Jlg 1350SJP Service Manual User Manual Page 327
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SECTION 5 - HYDRAULICS
3121142 – JLG Lift – 5-3
5.2 CYLINDER REPAIR
NOTE: The following are general procedures that apply to all of
the cylinders on this machine. Procedures that apply to a
specific cylinder will be so noted.
Disassembly
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to
the cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding valve
and fittings from the cylinder port block. Discard o-
rings.
4. Place the cylinder barrel into a suitable holding fixture.
5. Mark cylinder head and barrel with a center punch for
easy realignment. Using an allen wrench, loosen the
eight (8) cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.
6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
Figure 5-1. Cylinder Barrel Support
Figure 5-2. Cap Screw Removal
- P/N - 3121142 1
- AGENERAL 3
- BHYDRAULIC SYSTEM SAFETY 3
- CMAINTENANCE 3
- REVISON LOG 4
- 10
- SECTION 5 - HYDRAULICS 10
- TABLE OF CONTENTS 11
- LIST OF FIGURES 13
- LIST OF TABLES 19
- SECTION 1. SPECIFICATIONS 21
- Reach Specifications 22
- Dimensional Data 22
- SECTION 1 - SPECIFICATIONS 23
- Torque Torque 36
- Tor qu e 36
- To rqu e 36
- To rq ue 36
- SECTION 2. GENERAL 37
- 2.2 SERVICE AND GUIDELINES 38
- Safety and Workmanship 38
- Cleanliness 38
- SECTION 2 - GENERAL 39
- Hydraulic Oil 40
- Changing Hydraulic Oil 40
- Lubrication Specifications 40
- 2.4 CYLINDER DRIFT TEST 40
- Platform Drift 40
- 3.1 TIRES & WHEELS 47
- Tire Inflation 47
- Tire Damage 47
- Wheel and Tire Replacement 47
- Wheel Installation 47
- 3.2 EXTENDING AXLES 48
- 3.4 DRIVE SYSTEM 49
- 3.5 STEERING CONTROL SYSTEM 49
- 3.7 TRACTION CONTROL SYSTEM 50
- 3.8 DRIVE ORIENTATION SYSTEM 50
- 3121142 – JLG Lift – 3-5 51
- 3-6 – JLG Lift – 3121142 52
- 3121142 – JLG Lift – 3-7 53
- 3-8 – JLG Lift – 3121142 54
- 3121142 – JLG Lift – 3-9 55
- DETAIL A 56
- DETAIL B 56
- 3-12 – JLG Lift – 3121142 58
- Apply Loctite #242 59
- Apply Loctite #271 59
- Apply Loctite #222 59
- 3.9 OSCILLATING AXLE SYSTEM 60
- LOCKOUT TEST 60
- Lockout Cylinder Bleeding 60
- Oscillating Axle Lockout Test 61
- 3-16 – JLG Lift – 3121142 62
- Final Assembly 63
- 3-18 – JLG Lift – 3121142 64
- 3121142 – JLG Lift – 3-19 65
- 3-20 – JLG Lift – 3121142 66
- General Information 67
- Connecting the Brake 67
- 3-22 – JLG Lift – 3121142 68
- Gearbox Disengagement 69
- 3-24 – JLG Lift – 3121142 70
- Maintenance Information 71
- Changing the Lubricating oil 71
- Troubleshooting 72
- Disassembly Information 72
- Disassembly Procedure 72
- 3121142 – JLG Lift – 3-27 73
- 3-28 – JLG Lift – 3121142 74
- 3121142 – JLG Lift – 3-29 75
- 3-30 – JLG Lift – 3121142 76
