVE HUB ASSEMBLY.......................................................................................................................................... 28
FIGURE 1-9. DRIVE MOTOR ASSEMBLY - 2WD ......................................................................................................................... 32
FIGURE 1-10. DRIVE MOTOR ASSEMBLY - 4WD ....................................................................................................................... 34
FIGURE 1-11. TIRE AND WHEEL INSTALLATION - FOAM-FILLED ............................................................................................ 36
FIGURE 1-12. TIRE AND WHEEL INSTALLATION - SOLID......................................................................................................... 38
FIGURE 1-13. VALVES INSTALLATION - FRAME (2WD) (SN B300001586 through B300001676)............................................. 40
FIGURE 1-14. VALVES INSTALLATION - FRAME (1030S WITH 2WD/2WS) (SN B300001677 to Present)................................ 42
FIGURE 1-15. VALVES INSTALLATION - FRAME (1100SJ WITH 2WD/2WS) (SN B300001677 to Present).............................. 44
FIGURE 1-16. VALVES INSTALLATION - FRAME (4WD) (SN B300001586 through B300001676)............................................. 46
FIGURE 1-17. VALVES INSTALLATION - FRAME (1030S WITH 4WD/2WS) (SN B300001677 to Present)................................ 48
FIGURE 1-18. VALVES INSTALLATION - FRAME (1030S WITH 4WD/4WS) .............................................................................. 50
FIGURE 1-19. VALVES INSTALLATION - FRAME (1100SJ WITH 4WD/2WS) (SN B300001677 to Present).............................. 52
FIGURE 1-20. VALVES INSTALLATION - FRAME (1100SJ WITH 4WD/4WS)............................................................................. 54
FIGURE 1-21. TRACTION VALVE ASSEMBLY - 2WD.................................................................................................................. 56
FIGURE 1-22. TRACTION VALVE ASSEMBLY - 4WD.................................................................................................................. 58
FIGURE 1-23. AXLE EXTEND/STEER ASSEMBLY...................................................................................................................... 60
FIGURE 1-24. STEER VALVE ASSEMBLY................................................................................................................................... 62
FIGURE 1-25. FRAME COVER INSTALLATION - STANDARD MACHINES (2WS)...................................................................... 64
FIGURE 1-26. FRAME COVER INSTALLATION - STANDARD MACHINES (4WS)...................................................................... 66
FIGURE 1-27. FRAME COVER INSTALLATION - SHIPYARD MACHINES (2WS)....................................................................... 68
FIGURE 1-28. FRAME COVER INSTALLATION - SHIPYARD MACHINES (4WS)....................................................................... 70
SECTION 2 - TURNTABLE................................................................................................................................................................ 73
FIGURE 2-1. VALVE INSTALLATION - TURNTABLE (1030S) (SN B300001586 through B300001676)...................................... 74
FIGURE 2-2. VALVE INSTALLATION - TURNTABLE (1030S WITH 2WD/2WS) (SN B300001677 to Present) ........................... 76
FIGURE 2-3. VALVE INSTALLATION - TURNTABLE (1030S WITH 4WD/2WS) (SN B300001677 to Present) ........................... 78
FIGURE 2-4. VALVE INSTALLATION - TURNTABLE (1030S WITH 4WD/4WS).......................................................................... 80
FIGURE 2-5. VALVE INSTALLATION - TURNTABLE (1100SJ) (SN B300001586 through B300001676).................................... 82
FIGURE 2-6. VALVE INSTALLATION - TURNTABLE (1100SJ WITH 2WD/2WS) (SN B300001677 to Present) ......................... 84
FIGURE 2-7. VALVE INSTALLATION - TURNTABLE (1100SJ WITH 4WD/2WS) (SN B300001677 to Present) ......................... 86
FIGURE 2-8. VALVE INSTALLATION - TURNTABLE (1100SJ WITH 4WD/4WS) ........................................................................ 88
FIGURE 2-9. MAIN VALVE ASSEMBLY (SN B300001586 through B300001676) ........................................................................ 90
FIGURE 2-10. MAIN VALVE ASSEMBLY (SN B300001677 to Present) ....................................................................................... 94
FIGURE 2-11. SWING DRIVE INSTALLATION ............................................................................................................................. 98
