Jlg 1100S Service Manual User Manual

Service and Maintenance ManualModel1100S1100SJPP/N - 3121256January 8, 2013

vi – JLG Lift – 3121256TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121256NOTE: The manifold is constructed of plates bondedtogether to form an integral component n

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-5912. Remove drive link (10) from coupling shaft (12) if itwas not removed with rotor set an

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 312125617. Remove thrust bearing (15) and thrust washer (14)Inspect for wear, brinelling, corrosi

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-61replaced. If the housing has passed this inspectionthe disassembly of the Torqlink™ is com

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121256AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlin

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-632. The Torqlink™ inner housing bearing/bushing (13)can now be pressed into its counterbore

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31212564. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, cl

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-65THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-TEM’S HYDRAULIC FLUID. BE SURE IT IS T

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 312125611. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-67NOTE: The manifold (7) is made up of several platesbonded together permanently to form an

3121256 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 312125620. Assemble a new seal ring (4) into end cover (2) andassemble end cover over the alignme

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-69NOTE: The special bolts required for use with the relief orshuttle valve (24) end cover as

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121256the seventh or full complement of seven vanes.Assemble the seven vanes using minimum force

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-715. Pre-torque the capscrews (shown below) to 90 foot-pounds (122 Nm) with Loctite #271.6.

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3121256The Swing Gearbox is to be filled with 79 ounces (2.3 L) ofAPI Service Classification GL-5

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-733.17 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckTHE SWING BEARING IS ONE

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121256FEELER GAUGEMEASURING POINTDIAL INDICATORMEASURING POINTBOOMFULLY ELEVATEDFigure 3-48. Sw

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-75DIAL INDICATOR &FEELER GAUGEMEASURING POINTTELESCOPEFULLY EXTENDEDFigure 3-49. Swing

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3121256Wear Tolerance1. From the underside of the machine, at rear center,with the main boom full

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-77CENTEROFGRAVITYCLROTATION1 ” (28 cm)11100S Upperstructure - 26,400 lbs. (11,975 kg)Figure

viii – JLG Lift – 3121256LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31212565. At the rear of the main valve, remove the lift hosefrom port #4. Immediately cap the li

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-793. Refer to the Torque Sequence diagram as shown inFigure 3-52., Swing Bearing Torque Sequ

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 31212563.18 SWING SPEED PROPORTIONINGSwing Speed Proportioning uses the boom length andangle sens

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-813.20 ROTARY COUPLINGUse the following procedure to for installing the seal kit.1. Remove s

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 31212561. Center Body2. Seal3. Housing4. O-ring5. Seal6. Thrust Ring7.

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-83568835A5B41,981,2 1. Loctite #2422. Bolt3. Bolt4. Swivel Bracket5. Ro

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3121256123457712376513216246743251Figure 3-56. Rotary Coupling Port Location

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-853.21 GENERATOR (SJP ONLY)Every 250 hoursEvery 250 hours of operation, check the drive belt

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 3121256Overload ProtectionSTOP THE ENGINE WHENEVER CHECKING OR INSPECTING THECIRCUIT BREAKER.The

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-8711/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecom

3121256 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 31212563.22 AUXILIARY POWER SYSTEMThe auxiliary power system is intended as a secondarymeans of m

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-893.23 ENGINENOTE: Refer to the engine manufacturer’s manual fordetailed operating and maint

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31212568. Pour in new engine oil. Refer to Section 1 for capac-ity and refer to Figure 3-59., Eng

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-91Replacing the Fuel FilterWHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARENO OPEN FLAME

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 31212563.24 DEUTZ EMR 2The EMR2 consists of the sensors, the control unit and theactuator. Engine

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-93Figure 3-60. EMR 2 Engine Side EquipmentGLOW POWER SUP-COOLANT TEMPERA-TURECONTROL ROD PO

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3121256Deutz EMR2;Fails to Start/Runs AbnormallyDoes the machinehave fuel and acharged battery?YE

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-95Figure 3-62. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121256Figure 3-63. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-97Figure 3-64. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

x – JLG Lift – 3121256LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121256Figure 3-65. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-99Figure 3-66. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121256Figure 3-67. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-101Figure 3-68. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121256Figure 3-69. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-103Figure 3-70. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3121256Figure 3-71. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-1053.25 BIO FUEL IN DEUTZ ENGINESGeneralUse of bio fuels is permitted for the compact engine

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3121256PLANT OILPURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARENOT CLASSIFIED AS BIO

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM SYSTEMSBroken Cable Indicator SystemThe boom on this mo

3121256 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121256Jib Stow System (1100SJP Only)This machine is equipped with a full function side swingrotator t

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-3Moment Control SystemThe Moment Control System is the secondary means ofcontrolling the stabili

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121256sor failure, any moment violation, any envelope violation,or with auxiliary power functions. Th

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-5Dual Capacity System (1100SJP Only)The Dual Capacity System on this machine is a multipleenvelo

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121256Boom Control SelectThe boom control select is controlled from the platform bya switch mounted o

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-74.2 BOOM ASSEMBLYRemoval1. Place machine on firm, level ground.2. Slightly elevate the boom and

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121256BABA11223344566771100SJP1100S1. Boom Base2. Boom Inner Mid3. Boom Outer Mid4. Boom Fly5. Jib Ro

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-9SECTION A-A SECTION B-B8192345671. Outer Mid Extend Block2. Outer Mid Retract Sheave3. Rope Ret

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31212561. Upper Rear Wear Pad2. Shim3. Telescope Cylinder4. Trunnion Keeper Block5. Lower Rear Wear