- 3121142 – JLG Lift – 3-31 77
- 3-32 – JLG Lift – 3121142 78
- 3121142 – JLG Lift – 3-33 79
- Inspection of Parts 80
- 3-36 – JLG Lift – 3121142 82
- 3121142 – JLG Lift – 3-37 83
- 3-38 – JLG Lift – 3121142 84
- 3121142 – JLG Lift – 3-39 85
- 3-40 – JLG Lift – 3121142 86
- 3121142 – JLG Lift – 3-41 87
- 3-42 – JLG Lift – 3121142 88
- 3121142 – JLG Lift – 3-43 89
- 3-44 – JLG Lift – 3121142 90
- Final Test and Reinstallation 91
- 3-46 – JLG Lift – 3121142 92
- 3121142 – JLG Lift – 3-47 93
- 3-48 – JLG Lift – 3121142 94
- 3121142 – JLG Lift – 3-49 95
- TO PRESENT) 96
- Symbol Nomenclature 96
- 3121142 – JLG Lift – 3-51 97
- 3121142 – JLG Lift – 3-53 99
- M- 1546 M- 1548 100
- Disassembly 101
- 3-56 – JLG Lift – 3121142 102
- 3121142 – JLG Lift – 3-57 103
- 3-58 – JLG Lift – 3121142 104
- Assembly 105
- 3-60 – JLG Lift – 3121142 106
- 3121142 – JLG Lift – 3-61 107
- 3-62 – JLG Lift – 3121142 108
- 3121142 – JLG Lift – 3-63 109
- 3-64 – JLG Lift – 3121142 110
- 3.14 SWING DRIVE 111
- Roll and Leak Testing 111
- Tightening and Torquing Bolts 111
- 3-66 – JLG Lift – 3121142 112
- Motor and Brake Disassembly 113
- Main Disassembly 114
- Hub-Shaft Disassembly 115
- Carrier Disassembly 116
- Hub-Shaft Sub-Assembly 117
- Carrier Sub-Assembly 118
- 3121142 – JLG Lift – 3-73 119
- Main Assembly 120
- 3121142 – JLG Lift – 3-75 121
- Motor and Brake Assembly 122
- Motor Control Valve Assembly 123
- 3.15 SWING BRAKE 124
- Pre-Installation Checks 124
- Installation 125
- Maintenance 125
- Examination 125
- 3-80 – JLG Lift – 3121142 126
- 3121142 – JLG Lift – 3-81 127
- 3.16 SWING MOTOR 128
- Disassembly and inspection 128
- 3121142 – JLG Lift – 3-83 129
- 3-84 – JLG Lift – 3121142 130
- 3-86 – JLG Lift – 3121142 132
- 3121142 – JLG Lift – 3-87 133
- 3-88 – JLG Lift – 3121142 134
- 3-90 – JLG Lift – 3121142 136
- 3121142 – JLG Lift – 3-91 137
- 3-92 – JLG Lift – 3121142 138
- 3121142 – JLG Lift – 3-93 139
- 3-94 – JLG Lift – 3121142 140
- 3121142 – JLG Lift – 3-95 141
- One Piece Stator Construction 142
- 3121142 – JLG Lift – 3-97 143
- 3.18 SWING DRIVE LUBRICATION 144
- 3.19 SWING BEARING 145
- 3-100 – JLG Lift – 3121142 146
- 3121142 – JLG Lift – 3-101 147
- Wear Tolerance 148
- Swing Bearing Removal 148
- 3121142 – JLG Lift – 3-103 149
- Swing Bearing Installation 150
- BACK OF VALVE 150
- Swing Bearing Torque Values 151
- 3-106 – JLG Lift – 3121142 152
- 3.22 ROTARY COUPLING 153
- 3-108 – JLG Lift – 3121142 154
- 3121142 – JLG Lift – 3-109 155
- 3-110 – JLG Lift – 3121142 156
- 3.23 GENERATOR 157
- Every 250 hours 157
- Every 500 hours 157
- Overload Protection 158
- Cleaning Slip Rings 158
- 3121142 – JLG Lift – 3-113 159
- 3.24 AUXILIARY POWER SYSTEM 160