FIGURE 2-12. SWING MOTOR/HUB ASSEMBLY....................................................................................................................... 100
FIGURE 2-13. PINION SHIELD INSTALLATION (OPTIONAL).................................................................................................... 106
FIGURE 2-14. TURNTABLE BEARING AND LUBE INSTALLATION .......................................................................................... 108
FIGURE 2-15. BEARING AND TURNTABLE SHIELDS INSTALLATION .................................................................................... 110
FIGURE 2-16. TURNTABLE LOCK INSTALLATION.................................................................................................................... 112
FIGURE 2-17. ROTARY COUPLING AND COLLECTOR RING INSTALLATION........................................................................ 114
FIGURE 2-18. BATTERY TRAY AND AUXILIARY PUMP INSTALLATION................................................................................. 116
FIGURE 2-19. TANKS INSTALLATION........................................................................................................................................ 118
FIGURE 2-20. FUEL TANK ASSEMBLY...................................................................................................................................... 120
FIGURE 2-21. HYDRAULIC TANK ASSEMBLY........................................................................................................................... 122
FIGURE 2-22. ELECTRICAL COMPONENTS INSTALLATION - 1030S ..................................................................................... 124
FIGURE 2-23. ELECTRICAL COMPONENTS INSTALLATION - 1100SJ.................................................................................... 126
FIGURE 2-24. GROUND CONTROL PANEL ASSEMBLY - 1030S............................................................................................. 128
FIGURE 2-25. GROUND CONTROL PANEL ASSEMBLY - 1100SJ ........................................................................................... 130
FIGURE 2-26. KEYSWITCH INSTALLATION .............................................................................................................................. 132
FIGURE 2-27. ELECTRICAL ASSEMBLY.................................................................................................................................... 134
FIGURE 2-28. STROBE LIGHT INSTALLATION - AMBER (OPTIONAL).................................................................................... 136
FIGURE 2-29. STROBE LIGHT INSTALLATION - BLUE (OPTIONAL) ....................................................................................... 138
FIGURE 2-30. ALARM AND TURNTABLE COVERS INSTALLATION ........................................................................................ 140
FIGURE 2-31. HOOD INSTALLATION - DEUTZ TD2011 ENGINE ............................................................................................. 142
FIGURE 2-32. HOOD INSTALLATION - DEUTZ TD2.9L4 ENGINE ............................................................................................ 146
FIGURE 2-33. HOOD ASSEMBLY - ENGINE SIDE (DEUTZ TD2011 ENGINE)......................................................................... 150

TABLE OF CONTENTS
8 1030S, 1100SJ 3121756
FIGURE 2-34. HOOD ASSEMBLY - ENGINE SIDE (DEUTZ TD2.9L4 ENGINE).........................................................................152
FIGURE 2-35. HOOD ASSEMBLY - TANK SIDE..........................................................................................................................154
SECTION 3 - ENGINE......................................................................................................................................................................157
FIGURE 3-1. DEUTZ TD2011 ENGINE INSTALLATION..............................................................................................................158
FIGURE 3-2. DEUTZ TD2011 ENGINE AND PUMPS SUB-ASSEMBLY.....................................................................................160
FIGURE 3-3. DEUTZ TD2011 ENGINE ASSEMBLY....................................................................................................................162
FIGURE 3-4. DEUTZ TD2011 ENGINE COMPONENTS..............................................................................................................166
