Jlg 1100S Service Manual manuals

Jlg 1100S Service Manual User Manual (442 pages)

Brand: Jlg | Category: Special machinery | Size: 32.57 MB |

English

Table of contents

P/N - 3121256

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

SECTION 5 - HYDRAULICS

8

10

LIST OF FIGURES

11

SECTION 1. SPECIFICATIONS

17

SECTION 1 - SPECIFICATIONS

18

1.6 HYDRAULIC OIL

19

1.7 MAJOR COMPONENT WEIGHTS

20

1.8 PRESSURE SETTINGS

20

1.9 LUBRICATION AND OPERATOR

22

MAINTENANCE

22

SECTION 2. GENERAL

33

2.2 SERVICE AND GUIDELINES

34

Safety and Workmanship

34

Cleanliness

34

SECTION 2 - GENERAL

35

Hydraulic Oil

36

Changing Hydraulic Oil

36

Lubrication Specifications

36

2.4 CYLINDER DRIFT TEST

36

Platform Drift

36

3.1 TIRES & WHEELS

43

Tire Inflation

43

Tire Damage

43

Wheel and Tire Replacement

43

Wheel Installation

43

3.2 EXTENDING AXLES

44

PROCEDURE

44

3.4 DRIVE SYSTEM (1100SJP)

45

3.5 STEERING CONTROL SYSTEM

45

3.7 TRACTION CONTROL SYSTEM

46

3.8 DRIVE ORIENTATION SYSTEM

46

3121256 – JLG Lift – 3-5

47

3-6 – JLG Lift – 3121256

48

3121256 – JLG Lift – 3-7

49

3-8 – JLG Lift – 3121256

50

3121256 – JLG Lift – 3-9

51

3-10 – JLG Lift – 3121256

52

3121256 – JLG Lift – 3-11

53

3-12 – JLG Lift – 3121256

54

3121256 – JLG Lift – 3-13

55

DETAIL B

56

3-18 – JLG Lift – 3121256

60

3121256 – JLG Lift – 3-19

61

3-20 – JLG Lift – 3121256

62

3121256 – JLG Lift – 3-21

63

PROCEDURE AND LOCKOUT TEST

64

(1100SJP)

