Jlg 4394RT Service Manual Manuel d'utilisateur

Service & Maintenance ManualModels3394RT4394RT Prior to S/N 0200191606excluding S/N’s:0200186972,0200187002,02001870133121133October 6, 2008

vi – JLG Lift – 3121133TABLE OF CONTENTS LIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Operating Specifications. . . . . . . . . . . . . .

SECTION 3 - CHASSIS & SCISSOR ARMS3-64 – JLG Sizzor – 3121133Engine Control ModuleTo obtain maximum effect from the catalyst and accuratecontrol o

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-65Gasoline Fuel PumpThe Gasoline is stored as a liquid in the fuel tank and indrawn int

SECTION 3 - CHASSIS & SCISSOR ARMS3-66 – JLG Sizzor – 31211333.13 GM ENGINE FUEL SYSTEM REPAIRPropane Fuel System Pressure ReliefTHE PROPANE FUEL

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-674. Drop the magnet into the bottom of the filter hous-ing. 5. Install the filter into

SECTION 3 - CHASSIS & SCISSOR ARMS3-68 – JLG Sizzor – 31211338. Connect the EPR electrical connector. 9. Open the manual valve. 10. Start the vehi

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-69Electronic Throttle Control Replacement See Figure 3-40.REMOVAL1. Disconnect the nega

SECTION 3 - CHASSIS & SCISSOR ARMS3-70 – JLG Sizzor – 31211334. Place gasket on intake manifold and attach mixer/throttle assembly to manifold.Mix

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-71Engine Control Module ReplacementREMOVAL1. Disconnect Negative battery cable.2. Remov

SECTION 3 - CHASSIS & SCISSOR ARMS3-72 – JLG Sizzor – 31211333.14 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionTo maintain fuel and e

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-73Table 3-9. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-1SECTION 1. SPECIFICATIONS1.1 SPECIFICATIONS 1.2 CAPACITIES 1.3 ENGINES Table 1-1. Operating Speci

SECTION 3 - CHASSIS & SCISSOR ARMS3-74 – JLG Sizzor – 312113313 1. Turn OFF the ignition.2. Disconnect the LPL connector.3. Install a test light b

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-7525 The fuel supply system is operating normally, if a failure of the control solenoid

SECTION 3 - CHASSIS & SCISSOR ARMS3-76 – JLG Sizzor – 31211333.15 JOYSTICK CONTROLLER Figure 3-43. Joystick Controller - (JLG P/N 1600308)Table 3

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-77Figure 3-44. Joystick Controller - (JLG P/N 1600403)Table 3-12. Joystick Specificati

SECTION 3 - CHASSIS & SCISSOR ARMS3-78 – JLG Sizzor – 3121133Table 3-14. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using Th

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-79Intermittent Malfunction Indicator Lamp (MIL)The following components can cause inter

SECTION 3 - CHASSIS & SCISSOR ARMS3-80 – JLG Sizzor – 3121133Exhaust System Checks ² Check the exhaust system for a possible restriction: - In

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-81Exhaust System Checks ² Check the exhaust system for a possible restriction: - In

SECTION 3 - CHASSIS & SCISSOR ARMS3-82 – JLG Sizzor – 3121133Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignit

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-83Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improp

SECTION 1 - SPECIFICATIONS1-2 – JLG Sizzor – 31211331.4 TIRES 1.5 MACHINE DIMENSIONS 1.6 PRESSURE SETTINGS 1.7 SERIAL NUMBER LOCATIONSFor machine iden

SECTION 3 - CHASSIS & SCISSOR ARMS3-84 – JLG Sizzor – 3121133Cooling System Checks ² Check the engine thermostat for always being open or for the

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-85Fuel System Checks ² Check for Rich or Lean symptom that causes the condition. Drive

SECTION 3 - CHASSIS & SCISSOR ARMS3-86 – JLG Sizzor – 3121133Table 3-15. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 C

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-87562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid

SECTION 3 - CHASSIS & SCISSOR ARMS3-88 – JLG Sizzor – 3121133 NOTES:

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-1SECTION 4. HYDRAULICS4.1 CYLINDERS - THEORY OF OPERATIONCylinders are of the double acting type. The st