- VIEW A-A 161
- VIEW B-B 161
- 3-116 – JLG Lift – 3121142 162
- Changing the Oil Filter 163
- Replacing the Fuel Filter 164
- Cleaning the Fuel Strainer 164
- 3121142 – JLG Lift – 3-119 165
- 3-120 – JLG Lift – 3121142 166
- 3121142 – JLG Lift – 3-121 167
- 3-122 – JLG Lift – 3121142 168
- 3121142 – JLG Lift – 3-123 169
- 3-124 – JLG Lift – 3121142 170
- 3121142 – JLG Lift – 3-125 171
- 3-126 – JLG Lift – 3121142 172
- 3121142 – JLG Lift – 3-127 173
- 3-128 – JLG Lift – 3121142 174
- 3121142 – JLG Lift – 3-129 175
- 3-130 – JLG Lift – 3121142 176
- 3121142 – JLG Lift – 3-131 177
- Bio Fuel 178
- CODE DEFINITIONS 180
- 3121142 – JLG Lift – 3-135 181
- 3-136 – JLG Lift – 3121142 182
- 3121142 – JLG Lift – 3-137 183
- Diagnostic Trouble Codes 184
- MIL Output 184
- Diagnostic Aids 185
- DTC 117- ECT/CHT Low Voltage 186
- 3121142 – JLG Lift – 3-141 187
- DTC 118- ECT/CHT High Voltage 188
- 3121142 – JLG Lift – 3-143 189
- 3-144 – JLG Lift – 3121142 190
- 3121142 – JLG Lift – 3-145 191
- 3-146 – JLG Lift – 3121142 192
- 3121142 – JLG Lift – 3-147 193
- TAN/WHITE 194
- BLACK/GREEN 194
- 3-150 – JLG Lift – 3121142 196
- 3121142 – JLG Lift – 3-151 197
- Pressure 199
- Normally Closed Switch 201
- 3-156 – JLG Lift – 3121142 202
- 3121142 – JLG Lift – 3-157 203
- 3-158 – JLG Lift – 3121142 204
- 3121142 – JLG Lift – 3-159 205
- Microprocessor 206
- 3121142 – JLG Lift – 3-161 207
- 3121142 – JLG Lift – 3-163 209
- 3121142 – JLG Lift – 3-165 211
- SFC 555- RTI 2 Loss 216
- SFC 556- RTI 3 Loss 218
- SFC 513- A/D Loss 220
- SFC 512- Invalid Interrupt 222
- 3-180 – JLG Lift – 3121142 226
- 3121142 – JLG Lift – 3-181 227
- 3-184 – JLG Lift – 3121142 230
- 3121142 – JLG Lift – 3-185 231
- 3-186 – JLG Lift – 3121142 232
- DTC to SPN/FMI Table 234
- 4.1 BOOM SYSTEMS 235
- Broken Cable Indicator System 235
- Jib Stow System 236
- Envelope Tracking System 236
- Moment Control System 237
- (Push to Test) System 237
- Controlled Arc System 237
- Controlled Boom Angle System 238
- Envelope Tracking 238
- Slow Down System 238
- Dual Capacity System 239
- Electronic Platform Leveling 239
- Boom Control Select 240
- CABLE REPLACEMENT 241
- 4-8 – JLG Lift – 3121142 242
- 3121142 – JLG Lift – 4-9 243
- 4-10 – JLG Lift – 3121142 244
- 3121142 – JLG Lift – 4-11 245
- 4-12 – JLG Lift – 3121142 246
- 3121142 – JLG Lift – 4-13 247
- 4-14 – JLG Lift – 3121142 248
- 3121142 – JLG Lift – 4-15 249
- 3121142 – JLG Lift – 4-17 251
- 4-18 – JLG Lift – 3121142 252
- 3121142 – JLG Lift – 4-19 253
- 4-20 – JLG Lift – 3121142 254
- 3121142 – JLG Lift – 4-21 255
- 4-22 – JLG Lift – 3121142 256
- 3121142 – JLG Lift – 4-23 257
- 4-24 – JLG Lift – 3121142 258
- 3121142 – JLG Lift – 4-25 259
