Service & Maintenance Manual Models 3394RT 4394RT Prior to S/N 0200191606 excluding S/N’s: 0200186972, 0200187002, 0200187013 3121133 October 6, 2008
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A 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.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - April 12, 2002 Revised - May 10, 2002 Revised - August 30, 2002 Revised - October 14, 2002 Revised - March 6, 2003 Revised - October 24, 2003 Revised - April 28, 2004 Revised - August 18, 2004 Revised - August 12, 2005 Revised - October 4, 2005 Revised - March 1, 2006 Revised - May 11, 2006 Revised - October 31, 2006 Revised - April 3, 2007 Revised - October 12, 2007 Revised - January 23, 2008 Revised - March 17, 2008 Revised - Oct
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A A.B A.C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .4-10 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14 Drive Header Valve (2WD) . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 2-1. 2-2. 2-3. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. 3-39. 3-40. 3-41. 3-42. 3121133 TITLE PAGE NO. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 3-43. 3-44. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 4-14. 4-15. 4-16. 4-17. 4-18. 4-19. 4-20. 4-21. 4-22. 4-23. 4-24. 4-25. 4-26. 4-27. 4-28. 4-29. 4-30. 4-31. 4-32. 4-33. 4-34. 5-1. 5-2. 5-3. 5-4. 5-5. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-9. 6-10. 6-11. 6-12. 6-13. 6-14. 6-15. 6-16. 6-17. iv Joystick Controller - (JLG P/N 1600308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 6-18. 6-19. 6-20. 6-21. 6-22. 6-23. 6-24. 6-25. 6-26. 6-27. 6-28. 6-29. 6-30. 6-31. 6-32. 6-33. 6-34. 6-35. 6-36. 6-37. 6-38. 6-39. 6-40. 6-41. 6-42. 6-43. 6-44. 6-45. 6-46. 6-47. 3121133 Electrical Schematic - Dual Fuel - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Electrical Schematic - Dual Fuel - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 4-1 4-2 4-3 5-1 5-2 5-3 5-4 vi TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS 1.2 CAPACITIES Table 1-1.
SECTION 1 - SPECIFICATIONS 1.5 Table 1-5. GM 3.0L Specifications Fuel Gasoline or Gasoline/LP Gas No. of Cylinders 4 BHP Gasoline LP 4.0 in. (101.6 mm) Stroke 3.6 in. (91.44 mm) Displacement 61.75 in (1.6 m) 70.4 in (1.8 m) 7ft 10in (2.4 m) 13 ft (4 m) PRESSURE SETTINGS Table 1-7. Pressure Settings Description 3394RT 4394RT 6 psi (0.4 Bar) @ 1000 rpm 18 psi (1.2 Bar) @ 2000 rpm Main Relief 3000 psi (207 bar) 9.
SECTION 1 - SPECIFICATIONS 1.8 SENSORS 1.9 CYLINDER SPECIFICATIONS Table 1-10. Cylinder Specifications The machine is equipped with the following limit switches: Elevation Switch/Rotary Position Sensor - High drive speed is cut out when platform is raised above the preset heights listed in Table 1-8, High Drive Cut-Out Height. Description Bore Stroke Rod Dia Lift Cylinder 4.5 in (11.4 cm) 83 in (211 cm) 3.5 in (8.9 cm) Table 1-8.
SECTION 1 - SPECIFICATIONS 1.11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152 .
SECTION 1 - SPECIFICATIONS 1.13 OPERATOR MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. NOTE: Fuel Tank Drive Hubs Hydraulic Oil Tank Sliding Wear Pads Oil Change w/Filter - Ford Oil Change w/Filter - Deutz Oil Change w/Filter - GM Fuel Filter - Ford Fuel Filter - Deutz Fuel Filter (Gasoline) - GM Air Filter Electronic Pressure Regulator (LP Only) Fuel Filter (Propane) - GM Item #5 through #13 are on the opposite side of the machine and not shown. Figure 1-2.
SECTION 1 - SPECIFICATIONS 5. Oil Change w/Filter - Ford 2. Drive Hub • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7014501) • Lube Points - Fill Plugs (4) • Capacity - 4.5 qt. (4.25 L) • Lube - EPGL • Lube - EO • Interval - Every 2 years or 1200 hours • Interval - 3 Months or 150 hours of operation • Comments - Check level daily/Change in accordance with engine manual. 3. Hydraulic Oil 6.
SECTION 1 - SPECIFICATIONS 9. Fuel Filter - Deutz 7. Oil Change w/Filter - GM • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) • Lube Point(s) - Replaceable Element • Capacity - 4.5 qt. (4.25 L) w/filter • Interval - Every Year or 600 hours of operation • Lube - EO 10. Fuel Filter (Gasoline) - GM • Interval - 3 Months or 150 hours of operation • Comments - Check level daily/Change in accordance with engine manual. 8.
SECTION 1 - SPECIFICATIONS 13. Fuel Filter (Propane) - GM 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. • Interval - 3 Months or 150 hours of operation • Comments - Replace filter. Refer to Propane Fuel Filter Replacement Draining Oil Build Up From The Propane Regulator During the course of normal operation oils may build inside the primary and secondary chambers of the propane pressure regulator.
SECTION 1 - SPECIFICATIONS Propane Fuel Filter Replacement INSTALLATION: NOTICE BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL. 1. Install the mounting plate to lock off O-ring seal. 2. Install the retaining bolt seal. 3. Install the housing seal. 4. Drop the magnet into the bottom of the filter housing. 5. Install the filter into the housing. 6. Install the retaining bolt into the filter housing. 7. Install the filter up to the bottom of the electric lock off. 1. 2.
SECTION 1 - SPECIFICATIONS 1.14 TORQUE CHARTS Figure 1-4.
SECTION 1 - SPECIFICATIONS Figure 1-5.
SECTION 1 - SPECIFICATIONS Figure 1-6.
SECTION 1 - SPECIFICATIONS Figure 1-7.
SECTION 1 - SPECIFICATIONS Figure 1-8.
SECTION 1 - SPECIFICATIONS Figure 1-9.
SECTION 1 - SPECIFICATIONS NOTES: 1-16 – JLG Sizzor – 3121133
SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Type Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION 3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20°F (-29°C). However, use of this oil will give poor performance at temperatures above 120° (49°C). Systems using DTE 13 oil should not be operated at temperatures above 200°F (94°C) under any condition. Hydraulic System 1. The primary enemy of a hydraulic system is contamination.
SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Maximum acceptable cylinder drift is to be measured using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. Platform Drift 1. Pinned joints should be disassembled inspected if the following occurs: Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, upper boom fully extended with the rated load in the platform and power off.
SECTION 2 - GENERAL 2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE NOTICE The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed.
SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 300 Hours (6 months) 600 Hours (1 year) 1200 Hours (2 years) PLATFORM 1. Controller 1,11 2. Switches 1,11 3. Placards and Decals 1,2 4. Control Tags 1,2 5. Hoses and Cables 4,8 6. Wear Pads 8 7. Handrails and Chains 1,4 CHASSIS 1. Engine Oil 3 5 2. Battery 3 5 3. Air Cleaner 1 14 4. Exhaust System 1 1,5 5. Engine Mounts 1 6. Hydraulic Pump 1 5 7. Valves 1 5 8.