SECTION 4 - HYDRAULICS4-2 – JLG Lift – 31211334.4 CYLINDER CHECKING PROCEDURENOTE: Cylinder check must be performed anytime a systemcomponent is repla

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-38. Place the 6 inch (15.2 cm) high block with ascensionramp in front of right front wheel.9. From platfo

SECTION 4 - HYDRAULICS4-4 – JLG Lift – 3121133.NOTE: Steps 6 and 7 apply only to the steer cylinder.5. Using a spanner wrench, loosen the spanner nutr

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-513. Remove the bushing from the piston.14. Screw the piston CCW, by hand, and remove thepiston from cyli

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-31.8 SENSORSThe machine is equipped with the following limit switches:Elevation Switch/Rotary Posit

SECTION 4 - HYDRAULICS4-6 – JLG Lift – 3121133AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-7 1. Using suitable protection, clamp the cylinder rod ina vise or similar holding fixture as close to pi

SECTION 4 - HYDRAULICS4-8 – JLG Lift – 31211339. Place new guide locks and seals in the applicableoutside diameter grooves of the cylinder piston.(See

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-920. With barrel clamped securely, and while adequatelysupporting the rod, insert the piston end into the

SECTION 4 - HYDRAULICS4-10 – JLG Lift – 31211334.7 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoint,

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-11Once charge pressure has been established, increasespeed to normal operating RPM. Charge pressure shoul

SECTION 4 - HYDRAULICS4-12 – JLG Lift – 3121133NOTE: During disassembly, take special note of the wearpatterns on the bearing blocks (2) and body (13)

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-13.2. Clamp front cover into vise so that the ring groove isup. Apply a small amount of grease tot he sea

SECTION 4 - HYDRAULICS4-14 – JLG Lift – 31211334.9 MAIN VALVE 1234567811MGMSMp1109Valve Ft-lb Mn1. Dump Valve 30 - 35 42 - 492. Lift Valve 25 - 30 35

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-15Pressure Setting ProceduresCold temperatures have a significant impact on pressurereadings. JLG Industr

SECTION 1 - SPECIFICATIONS1-4 – JLG Sizzor – 31211331.11 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMSOF DIFFERENT W

SECTION 4 - HYDRAULICS4-16 – JLG Lift – 31211334.10 DRIVE HEADER VALVE (2WD) 4.11 DRIVE HEADER VALVE (4WD) A1B1CVLRB RRALRARRB12LRBRRALRARRBCVB1A1Figu

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-174.12 HEADER VALVES (4WD) X3CDXXX3CDCDX3XMXMX3MCDX3CDXXX3CDCDX3XMXMX3MCDFigure 4-19. Header Valve (Fix)

SECTION 4 - HYDRAULICS4-18 – JLG Lift – 31211334.13 DIRECTIONAL VALVE Pressure Setting ProcedureCold temperatures have a significant impact on pressur

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-194.14 POWER DECK SANDWICH VALVE 4.15 POWER DECK MANIFOLD VALVE NOTE: Power Deck Manifold Valve is locat

SECTION 4 - HYDRAULICS4-20 – JLG Lift – 31211334.16 HYDRAULIC PUMP Figure 4-24. Pump Pressure LocationsTable 4-3. Pump PressureItem # Name Pressure1

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-21Auxiliary Pump Motor • Displacement: 0.097 CU. IN/REV (1.59 CC/REV) • Delivers 1.2 min. GPM (4.5 min Li

SECTION 4 - HYDRAULICS4-22 – JLG Lift – 31211334.17 CYLINDER ASSEMBLIES 5461137891987311645101221. Barrel2. Rod3. Cap4. Ring, Washer5. Socket Head Bol

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-2311102893765414567398Figure 4-27. Steer Cylinder - S/N 137518 to Present1. Barrel Weldment2. Rod Weldme

SECTION 4 - HYDRAULICS4-24 – JLG Lift – 3121133OROROROR66119417101010558552326262530211920232223272414151628181312172926261. Cable Adapter2. Bolt3. Br

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-2512345Item Ft-Lbs Nm125 352 10 - 12 14 - 17335 4945 7530 42Figure 4-29. Lift Cylinder Valve Cartridge T

