Jlg 1100S Service Manual User Manual Page 331
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 6 - JLG CONTROL SYSTEM
3121256 – JLG Lift – 6-57
11. Using UP ARROW, increase the value until you see
the basket up movement.
12. Hit ENTER again. CAL. COMPLETE message
should appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER
again.
17. You will hear engine go to 1800 rpm.
Using UP ARROW, increase the value until you see the
basket down movement.
Hit ENTER again. CAL. COMPLETE message should
appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
6.16 CALIBRATING LIFT CRACK POINT
1. Position the Platform/Ground select switch to the
Platform position.
2. Plug the analyzer into the connector at the base of
the platform control box.
3. Pull out the Emergency Stop switch and Start the
engine.
- 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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