Jlg 4394RT Service Manual Bedienungsanleitung Seite 78
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SECTION 3 - CHASSIS & SCISSOR ARMS
3-42 – JLG Sizzor – 3121133
ELECTRONIC IGNITION
The electronic ignition system controls fuel combustion by
providing a spark to ignite the compressed air/fuel w mix-
ture at the correct time. To provide optimum engine perfor-
mance, fuel economy, and control of exhaust emissions,
the ECM controls the spark advance of the ignition system.
Electronic ignition has the following advantages over a
mechanical distributor system:
• No moving parts
• Less maintenance
• Remote mounting capability
• No mechanical load on the engine
• More coil cooldown time between firing events
• Elimination of mechanical timing adjustments
• Increased available ignition coil saturation time
IGNITION COIL
The electronic ignition system uses a coil pack with one
ignition coil for each two cylinders in the engine. Each cyl-
inder is paired with its opposing cylinder in the firing order,
so that one cylinder on compression fires simultaneously
with the opposing cylinder on exhaust. The spark that
occurs in the cylinder on the exhaust stroke is referred to
as a "waste spark."
The primary coils in the coil pack are triggered by the
"Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals
from the ECM.
ENGINE CONTROL MODULE (ECM)
The ECM is responsible for maintaining proper spark and
fuel injection timing for all operating conditions. To provide
optimum operation and emissions, the ECM monitors the
input signals from the following components in order to
calculate spark timing:
• Engine coolant temperature (ECT) sensor
• Intake air temperature (IAT) sensor
• Throttle position sensor
• Crankshaft position sensor
- October 6, 2008 1
- PRECAUTIONS 3
- REVISION LOG 4
- 5
- TABLE OF CONTENTS 10
- SECTION 1. SPECIFICATIONS 11
- 1.4 TIRES 12
- 1.5 MACHINE DIMENSIONS 12
- 1.6 PRESSURE SETTINGS 12
- 1.7 SERIAL NUMBER LOCATIONS 12
- 1.8 SENSORS 13
- 1.9 CYLINDER SPECIFICATIONS 13
- 1.10 MAJOR COMPONENT WEIGHTS 13
- SECTION 1 - SPECIFICATIONS 14
- 1.13 OPERATOR MAINTENANCE 15
- Regulator 18
- 1.14 TORQUE CHARTS 20
- SECTION 2. GENERAL 27
- 2.2 SERVICE AND GUIDELINES 28
- Safety and Workmanship 28
- Cleanliness 28
- SECTION 2 - GENERAL 29
- Hydraulic System 30
- Hydraulic Oil 30
- Changing Hydraulic Oil 30
- Lubrication Specifications 30
- 2.4 CYLINDER DRIFT TEST 31
- Platform Drift 31
- Cylinder Drift 31
- REPAIR GUIDELINES 31
- INSPECTION SCHEDULE 32
- 3121133 – JLG Sizzor – 3-1 37
- 0.50v-1.0v x-xxv 38
- Elevation Sensor Calibration 39
- (Software P1.20 & Higher) 39
- Joystick Calibration 39
- Tilt Sensor Calibration: 39
- 3-4 – JLG Sizzor – 3121133 40
- Tilt Sensor, JLG P/N 4000006: 42
- Tilt Sensor, JLG P/N 4000021: 43
- Roll Test 44
- Leak Test 44
- 3121133 – JLG Sizzor – 3-9 45
- Disconnect Mechanism 46
- Gearbox Disassembly 47
- 3-12 – JLG Sizzor – 3121133 48