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-111234567891100SJP1. Sheave Deflector2. Sheave Deflector3. Rope Retainer Block4. Fly Extension S

xii – JLG Lift – 3121256LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31212561234567891100S1. Sheave Deflector2. Sheave Deflector3. Rope Retainer Block4. Fly Extension She

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-131,23456789,1011125641100SJP1. Front Upper Wear Pad2. Shim3. Pivot Assembly4. Platform Rotator5

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31212561,234569,10125641100S1. Front Upper Wear Pad2. Shim3. Pivot Assembly4. Platform Rotator5. Jib

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-151. Outer Mid Extend Rope2. Fly Extend Rope3. Fly Retract Rope4. Outer Mid Retract Rope5. Proxi

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121256Figure 4-9. Boom Assembly - Sheet 9 of 9

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-177. Tag and disconnect the three electrical wires that runto the power track and the wire that

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3121256DisassemblyNOTE: By dismounting the push tubes and push tube sup-port brackets from the fly bo

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-1913. Remove the proximity sensor.14. Loosen the four extend wire ropes at the front of theboom.

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 312125625. Pull telescope cylinder and wire ropes out of theboom approximately 3/4 of the way.26. Unb

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-212. Install the fly extend wire rope button ends into theslots on the bottom of the fly boom se

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 TIRES1.3 ENGINE DATA1.4 SPECIFICATIONS AND PERFORMANCE D

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121256ABDCFt-Lbs. NmA 165 231B 165 231C 35 49D 50 70Figure 4-10. Boom Assembly Torque Values - Shee

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-23EFGFt-Lbs. NmE 420 588F 480 672G 190 260Figure 4-11. Boom Assembly Torque Values - Sheet 2 of

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31212568. Install the wire rope retainer blocks, retainer plates,and bolts. Torque the main sheave bo

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-2517. Route the threaded ends of the fly retract wire ropesthrough the inner mid wire rope adjus

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121256AASECTION A-A#242#242#242#242#271#271#271Figure 4-12. Locations for Loctite Application - She

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-27Figure 4-13. Locations for Loctite Application - Sheet 2 of 4

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3121256Figure 4-14. Locations for Loctite Application - Sheet 3 of 4

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-29Figure 4-15. Locations for Loctite Application - Sheet 4 of 4

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 312125627. Install the wire rope retainer block to the end of thetelescope cylinder.28. Install the o

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-3140. Install the remaining top and side wear pads andshims to forward end of the boom assembly.

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121256Chassis 1.5 TORQUE REQUIREMENTSTable 1-6. Chassis SpecificationsMaximum Travel Grade With boom in st

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 31212564. Run a nylon strap capable of supporting the weightof the lift cylinder around the bottom of

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-33Figure 4-17. Load Pin Removal Tool, JLG P/N 4846765

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 3121256SEE DETAIL ABOOM LENGTHSENSORSEE DETAIL CDETAIL ADETAIL CANGLE SENSOR INSTALLATIONTYPICAL ON L

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-350273696-E1001110558-ASEE DETAIL DSEE DETAIL ESENSOR TO BE CALIBRATEDTYPICAL 2-PLACES1100SJPWHI

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 3121256POSITION SWITCH MOUNT TO ACHIEVE 0.000” - 0.030” CLEARANCE BETWEEN SWITCH ROLLERS AND ROTATOR

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-37SEE DETAIL BSEE DETAIL FPROXIMITY SWITCHDETAIL BDETAIL FBOOM LENGTH LIMIT SWITCH TO ACTIVATE W

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31212560273696-E1001110558-ASEE DETAIL PUSH NUTSDETAIL GDETAIL GSENSOR TO BE CALIBRATEDTYPICAL 2-PLAC

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-391.Bar2.Blade3.MountAAdjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plateBA

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3121256Figure 4-24. Pivot Pin Installation1 Pivot Pin2 Bolt3 Keeper Rod4 Load Sensing Pin5 Pin Orien

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-414.6 POWERTRACK MAINTENANCEOne Piece Bracket Maintenance1. Place the powertrack on a workbench.

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-31.6 HYDRAULIC OILNOTE: Hydraulic oils must have anti-wear qualities at leastto API Service Classific

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 31212565. Slide the poly roller off of the round bar.6. Hold the round bar to remove the other screw.

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-4310. Push down with slight pressure on the link and slidethe bracket side up and over the extru

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 31212564. Hold the flat bar and remove the screws.5. Remove the snap rings and pins.6. Remove the scr

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-45Make sure that all snap rings are closed and seated. An open snap ring is shown below.A snap r

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 3121256Figure 4-25. Powertrack Installation - Sheet 1 of 60271800-J0271570-K

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-47Figure 4-26. Powertrack Installation - Sheet 2 of 60271800-J0271570-K

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 3121256Figure 4-27. Powertrack Installation - Sheet 3 of 60271800-J0271570-K

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-49Figure 4-28. Powertrack Installation - Sheet 4 of 60271800-J0271570-K

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 3121256Figure 4-29. Powertrack Installation - Sheet 5 of 6Table 4-1. Hose/Cable Pull ChartLETTER DES

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-51Figure 4-30. Powertrack Installation - Sheet 6 of 60271800-J

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31212561.7 MAJOR COMPONENT WEIGHTS1.8 PRESSURE SETTINGSTable 1-15. Component WeightsComponent Pounds Kilogr

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 31212564.7 BOOM CLEANLINESS GUIDELINESThe following are guidelines for internal boom cleanlinessfor m

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-536. Inspect sheaves with a groove wearout gauge forexcessive wear.7. Ropes passing inspection s

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3121256Wire Rope Tensioning ProcedureWith the boom assembly in the fully retracted position andbefore

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-55NOTE: Ensure the boom is not fully retracted for followingsteps. 6. Using tool P/N 4120043, to

