JLG 1100S, 1100SJP Boom Lift Service Manual
442 pages · Publication 3121256
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What's inside
From the manual's own table of contents: 421 sections, 504 entries. See sample pages (PDF, 603 KB)
General
Hydraulic System Safety
Maintenance4 topics
- Capacities
- Tires
- Engine Data
- Specifications and Performance Data
Dimensional Data
Chassis6 topics
- Torque Requirements
- Hydraulic Oil
- Major Component Weights
- Pressure Settings
- Lubrication and Operator Maintenance
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Show all 421 sections
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Wheel and Tire Replacement
Wheel Installation9 topics
- Extending Axles
- Axle Limit Switch Adjustment Procedure
- Drive System (1100SJP)
- Steering Control System
- Drive/Steering Speed Control
- Traction Control System
- Drive Orientation System
- Oscillating Axle System (1100SJP)
- Oscillating Axle Bleeding Procedure and Lockout Test (1100SJP)
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test1 topic
- Drive Hub - Reggiana Riduttori
Removal
Symbol Nomenclature
Tools
Disassembly
Assembly
Installation1 topic
- Swing Drive
Roll and Leak Testing
Tightening and Torquing Bolts
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Sub-Assembly
Carrier Sub-Assembly
Main Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Brake
Pre-Installation Checks
Examination1 topic
- Swing Motor
Disassembly and inspection
One Piece Stator Construction3 topics
- SECTION NO. TITLE PAGE NO. Procedure For Setting Gear Backlash
- Swing Drive Lubrication
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Removal
Swing Bearing Installation
Swing Bearing Torque Values4 topics
- Swing Speed Proportioning
- Chassis Tilt Indicator System
- Rotary Coupling
- Generator (SJP Only)
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings2 topics
- Auxiliary Power System
- Engine
Glow Plugs
Checking Oil Level
Changing Engine Oil
Changing the Oil Filter
Replacing the Fuel Filter
Cleaning the Fuel Strainer2 topics
- Deutz EMR 2
- Bio Fuel in Deutz Engines
Bio Fuel
Biological Contamination In Fuels1 topic
- Boom Systems
Broken Cable Indicator System
Platform Control Enable System
Transport Position Sensing System
Beyond Transport - Drive Speed Cutback System
Jib Stow System (1100SJP Only)
Envelope Tracking System
Moment Control System
Boom Control System (BCS) Functional Check (Push to Test) System
Controlled Arc System
Controlled Boom Angle System
Envelope Tracking
Slow Down System
Dual Capacity System (1100SJP Only)
Electronic Platform Leveling
Boom Control Select5 topics
- Boom Assembly
- SECTION NO. TITLE PAGE NO. Jib Rotator Orientation (1100SJP Only)
- Jib Lift End of Stroke Dampening
- Load Sensing Pin Removal and Installation
- Powertrack Maintenance
One Piece Bracket Maintenance
Two Piece Bracket Maintenance
Snap Rings and Screws3 topics
- Boom Cleanliness Guidelines
- Hose Routing Procedure
- Wire Rope
Inspection
Three Month Inspection
Year or 7000 Hour Replacement
Additional Replacement Criteria
Wire Rope Tensioning Procedure1 topic
- Broken Boom Cable Proximity Switch
Adjusting the Proximity Switch1 topic
- Electronic Platform Leveling
Description
Normal Operation1 topic
- Rotary Actuator
Theory of Operation
Required Tools
Installing Counterbalance Valve
Testing the Actuator
Troubleshooting
Bleeding After Installation1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Cylinder Repair
Cleaning and Inspection2 topics
- Hydraulic Tank
- Pressure Setting Procedure