64

Lockout Cylinder Bleeding

64

Oscillating Axle Lockout Test

65

Symbol Nomenclature

66

LOCTITE 2701

67

3-28 – JLG Lift – 3121256

70

M- 1546 M- 1548

71

3121256 – JLG Lift – 3-31

73

3-32 – JLG Lift – 3121256

74

3121256 – JLG Lift – 3-33

75

3121256 – JLG Lift – 3-35

77

3-36 – JLG Lift – 3121256

78

3121256 – JLG Lift – 3-37

79

Installation

80

3.12 SWING DRIVE

81

Roll and Leak Testing

81

Tightening and Torquing Bolts

81

3-40 – JLG Lift – 3121256

82

Motor and Brake Disassembly

83

Main Disassembly

84

Hub-Shaft Disassembly

85

Carrier Disassembly

86

Hub-Shaft Sub-Assembly

87

Carrier Sub-Assembly

88

3121256 – JLG Lift – 3-47

89

Main Assembly

90

3121256 – JLG Lift – 3-49

91

Motor and Brake Assembly

92

Motor Control Valve Assembly

93

3.13 SWING BRAKE

94

Pre-Installation Checks

94

Maintenance

95

Examination

95

3-54 – JLG Lift – 3121256

96

3.14 SWING MOTOR

97

Disassembly and inspection

97

3-56 – JLG Lift – 3121256

98

3121256 – JLG Lift – 3-57

99

3121256 – JLG Lift – 3-59

101

3-60 – JLG Lift – 3121256

102

3121256 – JLG Lift – 3-61

103

Assembly

104

3121256 – JLG Lift – 3-63

105

3-64 – JLG Lift – 3121256

106

3121256 – JLG Lift – 3-65

107

3-66 – JLG Lift – 3121256

108

3121256 – JLG Lift – 3-67

109

3-68 – JLG Lift – 3121256

110

One Piece Stator Construction

111

BACKLASH

112

3.16 SWING DRIVE LUBRICATION

113

3-72 – JLG Lift – 3121256

114

3.17 SWING BEARING

115

3-74 – JLG Lift – 3121256

116

DIAL INDICATOR &

117

FEELER GAUGE

117

MEASURING POINT

117

TELESCOPE

117

FULLY EXTENDED

117

Wear Tolerance

118

Swing Bearing Removal

118

3121256 – JLG Lift – 3-77

119

Swing Bearing Installation

120

Swing Bearing Torque Values

121

3-80 – JLG Lift – 3121256

122

3.20 ROTARY COUPLING

123

3-82 – JLG Lift – 3121256

124

3121256 – JLG Lift – 3-83

125

3-84 – JLG Lift – 3121256

126

3.21 GENERATOR (SJP ONLY)

127

Every 250 hours

127

Every 500 hours

127

Overload Protection

128

Cleaning Slip Rings

128

3121256 – JLG Lift – 3-87

129

3.22 AUXILIARY POWER SYSTEM

130

3.23 ENGINE

131

Glow Plugs

131

Checking Oil Level

131

Changing Engine Oil

131

Changing the Oil Filter

132

Replacing the Fuel Filter

133

Cleaning the Fuel Strainer

133

3.24 DEUTZ EMR 2

134

3121256 – JLG Lift – 3-93

135

3-94 – JLG Lift – 3121256

136

3121256 – JLG Lift – 3-95

137

3-96 – JLG Lift – 3121256

138

3121256 – JLG Lift – 3-97

139

3-98 – JLG Lift – 3121256

140

3121256 – JLG Lift – 3-99

141

3-100 – JLG Lift – 3121256

142

3121256 – JLG Lift – 3-101

143

3-102 – JLG Lift – 3121256

144

3121256 – JLG Lift – 3-103

145

3-104 – JLG Lift – 3121256

146

Bio Fuel

147

3121256 – JLG Lift – 4-1

149

Envelope Tracking System

150

Moment Control System

151

Check (Push to Test) System

151

Controlled Arc System

151

Controlled Boom Angle System

152

Envelope Tracking

152

Slow Down System

152

Electronic Platform Leveling

153

Boom Control Select

154

4.2 BOOM ASSEMBLY

155

4-8 – JLG Lift – 3121256

156

3121256 – JLG Lift – 4-9

157

4-10 – JLG Lift – 3121256

158

3121256 – JLG Lift – 4-11

159

4-12 – JLG Lift – 3121256

160

3121256 – JLG Lift – 4-13

161

4-14 – JLG Lift – 3121256

162

3121256 – JLG Lift – 4-15

163

4-16 – JLG Lift – 3121256

164

3121256 – JLG Lift – 4-17

165

Disassembly

166

3121256 – JLG Lift – 4-19

167

3121256 – JLG Lift – 4-21

169

4-22 – JLG Lift – 3121256

170

3121256 – JLG Lift – 4-23

171

4-24 – JLG Lift – 3121256

172

3121256 – JLG Lift – 4-25

173

4-26 – JLG Lift – 3121256

174

3121256 – JLG Lift – 4-27

175

4-28 – JLG Lift – 3121256

176

3121256 – JLG Lift – 4-29