- Gearbox Assembly 49
- 3-14 – JLG Sizzor – 3121133 50
- 3121133 – JLG Sizzor – 3-15 51
- 3-16 – JLG Sizzor – 3121133 52
- 3121133 – JLG Sizzor – 3-17 53
- 3-18 – JLG Sizzor – 3121133 54
- Motor Disassembly 55
- 3-20 – JLG Sizzor – 3121133 56
- 3121133 – JLG Sizzor – 3-21 57
- 3-22 – JLG Sizzor – 3121133 58
- 3121133 – JLG Sizzor – 3-23 59
- 3-24 – JLG Sizzor – 3121133 60
- Motor Assembly 61
- 3-26 – JLG Sizzor – 3121133 62
- 3121133 – JLG Sizzor – 3-27 63
- 3-28 – JLG Sizzor – 3121133 64
- 3121133 – JLG Sizzor – 3-29 65
- 3.5 DUAL FUEL/LPG SYSTEM 66
- 3.6 FORD EFI ENGINE 67
- Performing Diagnostics 67
- EFI Diagnostics 67
- ECM and Sensors 67
- 3-32 – JLG Sizzor – 3121133 68
- 3121133 – JLG Sizzor – 3-33 69
- 3121133 – JLG Sizzor – 3-35 71
- 3-36 – JLG Sizzor – 3121133 72
- ENGINE CONTROL MODULE (ECM) 72
- 3121133 – JLG Sizzor – 3-37 73
- ECM INPUTS/OUTPUTS 73
- ECM SERVICE PRECAUTIONS 73
- THROTTLE POSITION (TP) SENSOR 73
- USE OF CIRCUIT TESTING TOOLS 73
- Fuel System 74
- 3121133 – JLG Sizzor – 3-39 75
- FUEL METERING SYSTEM PURPOSE 75
- 3121133 – JLG Sizzor – 3-41 77
- 3-42 – JLG Sizzor – 3121133 78
- ELECTRONIC IGNITION 78
- IGNITION COIL 78
- 3.7 GENERATOR - FORD ENGINE 79
- PRESENT) 80
- 3121133 – JLG Sizzor – 3-45 81
- 3-46 – JLG Sizzor – 3121133 82
- 3121133 – JLG Sizzor – 3-47 83
- 3-48 – JLG Sizzor – 3121133 84
- 3121133 – JLG Sizzor – 3-49 85
- 3-50 – JLG Sizzor – 3121133 86
- 3121133 – JLG Sizzor – 3-51 87
- 3-52 – JLG Sizzor – 3121133 88
- 3121133 – JLG Sizzor – 3-53 89
- 3-54 – JLG Sizzor – 3121133 90
- 3121133 – JLG Sizzor – 3-55 91
- 3-56 – JLG Sizzor – 3121133 92
- 3.9 GENERATOR - DUETZ ENGINE 93
- Maintenance of the Drive Belt 94
- Changing The Engine Oil 95
- 3.11 GENERATOR - GM ENGINE 96
- Fuel Filter 97
- Electric Lock Off 97
- EPR Assembly 98
- Low Pressure Regulator (LPR) 98
- Air Fuel Mixer 99
- Engine Control Module 100
- 3121133 – JLG Sizzor – 3-65 101
- Propane Fuel System Leak Test 102
- Assembly Replacement 103
- (TMAP) Sensor 104
- 3121133 – JLG Sizzor – 3-69 105
- Coolant Hose Replacement 106
- Vapor Hose Replacement 106
- Mixer Replacement 106
- Replacement 107
- DIAGNOSIS 108
- Fuel System Description 108
- Diagnostic Aids 108
- 3121133 – JLG Sizzor – 3-73 109
- 3-74 – JLG Sizzor – 3121133 110
- 3121133 – JLG Sizzor – 3-75 111
- 3.15 JOYSTICK CONTROLLER 112
- 3121133 – JLG Sizzor – 3-77 113
- 3-78 – JLG Sizzor – 3121133 114
- 3121133 – JLG Sizzor – 3-79 115
- 3-80 – JLG Sizzor – 3121133 116
- 3121133 – JLG Sizzor – 3-81 117
- 3-82 – JLG Sizzor – 3121133 118
- 3121133 – JLG Sizzor – 3-83 119
- 3-84 – JLG Sizzor – 3121133 120
- 3121133 – JLG Sizzor – 3-85 121
- 3-86 – JLG Sizzor – 3121133 122
- 3121133 – JLG Sizzor – 3-87 123
- 3-88 – JLG Sizzor – 3121133 124
- SECTION 4. HYDRAULICS 125
- Steer Cylinder 126
- Oscillating Axle Lockout Test 126
- 4.5 CYLINDER REPAIR 127
- Disassembly 127
- SECTION 4 - HYDRAULICS 128
- Cleaning and Inspection 129