SECTION 4 - BOOM & PLATFORM4-56 – JLG Lift – 31212568. Fully retract the boom assembly and verify theexposed boom section dimensions meet the dime

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-571. 2" Socket2. 3/4” Socket3. Retaining BoltFigure 4-32. Wire Rope Adjustment

SECTION 4 - BOOM & PLATFORM4-58 – JLG Lift – 31212564.10 BROKEN BOOM CABLE PROXIMITY SWITCHThis system uses a proximity switch to detect excessive

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-59PLATFORM VALVESThe platform specific valves are located in a manifold atthe platform. There ar

SECTION 4 - BOOM & PLATFORM4-60 – JLG Lift – 31212564.12 ROTARY ACTUATORTheory of OperationThe L20 Series rotary actuator is a simple mechanism th

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-61PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-5444134578110,118122,36Figure 1-1. Lubrication and Operator Maintenance Diagram

SECTION 4 - BOOM & PLATFORM4-62 – JLG Lift – 3121256PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-63Disassembly1. Remove the cap screws (113) over end cap lockpins (109). 2. Using a 1/8” (3.18mm

SECTION 4 - BOOM & PLATFORM4-64 – JLG Lift – 31212566. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-6510. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 4 - BOOM & PLATFORM4-66 – JLG Lift – 312125616. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-67Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM4-68 – JLG Lift – 31212562. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-69Each T-seal has 2 back-up rings (see drawing for ori-entation). Beginning with the inner seal

SECTION 4 - BOOM & PLATFORM4-70 – JLG Lift – 31212569. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-7114. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212561.9 LUBRICATION AND OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1

SECTION 4 - BOOM & PLATFORM4-72 – JLG Lift – 3121256Installing Counterbalance ValveRefer to Figure 4-36., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM3121256 – JLG Lift – 4-73TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM4-74 – JLG Lift – 3121256Bleeding After InstallationNOTE: Bleeding will be necessary if excessive backlash isdisplayed

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121256Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-35.2 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31212561. Loctite #242 (Not Shown)2. Locking Primer (Not Shown) 3. Loctite #RC 609 (Not Shown)4. Capscrew5. Tap

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-56111111112412241101043191815201652321171722251321684081-C1. Barrel2. Rod 3. Piston4. Bushing5. Head6. Co

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 312125612 13, 249521, 2523201615156 1818194101717222232A287111 1A1684149-D1. Barrel 1A. Bushing2. Rod 2A. Bushi

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-71,2,2426213030232520784522131314151419102728299182,3,171212161684162-D1. Loctite #2422. Locking Primer3.

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-74. Wheel HubLube Point(s) - Level/Fill PlugCapacity - 0.5 quarts (0.5 liters) ± 10%Lube - EPGLInterv

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31212561. Barrel1A. Bushing 2. Rod2A. Bushing3. Piston4. Head5. Spacer6. Tapered Bushing7. Counterbalance Car

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-91. Barrel 2. Rod 3. Head4. Piston5. Nut6. Loctite #222 (not shown)7. Not Used8. Rod End Bushing9. Barrel

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31212562143121397118101465*1684314-D1. Cylinder Cap2. Rod3. Head4. Barrel5. Nut6. Piston7. Backup Ring

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-115528282121308304722142426111118161315123119172029625**92723*1684108 J1. Loctite #2422. Locking Primer3.

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121256EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD O

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-134. Inspect inner surface of cylinder barrel tube for scor-ing or other damage. Check inside diameter fo

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3121256AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-153. Place a new “O-ring and back-up seal in the applica-ble outside diameter groove of the cylinder head

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 312125610. Thread piston onto rod until it abuts the spacer endand install the tapered bushing.NOTE: When inst

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-1720. Secure the cylinder head gland using the washerring and socket head bolts. (See Table 5-1, Cylinder

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31212568. Suction Strainers (In Tank)Lube Point(s) - 2Interval - Every 2 years or 1200 hours of operation.R

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 312125612345Figure 5-22. Hydraulic Tank1. Return Filter2. Vented Fill Cap3. Sight/Temperature Gauge4. Suction

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-19AABBCCDDEEF1100SJPONLY1100SJPONLY1100SONLY1100SJPONLYorA. Front Steer Valve/Axle ExtendB. Tr a

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31212561. Level Up2. Rotate Right3. Level Down4. Rotate Left5. Jib Down6. Jib Swing Left (1100SJP Only)7. Jib

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-211. Aux Lift Down2. Tele Out3. Lift Up4. Swing Right5. Dump6. Swing Relief7.

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121256Table 5-3. Cartridge Torque ValuesFt-Lbs. Nm Ft-Lbs. Nm1 25-30 33.9-40.6 9 30-35 40.6-47.42 25-30 33.9-

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-2323144Table 5-4. Plug Torque ValuesFt-Lbs. Nm1 115 1562 100 135.53 40 544 13 17.5Figure 5-26. Main Valv

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 31212565.3 HYDRAULIC TANKThe hydraulic tank has a capacity of 55 gallons (208 liters)and includes the hydrauli

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-254. To make an adjustment to this pressure, go back tothe engine compartment to the function pump whichi

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121256SWING - 1500 PSI (103.4 BAR)NOTE: Left and right are done with one adjustment. 1. Install a high pressu

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-27Left Front SensorRight Front SensorRight Rear Sensor(1100SJP Only)Left Rear Sensor(1100SJP Only)FRONT A

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-911. Fuel StrainerLube Point(s) - Replaceable ElementInterval - Every year or 600 hours of operation1

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 31212564. Remove the front circular steer/axle access coversat the front of the chassis, and the rear square c

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-298. Checking the left rear steer cylinder is identical tothe procedure for left front steer cylinder, ex

