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SECTION 3 - ENGINE
3121756
1030S, 1100SJ
189
FIGURE 3-10. DEUTZ TD2.9L4 T4I ENGINE AND PUMPS SUB-ASSEMBLY
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001219403
Ref
DEUTZ TD2.9L4 T4I ENGINE AND PUMPS SUB-ASSEMBLY
c
1
0100011
AR
Compound, Locking
2
0641812
2
Bolt 1/2 x 1-1/2
3
0761216
2
Bolt M12 x 40
4
2902065
1
Pump Coupling Kit (See Separate Breakdown in this Section)
5
3520054
1
Plug
6
3790152
1
O-Ring
7
3790155
1
O-Ring
8
3931620
2
Capscrew 3/8 x 1-1/4
9
4891600
2
Washer 3/8
10
4891800
2
Washer 1/2
11
5241200
2
Washer M12
12
1001108616
1
Tandem Pump Assembly (See Separate Breakdwon in this
Section)
13
1001112927
1
Gear Pump Assembly (See Separate Breakdown in this Section)
14
1001171095
1
Piston Pump Assembly (See Separate Breakdown in this Section)
15
1001219404
1
Deutz TD2.9L4 T4i Engine Assembly (See Separate Breakdown in
this Section)
Summary of Contents for JLG 1030S
Page 1: ......
Page 2: ......
Page 3: ...3121756 1030S 1100SJ 3...
Page 4: ...4 1030S 1100SJ 3121756...
Page 5: ...3121756 1030S 1100SJ 5...
Page 6: ......
Page 11: ...SECTION 1 FRAME 3121756 1030S 1100SJ 11 SECTION 1 FRAME...
Page 12: ...SECTION 1 FRAME 12 1030S 1100SJ 3121756 FIGURE 1 1 AXLE INSTALLATION 2WS...
Page 14: ...SECTION 1 FRAME 14 1030S 1100SJ 3121756 FIGURE 1 2 AXLE INSTALLATION 4WS...
Page 16: ...SECTION 1 FRAME 16 1030S 1100SJ 3121756 FIGURE 1 3 STEER INSTALLATION 2WS...
Page 18: ...SECTION 1 FRAME 18 1030S 1100SJ 3121756 FIGURE 1 4 STEER INSTALLATION 4WS...
Page 21: ......
Page 22: ...SECTION 1 FRAME 22 1030S 1100SJ 3121756 FIGURE 1 5 WHEEL DRIVE INSTALLATION 2WD...
Page 24: ...SECTION 1 FRAME 24 1030S 1100SJ 3121756 FIGURE 1 6 WHEEL DRIVE INSTALLATION 4WD...
Page 26: ...SECTION 1 FRAME 26 1030S 1100SJ 3121756 FIGURE 1 7 DRIVE HUB ASSEMBLY 2WD FRONT...
Page 28: ...SECTION 1 FRAME 28 1030S 1100SJ 3121756 FIGURE 1 8 DRIVE HUB ASSEMBLY...
Page 31: ......
Page 32: ...SECTION 1 FRAME 32 1030S 1100SJ 3121756 FIGURE 1 9 DRIVE MOTOR ASSEMBLY 2WD...
Page 34: ...SECTION 1 FRAME 34 1030S 1100SJ 3121756 FIGURE 1 10 DRIVE MOTOR ASSEMBLY 4WD...
Page 36: ...SECTION 1 FRAME 36 1030S 1100SJ 3121756 FIGURE 1 11 TIRE AND WHEEL INSTALLATION FOAM FILLED...
Page 38: ...SECTION 1 FRAME 38 1030S 1100SJ 3121756 FIGURE 1 12 TIRE AND WHEEL INSTALLATION SOLID...
Page 56: ...SECTION 1 FRAME 56 1030S 1100SJ 3121756 FIGURE 1 21 TRACTION VALVE ASSEMBLY 2WD...
Page 58: ...SECTION 1 FRAME 58 1030S 1100SJ 3121756 FIGURE 1 22 TRACTION VALVE ASSEMBLY 4WD...