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-51.13 OPERATOR MAINTENANCE TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALLMAINTENANCE REQUIRING P

SECTION 4 - HYDRAULICS4-26 – JLG Lift – 3121133181718171688345159761215131114101219Figure 4-30. Oscillating Axle Cylinder1. Ring, Wear2. T-Seal3. Rin

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-27 123Item # Ft-Lbs Nm1 18.5 - 22 25 - 302 3 - 4.5 4.2 - 6.33 20 - 25 28 - 35Figure 4-31. Oscillating Ax

SECTION 4 - HYDRAULICS4-28 – JLG Lift – 312113321614912137111010101684835155Figure 4-32. Leveling Jack Cylinder1. Head2. Barrel3. Rod4. Jack Plate5.

SECTION 4 - HYDRAULICS3121133 – JLG Lift – 4-29732469108111213511. Locknut2. Piston3. Seal4. O-Ring5. Barrel6. Spacer Tube7. Head8. Rod9. O-Ring10. Ba

SECTION 4 - HYDRAULICS4-30 – JLG Lift – 3121133Oscillating Axle Bleeding Procedure 1. Attach 1/4" hose to bleeder valve to capture oil.2. Oscilla

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-1SECTION 5. JLG CONTROL SYSTEM5.1 HAND HELD ANALYZER To Connect the Hand Held Analyzer: 1. Conne

SECTION 5 - JLG CONTROL SYSTEM5-2 – JLG Lift– 3121133NOTE: The cable has a four pin connector at each end ofthe cable; the cable cannot be connected b

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-3Changing the Access Level of the Hand Held Analyzer: When the analyzer is first connected, you w

SECTION 5 - JLG CONTROL SYSTEM5-4 – JLG Lift– 3121133Adjusting Parameters Using the Hand Held AnalyzerOnce you have gained access to level 1, and a pe

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-5NOTE: Refer to the appropriate Machine Personality Set-tings Table, and the Machine Setup Table

SECTION 1 - SPECIFICATIONS1-6 – JLG Sizzor – 31211332. Drive Hub• Lube Points - Fill Plugs (4)•Lube - EPGL• Interval - Every 2 years or 1200 hours3. H

SECTION 5 - JLG CONTROL SYSTEM5-6 – JLG Lift– 31211335.2 FLASH CODES AND DESCRIPTIONS Table 5-1. Fault Code Listing - Software P1.XFault Flash CodeCom

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-72/2 Flash code 2/2 indicates difficultly with the platform controls.3TRIGGER SWITCH WIRING SHORT

SECTION 5 - JLG CONTROL SYSTEM5-8 – JLG Lift– 31211332/3 Flash code 2/3 indicates difficultly with ground controls.4FUNCTION LOCKED OUT – GROUND LIFT

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-92/5 Flash code 2/5 indicates issues that may cutout functions.5ELEV ANGLE SENSOR FAULTY – NOT MO

SECTION 5 - JLG CONTROL SYSTEM5-10 – JLG Lift– 31211332/6 Flash code 2/6 indicates leveling jack or power deck issues.6FRONT LEFT LEVELING JACK OPEN C

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-112/6 LEVELING JACK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system tes

SECTION 5 - JLG CONTROL SYSTEM5-12 – JLG Lift– 31211334/3 Flash code 4/3 indicates engine issues.7FUEL SENSOR SHORT TO BATTERY Reported when the fuel

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-138/* Flash codes 8/* indicate load cells issues.118/1 LSS CELL #1 ERROR Reported when there is a

SECTION 5 - JLG CONTROL SYSTEM5-14 – JLG Lift– 3121133ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESACCESS LEVEL:CODE 00000PERSONALITIES

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-15MENU:MACHINE SETUPMODEL NUMBER:0=33RT 2WDMODEL NUMBER:1=33RT 4WDMODEL NUMBER:2=43RT 2WDMODEL NU

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-77. Oil Change w/Filter - GM• Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)• Capacity

SECTION 5 - JLG CONTROL SYSTEM5-16 – JLG Lift– 3121133MENU:SYSTEM TESTACTIVATE TEST:YES: ENTER NO: ESCFROM SHEET 2MENU:DIAGNOSTICSDIAGNOSTICS:GROUND