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 312125612. Remove the gauge from MS3 port and install onMS4 port, which is on the left side of the front axle/

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-315.5 DRIVE PUMPSNOTE: The following procedures cover both 1100S and1100SJP models. Some procedures will

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3121256h. Remove charge pressure relief valve from themiddle pump and inspect. Is it damaged?No - Refit cartri

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-335. Transmission Drives in one direction onlya. Are electrical connections to pump control pro-portional

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3121256f. Is a wheel drive hydraulic motor operating atexcessive speed?Yes - Check minimum displacement stop s

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-35NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims areavailable in 0.3, 0.5, and 1.0 mm thickness.Mec

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3121256the control spring are correctly located in the groovesnear the end of the feedback lever arms. High Pr

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-37to reassembly. Make sure 0-rings are completely seated intheir grooves. Withdraw pinion shaft and inspe

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121256Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 3)

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 3121256g. Under application conditions with a heavyoccurrence of dust or severe temperature fluctu-ations, the

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-39Removal and Installation of Shaft SealRemove the retaining ring with snap ring pliers.Screw in sheet me

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 31212565.6 FUNCTION PUMPSpare Parts1. Sealing kit, existing spare parts: shaft sealing ring,o-rings, and a cir

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-414. Rotary Group complete: 9 pistons, cylinder subas-sembly, valve plate, retaining plate, and retaining

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 31212564. Assemble the sealing ring, fitting tool holds the cor-rect position of the sealing ring in the pump

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-436. Remove the adjustment shim.7. Unscrew the cap nut and remove it.8. Loosen the fixing nut of the stop

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 312125614. Disassemble the control piston while moving theswash plate.15. The swash plate must be lifted a lit

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-4522. The external front bearing ring is pulled out of thepump housing.23. Remove the o-ring. Lifting of

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 31212563. Pumps clockwise driven must have a position of thevalve plate 4 degrees out of center in the samedir

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-47Figure 5-29. Function Pump, Pressure and Flow Control - Sheet 1Figure 5-30. Function Pump, Pressure a

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-11Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 3)

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 3121256Pump Control Disassembly For Cleaning NOTE: If the Function Pump does not perform correctlyafter follow

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-499. Remove the spring cover hex cap for the ”outer”flow regulation adjustment this requires a 19-mmwrenc

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 31212565.7 DRIVE & FUNCTION PUMP START UP PROCEDURESStart-Up ProcedureThe machine utilizes a Triple Combin

SECTION 5 - HYDRAULICS3121256 – JLG Lift – 5-5110. Operate the drive system in the "turtle mode", for-ward and reverse.11. De-aerate the sys

SECTION 5 - HYDRAULICS5-52 – JLG Lift – 3121256NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING ANY NEW MODULE CONTROLLER ON THEMA

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 31212566.2 CANBUS COMMUNICATIONSCANbus: CAN (Control Area Network) is a two wire differ-ential serial l

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-3Figure 6-2. Control System Block Diagram

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 31212566.3 CALIBRATION INSTRUCTIONSThis machine incorporates a variety of sensors and a highdegree of f

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-5Figure 6-3. Analyzer Flow Chart(See Figure 6-4.)(See Figure 6-5.) (See Figure 6-6.)(See Figure

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121256Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121256Figure 6-4. Analyzer Flow Chart - PersonalitiesNOTE: The layout shown includes all possible ana

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-7Figure 6-5. Analyzer Flow Chart - Machine SetupNOTE: The layout shown includes all possibleanal

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121256FROM:MACHINE SETUPMENU:CALIBRATIONSCALIBRATIONS:CALIBRATIONS:STEERUNLOCK BOOMCALIBRATIONS:DRIVEC

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-9Figure 6-7. Analyzer Flow Chart - Diagnostics- Sheet 1 of 3NOTE: The layout shown includes all

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121256Figure 6-8. Analyzer Flow Chart - Diagnostics - Sheet 2 of 3NOTE: The layout shown includes al

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-11Figure 6-9. Analyzer Flow Chart - Diagnostics - Sheet 3 of 3NOTE: The layout shown includes al

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121256Figure 6-10. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-13Figure 6-11. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31212566.4 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the cable supplied with the analyzer,

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-15When a top level menu is selected, a new set of menuitems may be offered: for example: DRIVEBOO

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-13Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 31212566.7 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZEROnce you have gained access to level 1, an

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-17Table 6-2. Machine Configuration Programming InformationConfiguration Digit Number DescriptionD

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121256GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.AIR INTAKE: Glow plugs installed in the ai

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-19DRIVE:11(1100S Only)012WD: 2 Wheel Drive installed.4WD: 4 Wheel Drive installed.0SOFT TOUCH:120

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121256FUNCTION CUTOUT:17*0123NO: No drive cutout.BOOM CUTOUT: Boom function cutout while driving abov

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-216.9 MACHINE PERSONALITY SETTINGS/FUNCTION SPEEDSNOTE: Personality settings can be adjusted with

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121256MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 1.0DECEL X.Xs

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-23MAIN TELE-SCOPE:ACCEL X.Xs Displays/adjusts main telescope accel-eration0.1 to 5.0 sec 1.5 1.5D

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121256JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 1.5DECEL X.Xs Di

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-25GROUNDMODE:U. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60 60U. LIFT DN

INTRODUCTION3121256 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121256Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 2 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 31212566.10 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDSLift Up: From platform control, lowest ele

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-276.11 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck the system compo

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 31212564. Pull out the Emergency Stop switch and Start theengine.5. The analyzer screen should read: 6

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-29Figure 6-12. System Test Flow Chart - Platform Tests

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121256Test from the Ground Station1. Position the Platform/Ground select switch to theGround position

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-31Figure 6-13. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121256Table 6-4. System Test MessagesMessage Displayed onAnalyzerMessage Displayed onAnalyzerDescript