Page 60: ...SECTION 1 FRAME 60 1030S 1100SJ 3121756 FIGURE 1 23 AXLE EXTEND STEER ASSEMBLY...
Page 62: ...SECTION 1 FRAME 62 1030S 1100SJ 3121756 FIGURE 1 24 STEER VALVE ASSEMBLY...
Page 72: ......
Page 73: ...SECTION 2 TURNTABLE 3121756 1030S 1100SJ 73 SECTION 2 TURNTABLE...
Page 93: ......
Page 97: ......
Page 98: ...SECTION 2 TURNTABLE 98 1030S 1100SJ 3121756 FIGURE 2 11 SWING DRIVE INSTALLATION...
Page 100: ...SECTION 2 TURNTABLE 100 1030S 1100SJ 3121756 FIGURE 2 12 SWING MOTOR HUB ASSEMBLY...
Page 101: ...SECTION 2 TURNTABLE 3121756 1030S 1100SJ 101...
Page 105: ......
Page 106: ...SECTION 2 TURNTABLE 106 1030S 1100SJ 3121756 FIGURE 2 13 PINION SHIELD INSTALLATION OPTIONAL...
Page 112: ...SECTION 2 TURNTABLE 112 1030S 1100SJ 3121756 FIGURE 2 16 TURNTABLE LOCK INSTALLATION...
Page 118: ...SECTION 2 TURNTABLE 118 1030S 1100SJ 3121756 FIGURE 2 19 TANKS INSTALLATION...
Page 120: ...SECTION 2 TURNTABLE 120 1030S 1100SJ 3121756 FIGURE 2 20 FUEL TANK ASSEMBLY...
Page 122: ...SECTION 2 TURNTABLE 122 1030S 1100SJ 3121756 FIGURE 2 21 HYDRAULIC TANK ASSEMBLY...
Page 128: ...SECTION 2 TURNTABLE 128 1030S 1100SJ 3121756 FIGURE 2 24 GROUND CONTROL PANEL ASSEMBLY 1030S...
Page 130: ...SECTION 2 TURNTABLE 130 1030S 1100SJ 3121756 FIGURE 2 25 GROUND CONTROL PANEL ASSEMBLY 1100SJ...
Page 132: ...SECTION 2 TURNTABLE 132 1030S 1100SJ 3121756 FIGURE 2 26 KEYSWITCH INSTALLATION...
Page 134: ...SECTION 2 TURNTABLE 134 1030S 1100SJ 3121756 FIGURE 2 27 ELECTRICAL ASSEMBLY...
Page 142: ...SECTION 2 TURNTABLE 142 1030S 1100SJ 3121756 FIGURE 2 31 HOOD INSTALLATION DEUTZ TD2011 ENGINE...
Page 143: ...SECTION 2 TURNTABLE 3121756 1030S 1100SJ 143...
Page 145: ......
Page 147: ...SECTION 2 TURNTABLE 3121756 1030S 1100SJ 147...
Page 149: ......
Page 154: ...SECTION 2 TURNTABLE 154 1030S 1100SJ 3121756 FIGURE 2 35 HOOD ASSEMBLY TANK SIDE...
Page 156: ......
Page 157: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 157 SECTION 3 ENGINE...
Page 158: ...SECTION 3 ENGINE 158 1030S 1100SJ 3121756 FIGURE 3 1 DEUTZ TD2011 ENGINE INSTALLATION...
Page 162: ...SECTION 3 ENGINE 162 1030S 1100SJ 3121756 FIGURE 3 3 DEUTZ TD2011 ENGINE ASSEMBLY...
Page 165: ......
Page 166: ...SECTION 3 ENGINE 166 1030S 1100SJ 3121756 FIGURE 3 4 DEUTZ TD2011 ENGINE COMPONENTS...
Page 168: ...SECTION 3 ENGINE 168 1030S 1100SJ 3121756 FIGURE 3 5 DEUTZ TD2 9L4 T4F ENGINE INSTALLATION...
Page 169: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 169...