FIGURE 3-5. DEUTZ TD2.9L4 T4F ENGINE INSTALLATION .....................................................................................................168
FIGURE 3-6. DEUTZ TD2.9L4 T4F ENGINE AND PUMPS SUB-ASSEMBLY.............................................................................172
FIGURE 3-7. DEUTZ TD2.9L4 T4F ENGINE ASSEMBLY............................................................................................................174
FIGURE 3-8. DEUTZ TD2.9L4 T4F ENGINE COMPONENTS .....................................................................................................180
FIGURE 3-9. DEUTZ TD2.9L4 T4I ENGINE INSTALLATION.......................................................................................................184
FIGURE 3-10. DEUTZ TD2.9L4 T4I ENGINE AND PUMPS SUB-ASSEMBLY............................................................................188
FIGURE 3-11. DEUTZ TD2.9L4 T4I ENGINE ASSEMBLY...........................................................................................................190
FIGURE 3-12. DEUTZ TD2.9L4 T4I ENGINE COMPONENTS ....................................................................................................196
FIGURE 3-13. PUMP COUPLING KIT..........................................................................................................................................200
FIGURE 3-14. TANDEM PUMP ASSEMBLY................................................................................................................................202
FIGURE 3-15. PISTON PUMP ASSEMBLY..................................................................................................................................206
FIGURE 3-16. GEAR PUMP ASSEMBLY.....................................................................................................................................210
FIGURE 3-17. FUEL FILTER INSTALLATION –DEUTZ TD2011 ENGINE (OPTIONAL)............................................................212
FIGURE 3-18. 7500W SKYPOWER GENERATOR INSTALLATION - 60HZ/240V (DEUTZ TD2.9L4 T4F ENGINES) (OPTIONAL)
......................................................................................................................................................................................................214
SECTION 4 - BOOM.........................................................................................................................................................................219
FIGURE 4-1. BOOM INSTALLATION - 1030S..............................................................................................................................220
FIGURE 4-2. BOOM INSTALLATION - 1100SJ............................................................................................................................224
FIGURE 4-3. BOOM ASSEMBLY .................................................................................................................................................228
FIGURE 4-4. TELESCOPE VALVE ASSEMBLY (SN B300001681 to Present) ...........................................................................232
FIGURE 4-5. JIB ASSEMBLY - 1100SJ........................................................................................................................................234
FIGURE 4-6. PLATFORM ROTATOR ASSEMBLY - 1030S (SN B300001586 through B300001726).........................................236
FIGURE 4-7. PLATFORM ROTATOR ASSEMBLY - 1030S (SN B300001727 to Present)..........................................................238
FIGURE 4-8. PLATFORM ROTATOR ASSEMBLY - 1100SJ.......................................................................................................240
FIGURE 4-9. POWER TRACK INSTALLATION ...........................................................................................................................242
FIGURE 4-10. PLATFORM SUPPORT INSTALLATION - 1030S WITHOUT LSS .......................................................................244
FIGURE 4-11. PLATFORM SUPPORT INSTALLATION - 1100SJ WITHOUT LSS......................................................................246
FIGURE 4-12. PLATFORM SUPPORT INSTALLATION - 1030S WITH 4 CELL LSS..................................................................248
FIGURE 4-13. PLATFORM SUPPORT INSTALLATION - 1030S WITH 1 CELL LSS..................................................................250
FIGURE 4-14. PLATFORM SUPPORT INSTALLATION - 1100SJ WITH 4 CELL LSS ................................................................252
