JLG 1100S 1100SJP Service & Maintenance Manual 3121256 – PDF DOWNLOAD
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JLG 1100S 1100SJP Service & Maintenance Manual 3121256 – PDF DOWNLOAD
Language : English
Pages :442
Downloadable : Yes
File Type : PDF
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JLG 1100S 1100SJP Service & Maintenance Manual 3121256 – PDF DOWNLOAD
GENERAL
This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
- The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.
- Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device.
- Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.
B HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.
MAINTENANCE
- NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.
- REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.
- DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.
- OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.
- KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.
- USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
- NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.
- BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.
- BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS
- KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
- USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
JLG 1100S 1100SJP Service & Maintenance Manual 3121256 – PDF DOWNLOAD
Section A INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS 3
A General 3
B Hydraulic System Safety 3
C Maintenance 3
Section 1 Specifications 17
1 1 Capacities 17
1 2 Tires 17
1 3 Engine Data 17
1 4 Specifications and Performance Data 17
Dimensional Data 17
Chassis 18
1 5 Torque Requirements 18
1 6 Hydraulic Oil 19
1 7 Major Component Weights 20
1 8 Pressure Settings 20
1 9 Lubrication and Operator Maintenance 22
Section 2 General 33
2 1 Machine Preparation, Inspection, and Maintenance 33
General 33
Preparation, Inspection, and Maintenance 33
Pre-Start Inspection 33
Pre-Delivery Inspection and Frequent Inspection 33
Annual Machine Inspection 33
Preventative Maintenance 33
2 2 Service and Guidelines 34
General 34
Safety and Workmanship 34
Cleanliness 34
Components Removal and Installation 34
Component Disassembly and Reassembly 35
Pressure-Fit Parts 35
Bearings 35
Gaskets 35
Bolt Usage and Torque Application 35
Hydraulic Lines and Electrical Wiring 35
Hydraulic System 35
Lubrication 35
Battery 35
Lubrication and Servicing 35
2 3 Lubrication and Information 35
Hydraulic System 35
Hydraulic Oil 36
Changing Hydraulic Oil 36
Lubrication Specifications 36
2 4 Cylinder Drift Test 36
Platform Drift 36
Cylinder Drift 37
2 5 Pins and Composite Bearing Repair Guidelines 37
2 6 Welding on JLG Equipment 37
Do the Following When Welding on JLG Equipment 37
Do NOT Do the Following When Welding on JLG Equipment 37
Section 3 Chassis & Turntable 43
3 1 Tires & Wheels 43
Tire Inflation 43
Tire Damage 43
Wheel and Tire Replacement 43
Wheel Installation 43
3 2 Extending Axles 44
3 3 Axle Limit Switch Adjustment Procedure 44
3 4 Drive System (1100SJP) 45
3 5 Steering Control System 45
3 6 Drive/Steering Speed Control 46
3 7 Traction Control System 46
3 8 Drive Orientation System 46
3 9 Oscillating Axle System (1100SJP) 64
3 10 Oscillating Axle Bleeding Procedure and Lockout Test (1100SJP) 64
Lockout Cylinder Bleeding 64
Oscillating Axle Lockout Test 65
3 11 Drive Hub – Reggiana Riduttori 66
Removal 66
Symbol Nomenclature 66
Tools 67
Disassembly 72
Assembly 76
Installation 80
3 12 Swing Drive 81
Roll and Leak Testing 81
Tightening and Torquing Bolts 81
Motor Control Valve Disassembly 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
Main Assembly 90
Motor and Brake Assembly 92
Motor Control Valve Assembly 93
3 13 Swing Brake 94
Pre-Installation Checks 94
Installation 95
Maintenance 95
Disassembly 95
Examination 95
Assembly 95
3 14 Swing Motor 97
Disassembly and inspection 97
Assembly 104
One Piece Stator Construction 111
3 15 Procedure For Setting Gear Backlash 112
3 16 Swing Drive Lubrication 113
3 17 Swing Bearing 115
Turntable Bearing Mounting Bolt Condition Check 115
Wear Tolerance 118
Swing Bearing Removal 118
Swing Bearing Installation 120
Swing Bearing Torque Values 121
3 18 Swing Speed Proportioning 122
3 19 Chassis Tilt Indicator System 122
3 20 Rotary Coupling 123
3 21 Generator (SJP Only) 127
Every 250 hours 127
Every 500 hours 127
Overload Protection 128
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings 128
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