SECTION 2 - GENERAL 4150548 C AMBIENT AIR TEMPERATURE 120°F (49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F (43°C) 100°F (38°C) 90°F (32°C) 70°F (21°C) SAE 20W-50 SAE 15W-40 SAE 10W-40 SAE 10W-30 SAE 5W-40 SAE 5W-30 SAE OW-40 SAE OW-30 SUMMER GRADE FUEL ENGINE SPECIFICATIONS 80°F (27°C) 60°F (16°C) 50°F (10°C) 40°F (4°C) 30°F (-1°C) WINTER GRADE FUEL ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 20°F (-7°C) 10°F (-
SECTION 2 - GENERAL 4150548 C AMBIENT AIR TEMPERATURE 120°F (49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F (43°C) 100°F (38°C) 90°F (32°C) SAE 10W-40 SAE 10W-30 SAE 5W-40 SAE 5W-20 SAE 5W-30 80°F (27°C) ENGINE SPECIFICATIONS 70°F (21°C) 60°F (16°C) 50°F (10°C) 40°F (4°C) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
SECTION 2 - GENERAL 4150548 C AMBIENT AIR TEMPERATURE 120°F (49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F (43°C) 100°F (38°C) 90°F (32°C) 80°F (27°C) SAE 10W-30 ENGINE SPECIFICATIONS 70°F (21°C) 60°F (16°C) 50°F (10°C) 40°F (4°C) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
SECTION 3 - CHASSIS & SCISSOR ARMS SECTION 3. CHASSIS & SCISSOR ARMS 3.1 OPERATING CHARACTERISTICS Power Deck Leveling Jacks The machine may be equipped with auto leveling jacks. These leveling jacks are operated through one switch unlike the traditional four switch system. The leveling jacks are operated by a bang bang valve. NOTE: The engine speed will drop when the leveling jacks are in contact with the ground. The power deck is operated through a non proportional valve.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.2 CALIBRATIONS 1 2 1. Proximity Sensor 2. Rotary Angle Sensor Figure 3-1. Limit Switch Location Elevation Sensor Calibration (Prior to Software P1.20) 5. The bottom line on the analyzer display will show the range of voltage the sensor must be within for proper calibration. the actual voltage is displayed on the bottom line to the right as shown. NOTE: Make sure your analyzer is in ACCESS LEVEL 1.
SECTION 3 - CHASSIS & SCISSOR ARMS 6. Press the left arrow button and then enter. 2. SET 26FT ELEV (3394RT) or SET 30FT ELEV (4394RT); NOTE: Anytime the ground control board or if the rotary sensor is replaced the rotary sensor must be reset (zeroed out). a. Raise platform to a height of 26 feet for the 3394RT or 30 feet for the 4394RT (measured deck to ground). When stowed, if angle sensor is within the range of CALIB (see below), the machine should be recalibrated.
SECTION 3 - CHASSIS & SCISSOR ARMS 3. Both axis’ raw angles need to be within ±5.0°, otherwise the machine is to unlevel and the software will prohibit calibration. Should this occur, attempt to dissect the three areas of error to find the primary contributor: a. Machine mounting and/or grade: With a digital level, measure the top of the Ground Control box for levelness. If unable to get a good reading, check the box’s mounting surface for levelness. c.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.3 LEVEL SENSOR AND ANALYZER CONNECTIONS The level sensor is located at the ground control station. Using a screwdriver, open the ground control station and locate the level sensor as shown in Figure 3-2., Level Sensor and Analyzer Connections. There are two analyzer connection ports. One in the ground control station and the other at the platform con- trol station on the under side of the platform control box as shown in Figure 3-2.
SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor, JLG P/N 4000006: 1 2 1 3 2 1. Ground Control Box 2. Tilt Sensor (JLG P/N 4000006) Figure 3-3. Tilt Sensor Location Tilt Sensor Removal: 1. Tilt Sensor (JLG P/N 4000006) NOTE: Refer to Figure 3-4., Tilt Sensor Removal for numbers in parenthesis. 2. Screw, 6-32 x 3/4 3. Lockwasher 1. Disconnect the batteries. Figure 3-4. Tilt Sensor Removal 2. Open the Ground Control Box to gain access to the Tilt Sensor Assembly. 3.
SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor, JLG P/N 4000021: 2 6 7 2 1 1 5 4 3 1. Ground Control Box 2. Tilt Sensor Assembly (JLG P/N 1810140) Figure 3-5. Tilt Sensor Location NOTE: Refer to Figure 3-6., Tilt Sensor Removal for numbers in parenthesis. 1. Tilt Sensor (JLG P/N 4000021) 1. Disconnect the batteries. 2. Sensor Mount 2. Open the Ground Control Box to gain access to the Tilt Sensor Assembly. 3. Screw, 6-32 x 1 4. Lockwasher 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.4 INTEGRATED TORQUE/DRIVE HUB . The Integrated Torque/Drive Hub is an axial piston-hydraulic motor with integrated, hydraulic released multi plate parking brake and a 2-stage planetary gearbox and a disconnect mechanism. To insure an optimum balancing of loads, each planetary stage comprises of planet gears in sets. The externally toothed wheels are case-hardened.
SECTION 3 - CHASSIS & SCISSOR ARMS 36 34 37 32 26 35 1 10 13 15 2 24 9 12 5 33 30 28 31 29 25 27 14 8 18 19 17 11 20 16 6 4 21 22 3 7 23 1. Planet Gear 11. Tapered Roller Bearing 21. Thrust Washer 31. O-Ring 2. Planet Gear 12. Retaining Ring 22. Gear, Ring Options 32. Spring 3. Sun Gear 13. Retaining Ring 23. O-Ring 33. Shift Rod 4. Shaft Nut 14. Retaining Ring 24. Retaining Ring 34. Brake Housing 5. Planet Pin 15. Support Disk 25. Sun Gear Shaft 35. Wheel Stud 6.
SECTION 3 - CHASSIS & SCISSOR ARMS NOTICE Table 3-4. Gearbox Maintenance Schedule THE MAXIMUM GEAR DRIVE TOWING SPEED OF 72 RPM MUST NOT BE EXCEEDED. ENGAGE GEAR DRIVE OR SECURE MACHINE WHEN MACHINE IS SEPARATED FROM THE TOWING VEHICLE.
SECTION 3 - CHASSIS & SCISSOR ARMS Gearbox Disassembly 4. Remove Sun Gear Shaft (25). For numbers in parenthesis, refer to Figure 3-8., Drive Motor/Hub Assembly. 1. Remove Screw Plugs (18, 19) and drain oil into appropriate container. 5. Remove complete 1st planet stage. 2. Remove Snap Ring (24). 6. Remove ring gear fastening Bolts (20), Ring Gear (22), and O-ring (16).. 3. Remove the assembled Cover (8) with Shift Rod (33) and O-ring (23).
