JLG 3394RT Service And Maintenance Manual
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JLG 3394RT Service And Maintenance Manual

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Service and Maintenance Manual
Model(s)
3394RT
4394RT
S/N 0200239053 to
Present
P/N - 3121642
January 23, 2018
AS/NZS

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Summary of Contents for JLG 3394RT

  • Page 1 Service and Maintenance Manual Model(s) 3394RT 4394RT S/N 0200239053 to Present P/N - 3121642 January 23, 2018 AS/NZS...
  • Page 3 • Remove all rings, watches and jewelry when perform- ing any maintenance. MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUSTRIES INC., IS A SAFETY VIOLATION. • Do not wear long hair unrestrained, or loose-fitting clothing and neckties which are apt to become caught The specific precautions to be observed during mainte- on or entangled in equipment.
  • Page 4 Manual Revised ......July 25, 2016 Manual Revised ..... January 23, 2018 – JLG Lift – 3121642...

  • Page 5: Table Of Contents

    Lubrication and Servicing ..............2-3 3121642 – JLG Lift –...
  • Page 6 Deck Extension Cylinders (If Equipped) ............3-43 – JLG Lift –...
  • Page 7 GM Engine Fuel System Repair ..............3-77 3121642 – JLG Lift –...
  • Page 8 Charge Pump Filter ................. 4-31 – JLG Lift –...
  • Page 9 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer ................5-1 To Connect the Hand Held Analyzer: .
  • Page 10 Fuel Tank Removal ................. 3-50 – JLG Lift –...
  • Page 11 Leveling Jack Valves................4-20 3121642 – JLG Lift –...
  • Page 12 Hydraulic Schematic (CE) ................6-32 viii – JLG Lift – 3121642...
  • Page 13 Machine Model Adjustment ............... . 5-25 3121642 – JLG Lift –...
  • Page 14 TABLE OF CONTENTS NOTES: – JLG Lift – 3121642...

  • Page 15: Specifications

    12 Volt Oil Capacity 8.5 Quarts (8 L) w/Filter Inside Turning Radius 14.5 ft (4.39 m) Low RPM 1200 High RPM 2800 Alternator 95 Amp, Belt Drive Battery 112 Amp-Hour, 950 Cold Cranking Amps, 12 VDC 3121642 – JLG Lift –...

  • Page 16: Tires

    Foam Fill to 170 lb-ft 2. Stamped Serial Number Filled - Sand 50 psi (3.4 bar) (230 Nm) 31 x 15.50-15 170 lb-ft 60 psi (4 bar) Figure 1-1. Serial Number Location Grass Master (230 Nm) – JLG Lift – 3121642...

  • Page 17: Sensors

    (6.4 cm) (10.5 cm) (4.4 cm) Power Deck 15 in 48 in 1 in Cylinders (38.1 mm) (1219.2 mm) (25.4 mm) 2.5 in 9.2 in 1.75 in Steer Cylinder (63.5 mm) (233.7 mm) (44.5 mm) 3121642 – JLG Lift –...

  • Page 18: 1.12 Lubrication Specifications

    NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stabil- ity for mobile hydraulic system service. JLG Industries rec- ommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152.

  • Page 19: 1.13 Maintenance Specifications

    ADD and FULL sight windows on tank. Do not overfill tank. Any time the pump coupling is removed, coat splines of coupling with Texaco Code 1912 grease prior to assembly. 3121642 – JLG Lift –...

  • Page 20: Engine Operating Temperature Specifications - Deutz

    SECTION 1 - SPECIFICATIONS Figure 1-3. Engine Operating Temperature Specifications - Deutz – JLG Lift – 3121642...

  • Page 21: Engine Operating Temperature Specifications - Gm

    SECTION 1 - SPECIFICATIONS Figure 1-4. Engine Operating Temperature Specifications - GM 3121642 – JLG Lift –...

  • Page 22: Drive Hub

    • Interval - Every month or 50 hours. • Lube Points - Fill Plugs (4) • Lube - EPGL - Mobilube HD 80W-90 or equivalent • Interval - Every 2 years or 1200 hours • Total Capacity - 23.75 oz. each hub – JLG Lift – 3121642...