177

4-30 – JLG Lift – 3121256

178

INSTALLATION

179

4-32 – JLG Lift – 3121256

180

3121256 – JLG Lift – 4-33

181

DETAIL A

182

DETAIL C

182

0273696-E

183

1001110558-A

183

SEE DETAIL D

183

SEE DETAIL E

183

DETAIL E

184

DETAIL F

185

DETAIL G

186

3121256 – JLG Lift – 4-39

187

4-40 – JLG Lift – 3121256

188

4.6 POWERTRACK MAINTENANCE

189

One Piece Bracket Maintenance

189

4-42 – JLG Lift – 3121256

190

Two Piece Bracket Maintenance

191

Snap Rings and Screws

192

3121256 – JLG Lift – 4-45

193

4-46 – JLG Lift – 3121256

194

3121256 – JLG Lift – 4-47

195

4-48 – JLG Lift – 3121256

196

3121256 – JLG Lift – 4-49

197

4-50 – JLG Lift – 3121256

198

3121256 – JLG Lift – 4-51

199

4.8 HOSE ROUTING PROCEDURE

200

4.9 WIRE ROPE

200

Inspection

200

Three Month Inspection

201

Seven Year Inspection

201

Replacement Criteria

201

4-54 – JLG Lift – 3121256

202

3121256 – JLG Lift – 4-55

203

4-56 – JLG Lift – 3121256

204

3121256 – JLG Lift – 4-57

205

Description

206

Normal Operation

207

4.12 ROTARY ACTUATOR

208

Theory of Operation

208

Required Tools

208

3121256 – JLG Lift – 4-61

209

4-62 – JLG Lift – 3121256

210

4-64 – JLG Lift – 3121256

212

3121256 – JLG Lift – 4-65

213

4-66 – JLG Lift – 3121256

214

4-68 – JLG Lift – 3121256

216

3121256 – JLG Lift – 4-69

217

4-70 – JLG Lift – 3121256

218

3121256 – JLG Lift – 4-71

219

Testing the Actuator

220

Troubleshooting

221

Bleeding After Installation

222

SECTION 5. HYDRAULICS

223

Dip Method

224

Spray Method

224

Brush-on Method

224

5.2 CYLINDER REPAIR

225

SECTION 5 - HYDRAULICS

226

Cleaning and Inspection

234

5.3 HYDRAULIC TANK

246

Set Up of the Function Pump

246

5.5 DRIVE PUMPS

253

Troubleshooting Procedure

253

Mechanical Centering of Pump

257

Routine Maintenance

259

5.6 FUNCTION PUMP

262

Spare Parts

262

Sealing the Drive Shaft

263

Adjustments

268

Tightening Torques

268

PROCEDURES

272

Start-Up Procedure

272

6.1 INTRODUCTION

275

6.2 CANBUS COMMUNICATIONS

276

3121256 – JLG Lift – 6-3

277

6.3 CALIBRATION INSTRUCTIONS

278

3121256 – JLG Lift – 6-5

279

6-6 – JLG Lift – 3121256

280

3121256 – JLG Lift – 6-7

281

6-8 – JLG Lift – 3121256

282

3121256 – JLG Lift – 6-9

283

6-10 – JLG Lift – 3121256

284

3121256 – JLG Lift – 6-11

285

6-12 – JLG Lift – 3121256

286

3121256 – JLG Lift – 6-13

287

SYSTEM ANALYZER

288

6.5 USING THE ANALYZER

288

HAND HELD ANALYZER

289

6.8 MACHINE SETUP

290

3121256 – JLG Lift – 6-17

291

6-18 – JLG Lift – 3121256

292

3121256 – JLG Lift – 6-19

293

6-20 – JLG Lift – 3121256

294

FUNCTION SPEEDS

295

6-22 – JLG Lift – 3121256

296

3121256 – JLG Lift – 6-23

297

6-24 – JLG Lift – 3121256

298

3121256 – JLG Lift – 6-25

299

Test Notes

300

6.11 SYSTEM TEST

301

Test from the Platform

301

6-28 – JLG Lift – 3121256

302

3121256 – JLG Lift – 6-29

303

Test from the Ground Station

304

3121256 – JLG Lift – 6-31

305

6-32 – JLG Lift – 3121256

306

3121256 – JLG Lift – 6-33

307

6-34 – JLG Lift – 3121256

308

3121256 – JLG Lift – 6-35

309

6-36 – JLG Lift – 3121256

310

3121256 – JLG Lift – 6-37

311

6-38 – JLG Lift – 3121256

312

3121256 – JLG Lift – 6-39

313

6-40 – JLG Lift – 3121256

314

3121256 – JLG Lift – 6-41

315

6-42 – JLG Lift – 3121256

316

3121256 – JLG Lift – 6-43

317

6-44 – JLG Lift – 3121256

318

6.12 CALIBRATING STEER

319

6-46 – JLG Lift – 3121256

320

3121256 – JLG Lift – 6-47

321

6.13 CALIBRATING DRIVE

322

3121256 – JLG Lift – 6-49

323

6-50 – JLG Lift – 3121256

324

Fault Response

325

CAN Errors

326

3121256 – JLG Lift – 6-53

327

MINIMUMS

328

3121256 – JLG Lift – 6-55