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-33TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121256TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, t

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-35Table 6-5. Machine Diagnostics ParametersDiagnostics Submenu(Displayed on Analyzer 1st Line)Par

SECTION 1 - SPECIFICATIONS3121256 – JLG Lift – 1-15Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121256BOOM:U LIFT UP/DOWN XXX% Displays main lift joystick direction & demandSWING RIGHT/LEFT XXX

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-37ENGINE:START ACTIVE/NOT ACTIVE Displays status of the engine start circuitAIR FILTER OP/CL Disp

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121256SYSTEM:GM BATTERY XX.XV Ground module battery voltagePM BATTERY XX.XV Platform module battery v

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-39R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed ONL

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121256OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLAT

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-41MOMENT: Displayed if MODEL NUMBER = 7 or 8(LB-IN) ACTUAL XXXXXXXX Displays current moment value

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121256ENVELOPE: Displayed if MODEL NUMBER = 7 or 8LENGTH XXXX.X Displays the current indicated boom l

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-43CALIBRATION DATABASKET UP XXX Displays the basket up calibration pointBASKET DOWN XXX Displays

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121256DATALOG:ON XXXXhXXm Displays total controller on (EMS) timeENGINE XXXXhXXm Display engine run t

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-456.12 CALIBRATING STEERNOTE: The following procedure is written for a machine with4 Wheel Steeri

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121256NOTES:

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 31212563. Pull out the Emergency Stop switch and Start theengine.4. The analyzer screen should read: 5

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-4710. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate th

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 31212566.13 CALIBRATING DRIVE1. Position the Platform/Ground select switch to thePlatform position.2.

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-498. Use the arrow keys to reach DRIVE.9. Hit Enter. The screen will read: 10. Hit Enter again. T

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 312125613. Hit Enter. The number displayed will be the valuethat the crack point is set to. The screen

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-516.14 ELECTRONIC PLATFORM LEVELINGPlatform Leveling Fault WarningIf a fault occurs in the platfo

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121256TILT SENSOR ERRORSIf the secondary tilt sensor is faulty, the control system willcontinue to ut

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-53Platform Leveling Calibration ProcedureSTEP 1: SETTING THE PLATFORM VALVE MINIMUMS1. Put machin

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 312125610. Hit ENTER again. “Cal. Complete” message shouldappear 11. Engine should again return to idl

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-557. Use the arrow button to reach PERSONALITIESadjust the following personalities. Refer to the

SECTION 2 - GENERAL3121256 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121256STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS1. Position the Platform/Gr

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-5711. Using UP ARROW, increase the value until you seethe basket up movement.12. Hit ENTER again.

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 31212564. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.6

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-5910. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate th

SECTION 6 - JLG CONTROL SYSTEM6-60 – JLG Lift – 31212566.17 CALIBRATING TELESCOPE CRACK POINT1. Position the Platform/Ground select switch to thePlatf

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-618. Use the arrow keys to reach Upper Telescope CrackPoint (UPPER TELE CRKPT). The screen will r

SECTION 6 - JLG CONTROL SYSTEM6-62 – JLG Lift – 312125613. Hit enter. The number displayed will be the valuethat the crack point is set to. The screen

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-636.18 CALIBRATING TILT SENSORA NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THETIME UNTIL

SECTION 6 - JLG CONTROL SYSTEM6-64 – JLG Lift – 31212569. Use the arrow keys to reach the TILT SENSOR. Thescreen should read: 10. Press ENTER.11. When

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-656.19 CALIBRATING THE BOOM SENSORSDURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT ISNORMAL FOR

SECTION 2 - GENERAL2-2 – JLG Lift – 31212562.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 6 - JLG CONTROL SYSTEM6-66 – JLG Lift – 31212565. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.7

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-6711. After verifying all the conditions listed in step 1 aremet, hit Enter. The screen will read

SECTION 6 - JLG CONTROL SYSTEM6-68 – JLG Lift – 312125615. After visually verifying the platform is centered, hitEnter. The screen will read: 16. Afte

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-6919. Use the up/down arrows to select YES if the acces-sory is installed, NO if it is not instal

SECTION 6 - JLG CONTROL SYSTEM6-70 – JLG Lift – 312125623. After making sure the machine is in Calibration Posi-tion 1, hit Enter. The screen will rea

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-7125. Swing 180 degrees (centered over opposite end ofchassis) for Calibration Position 3. When t

SECTION 6 - JLG CONTROL SYSTEM6-72 – JLG Lift – 312125626. Press Enter. The screen will read: Swing the machine back 180 degrees (centeredover origina

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-7327. Press Enter. The screen will read: Telescope out to stop (boom must be fullyextended) for C

SECTION 6 - JLG CONTROL SYSTEM6-74 – JLG Lift – 312125628. Retract to stop (boom must be fully retracted) forCalibration Position 6.When the machine i

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-75When Position 7 Calibrating is complete, the screenwill read: Press Enter. The screen will read

SECTION 2 - GENERAL3121256 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 6 - JLG CONTROL SYSTEM6-76 – JLG Lift – 3121256Press Enter. The screen will read: 31. Telescope to the yellow witness mark (controller willbe

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-77Press Enter. The screen will read: 32. Telescope in to green witness mark (controller willfind

SECTION 6 - JLG CONTROL SYSTEM6-78 – JLG Lift – 3121256Boom Control System Check ProcedurePerform the following check with no load (personnel ormateri

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-79PLATFORMCONTROLMODULEGROUNDCONTROLMODULEFAULTCODELIGHTFAULTCODELIGHT170368917036791703680830 lb