  • Page 23: Oil Change W/Filter - Deutz - D 2011 L03

    • Lube - EO - Spec: API CJ-4 class, for Viscosity Ref. Figure 1-3. on page 1-6 - Operating Temperature Range Chart • Interval - Every Year or 600 hours of operation • Comments - Check level daily/Change in accordance with engine manual. 3121642 – JLG Lift –...

  • Page 24: Engine Fuel Filter - Deutz D 2.9 L4 - T4F

    • Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator • Interval - 3 Months or 150 hours of operation • Comments - Replace filter. Refer to Propane Fuel Filter Replacement 1-10 – JLG Lift – 3121642...

  • Page 25: Draining Oil Build Up From The Propane Regulator

    EPR. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 3121642 – JLG Lift – 1-11...

  • Page 26: Propane Fuel Filter Replacement

    INSTALLING NEW SEAL. 1. Install the mounting plate to lock off O-ring seal. 2. Install the retaining bolt seal. 3. Install the housing seal. 4. Drop the magnet into the bottom of the filter housing. 1-12 – JLG Lift – 3121642...

  • Page 27: 1.14 Torque Charts

    SECTION 1 - SPECIFICATIONS 1.14 TORQUE CHARTS Figure 1-6. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121642 – JLG Lift – 1-13...

  • Page 28: Torque Chart - Sheet 2 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-14 – JLG Lift – 3121642...

  • Page 29: Torque Chart - Sheet 3 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121642 – JLG Lift – 1-15...

  • Page 30: Torque Chart - Sheet 4 Of 5 - (Metric Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-16 – JLG Lift – 3121642...

  • Page 31: Torque Chart - Sheet 5 Of 5 - (Metric Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-10. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121642 – JLG Lift – 1-17...
  • Page 32 SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121642...

  • Page 33: General

    Inspection. ence, has successfully demonstrated the ability and profi- Pre-Delivery Inspection and Frequent Inspection ciency to service, repair, and maintain the subject JLG product model. The Pre-Delivery Inspection and Frequent Inspection shall be Reference the Preventative Maintenance Schedule and the performed by a qualified JLG equipment mechanic.

  • Page 34: Service And Guidelines

    Service and Maintenance Manual Owner, Dealer, or User Qualified JLG Mechanic Inspection rental delivery. and applicable JLG inspection form. In service for 3 months or 150 hours, whichever comes first; or Frequent Service and Maintenance Manual Out of service for a period of more than 3 months;...

  • Page 35: Component Disassembly And Reassembly

    When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3121642 – JLG Lift –...

  • Page 36: Lubrication And Information

    Avoid mixing nent working parts are very close, therefore, even the petroleum and synthetic base oils. JLG Industries recom- smallest amount of dirt or foreign matter entering a sys- mends changing the hydraulic oil annually.

  • Page 37: Cylinder Drift Test

    Pins should be inspected to ensure it is free of burrs, If the cylinder passes this test, it is acceptable. nicks, and scratches which would damage the bear- NOTE: This information is based on 6 drops per minute cylinder ing during installation and operation. leakage. 3121642 – JLG Lift –...

  • Page 38: Preventive Maintenance And Inspection Schedule

    NOTE: This machine requires periodic safety and maintenance VAL” at which the inspection is to take place. Under the “AREA” inspections by a JLG Dealer. A decal located on the frame portion of the table, the various systems along with the com- affords a place to record (stamp) inspection dates.

  • Page 39: Preventive Maintenance And Safety Inspection

    1,3,5,6 21. Steer Cylinder 5,6,13 22. Steer Components 23. Wheel Bearings (2 Wheel Drive) 24. Sizzor Arms 25. Safety Props 26. Sliding Wear Pads 27. Pivot Pins/Bolts 28. Switches, Ground Control 1,11 29. Control Tags 3121642 – JLG Lift –...
  • Page 40 SECTION 2 - GENERAL NOTES: – JLG Lift – 3121642...

  • Page 41: Chassis, Platform & Scissor Arms

    The air pressure for pneumatic tires must be equal to the air light at the platform control station the machine is unable pressure that is stenciled on the side of the JLG product or rim to level. You must reposition and try again.

