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SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)
3120895 – JLG Lift – 6-1
SECTION 6. JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)
6.1 INTRODUCTION
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER ON
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON-
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD-
ING OPTIONS.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 12 volt based
motor control unit installed on the boom lift.
The JLG Control System has reduced the need for
exposed terminal strips, diodes and trimpots and provides
simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,
creep, min speed, and max.-speed for all boom, drive,
and steering functions.
The upper lift, swing, and drive are controlled by individual
joysticks, with steering being controlled by a rocker switch
built into the top the drive joystick. To activate Drive, Lift,
and Swing simply pull up on the slide lock location on the
joystick and move the handle into the direction desired.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation
and maximum cycle time. Ground control speeds for all
boom functions can also be programmed into the control
system.
The JLG Control System controller has a built in LED to
indicate any faults. The system stores recent faults which
may be accessed for troubleshooting. Optional equip-
ment includes a soft touch system, head and tail lights,
and ground alarm. These options may be added later but
must be programmed into the control system when
installed.
The Control System may be accessed utilizing a custom
designed, hand held analyzer (Analyzer, JLG part no.
1600244 & Cable, JLG part no. 1600633) which will dis-
play two lines of information at a time, by scrolling through
the program.
NOTE: Each module has a label with the JLG part number
and a serial number which contains a date code.
Analyzer Display
Escape Key
To return home or access
previous menu
Enter Key
Stores and selects Top Level, Sub
Level, and item menus
Left & Right Arrow Keys
Used to move between Top Level,
Sub Level, and item menus
Up & Down Arrow Keys
Value Selector
Figure 6-1. Hand Held Analyzer
- P/N - 3120895 1
- A GENERAL 3
- B HYDRAULIC SYSTEM SAFETY 3
- CMAINTENANCE 3
- REVISON LOG 4
- 10
- TABLE OF CONTENTS 11
- LIST OF FIGURES 13
- LIST OF TABLES 19
- SECTION 1. SPECIFICATIONS 21
- 1.3 TIRES 22
- 1.5 TORQUE REQUIREMENTS 23
- SECTION 1 - SPECIFICATIONS 24
- 1.10 CYLINDER SPECIFICATIONS 25
- 1.11 LUBRICATION 25
- Hydraulic Oil 25
- 1.13 SERIAL NUMBER LOCATION 26
- LUBRICATION 27
- Regulator 30
- SOCKET HEAD CAP SCREWS 34
- Magni Coating (Ref 4150701)* 38
- SECTION 2. GENERAL 39
- 2.2 SERVICE AND GUIDELINES 40
- Safety and Workmanship 40
- Cleanliness 40
- SECTION 2 - GENERAL 41
- AMBIENT AIR 49
- TEMPERATURE 49
- 3120895 – JLG Lift – 3-1 53
- 3120895 – JLG Lift – 3-3 55
- 3-4 – JLG Lift – 3120895 56
- 3120895 – JLG Lift – 3-5 57
- Final Assembly 58
- 3120895 – JLG Lift – 3-7 59
- 3-8 – JLG Lift – 3120895 60
- Hub-Spindle Disassembly 61
- Cover Disassembly 61
- Carrier Disassembly 61
- Assembly of the Carrier 62
