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SECTION 6 - JLG CONTROL SYSTEM
6-24 – JLG Lift – 3121259
MENU:
DIAGNOSTICS
PLATFORM LOAD
PLATFORM LOAD
STATE : OK/
OVERLOAD
PLATFORM LOAD
ACTUAL: XXX.XKG
PLATFORM LOAD
GROSS: XXX.XKG
PLATFORM LOAD
OFFSET : XXX.XKG
PLATFORM LOAD
CELL1: XXX.XKG
PLATFORM LOAD
CELL2: XXX.XKG
PLATFORM LOAD
CELL3: XXX.XKG
PLATFORM LOAD
CELL4: XXX.XKG
DIAGNOSTICS:
CALIBRATION
DATA
2
UGM TILT 1 X
XXXXX COUNTS
UGM TILT 1 Y
XXXXX COUNTS
UGM TILT 2 X
XXXXX COUNTS
UGM TILT 2 Y
VERSIONS
UGM
SOFTWARE PX .X
UGM
CNST DATA PX .X
UGM
HARDWARE REV
X
U
G
M
S/N X
X
X
X
X
X
X
U
G
M
P
/
N
X
X
X
X
X
X
X
X
X
X
P
L
A
T
F
O
R
M
M
O
D
U
L
E
S
O
F
T
W
A
R
E
P
X
.
X
L
S
S
M
O
D
U
L
E
S
O
F
T
W
A
R
E
P
X
.
X
L
S
S
M
O
D
U
L
E
H
A
R
D
W
A
R
E
R
E
V
X
CAN STATISTICS
CAN 1 STATISTICS
RX/SEC: XXX
2
2
2
2
2
2
2
2
2
PLAT LEVEL UP SW
OPEN/CLOSED
JIB LIFT DN SW
OPEN/CLOSED
TELE OUT SW
OPEN/CLOSED
JIB LIFT UP SW
OPEN/CLOSED
PLAT LEVEL DN SW
OPEN/CLOSED
CREEP SW
OPEN/CLOSED
HORN SW
OPEN/CLOSED
PLAT ROT LEFT SW
OPEN/CLOSED
PLAT ROT RGHT SW
OPEN/CLOSED
MAX SPEED SW
OPEN/CLOSED
MAX TORQUE SW
OPEN/CLOSED
FUEL SELECT SW
OPEN/CLOSED
H&T LIGHTS SW
OPEN/CLOSED
GENSET/WELDER SW
OPEN/CLOSED
2
CAN 1 STATISTICS
BUS OFF : XXX
CAN 1 STATISTICS
TX/SEC: XXX
CAN 1 STATISTICS
PASSIVE : XXX
CAN 1 STATISTICS
MSG ERROR : XXXX
CAN 2 STATISTICS
RX/SEC: XXX
CAN 2 STATISTICS
TX/SEC: XXX
CAN 2 STATISTICS
BUS OFF : XXX
CAN 2 STATISTICS
PASSIVE : XXX
CAN 2 STATISTICS
MSG ERROR : XXXX
P
L
A
T
F
O
R
M
M
O
D
U
L
E
H
A
R
D
W
A
R
E
R
E
V
X
P
L
A
T
F
O
R
M
M
O
D
U
L
E
S
/
N
X
X
X
X
X
X
T
C
U
M
O
D
U
L
E
S
O
F
T
W
A
R
E
P
X
.
X
T
C
U
M
O
D
U
L
E
H
A
R
D
W
A
R
E
R
E
V
X
T
C
U
M
O
D
U
L
E
S
/
N
X
X
X
X
X
X
X
A
N
A
L
Y
Z
E
R
A
N
A
L
Y
Z
E
R
v
X
.