  • Page 42: Tire Replacement

    Please refer to the for attaching wheels is as follows: JLG Parts Manual for the part number of the approved tires for Start all nuts by hand to prevent cross threading. DO a particular machine model. If not using a JLG approved NOT use a lubricant on threads or nuts.

  • Page 43: Drive Assembly

    With axle raised and supported, remove the Tires (1) from the drive motor/hub assembly by removing the 9 Lugnuts (2). Remove the Drive Motor/Hub Assembly (3) by removing the 6 Bolts (4) and Hardened Washers (5). 3121642 – JLG Lift –...

  • Page 44: Drive Assembly - (Fairfield/Sauer)

    Remove the Drive Hub (3) and Drive Motor (6) from the axle by removing the 6 Bolts (4) and Washers (5). The Drive Motor (6) can be removed from the Drive Hub (3) by removing the 2 Nuts (7) and Washers (8). – JLG Lift – 3121642...

  • Page 45: Drive Hub (Fairfield)

    Never use an impact wrench to tighten shoulder bolts. Always tighten all shoulder bolts by hand. The following steps describe the proper procedure for tighten- ing and torquing bolts or socket head cap screws in a bolt cir- cle. 3121642 – JLG Lift –...

  • Page 46: Drive Hub

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 6H 6G Figure 3-2. Drive Hub – JLG Lift – 3121642...

  • Page 47: Drive Hub Part Description

    Plug Disconnect Rod Plug Disengage Cap Spring Kit (Natural) Bolt 1/2"-20NC x 1/2" Spring Kit (Blue) Pipe Plug Rivet ID Plate Input Shaft Assembly Shaft Retaining Ring Spring Thrust Spacer Sun Gear Thrust Washer Bolt 3121642 – JLG Lift –...

  • Page 48: Drive Hub (Cross-Section)

    Flat Washer 1 I. Retaining Ring Ring Gear Input Shaft Sub Assembly 1 J. Pipe Plug O Ring 7 A. Seal 1 K. Stud Cover Sub-Assembly 7 B. Retaining Ring Figure 3-3. Drive Hub (Cross-Section) – JLG Lift – 3121642...

  • Page 49: Main Disassembly For Drive Hub

    NOTE: If the unit does not have studs, skip this step: Press the nine studs (1N) out of the stud holes in hub BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU REMOVE THE O- (1G). RING. 3121642 – JLG Lift –...

  • Page 50: Cover Disassembly

    Remove the remaining 16 needle rollers (3C) from the other side of cluster gear (3F). Discard the needle rollers. Repeat steps 1-6 to remove and disassemble the two remaining cluster gears. At this point the carrier disassembly is complete. 3-10 – JLG Lift – 3121642...
  • Page 51 (3E). Repeat steps 1 thru 9 to assemble and install the two remaining cluster gears. At this point the carrier sub-assembly is complete. 3121642 – JLG Lift – 3-11...

  • Page 52: Cover Sub-Assembly

    Insert disconnect rod (6E) into cover cap (6B). Using a torque wrench, apply 2.95 to 3.69 ft. lbs. (4 to 5 Nm) of torque to both bolts (6C). 3-12 – JLG Lift – 3121642...

  • Page 53: Hub-Spindle Sub-Assembly

    (1G). Using a torque wrench, apply 2.95 to 3.69 ft. lbs. (4 to 5 Nm) of torque to both bolts (6C). Press the nine studs (1N) into the stud holes in hub (1G). 3121642 – JLG Lift – 3-13...
  • Page 54 (1E) down into the counterbore in the deep end of the hub (1G). Press bearing cone (1F) onto spindle (1A) in hub (1G). Set hub (1G) onto its large end. Place bearing cone (1D) into bearing cup (1C). 3-14 – JLG Lift – 3121642...

  • Page 55: Main Assembly

    Oil all exposed surfaces inside hub (1G). At this point the hub-spindle sub-assembly is complete. Place internal gear (2) into hub (1G) so that its internal splines mesh with the external splines of spindle (1A). Oil internal gear (2). 3121642 – JLG Lift – 3-15...
  • Page 56 (7A) by compressing the spring and spacers together. Place one spring (7C) onto the smooth end of input shaft (7A). With large splined end down, place input shaft sub- assembly (7) into spindle (1A). 3-16 – JLG Lift – 3121642...