SECTION 3 - CHASSIS & SCISSOR ARMS 7. Remove Snap Rings (13). 10. Drilling Hole Sketch 8. Pull Plane Gears (1). 11. Split the Shaft Nut (4) in the area of the two drill holes by means of a chisel, and remove from Spindle (34). 9. Drill 2 holes into Shaft Nut (4) at 180° spacing according to Drilling Hole Sketch (step 10). NOTICE DO NOT DAMAGE THE BEARING CAGE OF THE BEARING (11). DO NOT TURN THE SHAFT NUT; POSSIBILITY OF SPINDLE THREAD DAMAGE.
SECTION 3 - CHASSIS & SCISSOR ARMS 12. Remove the Support Ring (6) from the Spindle (34). Components stay in Supporting Ring (6). 15. Repair deformed threads on the Spindle (34) in the area of the ball detend with a thread file of 1.5mm pitch. 13. Remove Radial Shaft Seal Ring (17). Gearbox Assembly NOTE: Clean all parts before assembling the gearbox. 1. Make sure during assembly of the preassembled planet gears that the larger radius on the bearing bore is oriented towards the planet carrier. 14.
SECTION 3 - CHASSIS & SCISSOR ARMS c. Secure the gears with new Snap Rings (12). NOTE: Heat Supporting Ring (6) up to approximately 189.5°F/70°C in a heating furnace. 3. Insert outer rings into heated Supporting Ring (6). (check for proper axial seat) 4. Coat bore in Supporting Ring (6) with Loctite 573 for Radial Shaft Seal Ring (17). 3-14 5. Insert the bottom part of the double Tapered Roller Bearing (11). 6.
SECTION 3 - CHASSIS & SCISSOR ARMS b. The Loctite setting time equals 24 hours at ambient temperature of 68°F/20°C. 8. Heat upper ring with roller cage of double Tapered Roller Bearing (11) to approximately 189.5°F/70°C and mount onto Spindle (34). Allow cooling time of approximately 15 minutes before continuing assembly. 9. De-grease threads of Spindle (34) and Shaft Nut (4). Then evenly apply coat of Loctite 270 to Shaft Nut (4) threads. 11.
SECTION 3 - CHASSIS & SCISSOR ARMS 13. Assembly of planet gear (Main Stage): a. Mount the planet gears with Bearing Assembly (1, 10), heated to approximately 189.5°F/70°C, onto the planet bolts of the Spindle (34) and secure the gears with new Snap Rings (13). 16. Install completely pre-assembled 1st planet stage into the gear drive. 17. Install Sun Gear Shaft (25). 14. Install the Ring Gear (22). 18. Check axial clearance: 15. Install the ring gear hex head bolts. Tighten bolts to proper torque of 15.
SECTION 3 - CHASSIS & SCISSOR ARMS 19. Carefully insert a new greased O-ring (23) into the oring groove of Ring Gear (22). 20. Insert Shift Rod (33) into preassembled Cover (8). 22. Install Snap Ring (24). NOTE: Prior to putting into operation fill the drive with new oil. 23. Install Plugs (18) with new Seal Rings (19) into Cover (8). 21. Install preassembled Cover (8) into Ring Gear (22).
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-9.
SECTION 3 - CHASSIS & SCISSOR ARMS Motor Disassembly 3. Disassemble guide ring: 1. Seal Ring 1. Mark port plate to the supporting axle. 2. Pressure Springs (quantity = 26) 3. Guide Ring 2 1 3 2. Remove port plate. 4. Disassemble retaining ring.
SECTION 3 - CHASSIS & SCISSOR ARMS 5. Disassemble bearing with synchronizing plate. 8. Disassemble lamination kit. 6. Press off pressure ring with extractor. 9. Disassemble Seeger snap ring. 7. Remove pressure ring. 3-20 10. Disassemble cradle stop with 2 screws M4 x 75mm.
SECTION 3 - CHASSIS & SCISSOR ARMS 11. Disassemble rotary group completely with cradle. 14. Disassemble shaft seal ring. 15. Insert disc. Pull off bearing ring with device. Remove disc. 12. Disassemble control piston with spring. 13. Pull out swivel balls. 3121133 16. Disassemble bearing ring from port plate.
SECTION 3 - CHASSIS & SCISSOR ARMS 17. Remove bearing ring (1). Disassemble spool (2). 1 19. Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (Otherwise: Pistons must be replaced in sets). 2 20. Check cylinder bores, splines. 18. Disassemble shuttle valve (1). Disassemble throttle screw with throttle pin (2). 2 3-22 1 21. Check that cylinder track is free of scratches, there are no traces of wear and no embedded foreign particles.
SECTION 3 - CHASSIS & SCISSOR ARMS 22. Check splines (1) for damage or fretting; running surfaces (2);groove cut by shaft seal (3). 25. Make sure the sealing surfaces are damage free. 3 1 2 23. Check that sliding surface is free of grooves (1); cups are free of groove and there are no pittings (2). 26. Press bearing ring in port plate (with tool). 1 2 24. Make sure the seat of the shaft seal in the case has no damage. 27. Press bearing ring in supporting axle (with tool).
SECTION 3 - CHASSIS & SCISSOR ARMS 28. Press bearing on drive shaft. 30. Place measuring device. Ascertain tolerance. Grip shaft with Seeger ring pincers and move up and down. [Simulation ring 1mm + tolerance + (bearing pretension 0.05 - 0.08) is resulting in thickness of the synchronizing disc]. Grind synchronizing disc to dimension. 29. Install shaft in supporting axle (1). Put in simulation ring (2).
SECTION 3 - CHASSIS & SCISSOR ARMS Motor Assembly 1. Press in swivel balls (with tool) (1). Insert shaft seal ring (with tool) (2). Insert control piston with spring (3).
SECTION 3 - CHASSIS & SCISSOR ARMS 2. Install rotary group with cradle. Observe installation position of swivel balls. 4. Mount Seeger snap ring. Opening of snap ring must be on the opposite side of the control piston. NOTE: Slightly grease swivel balls. 3. Mount sleeve and pressure ring in cradle stop. Insert cradle stop. 5. Fit pressure pins using an assembly aid. Pre-tension the spring using a suitable device. NOTE: Stick with grease. 6. Assemble piston with retaining plate.
SECTION 3 - CHASSIS & SCISSOR ARMS 7. Assembly aid: Hold the pistons by using an o-ring. 9. Mount support ring (1) and quad ring (2) in pressure ring. Be careful not to excessively extend the rings. 1 2 21 10. Grease seal rings, install in supporting axle. 8. Install laminations in correct order.
SECTION 3 - CHASSIS & SCISSOR ARMS 11. Mount retaining ring. 13. Align the two holes for fixation cylinder pin - port plate (item 2). Item 2 14. Mount synchronizing disc (1) and bearing (2). 12. Mount seal rings (1). Insert and line-up guide ring.