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-17Table 5-2. Machine Model Adjustment Adjustment Adjustment RangeModel Default Values3394RT 2WD

SECTION 5 - JLG CONTROL SYSTEM5-18 – JLG Lift– 3121133NOTE: When configuring an RT, the Machine Configuration must be completed before any Personality

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-19 10(LOAD)012NOT INSTALLED – Load Sensing System (LSS) is not fitted to the vehicle.CUTOUT PLT –

SECTION 5 - JLG CONTROL SYSTEM5-20 – JLG Lift– 3121133NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available s

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-21NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available

SECTION 5 - JLG CONTROL SYSTEM5-22 – JLG Lift– 3121133NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available s

SECTION 5 - JLG CONTROL SYSTEM3121133 – JLG Lift – 5-23NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available

SECTION 5 - JLG CONTROL SYSTEM5-24 – JLG Lift– 3121133NOTES:

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-1SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS6.1 GE

SECTION 1 - SPECIFICATIONS1-8 – JLG Sizzor – 312113313. Fuel Filter (Propane) - GM• Interval - 3 Months or 150 hours of operation• Comments - Replace

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-2 – JLG Sizzor – 3121133 Voltage Measurement Resistance MeasurementFigure 6-1. Voltage

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-3 Continuity Measurement Current MeasurementFigure 6-3. Continui

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-4 – JLG Sizzor – 3121133Continuity Measurement Over Long DistancesWhen trying to determin

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-56.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORSSilico

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-6 – JLG Sizzor – 3121133AssemblyCheck to be sure the wedge lock is in the open, or as-shi

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-7Figure 6-8. Connector Assembly (3 of 4)Figure 6-9. Connector As

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-8 – JLG Sizzor – 3121133Disassembly5. Insert a 4.8 mm (3/16”) wide screwdriver blade betw

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-9Service - Voltage ReadingDO NOT PIERCE WIRE INSULATION TO TAKE VO

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-10 – JLG Sizzor – 31211336.4 WORKING WITH DEUTSCH CONNECTORSDT/DTP Series AssemblyFigure

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-1110. Push contact straight into connector grommet until a positiv

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-9Propane Fuel Filter Replacement REMOVAL:1. Relieve the propane fuel system pressure. Refer toPropa

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-12 – JLG Sizzor – 31211336.5 SWITCHESBasic checkThe following check determines if the swi

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-13Automatic SwitchesIf the switch is actuated automatically, by te

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-14 – JLG Sizzor – 31211336.6 SCHEMATICS Figure 6-18. Electrical Schematic - Dual Fuel -

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-15Figure 6-19. Electrical Schematic - Dual Fuel - Sheet 2 of 3

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-16 – JLG Sizzor – 31211331870143 HFigure 6-20. Electrical Schematic - Dual Fuel - Sheet

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-17NOTES:

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-18 – JLG Sizzor – 3121133Figure 6-21. Electrical Schematic Diesel (Prior to S/N 138634)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-19Figure 6-22. Electrical Schematic Diesel (Prior to S/N 138634)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-20 – JLG Sizzor – 3121133BLACKYEL/RED 2-7-3RED __BLACK _SHIELDORN/WHT 55-20ORN/WHT 55-21O

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-21NOTES:

SECTION 1 - SPECIFICATIONS1-10 – JLG Sizzor – 31211331.14 TORQUE CHARTS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-22 – JLG Sizzor – 3121133Figure 6-24. Electrical Schematic - Dual Fuel GM - Sheet 1 of 5

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-23Figure 6-25. Electrical Schematic - Dual Fuel GM - Sheet 2 of 5

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-24 – JLG Sizzor – 3121133Figure 6-26. Electrical Schematic Dual Fuel - GM - Sheet 3 of 5

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-25NOTES:

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-26 – JLG Sizzor – 3121133Figure 6-27. Electrical Schematic Dual Fuel - GM - Sheet 4 of 5

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-27Figure 6-28. Electrical Schematic Dual Fuel - GM - Sheet 5 of 5

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-28 – JLG Sizzor – 3121133Figure 6-29. Electrical Schematic Diesel (S/N 138634 to Present

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-29Figure 6-30. Electrical Schematic Diesel (S/N 138634 to Present

