Jlg 1350SJP Service Manual User Manual Page 550
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- TROUBLESHOOTING
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SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS
7-42 – JLG Lift – 3121142
Figure 7-49. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2
- 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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