SECTION 3 - CHASSIS & SCISSOR ARMS 15. Mount bearing ring with device. Mount fixation pin. Mount spool. 17. Fill case with oil. 16. Fix control plate with grease at port plate. 18. Mount and screw port plate on supporting axle.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.5 DUAL FUEL/LPG SYSTEM Using Liquid Petroleum (LP) Gas IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN MOMENTARILY. WHEN REFUELING LPG POWERED SIZZOR LIFTS, ALWAYS FOLLOW MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE REGULATIONS.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 FORD EFI ENGINE • Inspect all wires and harnesses for proper connections and routing; bent or broken connector pins; burned, chafed, or pinched wires; and corrosion. Verify that harness grounds are clean and tight. Performing Diagnostics 1. Verify the complaint and determine if it is a deviation from normal operation. • Inspect engine control module (ECM), sensors, and actuators for physical damage. 2.
SECTION 3 - CHASSIS & SCISSOR ARMS CAMSHAFT POSITION (CMP) SENSOR AND SIGNAL The camshaft position (CMP) sensor sends a CMP signal to the ECM. The ECM uses this signal as a "sync pulse" to trigger the injectors in the proper sequence. The ECM uses the CMP signal to indicate the position of the #1 piston during its power stroke. The CMP uses a Hall Effect sensor to measure piston position. This allows the ECM to calculate true sequential fuel injection (SFI) mode of operation.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-5.
SECTION 3 - CHASSIS & SCISSOR ARMS HEATED OXYGEN SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor is a g thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5volt signal to the ECT sensor through resistors in the ECM and measures the voltage.
Figure 3-10.
SECTION 3 - CHASSIS & SCISSOR ARMS INTAKE AIR TEMPERATURE (IAT) SENSOR The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The ECM supplies a 5-volt signal to the sensor through a resistor in the ECM and monitors the signal voltage.
SECTION 3 - CHASSIS & SCISSOR ARMS The ECM is designed to maintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency. The ECM monitors numerous engine functions via electronic sensors such as the throttle position (TP) sensor and the heated oxygen sensor (HO2S). • When measuring voltages, use only a digital voltmeter with an input impedance of at least 10 megohms. • Do not jump start with more than 12 volts.
SECTION 3 - CHASSIS & SCISSOR ARMS ELECTROSTATIC DISCHARGE DAMAGE Electronic components used in the ECM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, It takes as much as 4000 volts for a person to feel the spark of a static discharge. There are several ways for a person to become statically charged.
SECTION 3 - CHASSIS & SCISSOR ARMS HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-11. Typical Fuel System FUEL METERING SYSTEM PURPOSE The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve. The ECM monitors signals from several sensors in order to determine the fuel needs of the engine.
SECTION 3 - CHASSIS & SCISSOR ARMS FUEL PRESSURE REGULATOR The fuel pressure regulator is a relief valve mounted in the fuel filter. It provides a constant fuel pressure of 441 kPa (64 psi). If the pressure is too low, poor performance and a DTC 32 will set. If the pressure is too high, excessive odor and/or a DTC 42 will result. ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2.
SECTION 3 - CHASSIS & SCISSOR ARMS OPEN LOOP AND CLOSED LOOP OPERATION CAMSHAFT POSITION (CMP) SENSOR The ECM will operate in the following two modes: The CMP sensor uses a variable reactor sensor to detect camshaft position. The CMP signal is created as piston #1 is a predetermined number of degrees after top dead center on the power stroke. • Open loop • Closed loop When the engine is first started, the system is in "open loop" operation.
SECTION 3 - CHASSIS & SCISSOR ARMS ELECTRONIC IGNITION ENGINE CONTROL MODULE (ECM) The electronic ignition system controls fuel combustion by providing a spark to ignite the compressed air/fuel w mixture at the correct time. To provide optimum engine performance, fuel economy, and control of exhaust emissions, the ECM controls the spark advance of the ignition system.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.7 GENERATOR - FORD ENGINE 2 1 3 1. Generator 2. Ford Engine 3. Voltage Regulator Figure 3-12. Generator (Ford Engine) Table 3-6. Generator Specifications 3121133 Description 220 Powermax Voltage 220V Continuous 2.5 KW Peak 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.8 DEUTZ EMR 2 (S/N 0200138634 TO PRESENT) The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp home) functions. The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control System are connected by means of separate cable harnesses to the EMR control unit.
SECTION 3 - CHASSIS & SCISSOR ARMS CONTROL ROD POSITION SENSOR/ACTUATOR COOLANT TEMPERATURE SENSOR POWER SUPPLY CAMSHAFT SPEED SENSOR GLOW PLUG JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS TO CONTROL THE ENGINE & FAULT REPORTING. OIL PRESSURE SENSOR Figure 3-13.
Figure 3-14.
Figure 3-15.
Figure 3-16.
Figure 3-17.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-18.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-19.
Figure 3-20.
Figure 3-21.
Figure 3-22.
Figure 3-23.
Figure 3-24.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.9 GENERATOR - DUETZ ENGINE 1 2 -OR- 3 1. Generator (120V or 220V) 3. Voltage Regulator 2. Deutz Engine Figure 3-25. Generator (Deutz Engine) Table 3-7. Generator Specifications 3121133 Description 110 Bluemax 220 Powermax Voltage 120V 220V Continuous 3.5 KW 2.0 KW Peak 4.5 KW 3.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 GM ENGINE GENERAL MAINTENANCE • Check the battery for any cracks or damage to the case Maintenance of the Drive Belt • Check the Positive and Negative battery cables for any corrosion build up, rubbing or chafing, check connection on the chassis to insure they are tight The serpentine drive belt utilizes a spring loaded tensioner which keeps the belt properly adjusted.
SECTION 3 - CHASSIS & SCISSOR ARMS 5. Oil level must be between the "FULL" and "ADD" marks. Changing The Engine Oil NOTICE WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER. CHANGE OIL WHEN THE ENGINE IS WARM FROM OPERATION AS THE OILS WILL FLOW FREELY AND CARRY AWAY MORE IMPURITIES. To change the oil use the following steps: 1. Start the engine and run until it reaches normal operating temperature. Figure 3-26. Engine Oil Dip Stick 6.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.11 GENERATOR - GM ENGINE 2 1 3 1. Generator 2. GM Engine 3. Voltage Regulator Figure 3-27. Generator (GM Engine) Table 3-8. Generator Specifications 3-60 Voltage 120V Continuous 3.5 KW Peak 4.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.12 GM ENGINE DUAL FUEL SYSTEM Fuel Filter The Dual Fuel system allows the operator to operate the vehicle on either gasoline or LPG by positioning a selector switch in the operator's platform. When the operator places the selector switch in the gasoline mode the gasoline fuel pump is energized. While in the gasoline mode the LPG fuel lock-off is isolated and will not energize.
SECTION 3 - CHASSIS & SCISSOR ARMS EPR Assembly Low Pressure Regulator (LPR) The EPR assembly is a combination Low Pressure Regulator and a Voice Coil Assembly. The Voice coil is an electronic actuator which is controlled by an internal microprocessor. The microprocessor provides output data to the ECM and receives input data over a CAN BUS connection.