Set Up of the Function Pump
Adjustments made at the Main Valve Bank
Adjustments Made at the Frame Valve Bank
Adjustments Made at the Platform Valve Bank1 topic
- Drive Pumps
Troubleshooting Procedure
Charge Pressure Relief Valve Adjustment
Mechanical Centering of Pump
Hydraulic Centering of Control Modules
High Pressure Relief Valve Adjustments
Removal and inspection of charge pump
Routine Maintenance
Removal and Installation of Shaft Seal1 topic
- SECTION NO. TITLE PAGE NO. Function Pump
Spare Parts
Sealing the Drive Shaft
Disassembly and Assembly of the Complete Unit
Adjustments
Tightening Torques
Pump Control Disassembly For Cleaning1 topic
- Drive & Function Pump Start Up Procedures
Start-Up Procedure10 topics
- Introduction
- CANbus Communications
- Calibration Instructions
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Machine Personality Settings/Function Speeds
- Machine Orientation When Setting Function Speeds
Test Notes1 topic
- System Test
Test from the Platform
Test from the Ground Station2 topics
- Calibrating Steer
- Calibrating Drive
Platform Leveling Fault Warning
Fault Response
CAN Errors
Additional Platform and Jib Valves
Platform Leveling Calibration Procedure1 topic
- Calibrating Platform Level
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
STEP 2: BLEEDING THE PLATFORM VALVES4 topics
- Calibrating Lift Crack Point
- Calibrating Telescope Crack point
- Calibrating Tilt Sensor
- Calibrating the Boom Sensors
Boom Control System Check Procedure1 topic
- CANbus Troubleshooting
CANbus Communication Failure
Load Moment Pin Troubleshooting2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Lubrication and Operator Maintenance Diagram
Deutz Engine Dipstick
Torque Chart (SAE Fasteners - Sheet 1 of 3)
Torque Chart (SAE Fasteners - Sheet 2 of 3)
Torque Chart (SAE Fasteners - Sheet 3 of 3)
Torque Chart (METRIC Fasteners - Sheet 1 of 3)
Torque Chart (METRIC Fasteners - Sheet 2 of 3)
Torque Chart (METRIC Fasteners - Sheet 3 of 3)
Engine Operating Temperature Specifications - Deutz
Axle Limit Switch Adjustment
Conventional Two Wheel Steer Mode
Crab Steer Mode - 1100SJP Only
Coordinated Steer Mode - 1100SJP Only
Chassis Component Location (1100S) - Sheet 1 of 2
Chassis Component Location (1100S) - Sheet 2 of 2
Turntable and Boom Component Location (1100SS) - Sheet 1 of 2
Turntable and Boom Component Location (1100SS) - Sheet 2 of 2
Chassis Component Location (1100SJP) - Sheet 1 of 2
Chassis Component Location (1100SJP) - Sheet 2 of 2
Turntable and Boom Component Location (1100SJP) - Sheet 1 of 2
Turntable and Boom Component Location (1100SJP) - Sheet 2 of 2
Oscillating Axle - Sheet 1 of 2
Oscillating Axle - Sheet 2 of 2
Fixed Axle - Sheet 1 of 2
Fixed Axle - Sheet 2 of 2
Axle Loctite Application
Steering Installation - Sheet 1 of 3
Steering Installation - Sheet 2 of 3
Steering Installation - Sheet 3 of 3
Bearing Track Spacer Mounting C016117
Oil Seal Spacer Mounting C125049
Bearing Spacer Mountng CO16117
Assembly Diagram 1
Wrench For Ring Nut
Anti-rotation Flange
Anti-rotation Block
Anti-rotation Pin
Assembly Diagram 2
Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
Reggiana Riduttori Hub - Sheet 1 of 2
Reggiana Riduttori Hub - Sheet 2 of 2
Swing Drive - Motor Control Valve Disassembly
Swing Drive - Motor and Brake Disassembly
Swing Drive - Main Disassembly
Swing Drive - Hub Shaft Disassembly
Swing Drive - Carrier Disassembly
Swing Drive - Hub Shaft Sub-Assembly
Swing Drive - Carrier Sub-Assembly
Swing Drive - Main Assembly
Swing Drive - Motor and Brake Assembly