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-30 – JLG Sizzor – 31211331870190 DFigure 6-31. Electrical Schematic Diesel (S/N 138634 t

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-31NOTES:

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-11Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3))

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-32 – JLG Sizzor – 3121133Figure 6-32. Hydraulic Schematic 4WD - Sheet 1 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-33Figure 6-33. Hydraulic Schematic 4WD - Sheet 2 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-34 – JLG Sizzor – 3121133Figure 6-34. Hydraulic Schematic 4WD - Sheet 3 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-352792543 DFigure 6-35. Hydraulic Schematic 4WD - Sheet 4 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-36 – JLG Sizzor – 3121133Figure 6-36. Hydraulic Schematic 2WD - Sheet 1 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-37Figure 6-37. Hydraulic Schematic 2WD - Sheet 2 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-38 – JLG Sizzor – 3121133Figure 6-38. Hydraulic Schematic 2WD - Sheet 3 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-392792544DFigure 6-39. Hydraulic Schematic 2WD - Sheet 4 of 4

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-40 – JLG Sizzor – 3121133Figure 6-40. Hydraulic Diagram - (2WD)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-41Figure 6-41. Hydraulic Diagram - (4WD)

SECTION 1 - SPECIFICATIONS1-12 – JLG Sizzor – 3121133Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-42 – JLG Sizzor – 312113388Figure 6-42. Hydraulic Diagram - (Leveling Jacks)

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-43Note: “*” on a line indicates a non-straight hose endPower Deck

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-44 – JLG Sizzor – 3121133Power Manifold ValvePower Deck ManifoldValveRightLeftRear Extens

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-45Power Deck ManifoldValvePower Deck ManifoldValveRightLeftRear Ex

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-46 – JLG Sizzor – 3121133AUXILIARYPOWERRELAYLEVELING JACKVALVELEVELING JACKPORTBLOCKSLEVE

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS3121133 – JLG Sizzor – 6-47BEACONLIGHTIGNITIONRELAYGLOWPLUGRELAYSTARTRELAYMAINVALVEPORTBLOC

SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS6-48 – JLG Sizzor – 3121133NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-13Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

SECTION 1 - SPECIFICATIONS1-14 – JLG Sizzor – 3121133Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3))

SECTION 1 - SPECIFICATIONS3121133 – JLG Sizzor – 1-15Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 1 - SPECIFICATIONS1-16 – JLG Sizzor – 3121133NOTES:

SECTION 2 - GENERAL3121133 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31211332.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121133 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS3121133 – JLG Lift – aSECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA.A GENERALThis section co

SECTION 2 - GENERAL2-4 – JLG Lift – 31211332.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121133 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

SECTION 2 - GENERAL2-6 – JLG Lift – 31211332.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULEThe preventive maintenance and inspection checks areliste

SECTION 2 - GENERAL3121133 – JLG Lift – 2-7Table 2-3. Preventive Maintenance and Safety InspectionAREA INTERVALDaily Weekly300 Hours(6 months)600 Hour

SECTION 2 - GENERAL2-8 – JLG Lift – 3121133NO OPERATION ABOVE THISAMBIENT TEMPERATUREENGINESPECIFICATIONSSUMMER GRADE FUELWINTERGRADE FUEL W

SECTION 2 - GENERAL3121133 – JLG Lift – 2-9NO OPERATION ABOVE THISAMBIENT TEMPERATUREENGINESPECIFICATIONSENGINE WILL START AND OPERATE ON LPG

SECTION 2 - GENERAL2-10 – JLG Lift – 3121133NO OPERATION ABOVE THISAMBIENT TEMPERATUREENGINESPECIFICATIONSENGINE WILL START AND OPERATE ON LP

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-1SECTION 3. CHASSIS & SCISSOR ARMS3.1 OPERATING CHARACTERISTICSLeveling JacksThe m

SECTION 3 - CHASSIS & SCISSOR ARMS3-2 – JLG Sizzor – 31211333.2 CALIBRATIONS Elevation Sensor Calibration(Prior to Software P1.20)NOTE: Make sure

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-36. Press the left arrow button and then enter.NOTE: Anytime the ground control board o

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSb – JLG Lift – 3121133REVISION LOGOriginal Issue - April 12, 2002Revised - May 10, 2002 Revised - August