- 4-26 – JLG Lift – 3121142 260
- 4-28 – JLG Lift – 3121142 262
- 3121142 – JLG Lift – 4-29 263
- 4-30 – JLG Lift – 3121142 264
- 3121142 – JLG Lift – 4-31 265
- 4-32 – JLG Lift – 3121142 266
- 3121142 – JLG Lift – 4-33 267
- 4-34 – JLG Lift – 3121142 268
- 3121142 – JLG Lift – 4-35 269
- 4-36 – JLG Lift – 3121142 270
- 3121142 – JLG Lift – 4-37 271
- 4-38 – JLG Lift – 3121142 272
- 3121142 – JLG Lift – 4-39 273
- #0100011 274
- 3121142 – JLG Lift – 4-41 275
- 4-42 – JLG Lift – 3121142 276
- 4.4 BOOM SHIMMING PROCEDURE 277
- 4.5 JIB ROTATOR ORIENTATION 278
- INSTALLATION 278
- 3121142 – JLG Lift – 4-45 279
- 4-46 – JLG Lift – 3121142 280
- 3121142 – JLG Lift – 4-47 281
- 4-48 – JLG Lift – 3121142 282
- 3121142 – JLG Lift – 4-49 283
- 4-50 – JLG Lift – 3121142 284
- 3121142 – JLG Lift – 4-51 285
- 4-52 – JLG Lift – 3121142 286
- 4.8 POWERTRACK MAINTENANCE 287
- One Piece Bracket Maintenance 287
- 4-54 – JLG Lift – 3121142 288
- Two Piece Bracket Maintenance 289
- Snap Rings and Screws 290
- 3121142 – JLG Lift – 4-57 291
- 4-58 – JLG Lift – 3121142 292
- 3121142 – JLG Lift – 4-59 293
- 4-60 – JLG Lift – 3121142 294
- 3121142 – JLG Lift – 4-61 295
- 4-62 – JLG Lift – 3121142 296
- 3121142 – JLG Lift – 4-63 297
- 4-64 – JLG Lift – 3121142 298
- Boom Section Re-Positioning 299
- 4-66 – JLG Lift – 3121142 300
- 3121142 – JLG Lift – 4-67 301
- 4-68 – JLG Lift – 3121142 302
- 3121142 – JLG Lift – 4-69 303
- 4-70 – JLG Lift – 3121142 304
- 3121142 – JLG Lift – 4-71 305
- 4-72 – JLG Lift – 3121142 306
- 3121142 – JLG Lift – 4-73 307
- Description 308
- Normal Operation 309
- 4.14 ROTARY ACTUATOR 310
- Theory of Operation 310
- Required Tools 310
- 3121142 – JLG Lift – 4-77 311
- 4-78 – JLG Lift – 3121142 312
- 4-80 – JLG Lift – 3121142 314
- 3121142 – JLG Lift – 4-81 315
- 4-82 – JLG Lift – 3121142 316
- Inspection 317
- 4-84 – JLG Lift – 3121142 318
- 3121142 – JLG Lift – 4-85 319
- 4-86 – JLG Lift – 3121142 320
- 3121142 – JLG Lift – 4-87 321
- Testing the Actuator 322
- Bleeding After Installation 322
- 3121142 – JLG Lift – 4-89 323
- 4-90 – JLG Lift – 3121142 324
- SECTION 5. HYDRAULICS 325
- Dip Method 326
- Spray Method 326
- Brush-on Method 326
- 5.2 CYLINDER REPAIR 327
- SECTION 5 - HYDRAULICS 328
- 1684149-D 330
- Cleaning and Inspection 336
- 5.3 HYDRAULIC TANK 349
- Set Up of the Function Pump 349
- 5.5 DRIVE PUMPS 356
- Troubleshooting Procedure 356
- CHARGE RELIEF 359
- Mechanical Centering of Pump 360
- Routine Maintenance 362
- 5.6 FUNCTION PUMP 365
- Spare Parts 365
- Sealing the Drive Shaft 366
- Adjustments 371
- Tightening Torques 371
- PROCEDURES 375
- Start-Up Procedure 375
- 6.1 INTRODUCTION 377
- 6.2 CANBUS COMMUNICATIONS 378