  • Page 57: Cluster Gear Punch Marks

    BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN YOU INSTALL THE O- "X" marked shoulder bolt hole in the ring gear (4) over RING. one of the shoulder bolt holes in the hub. Mark the loca- 3121642 – JLG Lift – 3-17...
  • Page 58 Place the 12 bolts into the remaining bolt holes in cover (6) and tighten. Place four flatwashers (16) on top of the bolt holes in the cover sub-assembly. 3-18 – JLG Lift – 3121642...
  • Page 59 Roll test the unit in both clockwise and counterclock- wise directions. Perform the same number of turns in each direction as the ratio of the unit. The ratio is the last two digits of the model number on the unit’s ID tag. 3121642 – JLG Lift – 3-19...

  • Page 60: Tool List

    13.8 bar) to release the brake. Verify that the brake is released by rotating the input coupling or hub spindle. Once the brake is released, the input coupling will be free to re-align with the drive motor. 3-20 – JLG Lift – 3121642...

  • Page 61: Drive Motor (Sauer)

    Drive the screw into the seal surface and use the slide hammer to pull the seal. Shaft Seal Discard the seal. Piston Bearing Endcap Slipper Valve plate Figure 3-5. Drive Motor Cross Section 3121642 – JLG Lift – 3-21...

  • Page 62: Loop Flushing Valve

    3. Plug 8. Spring 13. Orifice Poppet 4. O-ring 9. Spring 5. O-ring 10. Washer Figure 3-7. Loop Flushing Spool Using a 1/4 in hex wrench, remove plug (3). Remove O-rings (4, 5, and 6). 3-22 – JLG Lift – 3121642...

  • Page 63: Troubleshooting

    Obstruction will that they are not obstructed. Clean or replace as necessary. installed, and are not obstructed. also increase shift times. 3121642 – JLG Lift – 3-23...

  • Page 64: Disassembly

    Using a 5/16 in internal hex wrench, remove drain plugs (19, 20). Discard O-rings. Remove orifice poppet (13). Using a 9/16 in internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 3-24 – JLG Lift – 3121642...
  • Page 65 The grease will force the bearing out. Use caution not to drive the bearing past the rear shaft jour- nal as the bearing may become trapped on the shaft and damaged. 3121642 – JLG Lift – 3-25...

  • Page 66: 31. Cylinder Kit Assembly

    34. Shaft Seal Figure 3-13. Shaft Seal Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal 3-26 – JLG Lift – 3121642...

  • Page 67: Swash Plate & Servo Piston

    FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. 3121642 – JLG Lift – 3-27...

  • Page 68: Inspection

    Table 3-8. Cylinder Block Measurements Measurement Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) 0.002 0.002 0.002 0.002 0.002 (in.) Cylinder Block Surface Flatness (0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079) 3-28 – JLG Lift – 3121642...
  • Page 69 Mea- worn splines, bearing surfaces, or sealing surfaces. sure the swashplate thickness from the journals to the running face. Replace swashplate if damaged or worn beyond mini- 3121642 – JLG Lift – 3-29...

  • Page 70: Assembly

    ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. 3-30 – JLG Lift – 3121642...

  • Page 71: Swash Plate And Journal Bearing

    If you're reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean surface until needed. 3121642 – JLG Lift – 3-31...

  • Page 72: Shaft And Front Bearing

    While holding the swashplate in place, turn the housing on its side. Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18). 20. Servo Spring 21. Minimum Angle Stop Figure 3-22. Servo Spring and Minimum Angle Stop 3-32 – JLG Lift – 3121642...

  • Page 73: Valve Plate And Rear Bearing

    Install the endcap (25) onto the housing with the end- cap screws (26). Check to ensure the endcap will prop- erly seat onto the housing without interference. Improper assembly of the internal components may 3121642 – JLG Lift – 3-33...

  • Page 74: 27. Shaft Seal

    27. Shaft Seal (2.03 to 3.39 Nm) 28. Seal Support Washer 29. Snap Ring Figure 3-25. Shaft Seal 1/4 in 33 ft.lbs. (45 Nm) 5/16in 63 ft.lbs. (85 Nm) Figure 3-26. Plugs and Fittings Installation 3-34 – JLG Lift – 3121642...