SECTION 6 - JLG CONTROL SYSTEM6-80 – JLG Lift – 3121256Table 6-6. Diagnostic Trouble Code ChartDTCFlash CodeSequenceFault Message Fault Description Ch

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-812211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for more then seven sec-onds.- Can b

SECTION 6 - JLG CONTROL SYSTEM6-82 – JLG Lift – 3121256236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCHA boom function was selected be

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-83330 33 0 <<< GROUND OUTPUT DRIVER >>>331 33 1 BRAKE - SHORT TO BATTERY There

SECTION 6 - JLG CONTROL SYSTEM6-84 – JLG Lift – 31212563339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the Alternator334

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-853372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the Ground Alarm.- Ground Al

SECTION 2 - GENERAL2-4 – JLG Lift – 3121256fied intervals required in the Lubrication Chart inSection 1. Always examine filters for evidence ofmetal p

SECTION 6 - JLG CONTROL SYSTEM6-86 – JLG Lift – 31212563397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Plat

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-8733135 33 135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the Platf

SECTION 6 - JLG CONTROL SYSTEM6-88 – JLG Lift – 312125633154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the Lift Down Auxil

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-8933176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Ro

SECTION 6 - JLG CONTROL SYSTEM6-90 – JLG Lift – 312125633306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing Left

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-91434 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading is < 0.1V for more the

SECTION 6 - JLG CONTROL SYSTEM6-92 – JLG Lift – 3121256454 45 4 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply voltage is high.- 12

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-934524 45 24 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPERThe Tower Teles cope P VG Valve comman

SECTION 6 - JLG CONTROL SYSTEM6-94 – JLG Lift – 3121256660 66 0 <<< COMMUNICATION >>>662 66 2 CANBUS FAILURE - PLATFORM MODULE Platf

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-95826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load Sensing System

SECTION 2 - GENERAL3121256 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 6 - JLG CONTROL SYSTEM6-96 – JLG Lift – 31212568313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGEPlatform Level Sensor #1 re

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-978411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of range.- Envelope Co

SECTION 6 - JLG CONTROL SYSTEM6-98 – JLG Lift – 31212568428 84 28 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 out of range.- Enve

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-998443 84 43 TWR TRANSPORT SWITCH DISAGREEMENT There is a disagreement between the Tower Boom Len

SECTION 6 - JLG CONTROL SYSTEM6-100 – JLG Lift – 3121256850 85 0 <<< MOMENT / LOAD PINS >>>851 85 1 MOMENT PIN - HORIZONTAL FORCE OU

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-101866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BAT-TERY OR OPEN CIRCUITThere is a Short to

SECTION 6 - JLG CONTROL SYSTEM6-102 – JLG Lift – 31212568620 86 20 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUITThere is a Short to Ba

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-1038636 86 36 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUITThere is a Short to Ground

SECTION 6 - JLG CONTROL SYSTEM6-104 – JLG Lift – 31212569923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has reported that the V(Low)

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-1059942 99 42 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup com-munications link test wa

SECTION 2 - GENERAL2-6 – JLG Lift – 3121256Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 6 - JLG CONTROL SYSTEM6-106 – JLG Lift – 31212566.20 CANBUS TROUBLESHOOTINGThe PLATFORM MODULE and the CHASSIS MODULEhave ”Terminator Resistor

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-107Figure 6-26. CANbus Connections - Sheet 2 of 41. Chassis Module CANbus Link2. Ground Mo

SECTION 6 - JLG CONTROL SYSTEM6-108 – JLG Lift – 3121256Figure 6-27. CANbus Connections - Sheet 3 of 4Remove Ground Module J7 plugand measure the A &

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-109Figure 6-28. CANbus Connections - Sheet 4 of 4"BEFORE" Slip Ring Connection"AF

SECTION 6 - JLG CONTROL SYSTEM6-110 – JLG Lift – 3121256Figure 6-29. CANbus CircuitWhen checking the 120 ohm resistor in the Chassis Module only (wit

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-111CANbus Communication FailureIf a problem in the CANbus system is suspected, use thefollowing s

SECTION 6 - JLG CONTROL SYSTEM6-112 – JLG Lift – 31212567. If the CANbus link from the platform module is lost,you will see the Ground Module SW versi

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-113Table 6-7. Troubleshooting: Platform Can Communications LostSTEP ACTION REQUIRED SPEC YES NO1

SECTION 6 - JLG CONTROL SYSTEM6-114 – JLG Lift – 312125610 Disconnect the Chassis Module connection at the right side of the battery at the turntable

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-115CANBUS LINK FROM THE GROUND MODULE LOST1. Position the Platform/Ground select switch to theGro

SECTION 2 - GENERAL3121256 – JLG Lift – 2-7Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 6 - JLG CONTROL SYSTEM6-116 – JLG Lift – 31212567. If the CANbus link from the ground module is lost,you will see the Ground Module SW version

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-117CANBUS LINK FROM THE BOOM LENGTH & ANGLEMODULE (BLAM) LOST1. Position the Platform/Ground

SECTION 6 - JLG CONTROL SYSTEM6-118 – JLG Lift – 31212567. If the CANbus link from the Boom Length & AngleModule is lost, you will see the Platfor

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-119Table 6-8. Troubleshooting: BLAM Can Communications LostSTEP ACTION REQUIRED SPEC YES NO1 Inst

SECTION 6 - JLG CONTROL SYSTEM6-120 – JLG Lift – 3121256CANBUS LINK FROM THE CHASSIS MODULE LOST1. Position the Platform/Ground select switch to theGr

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-1217. If the CANbus link from the Chassis Module is lost,you will NOT see the Platform Module SW

SECTION 6 - JLG CONTROL SYSTEM6-122 – JLG Lift – 312125611. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMU

