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Table of contents
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SECTION 7 - BASIC ELECTRICAL INFOR
MATION & SCHEMATICS
3120895
– JLG Lift –
7-35
Figure 7-40. Elec
trical
Schematic - Cater
pillar Engine - Sh
eet 4 of 6
1870132 M
1
2
...
432
433
434
435
436
437
438
439
440
441
442
...
461
462
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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