FIGURE 4-15. PLATFORM SUPPORT INSTALLATION - 1100SJ WITH 1 CELL LSS ................................................................254
FIGURE 4-16. VALVE INSTALLATION - BOOM (1030S) (SN B300001586 through B300001676).............................................256
FIGURE 4-17. VALVE INSTALLATION - BOOM (1030S WITH 2WD/2WS) (SN B300001677 to Present)..................................258
FIGURE 4-18. VALVE INSTALLATION - BOOM (1030S WITH 4WD/2WS) (SN B300001677 to Present)..................................260
FIGURE 4-19. VALVE INSTALLATION - BOOM (1030S WITH 4WD/4WS).................................................................................262
FIGURE 4-20. VALVE INSTALLATION - BOOM (1100SJ) (SN B300001586 through B300001676)...........................................264
FIGURE 4-21. VALVE INSTALLATION - BOOM (1100SJ WITH 2WD/2WS) (SN B300001677 to Present) ................................266
FIGURE 4-22. VALVE INSTALLATION - BOOM (1100SJ WITH 4WD/2WS) (SN B300001677 to Present) ................................268
FIGURE 4-23. VALVE INSTALLATION - BOOM (1100SJ WITH 4WD/4WS)...............................................................................270
FIGURE 4-24. PLATFORM ROTATE VALVE ASSEMBLY (1030S).............................................................................................272
FIGURE 4-25. JIB AND PLATFORM ROTATE VALVE ASSEMBLY (1100SJ).............................................................................274
FIGURE 4-26. BOOM SENSORS INSTALLATION.......................................................................................................................276
FIGURE 4-27. BOOM SENSORS INSTALLATION (WITH VERTICAL/HORIZONTAL CONTROLS)...........................................278
FIGURE 4-28. BOOM SHIELDS INSTALLATION.........................................................................................................................280
SECTION 5 - PLATFORM................................................................................................................................................................283
FIGURE 5-1. PLATFORM ASSEMBLY - STANDARD MACHINES (SN B300001586 through B300001680)..............................284
FIGURE 5-2. PLATFORM ASSEMBLY - STANDARD MACHINES (SN B300001681 to Present) ...............................................286
FIGURE 5-3. PLATFORM ASSEMBLY - SHIPYARD MACHINES ...............................................................................................288
FIGURE 5-4. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH LANGUAGE)
......................................................................................................................................................................................................290
FIGURE 5-5. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/CHINESE
LANGUAGE).................................................................................................................................................................................292
FIGURE 5-6. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/JAPANESE
LANGUAGE).................................................................................................................................................................................294

TABLE OF CONTENTS
3121756 1030S, 1100SJ 9
FIGURE 5-7. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - STANDARD MACHINES (ENGLISH/KOREAN
LANGUAGE) ................................................................................................................................................................................ 296
FIGURE 5-8. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH LANGUAGE)
...................................................................................................................................................................................................... 298
FIGURE 5-9. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/CHINESE
LANGUAGE) ................................................................................................................................................................................ 300
FIGURE 5-10. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/JAPANESE
LANGUAGE) ................................................................................................................................................................................ 302
FIGURE 5-11. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION - SHIPYARD MACHINES (ENGLISH/KOREAN
LANGUAGE) ................................................................................................................................................................................ 304