X
DATALOG
DATALOG TIME
ON XXXXH XXM
DATALOG TIME
ENGINE XXXXH
XXM
DATALOG TIME
ENABLD XXXXH
XXM
DATALOG TIME
AUX XXXXH XXM
DATALOG TIME
DRIVE XXXH XXM
DATALOG TIME
STEER XXXXH XXM
DATALOG TIME
SWING XXXXH XXM
DATALOG TIME
TOWER XXXXH XXM
DATALOG TIME
LIFT XXXXH XXM
DATALOG TIME
TELE XXXXH XXM
DATALOG TIME
JIB XXXXH XXM
DATALOG TIME
LEVEL XXXXH XXM
DATALOG CYCLES
DRIVE FWD XXXXXXX
DATALOG CYCLES
STEER LT XXXXXXX
DATALOG CYCLES
TOWER DN XXXXXXX
DATALOG CYCLES
STEER RT XXXXXXX
D
A
T
A
L
O
G
C
Y
C
L
E
S
L
I
F
T
D
N
X
X
X
X
X
X
X
DATALOG
C
Y
C
L
E
S
LIFT UP X
X
X
X
X
X
X
DATALOG CYCLES
TOWER UP XXXXXXX
DATALOG CYCLES
DRIVE REV XXXXXXX
DATALOG CYCLES
SWING LT XXXXXXX
DATALOG CYCLES
SWING RT XXXXXXX
DAT
A
L
O
G
C
Y
C
L
E
S
AUX
O
P
S
X
X
X
X
X
X
X
D
A
T
A
L
O
G
C
Y
C
L
E
S
G
E
N
O
N
X
X
X
X
X
X
X
D
A
T
A
L
O
G
:
M
A
X
U
G
M
T
E
M
P
X
X
X
C
U
G
M
T
E
M
P
X
X
X
F
DATALOG CY
C
L
E
S
PLAT OPS XX
X
X
X
X
X
D
A
T
A
L
O
G
:
M
I
N
D
A
T
A
L
O
G
:
M
A
C
H
I
N
E
R
E
N
T
A
L
X
X
X
X
H
X
X
M
D
A
T
A
L
O
G
:
M
A
X
U
G
M
V
O
L
T
X
X
.
X
V
D
A
T
A
L
O
G
:
E
R
A
S
E
M
A
C
H
I
N
E
R
E
N
T
A
L
?
DATALO
G
T
I
M
E
ROTATE X
X
X
X
H
X
X
M
D
A
T
A
L
O
G
T
I
M
E
G
E
N
X
X
X
X
H
X
X
M
D
A
T
A
L
O
G
C
Y
C
L
E
S
T
E
L
E
O
U
T
X
X
X
X
X
X
X
D
A
T
A
L
O
G
C
Y
C
L
E
S
T
E
L
E
I
N
X
X
X
X
X
X
X
D
A
T
A
L
O
G
C
Y
C
L
E
S
J
I
B
U
P
X
X
X
X
X
X
X
D
A
T
A
L
O
G
C
Y
C
L
E
S
J
I
B
D
O
W
N
X
X
X
X
X
X
X
DATALOG CYCLES
LEVEL UP XXXXXXX
DATALOG CYCLES
ROT RGHT XXXXXXX
DATALOG CYCLES
LEVEL DN XXXXXXX
DATALOG CYCLES
UGM ON XXXXXXX
DATALOG CYCLES
GND OPS XXXXXXX
DATALOG CYCLES
ROT LEFT XXXXXXX
*
* From Sheet 1
2
Only Available in Access Level 2
*
XXXXX COUNTS
UGM TEMP XXXC
UGM TEMP XXXF
Figure 6-13. Analyzer Diagnostics Menu - Sheet 2 of 2
- P/N - 3121259 1
- AGENERAL 3
- BHYDRAULIC SYSTEM SAFETY 3
- CMAINTENANCE 3
- REVISON LOG 4
- TABLE OF CONTENTS 5
- SECTION 5 - HYDRAULICS 8
- 10
- LIST OF FIGURES 11
- SECTION 1. SPECIFICATIONS 17
- Major Component Weights 18
- Hydraulic Oil 18
- 1.6 FUNCTION SPEEDS 19
- Test Notes 19
- SECTION 1 - SPECIFICATIONS 20
- 1.7 OPERATOR MAINTENANCE 21
- SOCKET HEAD CAP SCREWS 26
- Magni Coating (Ref 4150701)* 30
- SECTION 2. GENERAL 31
- 2.2 SERVICE AND GUIDELINES 32
- Safety and Workmanship 32
- Cleanliness 32
- SECTION 2 - GENERAL 33
- Changing Hydraulic Oil 34
- Lubrication Specifications 34
- 2.4 CYLINDER DRIFT TEST 34
- Platform Drift 34
- 2-10 – JLG Lift – 3121259 40
- 3.1 TIRES AND WHEELS 41
- Tire Replacement 41
- Wheel and Tire Replacement 41
- Wheel Installation 41
- 3-2 – JLG Lift – 3121259 42
- 3.6 DRIVE MOTOR 43
- 3-4 – JLG Lift – 3121259 44
- 3121259 – JLG Lift – 3-5 45
- 3-6 – JLG Lift – 3121259 46
- 3121259 – JLG Lift – 3-7 47