SECTION 3 - CHASSIS & SCISSOR ARMS3-4 – JLG Sizzor – 31211333. Both axis’ raw angles need to be within ±5.0°, other-wise the machine is to unlevel

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-53.3 LEVEL SENSOR AND ANALYZER CONNECTIONSThe level sensor is located at the ground con

SECTION 3 - CHASSIS & SCISSOR ARMS3-6 – JLG Sizzor – 3121133Tilt Sensor, JLG P/N 4000006: Tilt Sensor Removal:NOTE: Refer to Figure 3-4., Tilt Sen

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-7Tilt Sensor, JLG P/N 4000021:NOTE: Refer to Figure 3-6., Tilt Sensor Removal for num-b

SECTION 3 - CHASSIS & SCISSOR ARMS3-8 – JLG Sizzor – 31211333.4 INTEGRATED TORQUE/DRIVE HUBThe Integrated Torque/Drive Hub is an axial piston-hydr

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-93634 32 26 35371101315 2 2491253330283129252714818192373222146162011171. Planet Gear2

SECTION 3 - CHASSIS & SCISSOR ARMS3-10 – JLG Sizzor – 3121133Disconnect MechanismThe disconnect mechanism on the torque/drive huballows the machin

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-11Gearbox DisassemblyFor numbers in parenthesis, refer to Figure 3-8., DriveMotor/Hub A

SECTION 3 - CHASSIS & SCISSOR ARMS3-12 – JLG Sizzor – 31211337. Remove Snap Rings (13). 8. Pull Plane Gears (1). 9. Drill 2 holes into Shaft Nut (

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-1312. Remove the Support Ring (6) from the Spindle (34).Components stay in Supporting R

3121133 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 3 - CHASSIS & SCISSOR ARMS3-14 – JLG Sizzor – 3121133c. Secure the gears with new Snap Rings (12). NOTE: Heat Supporting Ring (6) up to a

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-158. Heat upper ring with roller cage of double TaperedRoller Bearing (11) to approxima

SECTION 3 - CHASSIS & SCISSOR ARMS3-16 – JLG Sizzor – 312113313. Assembly of planet gear (Main Stage):a. Mount the planet gears with Bearing Assem

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-1719. Carefully insert a new greased O-ring (23) into the o-ring groove of Ring Gear (2

SECTION 3 - CHASSIS & SCISSOR ARMS3-18 – JLG Sizzor – 3121133Figure 3-9. Drive Hub Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-19Motor Disassembly1. Mark port plate to the supporting axle. 2. Remove port plate. 3.

SECTION 3 - CHASSIS & SCISSOR ARMS3-20 – JLG Sizzor – 31211335. Disassemble bearing with synchronizing plate. 6. Press off pressure ring with

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-2111. Disassemble rotary group completely with cradle. 12. Disassemble control pist

SECTION 3 - CHASSIS & SCISSOR ARMS3-22 – JLG Sizzor – 312113317. Remove bearing ring (1). Disassemble spool (2). 18. Disassemble shuttle valv

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-2322. Check splines (1) for damage or fretting; runningsurfaces (2);groove cut by sha

ii – JLG Lift – 3121133TABLE OF CONTENTS 4.7 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & SCISSOR ARMS3-24 – JLG Sizzor – 312113328. Press bearing on drive shaft. 29. Install shaft in supporting axle (1). Put

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-25Motor Assembly1. Press in swivel balls (with tool) (1). Insert shaft sealring (with

SECTION 3 - CHASSIS & SCISSOR ARMS3-26 – JLG Sizzor – 31211332. Install rotary group with cradle. Observe installationposition of swivel balls.NO

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-277. Assembly aid: Hold the pistons by using an o-ring. 8. Install laminations in corr

SECTION 3 - CHASSIS & SCISSOR ARMS3-28 – JLG Sizzor – 312113311. Mount retaining ring. 12. Mount seal rings (1). Insert and line-up guide ring. 1

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-2915. Mount bearing ring with device. Mount spool.Mount fixation pin. 16. Fix control

SECTION 3 - CHASSIS & SCISSOR ARMS3-30 – JLG Sizzor – 31211333.5 DUAL FUEL/LPG SYSTEMIT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THEOTHER WIT

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-313.6 FORD EFI ENGINEPerforming Diagnostics1. Verify the complaint and determine if it

SECTION 3 - CHASSIS & SCISSOR ARMS3-32 – JLG Sizzor – 3121133CAMSHAFT POSITION (CMP) SENSOR ANDSIGNALThe camshaft position (CMP) sensor sends a CM

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-33Table 3-5. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11 All Systems

3121133 – JLG Lift – iii TABLE OF CONTENTSLIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Location. . . . . . . . . . . . . .