- Assembly 130
- PROCEDURES AND 134
- RECOMMENDATIONS 134
- 4.8 HYDRAULIC GEAR PUMP 135
- Pump Disassembly 135
- Parts Inspection 136
- Pump Reassembly 136
- 4.9 MAIN VALVE 138
- Pressure Setting Procedures 139
- 4.12 HEADER VALVES (4WD) 141
- 4.13 DIRECTIONAL VALVE 142
- Pressure Setting Procedure 142
- 4.16 HYDRAULIC PUMP 144
- Auxiliary Pump Motor 145
- 4.17 CYLINDER ASSEMBLIES 146
- 3121133 – JLG Lift – 4-25 149
- 4-26 – JLG Lift – 3121133 150
- 4-28 – JLG Lift – 3121133 152
- 3121133 – JLG Lift – 4-29 153
- OSCILLATING AXLE 154
- OSCILLATING AXLE CYLINDER 154
- 5.1 HAND HELD ANALYZER 155
- Using the Analyzer: 156
- Analyzer: 157
- Analyzer 158
- Machine Setup 158
- 3121133 – JLG Lift – 5-5 159
- 5-6 – JLG Lift– 3121133 160
- 3121133 – JLG Lift – 5-7 161
- 5-8 – JLG Lift– 3121133 162
- 3121133 – JLG Lift – 5-9 163
- 5-10 – JLG Lift– 3121133 164
- 3121133 – JLG Lift – 5-11 165
- 5-12 – JLG Lift– 3121133 166
- 3121133 – JLG Lift – 5-13 167
- 4150588 D 167
- CONT’D ON SHEET 2 168
- FROM SHEET 1 169
- TO SHEET 3 169
- FROM SHEET 2 170
- 3121133 – JLG Lift – 5-17 171
- 4150389 D 171
- 5-18 – JLG Lift– 3121133 172
- 3121133 – JLG Lift – 5-19 173
- 4150390 J 173
- 5-24 – JLG Lift– 3121133 178
- 3121133 – JLG Sizzor – 6-1 179
- 6-2 – JLG Sizzor – 3121133 180
- 3121133 – JLG Sizzor – 6-3 181
- Procedure 182
- Requirements: 182
- 3121133 – JLG Sizzor – 6-5 183
- 3121133 – JLG Sizzor – 6-7 185
- Wedge Lock 186
- Service - Voltage Reading 187
- DT/DTP Series Assembly 188
- DT/DTP Series Disassembly 188
- HD30/HDP20 Series Assembly 188
- HD30/HDP20 Series Disassembly 189
- 6.5 SWITCHES 190
- Basic check 190
- Limit Switches 190
- Automatic Switches 191
- 6.6 SCHEMATICS 192
- 3121133 – JLG Sizzor – 6-15 193
- 6-16 – JLG Sizzor – 3121133 194
- 1870143 H 194
- 3121133 – JLG Sizzor – 6-17 195
- 6-18 – JLG Sizzor – 3121133 196
- 3121133 – JLG Sizzor – 6-19 197
- 1870153 G 198
- 3121133 – JLG Sizzor – 6-21 199
- 6-22 – JLG Sizzor – 3121133 200
- 3121133 – JLG Sizzor – 6-23 201
- 6-24 – JLG Sizzor – 3121133 202
- 3121133 – JLG Sizzor – 6-25 203
- 6-26 – JLG Sizzor – 3121133 204
- 6-28 – JLG Sizzor – 3121133 206
- 3121133 – JLG Sizzor – 6-29 207
- 6-30 – JLG Sizzor – 3121133 208
- 1870190 D 208
- 3121133 – JLG Sizzor – 6-31 209
- 6-32 – JLG Sizzor – 3121133 210
- 3121133 – JLG Sizzor – 6-33 211
- 6-34 – JLG Sizzor – 3121133 212
- 3121133 – JLG Sizzor – 6-35 213
- 6-36 – JLG Sizzor – 3121133 214
- 3121133 – JLG Sizzor – 6-37 215
- 6-38 – JLG Sizzor – 3121133 216
- 3121133 – JLG Sizzor – 6-39 217
- 6-40 – JLG Sizzor – 3121133 218
- 3121133 – JLG Sizzor – 6-41 219
- 6-42 – JLG Sizzor – 3121133 220
- 3121133 – JLG Sizzor – 6-43 221
- 6-44 – JLG Sizzor – 3121133 222
- 3121133 – JLG Sizzor – 6-45 223
- 6-46 – JLG Sizzor – 3121133 224
- 3121133 – JLG Sizzor – 6-47 225
- 6-48 – JLG Sizzor – 3121133 226
- JLG Worldwide Locations 228
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