Jlg 4394RT Service Manual Bedienungsanleitung Seite 245
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SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
3121249 – JLG Lift – 6-13
Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener-
gized to actuate.
1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.
2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do
this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for exam-
ple. The state indicated in the control system should change.
Switch Wiring - Low Side, High Side
When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can mea-
sure the voltage at both power terminals with respect to battery ground. The difference between those two measure-
ments is the voltage applied to the load.
- 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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