  • Page 75: Initial Start-Up Procedures

    Shut down the prime mover and remove the pressure lb-ft (37 Nm). gauge. Replace plug at the charge pressure gauge port. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The motor is now ready for operation. 3121642 – JLG Lift – 3-35...

  • Page 76: Front Axle

    Ensure thrust washer (5) is between tie rod (7) and top side of spindle (13). Remove wheel and drive assembly prior to spindle (13) Refer to Figure 4-28., Steer Cylinder for steer cylinder break- removal (refer to Figure 3-1., Drive Assembly (Bosch down. Rexroth )). 3-36 – JLG Lift – 3121642...

  • Page 77: Axle Assembly

    Remove the bolt (2) and pin keeper (3). Push the axle pivot pin (4) out and remove the thrust washers (5, 6) and bearings (7). Axle can now be moved away from the frame. 3121642 – JLG Lift – 3-37...

  • Page 78: Front Axle - Tow Bar Installation (If Equipped)

    Apply thread locking compound-(#242) to threads of screw, then tighten. Install the steering link (4) to the tow bar (3) with the shoulder screw (6), placing a thrust washer between the 3-38 – JLG Lift – 3121642...

  • Page 79: Axle Lockout Cylinder

    NOTE: Refer to Section 4.14, Cylinder Assemblies for axle lockout Carefully remove cylinder from the frame. cylnder breakdown and bleeding procedure. Operate axle lockout cylinder function to ensure proper functioning. 3121642 – JLG Lift – 3-39...

  • Page 80: Leveling Jacks (If Equipped)

    Disconnect, cap and label all hydraulic lines and wires connected to the leveling jack cylinder (8). Support cylinder. Remove the four bolts (6) and nuts (7) attaching cylinder to cylinder mount. Remove jack cover bracket (5). Carefully remove cylinder from mount. 3-40 – JLG Lift – 3121642...

  • Page 81: Assembly Removal

    Disconnect, cap and label hydraulic lines connected to leveling jack cylinders. Disconnect and label all electrical Operate leveling jacks to ensure proper operation. wiring attached to cylinder and switches. Remove the four bolts (2), nuts (3) and washers (4). 3121642 – JLG Lift – 3-41...

  • Page 82: Platform

    NOTE: Use lifting straps and overhead crane capable of lifing at NOTE: For machines equipped with Load Sensing System, refer to least 6000 lbs (2722 kg). JLG Supplement P/N 3124288. Disconnect, cap and label hydraulic lines on deck exten- sion cylinders. Disconnect and label all electrical wires going to platform.

  • Page 83: Deck Extension Cylinders (If Equipped)

    Support extension cylinders before disconnecting from bottom side of platform (1). Remove the shoulder screws (3, 12), locknuts (5, 9), bolts (8) and flatwashers (4, 10, 13). Carefully remove the extension cylinder. INSTALLATION: 3121642 – JLG Lift – 3-43...

  • Page 84: Platform Control Station

    (14). Operate functions with platfrom control console to ensure proper operation. The harness (13) can be removed from the box by removing the terminal nut (11), two screws (10) and d- ring bracket. 3-44 – JLG Lift – 3121642...

  • Page 85: Joystick Controller

    Steer Right Reverse Voltage 4.60V to 4.80V Green Steer Left Forward Voltage 0.40V to 0.60V Brown Pot Wiper Handle Common Not Connected White/Red Pot (+) Violet Trigger Switch Blue Trigger Supply White/Black Pot (-) 3121642 – JLG Lift – 3-45...

  • Page 86: Scissor Arms

    Disconnect, cap and label all hydraulic lines connected to lift cylinder (1). Disconnect and label all electrical After assembly, operate lift cylinder to ensure proper wires connected to lift cylinder. operation. NOTE: Refer to Figure 4-29., Lift Cylinder for cylinder breakdown. 3-46 – JLG Lift – 3121642...