329

6-56 – JLG Lift – 3121256

330

3121256 – JLG Lift – 6-57

331

6-58 – JLG Lift – 3121256

332

3121256 – JLG Lift – 6-59

333

6-60 – JLG Lift – 3121256

334

3121256 – JLG Lift – 6-61

335

6-62 – JLG Lift – 3121256

336

6.18 CALIBRATING TILT SENSOR

337

6-64 – JLG Lift – 3121256

338

3121256 – JLG Lift – 6-65

339

6-66 – JLG Lift – 3121256

340

3121256 – JLG Lift – 6-67

341

6-68 – JLG Lift – 3121256

342

3121256 – JLG Lift – 6-69

343

6-70 – JLG Lift – 3121256

344

3121256 – JLG Lift – 6-71

345

6-72 – JLG Lift – 3121256

346

3121256 – JLG Lift – 6-73

347

6-74 – JLG Lift – 3121256

348

3121256 – JLG Lift – 6-75

349

6-76 – JLG Lift – 3121256

350

3121256 – JLG Lift – 6-77

351

6-78 – JLG Lift – 3121256

352

830 lb MAX

353

375 kg MA X

353

6-80 – JLG Lift – 3121256

354

3121256 – JLG Lift – 6-81

355

6-82 – JLG Lift – 3121256

356

3121256 – JLG Lift – 6-83

357

6-84 – JLG Lift – 3121256

358

3121256 – JLG Lift – 6-85

359

6-86 – JLG Lift – 3121256

360

3121256 – JLG Lift – 6-87

361

6-88 – JLG Lift – 3121256

362

3121256 – JLG Lift – 6-89

363

6-90 – JLG Lift – 3121256

364

3121256 – JLG Lift – 6-91

365

6-92 – JLG Lift – 3121256

366

3121256 – JLG Lift – 6-93

367

6-94 – JLG Lift – 3121256

368

3121256 – JLG Lift – 6-95

369

6-96 – JLG Lift – 3121256

370

3121256 – JLG Lift – 6-97

371

6-98 – JLG Lift – 3121256

372

3121256 – JLG Lift – 6-99

373

6-100 – JLG Lift – 3121256

374

3121256 – JLG Lift – 6-101

375

6-102 – JLG Lift – 3121256

376

3121256 – JLG Lift – 6-103

377

6-104 – JLG Lift – 3121256

378

3121256 – JLG Lift – 6-105

379

6.20 CANBUS TROUBLESHOOTING

380

3121256 – JLG Lift – 6-107

381

6-108 – JLG Lift – 3121256

382

3121256 – JLG Lift – 6-109

383

6-110 – JLG Lift – 3121256

384

CANbus Communication Failure

385

6-112 – JLG Lift – 3121256

386

3121256 – JLG Lift – 6-113

387

6-114 – JLG Lift – 3121256

388

3121256 – JLG Lift – 6-115

389

6-116 – JLG Lift – 3121256

390

3121256 – JLG Lift – 6-117

391

6-118 – JLG Lift – 3121256

392

3121256 – JLG Lift – 6-119

393

6-120 – JLG Lift – 3121256

394

3121256 – JLG Lift – 6-121

395

6-122 – JLG Lift – 3121256

396

3121256 – JLG Lift – 6-123

397

6-124 – JLG Lift – 3121256

398

3121256 – JLG Lift – 6-125

399

6-126 – JLG Lift – 3121256

400

3121256 – JLG Lift – 6-127

401

6-128 – JLG Lift – 3121256

402

3121256 – JLG Lift – 7-1

403

Resistance Measurement

404

Continuity Measurement

404

Current Measurement

405

COMPOUND TO ELECTRICAL

405

CONNECTIONS

405

7.4 AMP CONNECTOR

406

AMP Connectors

406

3121256 – JLG Lift – 7-5

407

Wedge Lock

408

Service - Voltage Reading

408

3121256 – JLG Lift – 7-7

409

7.5 DEUTSCH CONNECTORS

410

DT/DTP Series Assembly

410

DT/DTP Series Disassembly

410

HD30/HDP20 Series Assembly

411

HD30/HDP20 Series Disassembly

411

7-10 – JLG Lift – 3121256

412

3121256 – JLG Lift – 7-11

413

7-12 – JLG Lift – 3121256

414

1001112761-A

415

7-14 – JLG Lift – 3121256

416

0274660 D

417

7-16 – JLG Lift – 3121256

418

0274660-D

419

7-18 – JLG Lift – 3121256

420

3121256 – JLG Lift – 7-19

421

7-20 – JLG Lift – 3121256

422

3121256 – JLG Lift – 7-21

423

7-22 – JLG Lift – 3121256

424

3121256 – JLG Lift – 7-23

425

BOOM CONTROL

426

3121256 – JLG Lift – 7-25

427

PUMP CIRCUIT

428

3121256 – JLG Lift – 7-27

429

PLATFORM CONTROL

430

1100SJP ONLY

431

7-30 – JLG Lift – 3121256

432

3121256 – JLG Lift – 7-31

433

7-32 – JLG Lift – 3121256

434

3121256 – JLG Lift – 7-33

435

TRACTION CONTROL

436

7-38 – JLG Lift – 3121256

440

JLG Worldwide Locations

442

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