Swing Drive - Motor Control Valve Assembly
Swing Brake
Swing Brake Assembly
Swing Drive Motor
Swing Drive Ports
Swing Drive Lubrication
Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
Swing Bolt Feeler Gauge Check
Swing Bearing Torque Sequence
Rotary Coupling Seal Installation
Rotary Coupling Cutaway
Rotary Coupling Installation
Rotary Coupling Port Location
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Auxiliary Pump Installation
Engine Oil Viscosity
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Boom Assembly - Sheet 1 of 9
Boom Assembly - Sheet 2 of 9
Boom Assembly - Sheet 3 of 9
Boom Assembly - Sheet 4 of 9
Boom Assembly - Sheet 5 of 9
Boom Assembly - Sheet 6 of 9
Boom Assembly - Sheet 7 of 9
Boom Assembly - Sheet 8 of 9
Boom Assembly - Sheet 9 of 9
Boom Assembly Torque Values - Sheet 1 of 2
Boom Assembly Torque Values - Sheet 2 of 2
Locations for Loctite Application - Sheet 1 of 4
Locations for Loctite Application - Sheet 2 of 4
Locations for Loctite Application - Sheet 3 of 4
Locations for Loctite Application - Sheet 4 of 4
Jib Rotator Orientation
Load Pin Removal Tool, JLG P/N 4846765
Boom/Jib Sensors and Switches Installation - Sheet 1 of 5
Boom/Jib Sensors and Switches Installation - Sheet 2 of 5
Boom/Jib Sensors and Switches Installation - Sheet 3 of 5
Boom/Jib Sensors and Switches Installation - Sheet 4 of 5
Boom/Jib Sensors and Switches Installation - Sheet 5 of 5
Boom Wiper Installation
Pivot Pin Installation
Powertrack Installation - Sheet 1 of 6
Powertrack Installation - Sheet 2 of 6
Powertrack Installation - Sheet 3 of 6
Powertrack Installation - Sheet 4 of 6
Powertrack Installation - Sheet 5 of 6
Powertrack Installation - Sheet 6 of 6
Wire Rope Tensioning Figure A
Wire Rope Adjustment Tools (Optional)
Broken Boom Cable Proximity Switch Location
Rotary Actuator - Exploded View
Rotary Actuator - Assembly Drawing
Rotator Counterbalance Valve
Platform Support Torque Values
Cylinder Barrel Support
Cap Screw Removal
Axle Extension Cylinder
Axle Lockout Cylinder
Level Cylinder
Lift Cylinder
Jib Cylinder
Steer Cylinder - Prior to S/N 73367
Steer Cylinder - S/N 73367 to Present
Telescope Cylinder
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Rod Assembly Installation
Hydraulic Tank
Chassis Control Valve Locations
Platform Valve Identification
Main Valve Identification
Main Valve Cartridge Torque Values
Main Valve Plug Torque Values
Hydraulic Oil Level Gauge
Steer Pressure Adjustments
Function Pump - Sectional View
Function Pump, Pressure and Flow Control - Sheet 1
Function Pump, Pressure and Flow Control - Sheet 2
Function Pump, Pressure and Flow Control - Sheet 3
Hand Held Analyzer
Control System Block Diagram
Analyzer Flow Chart
Analyzer Flow Chart - Personalities
Analyzer Flow Chart - Machine Setup
Analyzer Flow Chart - Calibrations
Analyzer Flow Chart - Diagnostics- Sheet 1 of 3
Analyzer Flow Chart - Diagnostics - Sheet 2 of 3
Analyzer Flow Chart - Diagnostics - Sheet 3 of 3
Control Module Location
Analyzer Connecting Points
System Test Flow Chart - Platform Tests
System Test Flow Chart - Ground Station Tests
Boom Sensor Calibration Position 1
Boom Sensor Calibration Position 2
Boom Sensor Calibration Position 3
Boom Sensor Calibration Position 4
Boom Sensor Calibration Position 5
Boom Sensor Calibration Position 6
Boom Sensor Calibration Position 7
Boom Sensor Calibration Position 8
Boom Sensor Calibration Position 9
Boom Sensor Calibration Position 10
Fault Code Light Location
CANbus Connections - Sheet 1 of 4
CANbus Connections - Sheet 2 of 4