- 3120895 – JLG Lift – 3-11 63
- Cover Sub-Assembly 64
- Hub-Spindle Sub-Assembly 65
- 3-14 – JLG Lift – 3120895 66
- Main Assembly 67
- 3-16 – JLG Lift – 3120895 68
- 3120895 – JLG Lift – 3-17 69
- 3-18 – JLG Lift – 3120895 70
- 3120895 – JLG Lift – 3-19 71
- Tool List 72
- COUPLING 73
- Equipment Required 73
- 3.6 DRIVE BRAKE 74
- Pre-Installation Checks 74
- Maintenance 75
- Examination 75
- 3-24 – JLG Lift – 3120895 76
- 3.7 DRIVE MOTOR 77
- Description 77
- Shaft Seal Replacement 77
- Loop Flushing Valve 78
- Troubleshooting 79
- 3120895 – JLG Lift – 3-29 81
- 3-30 – JLG Lift – 3120895 82
- 3120895 – JLG Lift – 3-31 83
- Slipper retainer 85
- Ball guide 85
- (47-61 Nm) 89
- 35-45 ft.lbs 89
- Initial Start-up Procedures 91
- 3.8 ADJUSTMENT PROCEDURE FOR 92
- LOCKOUT VALVE 92
- 3.9 TOE-IN ADJUSTMENT 92
- 3.10 2WD HUB 93
- Removal & Disassembly 93
- Cleaning & Inspection 93
- Assembly & Installation 94
- PROCEDURE 95
- 3.13 SWING BEARING 96
- Wear Tolerance 97
- Replacement of Swing Bearing 98
- Swing Bearing Torque Value 99
- Swing Drive Installation 99
- 3-48 – JLG Lift – 3120895 100
- 3120895 – JLG Lift – 3-49 101
- Installation 102
- Brake Disassembly 102
- Assembly Information 102
- 3120895 – JLG Lift – 3-51 103
- Assembly 104
- Disassembly 104
- 3.16 SWING DRIVE TORQUE HUB 106
- Disassembly Procedure 106
- 3120895 – JLG Lift – 3-55 107
- 3-56 – JLG Lift – 3120895 108
- 3120895 – JLG Lift – 3-57 109
- 3-58 – JLG Lift – 3120895 110
- 3120895 – JLG Lift – 3-59 111
- 3-60 – JLG Lift – 3120895 112
- 3.17 SEMI-TRACK 113
- Testing the Track 113
- Removing the Track 114
- Assuming Normal Wear 114
- Adjustment 114
- 3120895 – JLG Lift – 3-63 115
- 3-64 – JLG Lift – 3120895 116
- 3120895 – JLG Lift – 3-65 117
- 3-66 – JLG Lift – 3120895 118
- INSPECTING BRUSH POSITION 118
- INSPECTING BRUSHES 118
- CLEANING SLIP RINGS 118
- 3120895 – JLG Lift – 3-67 119
- 3.19 FORD EFI ENGINE 120
- Performing Diagnostics 120
- ECM and Sensors 121
- 3-70 – JLG Lift – 3120895 122
- 3120895 – JLG Lift – 3-71 123
- READ ONLY MEMORY (EEPROM) 123
- HEATED OXYGEN SENSOR 123
- 3-72 – JLG Lift – 3120895 124
- 3120895 – JLG Lift – 3-73 125
- ENGINE CONTROL MODULE (ECM) 125
- 3-74 – JLG Lift – 3120895 126
- ECM INPUTS/OUTPUTS 126
- ECM SERVICE PRECAUTIONS 126
- THROTTLE POSITION (TP) SENSOR 126
- USE OF CIRCUIT TESTING TOOLS 126
- Fuel System 127
- 3-76 – JLG Lift – 3120895 128
- FUEL METERING SYSTEM PURPOSE 128
- 3-78 – JLG Lift – 3120895 130
- ELECTRONIC IGNITION 130
- 3120895 – JLG Lift – 3-79 131
- IGNITION COIL 131
- Procedure 132
- Controller Status 132
- Failure Modes 132
- 3120895 – JLG Lift – 3-81 133
- 3-82 – JLG Lift – 3120895 134
- Manual Adjustment 135
- 3-84 – JLG Lift – 3120895 136
- 3120895 – JLG Lift – 3-85 137
- 3.22 HYDRAULIC WELDER (225-4) 138
- Replacement of Fine Control 138
- Rotor Replacement 139
- Replacement of Flow Regulator 139
- Replace Brushes on Sky Welder 140
- Replacing Range Switch 140
- Replacing Selector Switch 140
- Replacement of Couplings 141
- 3-90 – JLG Lift – 3120895 142
- 3120895 – JLG Lift – 3-91 143
- 3-92 – JLG Lift – 3120895 144
- 3120895 – JLG Lift – 3-93 145