SECTION 3 - CHASSIS & SCISSOR ARMS3-34 – JLG Sizzor – 3121133ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-35Figure 3-10. EFI Component Location

SECTION 3 - CHASSIS & SCISSOR ARMS3-36 – JLG Sizzor – 3121133INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a therm

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-37The ECM is designed to maintain exhaust emission levelsto government mandated standar

SECTION 3 - CHASSIS & SCISSOR ARMS3-38 – JLG Sizzor – 3121133ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the ECM are oftendesigned

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-39FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is toc

SECTION 3 - CHASSIS & SCISSOR ARMS3-40 – JLG Sizzor – 3121133FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefu

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-41OPEN LOOP AND CLOSED LOOP OPERATIONThe ECM will operate in the following two modes:•

SECTION 3 - CHASSIS & SCISSOR ARMS3-42 – JLG Sizzor – 3121133ELECTRONIC IGNITIONThe electronic ignition system controls fuel combustion byprovidin

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-433.7 GENERATOR - FORD ENGINE 312Figure 3-12. Generator (Ford Engine)1. Generator 2. F

iv – JLG Lift – 3121133TABLE OF CONTENTS 3-43. Joystick Controller - (JLG P/N 1600308) . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & SCISSOR ARMS3-44 – JLG Sizzor – 31211333.8 DEUTZ EMR 2 (S/N 0200138634 TO PRESENT)The EMR2 consists of the sensors, the cont

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-45Figure 3-13. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENS

SECTION 3 - CHASSIS & SCISSOR ARMS3-46 – JLG Sizzor – 3121133Figure 3-14. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-47Figure 3-15. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & SCISSOR ARMS3-48 – JLG Sizzor – 3121133Figure 3-16. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-49Figure 3-17. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & SCISSOR ARMS3-50 – JLG Sizzor – 3121133Figure 3-18. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-51Figure 3-19. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & SCISSOR ARMS3-52 – JLG Sizzor – 3121133Figure 3-20. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-53Figure 3-21. EMR2 Fault Codes - Sheet 2 of 5

3121133 – JLG Lift – v TABLE OF CONTENTS6-18. Electrical Schematic - Dual Fuel - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . .

SECTION 3 - CHASSIS & SCISSOR ARMS3-54 – JLG Sizzor – 3121133Figure 3-22. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-55Figure 3-23. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & SCISSOR ARMS3-56 – JLG Sizzor – 3121133Figure 3-24. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-573.9 GENERATOR - DUETZ ENGINE 123-OR-1. Generator (120V or 220V)2. Deutz Engine3. Volt

SECTION 3 - CHASSIS & SCISSOR ARMS3-58 – JLG Sizzor – 31211333.10 GM ENGINE GENERAL MAINTENANCEMaintenance of the Drive BeltThe serpentine drive b

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-595. Oil level must be between the "FULL" and "ADD"marks.6. If the

SECTION 3 - CHASSIS & SCISSOR ARMS3-60 – JLG Sizzor – 31211333.11 GENERATOR - GM ENGINE 1231. Generator 2. GM Engine 3. Voltage RegulatorFigure 3-

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-613.12 GM ENGINE DUAL FUEL SYSTEMThe Dual Fuel system allows the operator to operate th

SECTION 3 - CHASSIS & SCISSOR ARMS3-62 – JLG Sizzor – 3121133EPR AssemblyThe EPR assembly is a combination Low Pressure Regu-lator and a Voice Coi

SECTION 3 - CHASSIS & SCISSOR ARMS3121133 – JLG Sizzor – 3-63Air Fuel MixerThe air valve mixer is an air-fuel metering device and iscompletely sel