FIGURE 5-12. CONSOLE BOX SUB-ASSEMBLY (ENGLISH LANGUAGE)............................................................................... 306
FIGURE 5-13. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/CHINESE LANGUAGE) .............................................................. 308
FIGURE 5-14. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/JAPANESE LANGUAGE)............................................................ 310
FIGURE 5-15. CONSOLE BOX SUB-ASSEMBLY (ENGLISH/KOREAN LANGUAGE) ............................................................... 312
FIGURE 5-16. CONSOLE BOX ASSEMBLY................................................................................................................................ 314
FIGURE 5-17. CONTROLLER ASSEMBLY (LIFT AND SWING)................................................................................................. 318
FIGURE 5-18. CONTROLLER ASSEMBLY (DRIVE AND STEER).............................................................................................. 322
FIGURE 5-19. JIB SWITCH INSTALLATION - 1100SJ................................................................................................................ 324
FIGURE 5-20. SKYGUARD INSTALLATION ............................................................................................................................... 326
FIGURE 5-21. OVERHEAD PROTECTION INSTALLATION - WITHOUT LSS (KOREAN/CHINA SPECS)................................ 328
FIGURE 5-22. OVERHEAD PROTECTION INSTALLATION - WITH LSS (KOREAN/CHINA SPECS)....................................... 330
SECTION 6 - CYLINDER................................................................................................................................................................. 333
FIGURE 6-1. AXLE EXTEND CYLINDER ASSEMBLY................................................................................................................ 334
FIGURE 6-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE .......................................................................................... 336
FIGURE 6-3. LIFT CYLINDER ASSEMBLY - BOOM................................................................................................................... 338
FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB......................................................................................................................... 340
FIGURE 6-5. MASTER CYLINDER ASSEMBLY.......................................................................................................................... 342
FIGURE 6-6. STEER CYLINDER ASSEMBLY............................................................................................................................. 344
FIGURE 6-7. TELESCOPE CYLINDER ....................................................................................................................................... 346
FIGURE 6-8. TELESCOPE CYLINDER (SN B300002340 to Present)......................................................................................... 348
SECTION 7 - HYDRAULIC .............................................................................................................................................................. 351
FIGURE 7-1. BOOM HYDRAULIC DIAGRAM - 1030S................................................................................................................ 352
FIGURE 7-2. BOOM HYDRAULIC DIAGRAM - 1100SJ .............................................................................................................. 356
FIGURE 7-3. CHASSIS HYDRAULIC DIAGRAM - 2WD/2WS..................................................................................................... 360
FIGURE 7-4. CHASSIS HYDRAULIC DIAGRAM - 4WD/2WS..................................................................................................... 364
FIGURE 7-5. CHASSIS HYDRAULIC DIAGRAM - 4WD/4WS..................................................................................................... 368
FIGURE 7-6. TURNTABLE HYDRAULIC DIAGRAM ................................................................................................................... 372
FIGURE 7-7. HYDRAULIC DIAGRAM LIST................................................................................................................................. 376
SECTION 8 - ELECTRICAL............................................................................................................................................................. 377