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-123Table 6-9. Troubleshooting: Chassis Can Communications LostSTEP ACTION REQUIRED SPEC YES NO1 I

SECTION 6 - JLG CONTROL SYSTEM6-124 – JLG Lift – 3121256Load Moment Pin TroubleshootingThe following Troubleshooting Charts outline diagnosticmeasures

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-125 Table 6-11. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of RangeSTEP FAU

INTRODUCTIONA-2 – JLG Lift – 3121256REVISON LOGOriginal Issue - April 15, 2009Revised - February 12, 2010Revised - January 8, 2013

SECTION 2 - GENERAL2-8 – JLG Lift – 3121256Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 6 - JLG CONTROL SYSTEM6-126 – JLG Lift – 3121256 Table 6-12. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of RangeSTEP FAULT

SECTION 6 - JLG CONTROL SYSTEM3121256 – JLG Lift – 6-127Table 6-13. Load Moment Pin Troubleshooting: Moment Pin Sensor FaultSTEP FAULT CODE/SYMPTOM RE

SECTION 6 - JLG CONTROL SYSTEM6-128 – JLG Lift – 3121256NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121256Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31212567.4 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121256Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 2 - GENERAL3121256 – JLG Lift – 2-9-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50 F

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31212567.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121256FRONT OFMACHINEWHITEBLACKAXLE LIMIT SWITCHWIRING - TYP.SWIVELSTEER V

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-11CHASSISMODULEAXLE LOCKOUTVALVEAXLE LOCKOUTPRESSURE SWITCHSTEER VALVE

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121256IN HEAD STYLEGLOW PLUGGLOW PLUGRELAY BROKEN CABLEPROXIMITYSWITCHHEAD

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-13Figure 7-21. Turntable Electrical Components (1100S) - Sheet 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121256Figure 7-22. Chassis Electrical Components (1100SJP) - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-15Figure 7-23. Chassis Electrical Components (1100SJP) - Sheet 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121256Figure 7-24. Turntable Electrical Components (1100SJP) - Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-17Figure 7-25. Turntable Electrical Components (1100SJP) - Sheet 2 of

SECTION 2 - GENERAL2-10 – JLG Lift – 3121256NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121256ALARMMAIN TELEINOUTROTATERIGHTLEFTLEVELUPDOWNJIBUPDOWNMTB MODE OUTPU

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-19AUXILIARY POWERPUMP MOTORMB+FUSIBLELINKRECTIFERREGULATORALTERNATORST

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121256ALARMFUEL GAGEFULL3/41/21/4MAIN TELEINOUTROTATERIGHTLEFTLEVELUPDOWNJ

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-21LEVELJIBUPDOWNRIGHTLEFTDOWNUPROTATEREDBLACKBLACKREDPLATFORM WORK LIG

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121256 RIGHT FRONT STEER RIGHT RIGHT FRONT STEER LEFT LEFT FRONT STEER RIG

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-23DRIVE ORIENTATIONSWITCH2SPDVALVEBRAKEVALV E6ORANGE 55-47 YELLOW (1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121256SWING DRIVEBearing to Pinion Ratio: 103:20Gearbox Ratio: 54.58:1Moto

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-25TELESCOPE CYLINDERBore: 5.00" 19.63 sq. in.Rod: 4.00" 12.5

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121256aPsMaTHROTTLEPOSITIONG (Fa)(Fe) BSWIVEL PORT#5SWIVEL PORT#61.2mm&quo

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-27L1"P1"SHT. #1PsabMaG (Fa)(Fe) BMbBLSSWIVEL PORT#4SWIVEL PO

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121256132121212122"T2"SHT. #1"P3"SHT. #1PLATFORM ROTAT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-29122121123JIB SWING ROTATORDisplacement: 74.2 cu. in. for 244 degrees

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3121256A3A1A2A4S1S2PTS3S4REAR AXLELEFT SIDELEFT SIDEREAR STEERRIGHT SIDERIG

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-312BABAABA3A1A2S2S1S3S4FRONT AXLELEFT SIDERIGHT SIDELEFT SIDEFRONT STE

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3121256212121211212BAaTPBAaPbaPTbABA3A1A2S2S1S3S4FRONT AXLELEFT SIDERIGHT S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-33REAR AXLELEFT SIDERIGHT SIDEV2V1V1V2AXLESTEERCONTROL1100SSTEERING CY

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-34 – JLG Lift – 3121256REAR1100SJP2.74 CU. IN. MAX1.0 CU. IN. MINTRACTION CONTROL2.74 CU. I

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-351100SJPSWIVEL PORT#7TRACTION CONTROL2.74 CU. IN. MAX1.0 CU. IN. MIN2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-36 – JLG Lift – 3121256REAR1100S2.74 CU. IN. MAX1.5 CU. IN. MINTRACTION CONTROL2.74 CU. IN.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121256 – JLG Lift – 7-371100STRACTION CONTROLMP2SET AT 500 PSI342SWIVEL PORT#7SWIVEL PORT#6S

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31212563.2 EXTENDING AXLESThe Axle Extension System allows each of the four axlesto be extended an

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-38 – JLG Lift – 3121256NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-33.4 DRIVE SYSTEM (1100SJP)The drive system utilizes 2 traction pumps so each side ispowered

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121256will allow the operator to move the machine until it can berepaired. The wheel at the faile

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-5This page left blank intentionally.