CANbus Connections - Sheet 3 of 4
CANbus Connections - Sheet 4 of 4
CANbus Circuit
Voltage Measurement (DC)
Current Measurement (DC)
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Chassis Electrical Components (1100S) - Sheet 1 of 2
Chassis Electrical Components (1100S) - Sheet 2 of 2
Turntable Electrical Components (1100S) - Sheet 1 of 2
Turntable Electrical Components (1100S) - Sheet 2 of 2
Chassis Electrical Components (1100SJP) - Sheet 1 of 2
Chassis Electrical Components (1100SJP) - Sheet 2 of 2
Turntable Electrical Components (1100SJP) - Sheet 1 of 2
Turntable Electrical Components (1100SJP) - Sheet 2 of 2
Electrical Schematic - Sheet 1 of 6
Electrical Schematic - Sheet 2 of 6
Electrical Schematic - Sheet 3 of 6
Electrical Schematic - Sheet 4 of 6
Electrical Schematic - Sheet 5 of 6
Electrical Schematic - Sheet 6 of 6
Hydraulic Schematic - Boom Control - Sheet 1 of 2
Hydraulic Schematic - Boom Control - Sheet 2 of 2
Hydraulic Schematic - Pump Circuit - Sheet 1 of 2
Hydraulic Schematic - Pump Circuit - Sheet 2 of 2
Hydraulic Schematic - Platform Control - Sheet 1 of 2
Hydraulic Schematic - Platform Control - Sheet 2 of 2
Hydraulic Schematic - Axle Steer Control (1100SJP) - Sheet 1 of 2
Hydraulic Schematic - Axle Steer Control (1100SJP) - Sheet 2 of 2
Hydraulic Schematic - Axle Steer Control (1100S) - Sheet 1 of 2
Hydraulic Schematic - Axle Steer Control (1100S) - Sheet 2 of 2
Hydraulic Schematic - Traction Control (1100SJP) - Sheet 1 of 2
Hydraulic Schematic - Traction Control (1100SJP) - Sheet 2 of 2
Hydraulic Schematic - Traction Control (1100S) - Sheet 1 of 2
Hydraulic Schematic - Traction Control (1100S) - Sheet 2 of 2
Capacities
Tire Specifications
Deutz TD2011L04O Specifications
Operating Specifications
Chassis Specifications
Torque Requirements
Engine Torque Requirements
Hydraulic Oil Specifications
Mobilfluid 424 Specs
Mobil DTE 13M Specs
UCon Hydrolube HP-5046
Mobil EAL H 46 Specs
Exxon Univis HVI 26 Specs
Component Weights
Pressure Settings
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Steering Assembly Notes
Coupling Port Information Table
Hose/Cable Pull Chart
Cylinder Head and Tapered Bushing Torque Specifications
Holding Valve Torque Specifications
Cartridge Torque Values
Plug Torque Values
Torque Specs for Relief Valves into Port Block
Calibration Instructions
Machine Configuration Programming Information
Personality Ranges/Defaults
System Test Messages
Machine Diagnostics Parameters
Diagnostic Trouble Code Chart
Troubleshooting: Platform Can Communications Lost
Troubleshooting: BLAM Can Communications Lost
Troubleshooting: Chassis Can Communications Lost
Load Moment Pin Troubleshooting: Can Communications Lost
Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range
Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range
Load Moment Pin Troubleshooting: Moment Pin Sensor Fault
Load Moment Pin Troubleshooting: New Moment Pin Detected Fault
Inside this manual
Real pages from this service manual (442 pages). Open the sample pages (PDF, 601 KB)
- Specifications, page 20: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 398: Table 6-9. Troubleshooting: Chassis Can Communications Lost
- Diagram, page 428: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 190: SECTION 4 - BOOM & PLATFORM
- Color page, page 250: SECTION 5 - HYDRAULICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 1100S, 1100SJP are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 442 pages
Quantity one is the manual described above.
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