- 3-8 – JLG Lift – 3121259 48
- 3121259 – JLG Lift – 3-9 49
- 3.7 DRIVE HUB 50
- Roll, Leak and Brake Testing 50
- Tightening and Torquing Bolts 50
- Measuring Rolling Torque 51
- Main Disassembly 51
- 3-12 – JLG Lift – 3121259 52
- Housing-Spindle Disassembly 53
- 3-14 – JLG Lift – 3121259 54
- 3121259 – JLG Lift – 3-15 55
- Cover Disassembly 56
- 3121259 – JLG Lift – 3-17 57
- Planet Gear Subassembly 58
- Spindle-Brake Subassembly 59
- 3-20 – JLG Lift – 3121259 60
- Housing-Spindle Subassembly 61
- Housing-Ring Gear Subassembly 62
- Cover Subassembly 63
- Main Assembly 64
- 3121259 – JLG Lift – 3-25 65
- 3-26 – JLG Lift – 3121259 66
- 3121259 – JLG Lift – 3-27 67
- 3-28 – JLG Lift – 3121259 68
- 3121259 – JLG Lift – 3-29 69
- 3.8 OSCILLATING AXLE SYSTEM 70
- 3121259 – JLG Lift – 3-31 71
- 3.10 SWING MOTOR 72
- 3121259 – JLG Lift – 3-33 73
- 3-34 – JLG Lift – 3121259 74
- Disassembly and Inspection 75
- 3-36 – JLG Lift – 3121259 76
- 3121259 – JLG Lift – 3-37 77
- 3-38 – JLG Lift – 3121259 78
- 3121259 – JLG Lift – 3-39 79
- 3-40 – JLG Lift – 3121259 80
- 3121259 – JLG Lift – 3-41 81
- 3121259 – JLG Lift – 3-43 83
- 3-44 – JLG Lift – 3121259 84
- 3121259 – JLG Lift – 3-45 85
- 3-46 – JLG Lift – 3121259 86
- 3121259 – JLG Lift – 3-47 87
- One Piece Stator Construction 88
- Two Piece Stator Construction 89
- Final Checks 90
- Installation 90
- 3.11 SWING DRIVE 90
- 3121259 – JLG Lift – 3-51 91
- 3-52 – JLG Lift – 3121259 92
- M20x2.5 Thread 93
- 3-54 – JLG Lift – 3121259 94
- Wear Tolerance 96
- Swing Bearing Torque Value 96
- 3121259 – JLG Lift – 3-59 99
- Assembly 100
- FROM LAST JIB 101
- (ORIENTATION LOOKING TOWARDS 102
- LOWER UPRIGHT) 102
- ROTATED 28.5° CW 102
- 3121259 – JLG Lift – 3-63 103
- 3-64 – JLG Lift – 3121259 104
- 3121259 – JLG Lift – 3-65 105
- (3) LIMIT SWITCHES ARE PART 105
- OF LOWER BOOM HARNESS 105
- SWITCH SW152 OF 105
- LOWER BOOM HARNESS 105
- 3-66 – JLG Lift – 3121259 106
- 3121259 – JLG Lift – 3-67 107
- SEE DETAIL 108
- 3121259 – JLG Lift – 3-69 109
- 3.13 ENGINE START CONDITIONS 110
- 3.14 ENGINE RPM LEVELS 110
- Engine Stop RPM 110
- Idle RPM 110
- Mid Engine RPM 110
- 3121259 – JLG Lift – 3-71 111
- 3-72 – JLG Lift – 3121259 112
- 3.17 KUBOTA ENGINE 113
- Engine Oil Pressure Switch 113
- Engine Speed Sensor 113
- Coolant Sensor 114
- Glow Plugs 114
- Engine Speed Actuators 115
- Engine Start 116
- Alternator Excitation 116
- Fuel Pump 116
- Shutdown 116
- 3121259 – JLG Lift – 3-77 117
- 3-78 – JLG Lift – 3121259 118
- 3121259 – JLG Lift – 3-79 119
- 3-80 – JLG Lift – 3121259 120
- 3121259 – JLG Lift – 3-81 121
- 3-82 – JLG Lift – 3121259 122
- 3121259 – JLG Lift – 3-83 123
- 3-84 – JLG Lift – 3121259 124
