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SECTION 4 - HYDRAULICS
4-16
– JLG Lift –
3121249
Flow Divider V
alve
9
13
7
CV3
CV2
6
CV4
9
3
CV5
8
10
CV6
OR2
11
FD1
CV7
OR3
2
1
4
5, OR1
12
CV8
FD3
FD2
Figure 4-18. Flow Divider V
alve
1
2
...
177
178
179
180
181
182
183
184
185
186
187
...
267
268
May 16, 2014
1
PRECAUTIONS
3
REVISION LOG
4
TABLE OF CONTENTS
5
10
LIST OF TABLES
10
TABLE NO. TITLE PAGE NO
10
SECTION 1. SPECIFICATIONS
11
1.4 TIRES
12
1.5 MACHINE DIMENSIONS
12
1.6 PRESSURE SETTINGS
12
1.7 SERIAL NUMBER LOCATIONS
13
1.8 SENSORS
13
1.9 CYLINDER SPECIFICATIONS
14
1.10 MAJOR COMPONENT WEIGHTS
14
SECTION 1 - SPECIFICATIONS
15
1.13 OPERATOR MAINTENANCE
16
Fuel Tank
16
Drive Hub
17
Hydraulic Oil
17
Fuel Filter (Propane) - GM
19
Regulator
19
1.14 TORQUE CHARTS
21
SECTION 2. GENERAL
27
2.2 SERVICE AND GUIDELINES
28
Safety and Workmanship
28
Cleanliness
28
SECTION 2 - GENERAL
29
Hydraulic System
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
3121249 – JLG Lift – 3-1
37
Tire Replacement
38
Wheel Replacement
38
Wheel Installation
38
Drive Assembly
39
3-4 – JLG Lift – 3121249
40
(BOSCH REXROTH)
41
Roll Test
41
Leak Test
41
3-6 – JLG Lift – 3121249
42
Disconnect Mechanism
43
Gearbox Disassembly
44
3121249 – JLG Lift – 3-9
45
Gearbox Assembly
46
3121249 – JLG Lift – 3-11
47
3-12 – JLG Lift – 3121249
48
3121249 – JLG Lift – 3-13
49
3-14 – JLG Lift – 3121249
50
3121249 – JLG Lift – 3-15
51
Motor Disassembly
52
3121249 – JLG Lift – 3-17
53
3-18 – JLG Lift – 3121249
54
3121249 – JLG Lift – 3-19
55
3-20 – JLG Lift – 3121249
56
3121249 – JLG Lift – 3-21
57
Motor Assembly
58
3121249 – JLG Lift – 3-23
59
3-24 – JLG Lift – 3121249
60
3121249 – JLG Lift – 3-25
61
3-26 – JLG Lift – 3121249
62
3.4 DRIVE HUB (FAIRFIELD)
63
Roll and Leak Testing
63
Oil Information
63
3-28 – JLG Lift – 3121249
64
3121249 – JLG Lift – 3-29
65
3-30 – JLG Lift – 3121249
66
Hub-Spindle Disassembly
67
Cover Disassembly
68
Carrier Disassembly
68
Assembly of the Carrier
68
3121249 – JLG Lift – 3-33
69
Cover Sub-Assembly
70
Hub-Spindle Sub-Assembly
71
3-36 – JLG Lift – 3121249
72
Main Assembly
73
3-38 – JLG Lift – 3121249
74
3121249 – JLG Lift – 3-39
75
3-40 – JLG Lift – 3121249
76
3121249 – JLG Lift – 3-41
77
Tool List
78
3.5 DRIVE MOTOR (SAUER)
79
Description
79
Shaft Seal Replacement
79
Loop Flushing Valve
80
Troubleshooting
81
3121249 – JLG Lift – 3-47
83
3-48 – JLG Lift – 3121249
84
3121249 – JLG Lift – 3-49
85
Inspection
86
3121249 – JLG Lift – 3-53
89
3-54 – JLG Lift – 3121249
90
3121249 – JLG Lift – 3-55
91
3-56 – JLG Lift – 3121249
92
Initial Start-up Procedures
93
3.6 FRONT AXLE
94
Steering Assembly
94
Axle Assembly
95
3-60 – JLG Lift – 3121249
96
Axle Lockout Cylinder
97
Cylinder Removal
98
Assembly Removal
99
3.8 PLATFORM
100
3121249 – JLG Lift – 3-65
101
REMOVAL:
101
INSTALLATION:
101
Platform Control Station
102
Joystick Controller
103
3.9 SCISSOR ARMS
104
Lift Cylinder Removal
104
Scissor Arms Removal
105
Scissor Arm Assembly Removal
105
3.10 SIDE COMPARTMENT COVERS
106
3.11 GROUND CONTROL STATION
107
Control Station Removal
107
Ground Control Station
107
3.12 FUEL TANK
108
3.13 HYDRAULIC TANK
109
3.14 BATTERY
110
3.15 DUAL FUEL/LPG SYSTEM
111
3.16 DEUTZ ENGINE
112
Engine Tray
112
Deutz EMR 2
112
Deutz EMR 4
112
3121249 – JLG Lift – 3-77
113
3-78 – JLG Lift – 3121249
114
3121249 – JLG Lift – 3-79
115
3-80 – JLG Lift – 3121249
116
3121249 – JLG Lift – 3-81
117
3-82 – JLG Lift – 3121249
118
3121249 – JLG Lift – 3-83
119
3-84 – JLG Lift – 3121249
120
3121249 – JLG Lift – 3-85
121
3-86 – JLG Lift – 3121249
122
3121249 – JLG Lift – 3-87
123
3-88 – JLG Lift – 3121249
124
Generator (if equipped)