  • Page 87: Scissor Arms Removal

    Push pin and bearing (6) out from scissor arms. Carefully lift arm assembly up and away from chassis. Repeat at each connecting pin. INSTALLATION: INSTALLATION: Follow Removal Steps in reverse. Follow Removal Steps in reverse. 3121642 – JLG Lift – 3-47...

  • Page 88: Side Compartment Covers

    INSTALLATION: Follow Removal Steps in reverse. Right Side - Engine Compartment Covers 1. Engine Compartment Door 4. Main Cover Support/Engine Door 2. Ladder Assembly Hinge Point 3. Exhaust Pipe Shield 5. Main Compartment Cover 3-48 – JLG Lift – 3121642...

  • Page 89: 3.10 Ground Control Station

    NOTE: If tilt sensor is removed and replaced, it must be calibrated mount (2) by removing the four bolts (3) and lockwash- (refer to Section 5.2, Calibrations). ers (4). INSTALLATION: Follow Removal Steps in reverse. NOTE: Apply Loctite® #242 to the four bolts (3). 3121642 – JLG Lift – 3-49...

  • Page 90: 3.11 Fuel Tank

    ENSURE PROPER FUEL LINES ARE ATTACHED TO PROPER FITTING ON FUEL TANK. FUEL TANK IS LABELED WITH RETURN LINE AND SUPPLY LINE. bracket on the frontside of the fuel tank. Remove the fuel tank from the hydraulic compartment. Ensure there is no fuel leakage. 3-50 – JLG Lift – 3121642...

  • Page 91: 3.12 Hydraulic Tank

    Remove the two bolts (7), washers (8) and nuts (9) attaching the hydraulic tank to the machine. Remove tank from machine. NOTE: Hydraulic tank has two lifting lugs on the top corners for lifting. Empty tank weighs approximately 105 lbs (47.6 kg). 3121642 – JLG Lift – 3-51...

  • Page 92: 3.13 Battery

    With the positive battery cable disconnected, the fuse mounting block (5) can be removed by first disconnect- ing the cables from the block. Remove the bolts, wash- ers and nuts securing the fuse block to the machine compartment cover. 3-52 – JLG Lift – 3121642...

  • Page 93: 3.14 Dual Fuel/Lpg System

    DO NOT USE AN LPG TANK THAT IS DAMAGED. A DAMAGED TANK MUST BE REMOVED FROM SERVICE. FROST ON THE SURFACE OF A TANK, VALVES, OR FITTINGS INDICATES LEAKAGE. A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK. 3121642 – JLG Lift – 3-53...

  • Page 94: 3.15 Deutz Engine

    Washer NOTE: When servicing the engine and components, remove the bolt (1), nut (2) and washer (3) to swing the engine tray out for better access (as shown below). Figure 3-49. Engine Tray Swing 3-54 – JLG Lift – 3121642...

  • Page 95: Generator (If Equipped)

    Remove the generator from the engine (2) by removing the three bolts (3, 5) and washers (4, 5). Continuous 3.5 KW 2.0 KW Replace belt if damaged. Peak 4.5 KW 3.0 KW Amps Peak 37 Amps 13 Amps INSTALLATION: 3121642 – JLG Lift – 3-55...

  • Page 96: Exhaust System

    Loosen clamp (3), and remove the exhaust pipe (2). Loosen clamp (6) and bracket clamps (5) holding the catalyst assembly to the mounting bracket. Remove cat- alyst assembly. Loosen clamp (8) and remove the compensator assem- bly. 3-56 – JLG Lift – 3121642...

  • Page 97: Air Cleaner System

    NOTE: The filter element can be removed from the air cleaner by releasing the latches on the end of the air cleaner. Replace filter element as needed. 3121642 – JLG Lift – 3-57...

  • Page 98: Relays

    Remove the relays from the mounting bracket (6) by removing the bolts (3), locknuts (4) and washers (5). The relay mounting bracket can be removed from the muffler mounting bracket (10) by removing the two bolts, nuts and washers (not shown). 3-58 – JLG Lift – 3121642...

  • Page 99: Pumps

    Torque mounting bolts (6) to 50 ft. lbs. (70 Nm) Remove and discard the o-ring (4). NOTE: Refer to Section 4.10, Gear Pump and Section 4.11, Axial HI 45 Pump for more information on pumps. 3121642 – JLG Lift – 3-59...