- 3121142 – JLG Lift – 6-3 379
- 6.3 CALIBRATION INSTRUCTIONS 380
- 3121142 – JLG Lift – 6-5 381
- 6-6 – JLG Lift – 3121142 382
- 3121142 – JLG Lift – 6-7 383
- 6-8 – JLG Lift – 3121142 384
- 3121142 – JLG Lift – 6-9 385
- 6-10 – JLG Lift – 3121142 386
- 3121142 – JLG Lift – 6-11 387
- 6-12 – JLG Lift – 3121142 388
- 3121142 – JLG Lift – 6-13 389
- ANALYZER 390
- 6.5 USING THE ANALYZER 390
- HELD ANALYZER 391
- 6.8 MACHINE SETUP 392
- 3121142 – JLG Lift – 6-17 393
- 6-18 – JLG Lift – 3121142 394
- 3121142 – JLG Lift – 6-19 395
- 6-20 – JLG Lift – 3121142 396
- 3121142 – JLG Lift – 6-23 399
- 6-24 – JLG Lift – 3121142 400
- 3121142 – JLG Lift – 6-25 401
- 6-26 – JLG Lift – 3121142 402
- FUNCTION SPEEDS 403
- Test Notes 403
- 6.11 SYSTEM TEST 404
- Test from the Platform 404
- 3121142 – JLG Lift – 6-29 405
- 6-30 – JLG Lift – 3121142 406
- Test from the Ground Station 407
- 6-32 – JLG Lift – 3121142 408
- 3121142 – JLG Lift – 6-33 409
- 6-34 – JLG Lift – 3121142 410
- 3121142 – JLG Lift – 6-35 411
- 6-36 – JLG Lift – 3121142 412
- 3121142 – JLG Lift – 6-37 413
- 6-38 – JLG Lift – 3121142 414
- 3121142 – JLG Lift – 6-39 415
- 6-40 – JLG Lift – 3121142 416
- 3121142 – JLG Lift – 6-41 417
- 6-42 – JLG Lift – 3121142 418
- 3121142 – JLG Lift – 6-43 419
- 6-44 – JLG Lift – 3121142 420
- 3121142 – JLG Lift – 6-45 421
- 6.12 CALIBRATING STEER 422
- 3121142 – JLG Lift – 6-47 423
- 6-48 – JLG Lift – 3121142 424
- 6.13 CALIBRATING DRIVE 425
- 6-50 – JLG Lift – 3121142 426
- 3121142 – JLG Lift – 6-51 427
- Fault Response 428
- CAN Errors 429
- 6-54 – JLG Lift – 3121142 430
- 3121142 – JLG Lift – 6-55 431
- 6-56 – JLG Lift – 3121142 432
- 3121142 – JLG Lift – 6-57 433
- DOWN VALVE CRACKPOINTS 434
- 3121142 – JLG Lift – 6-59 435
- 6-60 – JLG Lift – 3121142 436
- 3121142 – JLG Lift – 6-61 437
- 6-62 – JLG Lift – 3121142 438
- 3121142 – JLG Lift – 6-63 439
- 6-64 – JLG Lift – 3121142 440
- 6.18 CALIBRATING TILT SENSOR 441
- 6-66 – JLG Lift – 3121142 442
- 3121142 – JLG Lift – 6-67 443
- 6-68 – JLG Lift – 3121142 444
- 3121142 – JLG Lift – 6-69 445
- 6-70 – JLG Lift – 3121142 446
- 3121142 – JLG Lift – 6-71 447
- 6-72 – JLG Lift – 3121142 448
- 3121142 – JLG Lift – 6-73 449
- 6-74 – JLG Lift – 3121142 450
- 3121142 – JLG Lift – 6-75 451
- 6-76 – JLG Lift – 3121142 452
- 3121142 – JLG Lift – 6-77 453
- 6-78 – JLG Lift – 3121142 454
- 3121142 – JLG Lift – 6-79 455
- 6-80 – JLG Lift – 3121142 456
- 3121142 – JLG Lift – 6-81 457
- 6-82 – JLG Lift – 3121142 458
- 3121142 – JLG Lift – 6-83 459
- 6-84 – JLG Lift – 3121142 460
- 3121142 – JLG Lift – 6-85 461
- 6-86 – JLG Lift – 3121142 462
- 3121142 – JLG Lift – 6-87 463
- 6-88 – JLG Lift – 3121142 464
- 3121142 – JLG Lift – 6-89 465