- Receptacle Output OK 146
- Intermittent Welder Operation 146
- 3120895 – JLG Lift – 3-95 147
- 3-96 – JLG Lift – 3120895 148
- 3120895 – JLG Lift – 3-97 149
- 3-98 – JLG Lift – 3120895 150
- 3120895 – JLG Lift – 3-99 151
- 3-100 – JLG Lift – 3120895 152
- 3120895 – JLG Lift – 3-101 153
- 3-102 – JLG Lift – 3120895 154
- 3120895 – JLG Lift – 3-103 155
- 3-104 – JLG Lift – 3120895 156
- 3120895 – JLG Lift – 3-105 157
- 3-106 – JLG Lift – 3120895 158
- 3120895 – JLG Lift – 3-107 159
- Maintenance of the Drive Belt 160
- Changing The Engine Oil 161
- 3-110 – JLG Lift – 3120895 162
- Fuel Filter 163
- Electric Lock Off 163
- EPR Assembly 164
- Low Pressure Regulator (LPR) 164
- Air Fuel Mixer 165
- Engine Control Module 166
- 3120895 – JLG Lift – 3-115 167
- Propane Fuel System Leak Test 168
- Assembly Replacement 169
- (TMAP) Sensor 170
- 3120895 – JLG Lift – 3-119 171
- MIXER REPLACEMENT 172
- Coolant Hose Replacement 172
- Vapor Hose Replacement 172
- 3120895 – JLG Lift – 3-121 173
- Diagnostic Aids 174
- 3120895 – JLG Lift – 3-123 175
- 3-124 – JLG Lift – 3120895 176
- 3120895 – JLG Lift – 3-125 177
- 3-126 – JLG Lift – 3120895 178
- 3120895 – JLG Lift – 3-127 179
- 3-128 – JLG Lift – 3120895 180
- 3120895 – JLG Lift – 3-129 181
- 3-130 – JLG Lift – 3120895 182
- 3120895 – JLG Lift – 3-131 183
- 3-132 – JLG Lift – 3120895 184
- 3120895 – JLG Lift – 3-133 185
- 3-134 – JLG Lift – 3120895 186
- 3120895 – JLG Lift – 3-135 187
- 3-136 – JLG Lift – 3120895 188
- 3120895 – JLG Lift – 3-137 189
- 3.29 PERKINS ENGINE GENERAL 190
- MAINTENANCE 190
- Engine Oil Level - Check 190
- 3120895 – JLG Lift – 3-139 191
- Fuel Filter/Water Separator 192
- Setting the Actuator 193
- Speed Sensor Installation 194
- PERKINS & CATERPILLAR 194
- 3120895 – JLG Lift – 3-143 195
- 3-144 – JLG Lift – 3120895 196
- 3120895 – JLG Lift – 3-145 197
- Fault Code Broadcast 198
- Diagnostic Trouble Codes 198
- MIL Output 199
- Corrective Actions 199
- 3-148 – JLG Lift – 3120895 200
- 3120895 – JLG Lift – 3-149 201
- 3-150 – JLG Lift – 3120895 202
- 3120895 – JLG Lift – 3-151 203
- 3-152 – JLG Lift – 3120895 204
- DBW Diagnostic Test 205
- DESCRIPTIONS 206
- DTC 117- ECT/CHT Low Voltage 207
- 3-156 – JLG Lift – 3120895 208
- DTC 118- ECT/CHT High Voltage 209
- 3-158 – JLG Lift – 3120895 210
- 3120895 – JLG Lift – 3-159 211
- 3-160 – JLG Lift – 3120895 212
- 3120895 – JLG Lift – 3-161 213
- 3-162 – JLG Lift – 3120895 214
- 3120895 – JLG Lift – 3-163 215
- 3-166 – JLG Lift – 3120895 218
- 3120895 – JLG Lift – 3-167 219
- Pressure 221
- Normally Open Switch 222
- Normally Closed Switch 222
- Sensor/Transducer Type 223
- DTC 524- Oil Pressure Low 224
- 3-176 – JLG Lift – 3120895 228
- 3120895 – JLG Lift – 3-177 229
- 3-178 – JLG Lift – 3120895 230
- 3120895 – JLG Lift – 3-179 231
- 3-180 – JLG Lift – 3120895 232
- 3120895 – JLG Lift – 3-181 233
- 3-182 – JLG Lift – 3120895 234
- 3120895 – JLG Lift – 3-183 235
- 3-184 – JLG Lift – 3120895 236
- 3120895 – JLG Lift – 3-185 237
- 3-186 – JLG Lift – 3120895 238
- 3-188 – JLG Lift – 3120895 240
- 3-190 – JLG Lift – 3120895 242
- 3120895 – JLG Lift – 3-191 243