- 3121259 – JLG Lift – 3-85 125
- 3-86 – JLG Lift – 3121259 126
- LP MIXER PURGE POINT 127
- HOSE FROM CARBON CANISTER 127
- 3-88 – JLG Lift – 3121259 128
- 3121259 – JLG Lift – 3-89 129
- VOLTAGE REGULATOR 130
- CONTROL BOX 130
- GENERATOR 130
- ASSEMBLY 130
- 3.22 COUNTERWEIGHT 131
- 3-92 – JLG Lift – 3121259 132
- 4.3 BOOM MAINTENANCE 133
- Disassembly of the Main Boom 133
- 4-2 – JLG Lift – 3121259 134
- Inspection 135
- Assembly of the Main Boom 135
- 4-4 – JLG Lift – 3121259 136
- 3121259 – JLG Lift – 4-5 137
- 4-6 – JLG Lift – 3121259 138
- 3121259 – JLG Lift – 4-7 139
- 4-8 – JLG Lift – 3121259 140
- 3121259 – JLG Lift – 4-9 141
- 4.5 ROTARY ACTUATOR 142
- Theory of Operation 142
- Tools Required 143
- Disassembly 144
- 3121259 – JLG Lift – 4-13 145
- 4-14 – JLG Lift – 3121259 146
- 3121259 – JLG Lift – 4-15 147
- 4-16 – JLG Lift – 3121259 148
- 3121259 – JLG Lift – 4-19 151
- 4-20 – JLG Lift – 3121259 152
- 3121259 – JLG Lift – 4-21 153
- Greasing Thrust Washers 154
- Testing the Actuator 154
- 3121259 – JLG Lift – 4-23 155
- Installation and Bleeding 156
- Troubleshooting 157
- 4-26 – JLG Lift – 3121259 158
- SECTION 5. HYDRAULICS 159
- Dip Method 160
- Spray Method 160
- Brush-on Method 160
- 5.2 HYDRAULIC CYLINDERS 161
- General Information 161
- Standard of Maintenance 161
- Inspection After Assembly 161
- SECTION 5 - HYDRAULICS 162
- Disassembly Procedure 164
- JIG FOR 168
- DUST WIPER 168
- 3121259 – JLG Lift – 5-21 179
- 3121259 – JLG Lift – 5-23 181
- 5-24 – JLG Lift – 3121259 182
- 3121259 – JLG Lift – 5-25 183
- 3121259 – JLG Lift – 5-29 187
- 5-30 – JLG Lift – 3121259 188
- 5.3 DRIVE PUMP 192
- Description 192
- The System Circuit 193
- Charge Pressure Relief Valve 194
- Plug Size and Torque Chart 215
- Initial Startup Procedures 218
- Pump Adjustment 222
- Control Neutral Adjustment 226
- Mechanical Neutral Adjustment 227
- Removing the Pump 228
- Electric Control Module 228
- Control Solenoids 229
- Charge Check / HPRV 231
- 5.4 GEAR PUMP 232
- 5.6 OIL SAMPLING 243
- Procedure 243
- INSTRUCTIONS 245
- Introduction 245
- 6.2 ANALYZER MENU STRUCTURE 246
- Using the Analyzer 247
- Analyzer 248
- Machine Setup 250
- Level Vehicle Description 250
- 3121259 – JLG Lift – 6-7 251
- 6-8 – JLG Lift – 3121259 252
- PLATFORM MODULE 253
- GROUND MODULE 253
- 6-10 – JLG Lift – 3121259 254
- 3121259 – JLG Lift – 6-11 255
- 6-12 – JLG Lift – 3121259 256
- 3121259 – JLG Lift – 6-13 257
- 6-14 – JLG Lift – 3121259 258
- 3121259 – JLG Lift – 6-15 259
- Ground Control Switches 260
- Platform Control Switches 260
- 3121259 – JLG Lift – 6-17 261
- 6-18 – JLG Lift – 3121259 262
- 3121259 – JLG Lift – 6-19 263
- ANALYZER 264