  • Page 100: Pump Coupling

    Remove the four bolts (2) and washers to remove the muffler mounting bracket (1) from the pump coupling (4). Remove the eight coupling bolts (5) to remove the pump coupling from the engine INSTALLATION: 3-60 – JLG Lift – 3121642...

  • Page 101: Engine Removal

    (227 kg) (refer to engine manual for proper lifting information). Remove the bolts (3) securing the motor to the rear engine mount (2). Remove the bolts (5) and spacer tubes (6) securing the engine to the front engine mount (4). 3121642 – JLG Lift – 3-61...

  • Page 102: Radiator

    - if necessary remove the air cleaner or disconnect the intake pipe hose connector at the radiator mounting plate Support the radiator mounting plate assembly and remove the four (4) large bolts holding the mounting plate to the engine swivel tray. 3-62 – JLG Lift – 3121642...

  • Page 103: 3.16 Gm Engine

    When inspecting the electrical system use the following: • Check and clean the battery terminal connections and ensure the connections are tight. Figure 3-43. Engine Oil Dip Stick • Check the battery for any cracks or damage to the case. 3121642 – JLG Lift – 3-63...

  • Page 104: Changing The Engine Oil

    Start the engine and check for oil leaks. Stop the engine and check the oil level to ensure the oil level is at "FULL". Dispose of the oil and filter in a safe manner. Figure 3-70. Engine Tray Swing 3-64 – JLG Lift – 3121642...

  • Page 105: Generator

    3.5 KW Remove the generator from the engine (2) by removing Peak 4.5 KW the three bolts (3, 5) and washers (4, 5). Amps Peak 37 Amps Replace belt if worn or damaged. INSTALLATION: 3121642 – JLG Lift – 3-65...

  • Page 106: Exhaust System

    Remove the tail pipe by removing the bolts (2), washers (3) and nuts (4). Remove exhaust pipe (7) from the muffler and engine by removing the bolts. Remove the bolts connecting the muffler to the mount- ing bracket (8). Remove muffler. INSTALLATION: 3-66 – JLG Lift – 3121642...

  • Page 107: Air Cleaner System

    Loosen the bolt on the mounting bracket (2) to remove the air cleaner (1). NOTE: The filter element can be removed from the air cleaner by releasing the latches on the end of the air cleaner. Replace filter element as needed. 3121642 – JLG Lift – 3-67...

  • Page 108: Radiator

    Remove the four bolts (9), washers (10) and nuts (11) to remove the radiator. NOTE: The engine must be removed before the radiator can be removed. 3-68 – JLG Lift – 3121642...

  • Page 109: Fuel Components

    (1), fuel filter (5) and fuel regulator (8) to the Uncap and connect the fuel line (10) to the fuel regula- machine. tor and the fuel rail on the engine. 3121642 – JLG Lift – 3-69...

  • Page 110: Pumps

    45 Pump for more information on pumps. Remove and discard the o-ring (4). Remove the two bolts (5) and washers (6) attaching the axial pump to the flange (7) of the coupling. Carefully remove the axial pump. 3-70 – JLG Lift – 3121642...

  • Page 111: Pump Coupling

    (1) from the coupling cover (2). Remove the bolts on the coupling cover to remove the cover from the engine. Remove the bolts on the coupling (3) to remove the cou- pling from the engine. INSTALLATION: 3121642 – JLG Lift – 3-71...

  • Page 112: Engine Removal

    (227 kg) (refer to engine manual for proper lifting information). Remove the bolts (1), washers (2) and nuts (3) at the four corners of the engine. Slowly lift the engine up and out of the engine compart- ment. 3-72 – JLG Lift – 3121642...

  • Page 113: 3.17 Gm Engine Dual Fuel System

    2. Fuel Inlet Port energized, the solenoid opens the valve and allows the Pro- pane fuel to flow through the device. The valve opens during 3. Coolant Passage 6. Voice Coil Section Figure 3-80. EPR Assembly 3121642 – JLG Lift – 3-73...

  • Page 114: Low Pressure Regulator (Lpr)

    THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMISSIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY. Figure 3-82. Air Fuel Mixer Figure 3-81. Low Pressure Regulators 3-74 – JLG Lift – 3121642...