- SFC 555- RTI 2 Loss 244
- 3120895 – JLG Lift – 3-193 245
- SFC 556- RTI 3 Loss 246
- 3120895 – JLG Lift – 3-195 247
- SFC 513- A/D Loss 248
- 3120895 – JLG Lift – 3-197 249
- SFC 512- Invalid Interrupt 250
- 3-202 – JLG Lift – 3120895 254
- 3120895 – JLG Lift – 3-203 255
- 3-206 – JLG Lift – 3120895 258
- 3120895 – JLG Lift – 3-207 259
- 3-208 – JLG Lift – 3120895 260
- DTC to SPN/FMI Table 262
- 3120895 – JLG Lift – 3-211 263
- 3-212 – JLG Lift – 3120895 264
- 4.1 BOOM 265
- Inspection 267
- 4-6 – JLG Lift – 3120895 270
- 3120895 – JLG Lift – 4-7 271
- 4-8 – JLG Lift – 3120895 272
- 3120895 – JLG Lift – 4-9 273
- Test Notes 274
- Lift, Swing, and Drive Cards 275
- Flow Control Card 275
- 4-12 – JLG Lift – 3120895 276
- 4.5 HELAC ROTARY ACTUATOR 277
- Theory Of Operation 277
- 4-14 – JLG Lift – 3120895 278
- 3120895 – JLG Lift – 4-15 279
- 3120895 – JLG Lift – 4-17 281
- 4-18 – JLG Lift – 3120895 282
- 3120895 – JLG Lift – 4-19 283
- 3120895 – JLG Lift – 4-21 285
- 4-22 – JLG Lift – 3120895 286
- 3120895 – JLG Lift – 4-23 287
- 4-24 – JLG Lift – 3120895 288
- SECTION 5. HYDRAULICS 289
- Cleaning and Inspection 291
- SECTION 5 - HYDRAULICS 293
- Solenoid Control Valve 302
- Reassembly Shaft End 308
- Gerotor End 310
- Timing Procedure 311
- Standard Rotation 311
- Reverse Rotation 311
- PROCEDURES AND 315
- RECOMMENDATIONS 315
- 6.1 INTRODUCTION 317
- 6-2 – JLG Lift – 3120895 318
- SYSTEM ANALYZER 319
- 6.3 USING THE ANALYZER 319
- 6-4 – JLG Lift – 3120895 320
- HAND HELD ANALYZER 321
- 6-6 – JLG Lift – 3120895 322
- 6.6 MACHINE SETUP 324
- 6.7 LEVEL VEHICLE DESCRIPTION 324
- 3120895 – JLG Lift – 6-9 325
- 6-10 – JLG Lift – 3120895 326
- 3120895 – JLG Lift – 6-11 327
- 6-12 – JLG Lift – 3120895 328
- 3120895 – JLG Lift – 6-13 329
- 6-14 – JLG Lift – 3120895 330
- 3120895 – JLG Lift – 6-15 331
- 6-16 – JLG Lift – 3120895 332
- 3120895 – JLG Lift – 6-17 333
- 6-18 – JLG Lift – 3120895 334
- 4150365-3 335
- 6-20 – JLG Lift – 3120895 336
- 3120895 – JLG Lift – 6-21 337
- 6-22 – JLG Lift – 3120895 338
- 3120895 – JLG Lift – 6-23 339
- 6-24 – JLG Lift – 3120895 340
- 3120895 – JLG Lift – 6-25 341
- 6-26 – JLG Lift – 3120895 342
- 3120895 – JLG Lift – 6-27 343
- 6-28 – JLG Lift – 3120895 344
- 3120895 – JLG Lift – 6-29 345
- 6-30 – JLG Lift – 3120895 346
- 3120895 – JLG Lift – 6-31 347
- 6-32 – JLG Lift – 3120895 348
- 3120895 – JLG Lift – 6-33 349
- 6-34 – JLG Lift – 3120895 350
- 3120895 – JLG Lift – 6-35 351
- 6-36 – JLG Lift – 3120895 352
- 3120895 – JLG Lift – 6-37 353
- 6-38 – JLG Lift – 3120895 354
- 3120895 – JLG Lift – 6-39 355
- 6-40 – JLG Lift – 3120895 356
- 3120895 – JLG Lift – 6-41 357
- 6-42 – JLG Lift – 3120895 358
- 3120895 – JLG Lift – 6-43 359
- 6-44 – JLG Lift – 3120895 360
- 3120895 – JLG Lift – 6-45 361
- 6-46 – JLG Lift – 3120895 362
- 3120895 – JLG Lift – 6-47 363
- 6-48 – JLG Lift – 3120895 364
- 3120895 – JLG Lift – 6-49 365
- 6-50 – JLG Lift – 3120895 366
- 3120895 – JLG Lift – 6-51 367
- 6-52 – JLG Lift – 3120895 368
- 4150364-18 369
- 6-54 – JLG Lift – 3120895 370
- 3120895 – JLG Lift – 6-55 371
- 6-56 – JLG Lift – 3120895 372
- 3120895 – JLG Lift – 6-57 373