Page 174: ...SECTION 3 ENGINE 174 1030S 1100SJ 3121756 FIGURE 3 7 DEUTZ TD2 9L4 T4F ENGINE ASSEMBLY...
Page 175: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 175...
Page 179: ......
Page 180: ...SECTION 3 ENGINE 180 1030S 1100SJ 3121756 FIGURE 3 8 DEUTZ TD2 9L4 T4F ENGINE COMPONENTS...
Page 184: ...SECTION 3 ENGINE 184 1030S 1100SJ 3121756 FIGURE 3 9 DEUTZ TD2 9L4 T4I ENGINE INSTALLATION...
Page 185: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 185...
Page 190: ...SECTION 3 ENGINE 190 1030S 1100SJ 3121756 FIGURE 3 11 DEUTZ TD2 9L4 T4I ENGINE ASSEMBLY...
Page 191: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 191...
Page 195: ......
Page 196: ...SECTION 3 ENGINE 196 1030S 1100SJ 3121756 FIGURE 3 12 DEUTZ TD2 9L4 T4I ENGINE COMPONENTS...
Page 200: ...SECTION 3 ENGINE 200 1030S 1100SJ 3121756 FIGURE 3 13 PUMP COUPLING KIT...
Page 202: ...SECTION 3 ENGINE 202 1030S 1100SJ 3121756 FIGURE 3 14 TANDEM PUMP ASSEMBLY...
Page 203: ...SECTION 3 ENGINE 3121756 1030S 1100SJ 203...
Page 206: ...SECTION 3 ENGINE 206 1030S 1100SJ 3121756 FIGURE 3 15 PISTON PUMP ASSEMBLY...
Page 209: ......
Page 210: ...SECTION 3 ENGINE 210 1030S 1100SJ 3121756 FIGURE 3 16 GEAR PUMP ASSEMBLY...
Page 218: ......
Page 219: ...SECTION 4 BOOM 3121756 1030S 1100SJ 219 SECTION 4 BOOM...
Page 220: ...SECTION 4 BOOM 220 1030S 1100SJ 3121756 FIGURE 4 1 BOOM INSTALLATION 1030S...
Page 221: ...SECTION 4 BOOM 3121756 1030S 1100SJ 221...
Page 223: ......
Page 224: ...SECTION 4 BOOM 224 1030S 1100SJ 3121756 FIGURE 4 2 BOOM INSTALLATION 1100SJ...
Page 225: ...SECTION 4 BOOM 3121756 1030S 1100SJ 225...
Page 227: ......
Page 228: ...SECTION 4 BOOM 228 1030S 1100SJ 3121756 FIGURE 4 3 BOOM ASSEMBLY...
Page 229: ...SECTION 4 BOOM 3121756 1030S 1100SJ 229...
Page 234: ...SECTION 4 BOOM 234 1030S 1100SJ 3121756 FIGURE 4 5 JIB ASSEMBLY 1100SJ...
Page 240: ...SECTION 4 BOOM 240 1030S 1100SJ 3121756 FIGURE 4 8 PLATFORM ROTATOR ASSEMBLY 1100SJ...
Page 242: ...SECTION 4 BOOM 242 1030S 1100SJ 3121756 FIGURE 4 9 POWER TRACK INSTALLATION...
Page 262: ...SECTION 4 BOOM 262 1030S 1100SJ 3121756 FIGURE 4 19 VALVE INSTALLATION BOOM 1030S WITH 4WD 4WS...
Page 272: ...SECTION 4 BOOM 272 1030S 1100SJ 3121756 FIGURE 4 24 PLATFORM ROTATE VALVE ASSEMBLY 1030S...
Page 276: ...SECTION 4 BOOM 276 1030S 1100SJ 3121756 FIGURE 4 26 BOOM SENSORS INSTALLATION...
Page 280: ...SECTION 4 BOOM 280 1030S 1100SJ 3121756 FIGURE 4 28 BOOM SHIELDS INSTALLATION...
Page 282: ......
Page 283: ...SECTION 5 PLATFORM 3121756 1030S 1100SJ 283 SECTION 5 PLATFORM...