- 3121259 – JLG Lift – 6-21 265
- 6-22 – JLG Lift – 3121259 266
- 3121259 – JLG Lift – 6-23 267
- 6-24 – JLG Lift – 3121259 268
- 3121259 – JLG Lift – 6-25 269
- 6-26 – JLG Lift – 3121259 270
- 3121259 – JLG Lift – 6-27 271
- 6-28 – JLG Lift – 3121259 272
- 3121259 – JLG Lift – 6-29 273
- 6-30 – JLG Lift – 3121259 274
- 3121259 – JLG Lift – 6-31 275
- 6-32 – JLG Lift – 3121259 276
- 6.6 SYSTEM FAULT MESSAGES 277
- 6-34 – JLG Lift – 3121259 278
- 3121259 – JLG Lift – 6-35 279
- 6-36 – JLG Lift – 3121259 280
- 3121259 – JLG Lift – 6-37 281
- 6-38 – JLG Lift – 3121259 282
- 3121259 – JLG Lift – 6-39 283
- 6-40 – JLG Lift – 3121259 284
- 3121259 – JLG Lift – 6-41 285
- 6-42 – JLG Lift – 3121259 286
- 3121259 – JLG Lift – 6-43 287
- 6-44 – JLG Lift – 3121259 288
- 3121259 – JLG Lift – 6-45 289
- 6-46 – JLG Lift – 3121259 290
- 3121259 – JLG Lift – 6-47 291
- 6-48 – JLG Lift – 3121259 292
- 3121259 – JLG Lift – 6-49 293
- 6-50 – JLG Lift – 3121259 294
- 3121259 – JLG Lift – 6-51 295
- 6-52 – JLG Lift – 3121259 296
- 3121259 – JLG Lift – 6-53 297
- 6-54 – JLG Lift – 3121259 298
- 3121259 – JLG Lift – 6-55 299
- 6-56 – JLG Lift – 3121259 300
- 3121259 – JLG Lift – 6-57 301
- 6-58 – JLG Lift – 3121259 302
- 3121259 – JLG Lift – 6-59 303
- 6-60 – JLG Lift – 3121259 304
- 3121259 – JLG Lift – 6-61 305
- 6-62 – JLG Lift – 3121259 306
- 3121259 – JLG Lift – 6-63 307
- 6-64 – JLG Lift – 3121259 308
- 3121259 – JLG Lift – 6-65 309
- 6-66 – JLG Lift – 3121259 310
- 3121259 – JLG Lift – 6-67 311
- 6-68 – JLG Lift – 3121259 312
- 3121259 – JLG Lift – 6-69 313
- 6-70 – JLG Lift – 3121259 314
- 3121259 – JLG Lift – 7-1 315
- Resistance Measurement 316
- Continuity Measurement 316
- Current Measurement 317
- TO ELECTRICAL CONNECTIONS 317
- AMP Seal 318
- AMP Mate-N-Lok 319
- DIN Connectors 319
- Exclusions 319
- 7-6 – JLG Lift – 3121259 320
- AMP JUNIOR TIMER 320
- SEALED ENCLOSURES 320
- 7.4 AMP CONNECTOR 321
- 7-8 – JLG Lift – 3121259 322
- Wedge Lock 323
- Service - Voltage Reading 323
- 7-10 – JLG Lift – 3121259 324
- 7.5 DEUTSCH CONNECTORS 325
- DT/DTP Series Assembly 325
- DT/DTP Series Disassembly 325
- HD30/HDP20 Series Assembly 326
- HD30/HDP20 Series Disassembly 326
- 3121259 – JLG Lift – 7-13 327
- 7-14 – JLG Lift – 3121259 328
- 00111963-G 329
- 7-16 – JLG Lift – 3121259 330
- 1001119638-G 331
- 7-18 – JLG Lift – 3121259 332
- 7-20 – JLG Lift – 3121259 334
- KUBOTA ENGINE HARNESS 336
- GENERATOR HARNESS 337
- GM ENGINE HARNESS 338
- 7-26 – JLG Lift – 3121259 340
- 3121259 – JLG Lift – 7-29 343
- 7-30 – JLG Lift – 3121259 344
- 1001120020-C 345
- 7-32 – JLG Lift – 3121259 346
- JLG Worldwide Locations 348
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