- 6-90 – JLG Lift – 3121142 466
- 3121142 – JLG Lift – 6-91 467
- 6-92 – JLG Lift – 3121142 468
- 3121142 – JLG Lift – 6-93 469
- 6-94 – JLG Lift – 3121142 470
- 3121142 – JLG Lift – 6-95 471
- 6-96 – JLG Lift – 3121142 472
- 3121142 – JLG Lift – 6-97 473
- 6-98 – JLG Lift – 3121142 474
- 3121142 – JLG Lift – 6-99 475
- 6-100 – JLG Lift – 3121142 476
- 3121142 – JLG Lift – 6-101 477
- 6-102 – JLG Lift – 3121142 478
- 3121142 – JLG Lift – 6-103 479
- 6-104 – JLG Lift – 3121142 480
- 3121142 – JLG Lift – 6-105 481
- 6-106 – JLG Lift – 3121142 482
- 3121142 – JLG Lift – 6-107 483
- 6.20 CANBUS TROUBLESHOOTING 484
- PLATFORM MODULE 485
- CANbus Link 485
- 6-110 – JLG Lift – 3121142 486
- 3121142 – JLG Lift – 6-111 487
- 6-112 – JLG Lift – 3121142 488
- 3121142 – JLG Lift – 6-113 489
- 6-114 – JLG Lift – 3121142 490
- CANbus Communication Failure 491
- 6-116 – JLG Lift – 3121142 492
- 3121142 – JLG Lift – 6-117 493
- 6-118 – JLG Lift – 3121142 494
- 3121142 – JLG Lift – 6-119 495
- 6-120 – JLG Lift – 3121142 496
- 3121142 – JLG Lift – 6-121 497
- 6-122 – JLG Lift – 3121142 498
- 3121142 – JLG Lift – 6-123 499
- 6-124 – JLG Lift – 3121142 500
- 3121142 – JLG Lift – 6-125 501
- 6-126 – JLG Lift – 3121142 502
- 3121142 – JLG Lift – 6-127 503
- 6-128 – JLG Lift – 3121142 504
- 3121142 – JLG Lift – 6-129 505
- 6-130 – JLG Lift – 3121142 506
- 3121142 – JLG Lift – 6-131 507
- 6-132 – JLG Lift – 3121142 508
- 3121142 – JLG Lift – 7-1 509
- Resistance Measurement 510
- Continuity Measurement 510
- Current Measurement 511
- ELECTRICAL CONNECTIONS 511
- 7.4 AMP CONNECTOR 512
- Connectors 512
- 3121142 – JLG Lift – 7-5 513
- Wedge Lock 514
- Service - Voltage Reading 514
- 3121142 – JLG Lift – 7-7 515
- 7.5 DEUTSCH CONNECTORS 516
- DT/DTP Series Assembly 516
- DT/DTP Series Disassembly 516
- HD30/HDP20 Series Assembly 517
- HD30/HDP20 Series Disassembly 517
- 7-10 – JLG Lift – 3121142 518
- 0274660 D 519
- 7-12 – JLG Lift – 3121142 520
- 0272445-E 521
- 7-14 – JLG Lift – 3121142 522
- 0274660-D 523
- 7-16 – JLG Lift – 3121142 524
- 1870214 H 525
- 7-18 – JLG Lift – 3121142 526
- 7-20 – JLG Lift – 3121142 528
- 7-22 – JLG Lift – 3121142 530
- 1001119860-G 531
- 7-24 – JLG Lift – 3121142 532
- 1001119860-GSHEET 2 533
- 7-26 – JLG Lift – 3121142 534
- 7-28 – JLG Lift – 3121142 536
- 7-30 – JLG Lift – 3121142 538
- 7-32 – JLG Lift – 3121142 540
- 7-34 – JLG Lift – 3121142 542
- 1001119860-GSHEET 7 543
- 7-36 – JLG Lift – 3121142 544
- 1001110749-C 545
- 7-38 – JLG Lift – 3121142 546
- 7-40 – JLG Lift – 3121142 548
- 7-42 – JLG Lift – 3121142 550
- 7-44 – JLG Lift – 3121142 552
- JLG Worldwide Locations 554
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