Page 288: ...SECTION 5 PLATFORM 288 1030S 1100SJ 3121756 FIGURE 5 3 PLATFORM ASSEMBLY SHIPYARD MACHINES...
Page 314: ...SECTION 5 PLATFORM 314 1030S 1100SJ 3121756 FIGURE 5 16 CONSOLE BOX ASSEMBLY...
Page 317: ......
Page 318: ...SECTION 5 PLATFORM 318 1030S 1100SJ 3121756 FIGURE 5 17 CONTROLLER ASSEMBLY LIFT AND SWING...
Page 321: ......
Page 322: ...SECTION 5 PLATFORM 322 1030S 1100SJ 3121756 FIGURE 5 18 CONTROLLER ASSEMBLY DRIVE AND STEER...
Page 324: ...SECTION 5 PLATFORM 324 1030S 1100SJ 3121756 FIGURE 5 19 JIB SWITCH INSTALLATION 1100SJ...
Page 326: ...SECTION 5 PLATFORM 326 1030S 1100SJ 3121756 FIGURE 5 20 SKYGUARD INSTALLATION...
Page 332: ......
Page 333: ...SECTION 6 CYLINDER 3121756 1030S 1100SJ 333 SECTION 6 CYLINDER...
Page 334: ...SECTION 6 CYLINDER 334 1030S 1100SJ 3121756 FIGURE 6 1 AXLE EXTEND CYLINDER ASSEMBLY...
Page 336: ...SECTION 6 CYLINDER 336 1030S 1100SJ 3121756 FIGURE 6 2 LEVEL CYLINDER ASSEMBLY PLATFORM SLAVE...
Page 338: ...SECTION 6 CYLINDER 338 1030S 1100SJ 3121756 FIGURE 6 3 LIFT CYLINDER ASSEMBLY BOOM...
Page 340: ...SECTION 6 CYLINDER 340 1030S 1100SJ 3121756 FIGURE 6 4 LIFT CYLINDER ASSEMBLY JIB...
Page 342: ...SECTION 6 CYLINDER 342 1030S 1100SJ 3121756 FIGURE 6 5 MASTER CYLINDER ASSEMBLY...
Page 344: ...SECTION 6 CYLINDER 344 1030S 1100SJ 3121756 FIGURE 6 6 STEER CYLINDER ASSEMBLY...
Page 346: ...SECTION 6 CYLINDER 346 1030S 1100SJ 3121756 FIGURE 6 7 TELESCOPE CYLINDER...
Page 350: ......
Page 351: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 351 SECTION 7 HYDRAULIC...
Page 352: ...SECTION 7 HYDRAULIC 352 1030S 1100SJ 3121756 FIGURE 7 1 BOOM HYDRAULIC DIAGRAM 1030S...
Page 353: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 353...
Page 356: ...SECTION 7 HYDRAULIC 356 1030S 1100SJ 3121756 FIGURE 7 2 BOOM HYDRAULIC DIAGRAM 1100SJ...
Page 357: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 357...
Page 360: ...SECTION 7 HYDRAULIC 360 1030S 1100SJ 3121756 FIGURE 7 3 CHASSIS HYDRAULIC DIAGRAM 2WD 2WS...
Page 361: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 361...
Page 363: ......
Page 364: ...SECTION 7 HYDRAULIC 364 1030S 1100SJ 3121756 FIGURE 7 4 CHASSIS HYDRAULIC DIAGRAM 4WD 2WS...
Page 365: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 365...
Page 367: ......
Page 368: ...SECTION 7 HYDRAULIC 368 1030S 1100SJ 3121756 FIGURE 7 5 CHASSIS HYDRAULIC DIAGRAM 4WD 4WS...
Page 369: ...SECTION 7 HYDRAULIC 3121756 1030S 1100SJ 369...
Page 371: ......
Page 372: ...SECTION 7 HYDRAULIC 372 1030S 1100SJ 3121756 FIGURE 7 6 TURNTABLE HYDRAULIC DIAGRAM...
Page 375: ......