3 25 Bio Fuel in Deutz Engines 147
General 147
Bio Fuel 147
Biological Contamination In Fuels 148
Section 4 Boom & Platform 149
4 1 Boom Systems 149
Broken Cable Indicator System 149
Platform Control Enable System 149
Transport Position Sensing System 149
Beyond Transport – Drive Speed Cutback System 149
Jib Stow System (1100SJP Only) 150
Envelope Tracking System 150
Moment Control System 151
Boom Control System (BCS) Functional Check (Push to Test) System 151
Controlled Arc System 151
Controlled Boom Angle System 152
Envelope Tracking 152
Slow Down System 152
Dual Capacity System (1100SJP Only) 153
Electronic Platform Leveling 153
Boom Control Select 154
4 2 Boom Assembly 155
Removal 155
Disassembly 166
Assembly 168
4 3 Jib Rotator Orientation (1100SJP Only) 179
4 4 Jib Lift End of Stroke Dampening 179
4 5 Load Sensing Pin Removal and Installation 179
4 6 Powertrack Maintenance 189
One Piece Bracket Maintenance 189
Two Piece Bracket Maintenance 191
Snap Rings and Screws 192
4 7 Boom Cleanliness Guidelines 200
4 8 Hose Routing Procedure 200
4 9 Wire Rope 200
Inspection 200
Three Month Inspection 201
Seven Year Inspection 201
Replacement Criteria 201
Wire Rope Tensioning Procedure 202
4 10 Broken Boom Cable Proximity Switch 206
Adjusting the Proximity Switch 206
4 11 Electronic Platform Leveling 206
Description 206
Normal Operation 207
4 12 Rotary Actuator 208
Theory of Operation 208
Required Tools 208
Disassembly 211
Inspection 215
Assembly 215
Installing Counterbalance Valve 220
Testing the Actuator 220
Troubleshooting 221
Bleeding After Installation 222
Section 5 Hydraulics 223
5 1 Lubricating O-Rings in the Hydraulic System 223
Cup and Brush 223
Dip Method 224
Spray Method 224
Brush-on Method 224
5 2 Cylinder Repair 225
Disassembly 225
Cleaning and Inspection 234
Assembly 236
5 3 Hydraulic Tank 246
5 4 Pressure Setting Procedure 246
Set Up of the Function Pump 246
Adjustments made at the Main Valve Bank 247
Adjustments Made at the Frame Valve Bank 248
Adjustments Made at the Platform Valve Bank 252
5 5 Drive Pumps 253
Troubleshooting Procedure 253
Charge Pressure Relief Valve Adjustment 256
Mechanical Centering of Pump 257
Hydraulic Centering of Control Modules 257
High Pressure Relief Valve Adjustments 258
Removal and inspection of charge pump 258
Routine Maintenance 259
Removal and Installation of Shaft Seal 261
5 6 Function Pump 262
Spare Parts 262
Sealing the Drive Shaft 263
Disassembly and Assembly of the Complete Unit 264
Assembly 267
Adjustments 268
Tightening Torques 268
Pump Control Disassembly For Cleaning 270
5 7 Drive & Function Pump Start Up Procedures 272
Start-Up Procedure 272
Section 6 JLG Control System 275
6 1 Introduction 275
6 2 CANbus Communications 276
6 3 Calibration Instructions 278
6 4 To Connect the JLG Control System Analyzer 288
6 5 Using the Analyzer 288
6 6 Changing the Access Level of the Hand Held Analyzer 289
6 7 Adjusting Parameters Using the Hand Held Analyzer 290
6 8 Machine Setup 290
6 9 Machine Personality Settings/ Function Speeds 295
6 10 Machine Orientation When Setting Function Speeds 300
Test Notes 300
6 11 System Test 301
Test from the Platform 301
Test from the Ground Station 304
6 12 Calibrating Steer 319
6 13 Calibrating Drive 322
6 14 Electronic Platform Leveling 325
Platform Leveling Fault Warning 325
Fault Response 325
CAN Errors 326
Additional Platform and Jib Valves 326
Platform Leveling Calibration Procedure 327
6 15 Calibrating Platform Level 328
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 328
STEP 2: BLEEDING THE PLATFORM VALVES 329
STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 330
6 16 Calibrating Lift Crack Point 331
6 17 Calibrating Telescope Crack point 334
6 18 Calibrating Tilt Sensor 337
6 19 Calibrating the Boom Sensors 339
Boom Control System Check Procedure 352
6 20 CANbus Troubleshooting 380
CANbus Communication Failure 385
Load Moment Pin Troubleshooting 398
Section 7 Basic Electrical Information & Schematics 403
7 1 General 403
7 2 Multimeter Basics 403
Grounding 403
Backprobing 403
Min/Max 403
Polarity 403
Scale 403
Voltage Measurement 403
Resistance Measurement 404
Continuity Measurement 404
Current Measurement 405
7 3 Applying Silicone Dielectric Compound to Electrical Connections 405
7 4 AMP Connector 406
Applying Silicone Dielectric Compound to AMP Connectors 406
Assembly 406
Disassembly 408
Wedge Lock 408
Service – Voltage Reading 408
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
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