FIGURE 8-1. ELECTRICAL DIAGRAM LIST................................................................................................................................ 378
FIGURE 8-2. AXLE POWER TRACK HARNESS......................................................................................................................... 380
FIGURE 8-3. BATTERY CABLE KIT - DEUTZ TD2011 ............................................................................................................... 382
FIGURE 8-4. BATTERY CABLE KIT - DEUTZ TD2.9L4 .............................................................................................................. 384
FIGURE 8-5. BLAM HARNESS.................................................................................................................................................... 386
FIGURE 8-6. BOOM CABLES INSTALLATION - 1030S WITHOUT POWER AT PLATFORM.................................................... 388
FIGURE 8-7. BOOM CABLES INSTALLATION - 1030S WITH AC POWER AT PLATFORM ..................................................... 390
FIGURE 8-8. BOOM CABLES INSTALLATION - 1030S WITH SKYPOWER .............................................................................. 392
FIGURE 8-9. BOOM CABLES INSTALLATION - 1100SJ WITHOUT POWER AT PLATFORM.................................................. 394
FIGURE 8-10. BOOM CABLES INSTALLATION - 1100SJ WITH AC POWER AT PLATFORM.................................................. 396
FIGURE 8-11. BOOM CABLES INSTALLATION - 1100SJ WITH SKYPOWER .......................................................................... 398
FIGURE 8-12. BOOM CABLE - MAIN.......................................................................................................................................... 400
FIGURE 8-13. BOOM CABLE - MAIN.......................................................................................................................................... 402
FIGURE 8-14. CHASSIS AND TURNTABLE HARNESS INSTALLATION................................................................................... 404
FIGURE 8-15. CHASSIS HARNESS............................................................................................................................................ 406
FIGURE 8-16. ENGINE HARNESS - DEUTZ TD2011 ENGINES................................................................................................ 408
FIGURE 8-17. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES............................................................................................... 410
FIGURE 8-18. FUEL FILTER HARNESS - DEUTZ TD2.9L4 T4I ................................................................................................. 414
FIGURE 8-19. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ......................................................................................................... 416
FIGURE 8-20. GENERATOR HARNESS - 7500W SKYPOWER (60HZ/240V) (DEUTZ TD2.9L4 T4F ENGINES) (OPTIONAL) 418
FIGURE 8-21. GENERATOR CABLE HARNESS - 7500W SKYPOWER (60HZ/240V) (DEUTZ TD2.9L4 T4F ENGINES) ........ 420
FIGURE 8-22. GROUND CONTROL PANEL HARNESS............................................................................................................. 422

TABLE OF CONTENTS
10 1030S, 1100SJ 3121756
FIGURE 8-23. LOAD SENSING PIN HARNESS ..........................................................................................................................424
FIGURE 8-24. MAIN VALVE HARNESS.......................................................................................................................................426
FIGURE 8-25. OVERHEAD SOFT TOUCH HARNESS................................................................................................................428
FIGURE 8-26. PLATFORM CONSOLE BOX HARNESS..............................................................................................................430
FIGURE 8-27. PLATFORM VALVE HARNESS (1030S)...............................................................................................................432
FIGURE 8-28. PLATFORM VALVE HARNESS (1100SJ) (SN B300001586 through B300002339).............................................434
FIGURE 8-29. PLATFORM VALVE HARNESS (1100SJ) (SN B300002340 to Present)..............................................................436
FIGURE 8-30. SKYGUARD SENSOR HARNESS........................................................................................................................438