SECTION 3 - CHASSIS & SCISSOR ARMS Air Fuel Mixer Electronic Throttle Control (ETC) The air valve mixer is an air-fuel metering device and is completely self-contained. The mixer is an air valve design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load. The mixer is mounted in the air stream ahead of the throttle control device. When the engine begins to crank, it draws in air with the air valve covering the inlet, negative pressure begins to build.
SECTION 3 - CHASSIS & SCISSOR ARMS Engine Control Module Heated Exhaust Gas Oxygen Sensor To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control Unit (ECM). The ECM is a 32 bit controller which receives input data from sensors fitted to the engine and fuel system and then outputs various signals to control engine operation.
SECTION 3 - CHASSIS & SCISSOR ARMS Gasoline Fuel Pump Fuel Filter The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by an electric fuel pump. The fuel pump will receive a signal from the ECM to prime the fuel system for approximately 2 seconds prior to start. Priming of the fuel system provides for a quicker start, when the engine begins to crank.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.13 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel Filter Replacement Propane Fuel System Pressure Relief THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS. To relieve propane fuel system pressure: 1. Close the manual shut-off valve on the propane fuel tank. 2.
SECTION 3 - CHASSIS & SCISSOR ARMS 4. Drop the magnet into the bottom of the filter housing. 5. Install the filter into the housing. 6. Install the retaining bolt into the filter housing. 7. Install the filter up to the bottom of the electric lock off. 8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test.
SECTION 3 - CHASSIS & SCISSOR ARMS Temperature Manifold Absolute Pressure (TMAP) Sensor 8. Connect the EPR electrical connector. 9. Open the manual valve. 10. Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test. Figure 3-39. Pressure Regulator Section Figure 3-40. (TMAP) Sensor & Electronic Throttle Control (ETC) PRESSURE REGULATOR SECTION REMOVAL 1. Remove the EPR refer to EPR Removal Procedure. 2.
SECTION 3 - CHASSIS & SCISSOR ARMS Electronic Throttle Control Replacement 2. Install the two quad seals. Install one seal at a time to insure the seal does not roll. The seal must sit flat on the throttle body. See Figure 3-40. REMOVAL 1. Disconnect the negative battery cable. 2. Remove the air intake duct. 3. Release the hose clamp on the vapor fuel line and remove the vapor hose. 4. Disconnect the TMAP electrical connector. 5. Disconnect the electronic throttle control connector. 6.
SECTION 3 - CHASSIS & SCISSOR ARMS 4. Place gasket on intake manifold and attach mixer/ throttle assembly to manifold. Coolant Hose Replacement REMOVAL 1. Drain the coolant. 2. Using hose clamp pliers, disconnect both hose clamps on each hose. 3. Remove the hose from each of the fittings. INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1. Install the hose clamps to each hose and set the clamp back on each hose to make installation easier. Figure 3-41. Mixer Assembly 2.
SECTION 3 - CHASSIS & SCISSOR ARMS Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL REMOVAL 1. Disconnect Negative battery cable. 2. Remove controller from mounting bracket. 1. Disconnect Negative battery cable. 3. Push connector lock back to unlock connector. 2. Disconnect the O2 sensor electrical connector. 4. Unplug controller and remove. 3. Using an O2 Sensor socket, remove the O2 Sensor and discard.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.14 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids This procedure is intended to diagnose a vehicle operating on LPG. If the vehicle will not continue to run on LPG, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel and that liquid fuel is being delivered to the LPR.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-9. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2 2 Perform the On Board Diagnostic (OBD) System Check.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-9. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO -- Go to Step 14 Go to Step 16 12Ω - 16Ω Go to Step 15 Go to Step 23 13 1. Turn OFF the ignition. 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. 4. Crank the engine. The test light should illuminate. Does the test light illuminate? 14 Using a DVOM, check the resistance of the low pressure lock-off (LPL).
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-9. LPF Fuel System Diagnosis STEP ACTION VALUE(S) YES NO 25 The fuel supply system is operating normally, if a failure of the control solenoids is suspected. Refer to Fuel Control System Diagnosis. -- System OK -- -- System OK -- 1. Install the test plug in the LPR secondary chamber. 2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic procedure. Is the action complete? 26 1.
SECTION 3 - CHASSIS & SCISSOR ARMS 3.15 JOYSTICK CONTROLLER Figure 3-43. Joystick Controller - (JLG P/N 1600308) Table 3-10. Joystick Specifications Table 3-11. Joystick Plug Loading Chart Input Voltage 4.3V (±0.1V) Terminal Color Function Centered Output Voltage 2.2V (±0.1V) 1 Yellow Steer Right Full Positive (Rev) Deflection Output Voltage 4.0V (±0.1V) 2 Green Steer Left Full Negative (Fwd) Output Voltage 0.4V (±0.
SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-44. Joystick Controller - (JLG P/N 1600403) Table 3-12. Joystick Specifications Input Voltage Table 3-13. Joystick Plug Loading Chart 5V Terminal Color Function Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right Reverse Voltage 4.60V to 4.80V 2 Green Steer Left Forward Voltage 0.40V to 0.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL. Several of the following symptom procedures call for a careful visual and physical check.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp (MIL) The following components can cause intermittent MIL and no DTC(s): ²A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating. ²The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Exhaust System Checks Action ²Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. ²Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis Hard Start DEFINITION: The engine cranks OK, but does not start for a long time.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Exhaust System Checks Action ²Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. ²Check for possible plugged catalytic converter.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly. ²Check for the proper ignition voltage output with J 26792 or the equivalent.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Fuel System Checks ²Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis. ²Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent. ²Check for proper installation of the mixer module assembly. ²Check all air inlet ducts for condition and proper installation. ²Check for fuel leaks between the LPR and the mixer.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Cooling System Checks ²Check the engine thermostat for always being open or for the wrong heat range Additional Check ²Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual. ²Check for dragging brakes. Rough, Unstable, or Incorrect Idle, Stalling DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-14. Symptom Diagnosis Checks Action Fuel System Checks ²Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will help identify the problem. ²Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis. ²Verify proper fuel control solenoid operation. ²Verify that the LPG manual shut-off valve is fully open.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-15.
SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-15.
SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-88 – JLG Sizzor – 3121133
SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 CYLINDERS - THEORY OF OPERATION Cylinders are of the double acting type. The steer system incorporates a double acting cylinder. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod).
SECTION 4 - HYDRAULICS 4.4 CYLINDER CHECKING PROCEDURE Carefully remove hydraulic hoses from appropriate cylinder port block. NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected. 3. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the ports.
SECTION 4 - HYDRAULICS 8. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel. 3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings. 9. From platform control station, select LOW drive speed. 10. Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until right front wheel is on top of block. 11. Raise machine platform approximately 9 ft (2.
SECTION 4 - HYDRAULICS . NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. Figure 4-3. Lift Cylinder Cap Screw Removal NOTE: Steps 6 and 7 apply only to the steer cylinder. 5.