- 6-58 – JLG Lift – 3120895 374
- 4150364-19 375
- 6.9 SYSTEM TEST 378
- Test from the Platform 378
- 3120895 – JLG Lift – 6-63 379
- Test from the Ground Station 380
- 3120895 – JLG Lift – 6-65 381
- 6-66 – JLG Lift – 3120895 382
- 3120895 – JLG Lift – 6-67 383
- 6-68 – JLG Lift – 3120895 384
- 3120895 – JLG Lift – 6-69 385
- 6-70 – JLG Lift – 3120895 386
- 3120895 – JLG Lift – 6-71 387
- 6-72 – JLG Lift – 3120895 388
- 3120895 – JLG Lift – 6-73 389
- 6-74 – JLG Lift – 3120895 390
- 3120895 – JLG Lift – 6-75 391
- 6-76 – JLG Lift – 3120895 392
- 3120895 – JLG Lift – 6-77 393
- 6-78 – JLG Lift – 3120895 394
- 3120895 – JLG Lift – 6-79 395
- 6-80 – JLG Lift – 3120895 396
- STRUCTURE 397
- 6-82 – JLG Lift – 3120895 398
- 3120895 – JLG Lift – 6-83 399
- 6-84 – JLG Lift – 3120895 400
- 3120895 – JLG Lift – 6-85 401
- 6-86 – JLG Lift – 3120895 402
- 3120895 – JLG Lift – 7-1 403
- Resistance Measurement 404
- Continuity Measurement 404
- Current Measurement 405
- 7.3 CHECKING SWITCHES 405
- Basic Check 405
- Limit Switches 405
- Automatic Switches 406
- COMPOUND TO ELECTRICAL 406
- CONNECTIONS 406
- AMP Seal 407
- AMP Mate-N-Lok 408
- DIN Connectors 408
- Exclusions 408
- 3120895 – JLG Lift – 7-7 409
- AMP JUNIOR TIMER 409
- SEALED ENCLOSURES 409
- MIL-C-5015 SPEC CONNECTORS 409
- 7.5 AMP CONNECTOR 410
- AMP Connectors 410
- 3120895 – JLG Lift – 7-9 411
- Wedge Lock 412
- Service - Voltage Reading 412
- 3120895 – JLG Lift – 7-11 413
- 7.6 DEUTSCH CONNECTORS 414
- DT/DTP Series Assembly 414
- DT/DTP Series Disassembly 414
- HD30/HDP20 Series Assembly 415
- HD30/HDP20 Series Disassembly 415
- 7-14 – JLG Lift – 3120895 416
- 3120895 – JLG Lift – 7-15 417
- 7-16 – JLG Lift – 3120895 418
- 3120895 – JLG Lift – 7-17 419
- 7-18 – JLG Lift – 3120895 420
- 3120895 – JLG Lift – 7-19 421
- 7-20 – JLG Lift – 3120895 422
- 3120895 – JLG Lift – 7-21 423
- 7-22 – JLG Lift – 3120895 424
- 3120895 – JLG Lift – 7-23 425
- 7-24 – JLG Lift – 3120895 426
- 3120895 – JLG Lift – 7-25 427
- 7-26 – JLG Lift – 3120895 428
- 3120895 – JLG Lift – 7-27 429
- 7-28 – JLG Lift – 3120895 430
- 3120895 – JLG Lift – 7-29 431
- 7-30 – JLG Lift – 3120895 432
- 3120895 – JLG Lift – 7-31 433
- 7-32 – JLG Lift – 3120895 434
- 3120895 – JLG Lift – 7-33 435
- 7-34 – JLG Lift – 3120895 436
- 3120895 – JLG Lift – 7-35 437
- 7-36 – JLG Lift – 3120895 438
- 3120895 – JLG Lift – 7-37 439
- 7-38 – JLG Lift – 3120895 440
- 3120895 – JLG Lift – 7-39 441
- 7-40 – JLG Lift – 3120895 442
- 3120895 – JLG Lift – 7-41 443
- 7-42 – JLG Lift – 3120895 444
- 3120895 – JLG Lift – 7-43 445
- 7-44 – JLG Lift – 3120895 446
- 3120895 – JLG Lift – 7-45 447
- 7-46 – JLG Lift – 3120895 448
- 3120895 – JLG Lift – 7-47 449
- 7-48 – JLG Lift – 3120895 450
- 3120895 – JLG Lift – 7-49 451
- 7-50 – JLG Lift – 3120895 452
- 3120895 – JLG Lift – 7-51 453
- 7-52 – JLG Lift – 3120895 454
- 3120895 – JLG Lift – 7-53 455
- 7-54 – JLG Lift – 3120895 456
- 3120895 – JLG Lift – 7-55 457
- 7-56 – JLG Lift – 3120895 458
- 3120895 – JLG Lift – 7-57 459
- 7-58 – JLG Lift – 3120895 460
- JLG Worldwide Locations 462
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