Page 377: ...SECTION 8 ELECTRICAL 3121756 1030S 1100SJ 377 SECTION 8 ELECTRICAL...
Page 379: ......
Page 380: ...SECTION 8 ELECTRICAL 380 1030S 1100SJ 3121756 FIGURE 8 2 AXLE POWER TRACK HARNESS...
Page 382: ...SECTION 8 ELECTRICAL 382 1030S 1100SJ 3121756 FIGURE 8 3 BATTERY CABLE KIT DEUTZ TD2011...
Page 384: ...SECTION 8 ELECTRICAL 384 1030S 1100SJ 3121756 FIGURE 8 4 BATTERY CABLE KIT DEUTZ TD2 9L4...
Page 386: ...SECTION 8 ELECTRICAL 386 1030S 1100SJ 3121756 FIGURE 8 5 BLAM HARNESS...
Page 400: ...SECTION 8 ELECTRICAL 400 1030S 1100SJ 3121756 FIGURE 8 12 BOOM CABLE MAIN...
Page 402: ...SECTION 8 ELECTRICAL 402 1030S 1100SJ 3121756 FIGURE 8 13 BOOM CABLE MAIN...
Page 406: ...SECTION 8 ELECTRICAL 406 1030S 1100SJ 3121756 FIGURE 8 15 CHASSIS HARNESS...
Page 408: ...SECTION 8 ELECTRICAL 408 1030S 1100SJ 3121756 FIGURE 8 16 ENGINE HARNESS DEUTZ TD2011 ENGINES...
Page 410: ...SECTION 8 ELECTRICAL 410 1030S 1100SJ 3121756 FIGURE 8 17 ENGINE HARNESS DEUTZ TD2 9L4 ENGINES...
Page 416: ...SECTION 8 ELECTRICAL 416 1030S 1100SJ 3121756 FIGURE 8 19 FUEL PUMP HARNESS DEUTZ TD2 9L4...
Page 422: ...SECTION 8 ELECTRICAL 422 1030S 1100SJ 3121756 FIGURE 8 22 GROUND CONTROL PANEL HARNESS...
Page 424: ...SECTION 8 ELECTRICAL 424 1030S 1100SJ 3121756 FIGURE 8 23 LOAD SENSING PIN HARNESS...
Page 426: ...SECTION 8 ELECTRICAL 426 1030S 1100SJ 3121756 FIGURE 8 24 MAIN VALVE HARNESS...
Page 428: ...SECTION 8 ELECTRICAL 428 1030S 1100SJ 3121756 FIGURE 8 25 OVERHEAD SOFT TOUCH HARNESS...
Page 430: ...SECTION 8 ELECTRICAL 430 1030S 1100SJ 3121756 FIGURE 8 26 PLATFORM CONSOLE BOX HARNESS...
Page 432: ...SECTION 8 ELECTRICAL 432 1030S 1100SJ 3121756 FIGURE 8 27 PLATFORM VALVE HARNESS 1030S...
Page 438: ...SECTION 8 ELECTRICAL 438 1030S 1100SJ 3121756 FIGURE 8 30 SKYGUARD SENSOR HARNESS...
Page 442: ...SECTION 8 ELECTRICAL 442 1030S 1100SJ 3121756 FIGURE 8 32 SWING DRIVE HARNESS...
Page 444: ...SECTION 8 ELECTRICAL 444 1030S 1100SJ 3121756 FIGURE 8 33 TURNTABLE HARNESS...
Page 447: ...SECTION 9 DECALS 3121756 1030S 1100SJ 447 SECTION 9 DECALS...
Page 480: ...SECTION 9 DECALS 480 1030S 1100SJ 3121756 FIGURE 9 17 DECAL INSTALLATIONS OPTIONS...
Page 482: ......
Page 486: ......
Page 487: ...SECTION 11 SPECIAL OPTIONS 3121756 1030S 1100SJ 487 SECTION 11 SPECIAL OPTIONS...
Page 490: ......
Page 491: ...PART NUMBER INDEX 3121756 1030S 1100SJ 491 PART NUMBER INDEX...
Page 503: ......
Page 504: ......