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121256123589111214151001112761-AFigure 3-5. Chassis Component Location (1100S) - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-71. Axle Limit Switch (Right Front)2. Steer Angle Sensor (Right Front)3. Steer Valve (Front)

3121256 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31212561001112761-A12723242928222120191812131716151478910113635343332306373844140393Figure 3-7. T

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-91. Platform Control Valve2. Not Used3. Platform Level Sensor (Secondary - Left)4. Tail Ligh

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121256Figure 3-9. Chassis Component Location (1100SJP) - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-111. Axle Limit Switch (Right Front)2. Steer Angle Sensor (Right Front)3. Steer Valve (Front

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31212560274660-D12725232429282622212019181213171615147891011363534333230637538441402393Figure 3-1

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-131. Platform Control Valve2. Jib Stow Switch3. Platform Level Sensor (Secondary - Left)4. T

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31212563126DETAIL ADETAIL B54Figure 3-13. Oscillating Axle - Sheet 1 of 2* AXLE WEAR PAD SHIMMIN

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-153987DETAIL ADETAIL B4611,12,A,G1011,12,B,G11,12,C,G11,12,E,G11,12,D,G11,12,F,G21. Axle Osc

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121256623DETAIL A*DETAIL B4Figure 3-15. Fixed Axle - Sheet 1 of 2* AXLE STOP SHIMMING PROCEDURE

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-173987DETAIL ADETAIL B4611,12,A,G1011,12,B,G11,12,C,G11,12,E,G11,12,E,G11,12,F,G21. Not Used

ii – JLG Lift – 3121256TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121256Figure 3-17. Axle Loctite Application

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-19SECTION A-AASSEMBLE SEAL, FOLLOWED BY SEAL CAP, AND FASTENED BY FLAT HEAD CAP SCREW TYP A

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121256BB26B,252423272829161720,21,22,A,DA301819AFigure 3-19. Steering Installation - Sheet 2 of

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-21SEE DETAIL ASENSOR COVER NOT SHOWN. SENSOR SHOWN IN PHANTOMFOR CLARITYASSEMBLE SEAL, FOLL

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31212563.9 OSCILLATING AXLE SYSTEM (1100SJP)The oscillating front axle is attached to the frame b

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-23Oscillating Axle Lockout TestThe front axles will oscillate when the boom is in the trans-

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 31212563.11 DRIVE HUB - REGGIANA RIDUTTORIRemoval1. Place the machine on a firm, level surface.2.

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-25ToolsTools required for assembling and disassembling thewheel gear RRTD1701TB1. Hammer;2.

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121256 Figure 3-24. Assembly Diagram 1

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-27M- 1316M- 1317M- 1317M- 1317M- 1317M- 1317Ø230Ø20555703810x45°45°45°45°216.545°2090Ø343012

3121256 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121256M- 1020M- 1126M- 1125VTCEI M6X12 n°12VTCEI M10X60 n°4M- 1126Figure 3-29. Assembly Diagram

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-29Ø46Ø485705805088.53.5M8Ø20 0-0.1Ø20+0.1+0.2Ø93.5Ø105Ø8.5Ø13.59208.55t.u. 122.5x15°Ø39.5M-

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121256Disassembly1. Remove the plugs and pour the lubricant in a con-tainer. 2. Release the scre

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-316. Loosen the M10x25 flathead socket screws andremove the planetary ring without damaging

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3121256Figure 3-31. Reggiana Riduttori Hub - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-331. Screw2. Motor Support3. O-ring4. Inner Retention Ring5. Brake Spring Spacer6. Brake Spr

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312125612. Disassemble the Ø160 inner snap ring and pull thespring holder spacer out. Remove the

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-354. Fit the brake sealing rings O-Ring and PARBAK(lubricated with grease) in the respective

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31212569. Now check the unit roll torque and proceed in thefollowing order:10. By keeping the spi

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-37the spindle pins. Lock with a ÿ40 outer snap ring.Lubricate the bearings.14. Using a marki

iv – JLG Lift – 3121256TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 312125618. Fit the O-Ring 2-177 suitably greased, mount thecover locking it with the BR250 ring.

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-393.12 SWING DRIVERoll and Leak TestingTorque-Hub units should always be roll and leak teste

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121256Motor Control Valve Disassembly1. Place unit on bench with the motor end up.2. Remove O-ri

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-41Motor and Brake Disassembly1. With unit resting on bench with Motor (10) end up,loosen Hex

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121256Main Disassembly1. With the unit resting on the Output Shaft (Pinion)(1A), remove the eigh

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-43Hub-Shaft Disassembly1. Using retaining ring pliers, remove Retaining Ring(1I) from groove

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121256Carrier Disassembly1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G)which holds t

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-45Hub-Shaft Sub-Assembly1. Press Bearing Cone (1D) onto Shaft (1A).2. Press Bearing Cup (1C)

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121256Carrier Sub-Assembly1. Apply a liberal coat of grease to the bore of ClusterGear (3F). Thi

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-473A. Carrier 3B . Tanged Thr us t Was he r3C. Needle Bearing3D . T hr us t

3121256 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121256Main Assembly1. With the Hub Shaft Sub-Assembly resting on theShaft (1A) install Internal

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-492. In ter na l Gear4. Ri ng Gear5. O-R ing6. In put Cover8.

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121256Motor and Brake Assembly1. Place O-ring (27) onto end of Brake (26) and locatebrake into p

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-51Motor Control Valve Assembly1. Lay assembly down with motor ports facing up.Remove the two

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31212563.13 SWING BRAKEPre-Installation ChecksMECHANICALCheck, That in the handling prior to asse

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-53InstallationPosition 1-off gasket (5) over male pilot on brake housing(4).Locate brake sha

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121256To ensure correct brake operation, it is importantthat the backing rings are assembled opp

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-553.14 SWING MOTORDisassembly and inspection1. Place the Torqlink™ in a soft jawed vice, wit

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31212565. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previous

SECTION 3 - CHASSIS & TURNTABLE3121256 – JLG Lift – 3-576. Thoroughly wash end cover (2) in proper solventand blow dry. Be sure the end cover valv