SECTION 4 - HYDRAULICS 13. Remove the bushing from the piston. 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. 10. Inspect threaded portion of head for damage. Dress threads as necessary. 11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary. 12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. 13.
SECTION 4 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove. Figure 4-9. Wiper Seal Installation 3. Place a new “o”ring and back-up seal in the applicable outside diameter groove of the cylinder head. Figure 4-7.
SECTION 4 - HYDRAULICS screws) through the drilled holes in the bushing and into the tapped holes in the piston. Figure 4-12. Tapered Bushing Installation 5. Tighten the capscrews evenly and progressively in rotation to the specified torque value. 6. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows; Figure 4-11. Piston Seal Kit Installation 1.
SECTION 4 - HYDRAULICS 9. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 4-11.) Table 4-1. Cylinder Piston Nut Torque Specifications 10. Position the cylinder barrel in a suitable holding fixture.
SECTION 4 - HYDRAULICS 20. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged. 21. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder. 22. If applicable, secure the cylinder head retainer using a suitable chain wrench. 23.
SECTION 4 - HYDRAULICS 4.7 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS needs to be pressurized in order to start the flow of oil, a vacuum reading should be taken at the inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher than it is capable of.
SECTION 4 - HYDRAULICS Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pressure is inadequate, shut down and determine the cause for improper pressure. Pump Disassembly INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR' S ABILITY TO CONTROL THE MACHINE. Shut down the engine and connect the external control input signal. Also reconnect the machine function(s), if disconnected earlier.
SECTION 4 - HYDRAULICS NOTE: During disassembly, take special note of the wear patterns on the bearing blocks (2) and body (13). Relate these patterns to the inlet and outlet sides of the pump. The large port whether in the body (13) or the rear cover (6) corresponds to the inlet side of the pump. The inlet side of the body can be identified by the gear contact pattern in the gear bore. The bearing block will have somewhat heavier wear patterns on the inlet side. Pump Reassembly 1.
SECTION 4 - HYDRAULICS . 2. Clamp front cover into vise so that the ring groove is up. Apply a small amount of grease tot he seal groove and install a new seal ring (8) into the groove. 8. Place a small amount of grease in seal groove on the rear bearing block (2). Install a new load seal and anti extrusion seal in groove. Insert the bearing block into the body, making sure that the load seal and anti extrusion seal are positioned properly.
SECTION 4 - HYDRAULICS 4.9 MAIN VALVE 7 1 6 8 2 3 MG 9 4 MS 10 Mp1 11 5 Valve Ft-lb Mn 1. Dump Valve 30 - 35 42 - 49 2. Lift Valve 25 - 30 35 - 42 3. Two Speed Valve 30 - 35 42 - 49 4. Brake Valve 30 - 35 42 - 49 5. Steer Valve 25 - 30 35 - 42 6. Lift Relief 30 - 35 42 - 49 7. Main Relief 25 - 30 35 - 42 8. Steer Relief 30 - 35 42 - 49 9. MG Port N/A N/A 10. MS Port N/A N/A 11. MP1 Port N/A N/A Figure 4-15.
SECTION 4 - HYDRAULICS Figure 4-16. Main Valve Hydraulic Schematic Pressure Setting Procedures 5. Bottom out Steer function. Adjust Main Relief to 3000 psi (207 bar). Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge.
SECTION 4 - HYDRAULICS 4.10 DRIVE HEADER VALVE (2WD) A1 B1 LRA RRB RRA LRB RRB LRA 2 CV LRB RRA 1 CV B1 A1 Figure 4-17. Drive Header Valve (2wd) item # Torque 1 (FSDH-XAN) 45 - 50 ft-lbs (61 - 68 Nm) 2 (CXAD-XCN) 25 - 30 ft-lbs (34 -41 Nm) 4.11 DRIVE HEADER VALVE (4WD) LRA RRA LFB RFB RRB B1 LRB LFA RFA RRB LRA RRA LRB RFA RFB A1 B1 B2 LFB A2 A1 B2 A2 LFA Figure 4-18.
SECTION 4 - HYDRAULICS 4.12 HEADER VALVES (4WD) MCD MX3 X3 CD CD CD X3 X3 X X X MX X3 MCD MX3 MX CD CD X3 X3 X X CD X Figure 4-19. Header Valve (Fix) OT X3 X3 CD CD OT OT OP OP B B TS TS OT OP MX3 X OP MCD MX TS B OP OT CD Figure 4-20.
SECTION 4 - HYDRAULICS PB1 PB2 PB3 PB4 PA1 PA2 PA3 PA4 4.13 DIRECTIONAL VALVE PA2 PA1 PB3 PB1 PA3 LP PB2 T PB4 PA4 LP T Figure 4-21. Directional Valve Pressure Setting Procedure item Torque PA1 40 ft-lbs (54 Nm) PB1 23 ft-lbs (31 Nm) Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc.
SECTION 4 - HYDRAULICS 4.14 POWER DECK SANDWICH VALVE P1 ET 2 ET 1 EP LP P Figure 4-22. Power Deck Sandwich Valve (Dual Deck Extension Only) item # Torque 1 30 - 35 ft-lbs (41 - 47 Nm) 2 25 - 30 ft-lbs (34 - 41 Nm) 4.15 POWER DECK MANIFOLD VALVE EPB M Power Deck (Optional) SET AT 1500 PSI M EPR EP ET EPR EPR EPB EPB ET EP EPB EPR Figure 4-23. Power Deck Manifold Valve 3121133 Port(s) Torque EP, ET 24 ft-lbs (32.5 Nm) EPR, EPB 32 ft-lbs (43.
SECTION 4 - HYDRAULICS 4.16 HYDRAULIC PUMP Figure 4-24. Pump Pressure Locations Table 4-3.
SECTION 4 - HYDRAULICS Auxiliary Pump Motor 1 4 5 2 3 Hydraulic Schematic 1. UNF -2A Terminal - Torque: 84 in-lbs (9.5 Nm) 2. 2x Torque: 96 - 120 in-lbs (11 - 14 Nm) 3. Check Valve Cap Torque: 144 - 180 in-lbs (16 - 20 Nm) 4. 4x Torque: 180 - 216 in-lbs (20 - 24 Nm) 5. 8x Torque: 114 - 150 in-lbs (13 - 17 Nm) Figure 4-25. Auxiliary Pump Motor • Displacement: 0.097 CU. IN/REV (1.59 CC/REV) 3121133 • Delivers 1.2 min. GPM (4.5 min Liters/Min) at 1500 psi (103.
SECTION 4 - HYDRAULICS 4.17 CYLINDER ASSEMBLIES 5 4 6 11 1. Barrel 2. Rod 3 3. Cap 7 8 9 4. Ring, Washer 5. Socket Head Bolt 6. Wiper 1 7. Ring, Back-Up 8. O-Ring 9 9. Ring, Wear 10. Ring, Wear 8 11. Seal 7 12. T-Seal 3 11 6 4 2 5 10 12 Figure 4-26.