FIGURE 8-31. STROBE LIGHT CONTROL HARNESS (BLUE LIGHT) .......................................................................................440
FIGURE 8-32. SWING DRIVE HARNESS....................................................................................................................................442
FIGURE 8-33. TURNTABLE HARNESS.......................................................................................................................................444
SECTION 9 - DECALS .....................................................................................................................................................................447
FIGURE 9-1. DECAL INSTALLATION - 1030S WITH STANDARD PLATFORM (ENGLISH LANGUAGE)..................................448
FIGURE 9-2. DECAL INSTALLATION - 1030S WITH SHIPYARD PLATFORM (ENGLISH LANGUAGE)...................................450
FIGURE 9-3. DECAL INSTALLATION - 1030S WITH STANDARD PLATFORM (ENGLISH/CHINESE LANGUAGE).................452
FIGURE 9-4. DECAL INSTALLATION - 1030S WITH SHIPYARD PLATFORM (ENGLISH/CHINESE LANGUAGE)..................454
FIGURE 9-5. DECAL INSTALLATION - 1030S WITH STANDARD PLATFORM (ENGLISH/JAPANESE LANGUAGE)..............456
FIGURE 9-6. DECAL INSTALLATION - 1030S WITH SHIPYARD PLATFORM (ENGLISH/JAPANESE LANGUAGE) ...............458
FIGURE 9-7. DECAL INSTALLATION - 1030S WITH STANDARD PLATFORM (ENGLISH/KOREAN LANGUAGE) .................460
FIGURE 9-8. DECAL INSTALLATION - 1030S WITH SHIPYARD PLATFORM (ENGLISH/KOREAN LANGUAGE)...................462
FIGURE 9-9. DECAL INSTALLATION - 1100SJ WITH STANDARD PLATFORM (ENGLISH LANGUAGE)................................464
FIGURE 9-10. DECAL INSTALLATION - 1100SJ WITH SHIPYARD PLATFORM (ENGLISH LANGUAGE)...............................466
FIGURE 9-11. DECAL INSTALLATION - 1100SJ WITH STANDARD PLATFORM (ENGLISH/CHINESE LANGUAGE).............468
FIGURE 9-12. DECAL INSTALLATION - 1100SJ WITH SHIPYARD PLATFORM (ENGLISH/CHINESE LANGUAGE) ..............470
FIGURE 9-13. DECAL INSTALLATION - 1100SJ WITH STANDARD PLATFORM (ENGLISH/JAPANESE LANGUAGE)..........472
FIGURE 9-14. DECAL INSTALLATION - 1100SJ WITH SHIPYARD PLATFORM (ENGLISH/JAPANESE LANGUAGE)............474
FIGURE 9-15. DECAL INSTALLATION - 1100SJ WITH STANDARD PLATFORM (ENGLISH/KOREAN LANGUAGE)..............476
FIGURE 9-16. DECAL INSTALLATION - 1100SJ WITH SHIPYARD PLATFORM (ENGLISH/KOREAN LANGUAGE)...............478
FIGURE 9-17. DECAL INSTALLATIONS - OPTIONS...................................................................................................................480
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK..........................................................................................................483
FIGURE 10-1. RECOMMENDED SERVICE PARTS STOCK.......................................................................................................484
SECTION 11 - SPECIAL OPTIONS .................................................................................................................................................487
FIGURE 11-1. SPECAIL OPTIONS ..............................................................................................................................................488
PART NUMBER INDEX....................................................................................................................................................................491

SECTION 1 - FRAME
3121756 1030S, 1100SJ 11
SECTION 1 - FRAME

SECTION 1 - FRAME
12 1030S, 1100SJ 3121756
FIGURE 1-1. AXLE INSTALLATION - 2WS

SECTION 1 - FRAME
3121756 1030S, 1100SJ 13
FIGURE 1-1. AXLE INSTALLATION - 2WS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001149658
Ref
AXLE INSTALLATION
G
1
0100011
AR
Compound, Locking
2
0100019
AR
Compound, Locking
3
0100081
AR
Adhesive (Not Shown)
4
0701014
8
Bolt M10 x 30
5
0701221
32
Bolt M12 x 65
6
0761012
8
Bolt M10 x 25
8
0761216
40
Bolt M12 x 40
9
0761217
8
Bolt M12 x 45
10
0761218
48
Bolt M12 x 50
11
1320263
4
Clamp
12
3290405
8
Nut M4
13
3291007
8
Nut M10
14
3573294
4
Plate, Switch
15
4031510
8
Capscrew M4 x 30
16
4360578
4
Switch, Limit
17
4811400
8
Washer M4
18
4812000
24
Washer M10
19
4812100
128
Washer M12
20
1001149464
2
Axle Extend Cylinder Assembly (See Separate Breakdown in
CYLINDER SECTION)
21
1001149671
1
Axle, Front (Left)
22
1001149672
1
Axle, Front (Right)
23
1001149785
1
Axle, Rear (Left)
24
1001149786
1
Axle, Rear (Right)
25
1001150320
4
Pad, Wear
26
1001150321
32
Pad, Wear
27
1001150322
4
Pad, Wear
28
1001150323
8
Shim 3mm
30
1001150325
8
Shim 1.2mm
31
1001150326
64
Shim 1.2mm
32
1001150407