125
Exhaust System
126
Air Cleaner System
127
3-92 – JLG Lift – 3121249
128
3121249 – JLG Lift – 3-93
129
Pump Coupling
130
Engine Removal
131
Radiator
132
3.17 GM ENGINE
133
Maintenance of the Drive Belt
133
Changing The Engine Oil
134
Generator
135
Fuel Components
139
Fuel Filter
143
Electric Lock Off
143
Low Pressure Regulator (LPR)
144
Air Fuel Mixer
144
Engine Control Module (ECM)
145
3-110 – JLG Lift – 3121249
146
3121249 – JLG Lift – 3-111
147
Assembly Replacement
148
3121249 – JLG Lift – 3-113
149
(TMAP) Sensor
150
Mixer Replacement
151
Coolant Hose Replacement
152
Vapor Hose Replacement
152
Replacement
152
DIAGNOSIS
153
Fuel System Description
153
Diagnostic Aids
153
3-118 – JLG Lift – 3121249
154
3121249 – JLG Lift – 3-119
155
3-120 – JLG Lift – 3121249
156
3121249 – JLG Lift – 3-121
157
3-122 – JLG Lift – 3121249
158
3121249 – JLG Lift – 3-123
159
3-124 – JLG Lift – 3121249
160
3121249 – JLG Lift – 3-125
161
3-126 – JLG Lift – 3121249
162
3121249 – JLG Lift – 3-127
163
3-128 – JLG Lift – 3121249
164
3121249 – JLG Lift – 3-129
165
3-130 – JLG Lift – 3121249
166
SECTION 4. HYDRAULICS
167
SECTION 4 - HYDRAULICS
168
4.4 CYLINDER REPAIR
169
Disassembly
169
Cleaning and Inspection
170
Assembly
171
4.7 HYDRAULIC GEAR PUMP
176
Pump Disassembly
176
Parts Inspection
177
Pump Reassembly
177
4.8 VALVES
179
Main Valve
180
Flow Divider Valve
182
Powerdeck Valves
184
Leveling Jack Valves
185
Pressure Setting Procedures
186
4.9 GEAR PUMP
187
Gear Pump Priming
187
4.10 AXIAL HI 45 PUMP
188
General Repair Instructions
190
Start-Up Procedure
190
Removing the pump
191
Electric Control Module
192
Control Solenoids
192
Charge Pump
193
Charge Check/HPRV
195
Charge Pressure Relief Valve
195
4.11 CHARGE PUMP FILTER
196
4.12 AUXILIARY PUMP MOTOR
197
4.13 CYLINDER ASSEMBLIES
198
Hydraulic
203
Schematic
203
PRESS ENTERHEL P:
207
ME N U :
208
HELP: PRESS ENTER
208
1: s t ar t up ( 2/ 1)
208
ACCESS LEVEL 2
209
ACCESS LEVEL 1
209
PERSONALI TI ES:
210
DRIVE ACCEL 3.0s
210
GROUND ALARM:
210
1=DESCENT
210
1705189A
211
5.2 CALIBRATIONS
212
Elevation Sensor Calibration
212
3121249 – JLG Lift – 5-7
213
5-8 – JLG Lift– 3121249
214
3121249 – JLG Lift – 5-9
215
5-10 – JLG Lift– 3121249
216
3121249 – JLG Lift – 5-11
217
5-12 – JLG Lift– 3121249
218
3121249 – JLG Lift – 5-13
219
5-14 – JLG Lift– 3121249
220
4150588 D
221
5-16 – JLG Lift– 3121249
222
3121249 – JLG Lift – 5-17
223
5-18 – JLG Lift– 3121249
224
3121249 – JLG Lift – 5-19
225
5-20 – JLG Lift– 3121249
226
4150390 K
227
4150389 D
231
5-26 – JLG Lift– 3121249
232
3121249 – JLG Lift – 6-1
233
6-2 – JLG Lift – 3121249
234
3121249 – JLG Lift – 6-3
235
Requirements:
236
Procedure
236
3121249 – JLG Lift – 6-5
237
3121249 – JLG Lift – 6-7
239
Wedge Lock
240
Service - Voltage Reading
241
DT/DTP Series Assembly
242
DT/DTP Series Disassembly
242
HD30/HDP20 Series Assembly
242
HD30/HDP20 Series Disassembly
243
6.5 SWITCHES
244
Basic check
244
Limit Switches
244
Automatic Switches
245
6.6 SCHEMATICS
246
3121249 – JLG Lift – 6-15
247
6-16 – JLG Lift – 3121249
248
3121249 – JLG Lift – 6-17
249
6-18 – JLG Lift – 3121249
250
3121249 – JLG Lift – 6-19
251
6-20 – JLG Lift – 3121249
252
3121249 – JLG Lift – 6-21
253
6-22 – JLG Lift – 3121249
254
3121249 – JLG Lift – 6-23
255
6-24 – JLG Lift – 3121249
256
3121249 – JLG Lift – 6-25
257
6-26 – JLG Lift – 3121249
258
1001103708_B
259
6-28 – JLG Lift – 3121249
260
3121249 – JLG Lift – 6-29
261
6-30 – JLG Lift – 3121249
262
3121249 – JLG Lift – 6-31
263
6-32 – JLG Lift – 3121249
264
3121249 – JLG Lift – 6-33
265
6-34 – JLG Lift – 3121249
266
JLG Worldwide Locations
268
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