SECTION 4 - HYDRAULICS 8 9 3 7 6 5 4 1. Barrel Weldment 2. Rod Weldment 3. Cylinder Head 4. Wear Ring 5. O-ring 1 6. Back-up Ring 7. O-ring 8. Wiper 4 9. Seal 10. Wear Ring 5 6 11. T-Seal 7 3 9 8 2 10 11 Figure 4-27.
SECTION 4 - HYDRAULICS 6 11 10 9 10 6 OR 7 5 4 26 OR 1 25 3 OR 5 26 5 2 10 5 OR 8 27 23 22 23 21 30 19 14 20 17 24 12 18 15 16 28 13 29 26 26 1. Cable Adapter 11. Flat Washer 21. Nut 2. Bolt 12. Wiper 22. Seal 3. Bracket 13. Seal 23. Ring, Back-Up 4. Manual Descent Cable 14. Ring, Wear 24. Spacer 5. Plug, O-Ring 15. Seal 25. Plug, O-Ring 6. Jam Nut 16. Ring, Back-Up 26. Bushing 7. Cotter Pin 17. Setscrew 27. Piston 8. Cartridge, Lift Holding Solenoid 18.
SECTION 4 - HYDRAULICS 1 2 4 3 5 Item Ft-Lbs Nm 1 25 35 2 10 - 12 14 - 17 3 35 49 4 5 7 5 30 42 Figure 4-29.
SECTION 4 - HYDRAULICS 18 17 3 18 16 1. Ring, Wear 17 4 2. T-Seal 5 3. Ring, Wear 4. O-Ring 15 5. Ring, Back-Up 1 8 6. Seal, WIper 7. Polyseal 9 2 8. Bushing 9. Head 8 11 7 10. Rod 6 11. Barrel 12. Plug, O-Ring 12 13. Ring, Washer 13 14. Capscrew 15 15. Bleeder 10 14 16. Plug, O-Ring 17. Solenoid 18. Relief Valve 19. Bearing 19 Figure 4-30.
SECTION 4 - HYDRAULICS 2 1 3 Item # Ft-Lbs Nm 1 18.5 - 22 25 - 30 2 3 - 4.5 4.2 - 6.3 3 20 - 25 28 - 35 Figure 4-31.
SECTION 4 - HYDRAULICS 5 15 5 1. Head 2. Barrel 2 3. Rod 4. Jack Plate 5. Ring, Lock 6. Ring, Wear 7. Ring, Washer 3 8. Ring, Retaining 9. O-Ring 10. Screw 11. Capscrew 12. Seal 9 6 13. WIper 14. Ring, Back-Up 8 15. T-Seal 1 4 14 12 10 16. Jack Pad 8 13 10 7 11 10 16 Figure 4-32.
SECTION 4 - HYDRAULICS 5 3 2 4 6 1 9 10 8 11 12 7 13 1. Locknut 6. Spacer Tube 11. Seal 2. Piston 7. Head 12. Wiper Ring 3. Seal 8. Rod 13. Retaining Ring 4. O-Ring 9. O-Ring 5. Barrel 10. Back-up Ring Figure 4-33.
SECTION 4 - HYDRAULICS Oscillating Axle Bleeding Procedure OSCILLATING AXLE BLEEDER OSCILLATING AXLE CYLINDER Figure 4-34. Oscillating Axle Bleeding 1. Attach 1/4" hose to bleeder valve to capture oil. 4. Run pump for 10 seconds, close bleeder valves. 2. Oscillate axle fully in one direction. 5. Oscillate axle fully in the opposite direction and repeat steps 3 and 4. 3. Open the bleeder valve at the top of the retracted cylinder approx.
SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER menu: HELP:PRESS ENTER Analyzer Display Escape Key Enter Key To return home or access previous menu Stores and selects Top Level, Sub Level, and item menus Left & Right Arrow Keys Up & Down Arrow Keys Used to move between Top Level, Sub Level, and item menus Value Selector Figure 5-1. Hand Held Analyzer To Connect the Hand Held Analyzer: 1.
SECTION 5 - JLG CONTROL SYSTEM NOTE: The cable has a four pin connector at each end of the cable; the cable cannot be connected backwards. 2. Power up the Control System by turning the lower key to the platform position and pulling both emergency stop buttons on. Using the Analyzer: If you press ENTER, at the HELP:PRESS ENTER display, and a fault is present during power up, the analyzer display will scroll the fault across the screen.
SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer: When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu.
SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION. PERSONALITIES: DRIVE ACCEL 3.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to the appropriate Machine Personality Settings Table, and the Machine Setup Table in the JLG Service Manual for the default settings. Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings. CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE. NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
SECTION 5 - JLG CONTROL SYSTEM 5.2 FLASH CODES AND DESCRIPTIONS Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault None 2/1 Description No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected. FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Reported when the trigger is not closed with function selected and joystick out of center.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault 2/2 Description Priority Flash code 2/2 indicates difficultly with the platform controls. TRIGGER SWITCH WIRING SHORTED HIGH IN PLATFORM CABLE Reports when the CAN message coming from the platform board and the DI on ground board conflict.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault Description FUNCTION LOCKED OUT – GROUND LIFT UP PERMANENTLY CLOSED Reported when the ground lift up switch is closed during power up. FUNCTION LOCKED OUT – GROUND LIFT DOWN PERMANENTLY CLOSED Reported when the ground lift down switch is closed during power up. 2/3 Priority Flash code 2/3 indicates difficultly with ground controls.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault 2/5 Description Priority Flash code 2/5 indicates issues that may cutout functions. ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLTAGE OUT OF RANGE Reported when the elevation rotary sensor voltage is outside the range of acceptable values. ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when the rotary calibration value does not exist.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault 2/6 5-10 Description Priority Flash code 2/6 indicates leveling jack or power deck issues. FRONT LEFT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the front left leveling jack is open circuit.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code 2/6 Communicated (Displayed on Analyzer) Fault Description LEVELING JACK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the leveling jack extend valve is short to ground. LEVELING JACK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the leveling jack extend valve is short to battery.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault 4/3 Priority Flash code 4/3 indicates engine issues. FUEL SENSOR SHORT TO BATTERY Reported when the fuel sensor is reading a value that is much too high. FUEL SENSOR SHORT TO GROUND Reported when the fuel sensor is reading ground. FUEL SENSOR DISCONNECTED Reported when the fuel sensor is reading a value that is too high.
SECTION 5 - JLG CONTROL SYSTEM Table 5-1. Fault Code Listing - Software P1.X Fault Flash Code Communicated (Displayed on Analyzer) Fault 8/* Description Priority Flash codes 8/* indicate load cells issues. 8/1 LSS CELL #1 ERROR Reported when there is a problem with cell #1 on the LSS. 8/2 LSS CELL #2 ERROR Reported when there is a problem with cell #2 on the LSS. 8/3 LSS CELL #3 ERROR Reported when there is a problem with cell #3 on the LSS.