4
Plate
33
1001150408
16
Shim 1.5mm
34
1001150458
4
Pad, Wear
35
1001150558
4
Stop
36
4460968
4
Connector, Strain Relief

SECTION 1 - FRAME
14 1030S, 1100SJ 3121756
FIGURE 1-2. AXLE INSTALLATION - 4WS

SECTION 1 - FRAME
3121756 1030S, 1100SJ 15
FIGURE 1-2. AXLE INSTALLATION - 4WS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001222642
Ref
AXLE INSTALLATION
B
1
0100011
AR
Compound, Locking
2
0100019
AR
Compound, Locking
3
0100081
AR
Adhesive (Not Shown)
4
0701014
8
Bolt M10 x 30
5
0701221
32
Bolt M12 x 65
6
0761012
8
Bolt M10 x 25
8
0761216
40
Bolt M12 x 40
9
0761217
8
Bolt M12 x 45
10
0761218
48
Bolt M12 x 50
11
1320263
4
Clamp
12
3290405
8
Nut M4
13
3291007
8
Nut M10
14
3573294
4
Plate, Switch
15
4031510
8
Capscrew M4 x 30
16
4360578
4
Switch, Limit
17
4811400
8
Washer M4
18
4812000
24
Washer M10
19
4812100
128
Washer M12
20
1001149464
2
Axle Extend Cylinder Assembly (See Separate Breakdown in
CYLINDER SECTION)
21
1001149671
1
Axle, Front (Left)
22
1001149672
1
Axle, Front (Right)
25
1001150320
4
Pad, Wear
26
1001150321
32
Pad, Wear
27
1001150322
4
Pad, Wear
28
1001150323
8
Shim 3mm
30
1001150325
8
Shim 1.2mm
31
1001150326
64
Shim 1.2mm
32
1001150407
4
Plate
33
1001150408
16
Shim 1.5mm
34
1001150458
4
Pad, Wear
35
1001150558
4
Stop
36
4460968
4
Connector, Strain Relief

SECTION 1 - FRAME
16 1030S, 1100SJ 3121756
FIGURE 1-3. STEER INSTALLATION - 2WS

SECTION 1 - FRAME
3121756 1030S, 1100SJ 17
FIGURE 1-3. STEER INSTALLATION - 2WS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001149657
Ref
STEER INSTALLATION
B
1
0100011
AR
Compound, Locking
2
0100019
AR
Compound, Locking
3
0100035
AR
Compound, Locking
4
0080277
2
Adapter, Sensor
5
0200833
2
Arm, Sensor
6
0630464
2
Screw #10 x 1/2
7
0641505
2
Bolt 5/16 x 5/8
8
0641511
2
Bolt 5/16 x 1-3/8
9
0701219
2
Bolt M12 x 55
10
0701622
2
Bolt M16 x 70
11
0962423
4
Bearing
12
1120549
2
Cap (Outer)
13
1120550
2
Cap (Inner)
14
3291207
2
Nut M12
15
3291607
2
Nut M16
16
3300464
2
Nut
17
3311505
2
Nut 5/16
18
3423256
2
Pin, Sensor
19
3451214
2
Pin 3/8 x 3-1/2
20
3760383
2
Ring
21
3841203
2
Keeper, Rod
22
3841258
2
Keeper, Rod
23
3931020
4
Capscrew #10 x 1-1/4
24
3960551
2
Seal (Outer)
25
3960552
2
Seal (Inner)
26
4031707
8
Capscrew M6 x 16
27
4032310
4
Capscrew M16 x 30
28
4360505
2
Switch, Sensor
29
4460914
2
Mount, Terminal
30
4711500
6
Washer 5/16
31
4711800
2
Washer 1/2
32
4740181
2
Washer
33
4740229
2
Washer
34
4740505
4
Washer
35
4750800
4
Washer #8
36
4755000
2
Washer 2-1/2
37
4812100
2
Washer M12
38
4812300
2
Washer M16
39
1001109730
2
Cover, Sensor
40
1001137125
4
Screw M8 x 20
41
1001149440
1
Spindle (Left)
42
1001149441
1
Spindle (Right)
43
1001149463
2
Steer Cylinder Assembly (See Separate Breakdown in CYLINDER
SECTION)
44
1001150418
2
Kingpin
45
1001150419
2
Pin (Inner)
46
1001150460
2
Pin (Outer)

SECTION 1 - FRAME
18 1030S, 1100SJ 3121756
FIGURE 1-4. STEER INSTALLATION - 4WS

SECTION 1 - FRAME
3121756 1030S, 1100SJ 19
FIGURE 1-4. STEER INSTALLATION - 4WS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001222688
Ref
STEER INSTALLATION
A
1
0080277
4
Adapter, Sensor
2
0100011
AR
Compound, Locking
3
0100019
AR
Compound, Locking
4
0100035
AR
Compound, Locking (Not Shown)
5
0200833
4
Arm, Sensor
6
0630464
4
Screw #10 x 1/2
7
0641505
4
Bolt 5/16 x 5/8
8
0641511
4
Bolt 5/16 x 1-3/8
9
0701219
4
Bolt M12 x 55
10
0701622
4
Bolt M16 x 70
11
0962423
8
Bearing
12
1120549
4
Cap (Outer)
13
1120550
4
Cap (Inner)
14
3291207
4
Nut M12
15
3291607
4
Nut M16
16
3300464
4
Nut
17
3311505
4
Nut 5/16
18
3423256
4
Pin, Sensor
19
3451214
4
Pin 3/8 x 3-1/2
20
3760383
4
Ring
21
3790012
1
O-Ring
22
3841203
4
Keeper, Rod
23
3841258
4
Keeper, Rod
24
3931020
8
Capscrew #10 x 1-1/4
25
3960551
4
Seal (Outer)
26
3960552
4
Seal (Inner)
27
4031707
16
Capscrew M6 x 16
28
4032310
4
Capscrew M16 x 30
29
4360505
4
Switch, Sensor
30
4460914
4
Mount, Terminal
31
4711500
12
Washer 5/16
32
4711800
4
Washer 1/2
33
4740181
4
Washer
34
4740229
4
Washer
35
4740397
1
Spacer
36
4740505
8
Washer
37
4750800
8
Washer #8
38
4755000
4
Washer 2-1/2
39
4812100
4
Washer M12
40
4812300
4
Washer M16
41
1001109730
4
Cover, Sensor
42
1001137125
8
Screw M8 x 20
43
1001149440
2
Spindle (Left)
44
1001149441
2
Spindle (Right)
45
1001149463
4
Steer Cylinder Assembly (See Separate Breakdown in CYLINDER
SECTION)
46
1001150418
4
Kingpin
47
1001150419
4
Pin (Inner)
48
1001150460
4
Pin (Outer)

SECTION 1 - FRAME
20 1030S, 1100SJ 3121756
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
49
1001152574
2
Axle Power Track Harness (Not Shown - See Separate Breakdown
in ELECTRICAL SECTION)
50
1001155044
1
Nut 15/32
51
1001161709
1
Switch, Toggle