5-14 – JLG Lift– LIFT: MIN UP X% LIFT: MAX UP X% LIFT: MIN DOWN X% LIFT: MAX DOWN X% LIFT: ENGINE XXXXRPM LIFT: MID ENG XXXXRPM DRIVE: DECEL X.
3121133 – JLG Lift – TO SHEET 3 MENU: CALIBRATIONS MENU: MACHINE SETUP FROM SHEET 1 MARKET: 4=AUSTRALIA ENGINE: 3=DEUTZ F3(T2) ENGINE: 4=DEUTZ ECM MODEL NUMBER: 3=43RT 4WD SET STOW ELEV: YES: ENTER NO: ESC LEVEL VEHICLE: YES: ENTER NO: ESC SET XXFT ELEV: YES: ENTER NO: ESC SET XXFT ELEV: YES: ENTER NO: ESC CALIBRATIONS: SET XXFT ELEV LOAD: YES: ENTER NO:ESC CALIBRATIONS: LOAD LOAD: 2=CUTOUT ALL GROUND ALARM: 2=MOTION CALIBRATIONS: SET XXFT ELEV LOAD: 1=CUTOUT PLT GROUND ALARM: 1=DESCENT
5-16 VALVES: 2 SPD XXX VALVES: LIFT UP XXX VALVES: LIFT DN XXX VALVES: PROP LIFT X% VALVES: LOSC AXLE XXX VALVES: ROSC AXLE XXX VALVES: FL L/J VLVE XXX VALVES: FR L/J VLVE XXX VALVES: RL L/J VLVE XXX VALVES: RR L/J VLVE XXX VALVES: L/J EXT XXX SYSTEM: PM BATTERY XX.XV SYSTEM: AUX POWER XXXX SYSTEM: HORN XXXX SYSTEM: TILT XX.X XX.
SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Machine Model Adjustment Adjustment Adjustment Range Model Default Values 3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD DRIVE Accel 0.1 - 5.0 (sec) 3 3 3 3 Decel 0.1 - 3.0 (sec) 1.2 1.2 1.2 1.
SECTION 5 - JLG CONTROL SYSTEM NOTE: When configuring an RT, the Machine Configuration must be completed before any Personality settings can be changed. Changing the Personality settings first and then changing the Model of the Machine Configuration will cause the Personality settings to return to default values. Table 5-3.
SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Configuration Programming Information Configuration Digit Setting Description 0 NOT INSTALLED – Load Sensing System (LSS) is not fitted to the vehicle. 1 CUTOUT PLT – Load Sensing System (LSS) is fitted, and Platform Controls are prevented in the event of an Overload. Ground Controls remain functional. This is the default setting for CE machines. 10 (LOAD) 2 Default Number 0 CUTOUT ALL – Load Sensing System (LSS) is fitted.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.
SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-24 – JLG Lift– 3121133
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance. 6.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector Assembly (2 of 4)). 2. Pull back on the contact wire with a force of 1 or 2 lbs.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Figure 6-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 6-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 6-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 6-16. HD/HDP Contact Removal 11.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.5 SWITCHES Basic check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3. Access the terminals to the switch. 4.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. 1. Connect instrumentation to monitor and/or control the parameter the switch is measuring. 2. Observe switch state in control system with the Analyzer.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.6 SCHEMATICS Figure 6-18.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-19.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870143 H Figure 6-20.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121133 – JLG Sizzor – 6-17
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22.
J2 & J5 RECEPTACLE SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS J1 RECEPTACLE PFDTH (J1-1) PFDTH1 (J1-2) SFDTH (J1-3) GND (J1-4) IGN (J1-5) CANH (J1-6) CANL (J1-7) CAN SHIELD (J1-8) BLACK YEL/RED 2-7-3 RED __ BLACK _ SHIELD PFDTH (J2-1) FL LJ VALVE Y18 PFDTH1 (J2-2) IGN (J5-9) GND (J2-3) DO00 (J2-11) DO01 (J2-12) DO02 (J5-1) DO03 (J5-2) DO04 (J5-3) DO05 (J5-4) DO06 (J5-5) BLACK ORN/WHT ORN/WHT ORN/WHT ORN/WHT ORN/WHT ORN/WHT 55-20 55-21 55-22 55-23 55-24 55-25 FR LJ VALVE Y19 RL LJ VALV
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121133 – JLG Sizzor – 6-21
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-24.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-25.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-26.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121133 – JLG Sizzor – 6-25
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-27.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870204 E Figure 6-28.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-29.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-30.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870190 D Figure 6-31.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121133 – JLG Sizzor – 6-31
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-32.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-33.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-34.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792543 D Figure 6-35.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-36.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-37.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-38.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792544D Figure 6-39.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-40.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-41.
8 8 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-42.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Power Deck Manifold Valve Right Front Extension Cylinders Left Power Deck Sandwich Valve Mounted on top of Main Manifold Note: “*” on a line indicates a non-straight hose end Hydraulic Oil Tank Aux. Pump Figure 6-43.
6-44 – JLG Sizzor – Aux. Pump Power Deck Sandwich Valve Mounted on top of Main Manifold Left Right Power Manifold Valve Hydraulic Oil Tank Note: “*” on a line indicates a non-straight hose end Front Extension Cylinders Rear Extension Cylinders Power Deck Manifold Valve Left Right SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-44.
3121133 – JLG Sizzor – Aux. Pump Power Deck Sandwich Valve Mounted on top of Main Manifold Left Right Power Deck Manifold Valve Rear Extension Cylinders Note: “*” on a line indicates a non-straight hose end Hydraulic Oil Tank Front Extension Cylinders Power Deck Manifold Valve Left Right SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-45.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS FUSE (FOR FUTURE OPTIONS) STARTER OIL PRESSURE SWITCH BATTERY THROTTLE ACTUATOR GLOW PLUG OIL TEMP SWITCH ALTERNATOR (DIESEL MACHINES) AC POWER AT PLATFORM AUXILIARY PUMP AUXILIARY POWER RELAY GENERATOR CONTROL BOX GENERATOR RELAY GENERATOR LEVELING JACK PORT BLOCKS LEVELING JACK PORT BLOCKS J2 J4 OPTIONS MODULE LEVELING JACK VALVE J5 J1 J3 Figure 6-46.
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PLATFORM CONTROL BOX START RELAY ENGINE SPEED SENSOR GLOW PLUG RELAY LP LOCK & ASSIST (GAS MACHINES) IGNITION RELAY ALTERNATOR (GAS MACHINES) THROTTLE CONTROLLER (GAS MACHINES) J2 LIFT CYLINDER PORT BLOCK J5 J4 PROP VALVE HYDRAULIC PUMPS J1 J3 PLATFORM MODULE LIFT DOWN VALVE FUEL LEVEL SENSOR BEACON LIGHT PORT BLOCKS (OSCILLATING AXLE CYLINDERS) HORN ROTARY SENSOR ALARM ELEVATION SWITCH MAIN VALVE FUEL PUMP (GAS MACHINES) GROUND
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 6-48 – JLG Sizzor – 3121133
3121133 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +61 2 65 811111 +61 2 65 810122 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.