  • Page 115: Electronic Throttle Control (Etc)

    Figure 3-84. LPG Engine Control Unit (ECM) Figure 3-83. ETC throttle control device Figure 3-85. ECM Assembly 3121642 – JLG Lift – 3-75...

  • Page 116: Heated Exhaust Gas Oxygen Sensor (Hego)

    Injection (MPFI) fuel system are the fuel tank, electric fuel pump, fuel pressure and temperature sensor manifold, fuel fil- ter and fuel rail. Figure 3-87. Gasoline Fuel Pressure and Temperature Manifold Assembly Fuel Filter 3-76 – JLG Lift – 3121642...

  • Page 117: Fuel Injector Rail

    Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use the electronic leak detector first to avoid con- tamination by the liquid leak detector. 3121642 – JLG Lift – 3-77...

  • Page 118: Propane Fuel Filter Replacement

    Disconnect the electrical connector from the Electric Lock off. Install the mounting plate to lock off O-ring seal. Remove the Electric Lock Off from the regulator. Install the retaining bolt seal. Install the housing seal. 3-78 – JLG Lift – 3121642...

  • Page 119: Temperature Manifold Absolute Pressure (Tmap) Sensor

    Connect the electrical con- nector. Connect the fuel supply line and tighten until fully Figure 3-91. (TMAP) Sensor & Electronic Throttle seated. Control (ETC) Connect the EPR electrical connector. REMOVAL: Open the manual valve. 3121642 – JLG Lift – 3-79...

  • Page 120: Electronic Throttle Control Replacement

    Remove electronic throttle control device. Remove the O-rings gasket and discard. INSTALLATION: LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO ADAPTER O-RINGS. Install the O-ring on throttle body. Press it down to the bottom of the surface. 3-80 – JLG Lift – 3121642...

  • Page 121: Mixer Replacement

    Install the mixer to the throttle control device to mixer adapter. Secure with 4 retaining screws. Tighten 80 lb-in (9 Nm). Install throttle body. Refer to Electronic Throttle Control Device Replacement. Start the engine and leak check all fittings and connec- tions. 3121642 – JLG Lift – 3-81...

  • Page 122: Coolant Hose Replacement

    Remove the hose from each of the fittings. Push lock into place. INSTALLATION: Mount controller into mounting bracket. NOTE: Use hose material and lengths specified by JLG. Reconnect battery cable. Start engine. Install the hose clamps to each hose and set the clamp back on each hose to make installation easier.

  • Page 123: 3.19 Gm Engine Lpg Fuel System Diagnosis

    This vacuum signal is most commonly referred to as air valve vacuum. In the mixer, the fuel mixes with the air entering the engine. This air/fuel mixture is then drawn into the engine for combustion. 3121642 – JLG Lift – 3-83...

  • Page 124: Lpf Fuel System Diagnosis

    Does the test light illuminate? Using a DVOM, check the resistance of the low pressure lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23 Is the resistance within the specified range? 3-84 – JLG Lift – 3121642...
  • Page 125 1. Disconnect all test equipment. 2. Install the primary and secondary test port plugs. 3. Start the engine. System OK 4. Using SNOOP or equivalent, leak check the test port plugs. Is the action complete? 3121642 – JLG Lift – 3-85...

  • Page 126: Symptom Diagnosis

    If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3-86 – JLG Lift – 3121642...
  • Page 127 • Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes 3121642 – JLG Lift – 3-87...
  • Page 128 - Inspect the muffler for signs of heat distress or for possible internal failure • Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service Manual. 3-88 – JLG Lift – 3121642...
  • Page 129 • Check the Manifold Absolute Pressure (MAP) sensor response and accuracy. • Check LPL electrical connection. • Check the mixer air valve for sticking or binding. • Check the mixer module assembly for proper installation and leakage. • Check the EPR electrical connections. 3121642 – JLG Lift – 3-89...
  • Page 130 LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics. • Remove the air filter and check for dirt or restriction. • Check the vehicle transmission Refer to the OEM transmission diagnostics. 3-90 – JLG Lift – 3121642...
  • Page 131 • Check the ignition wires for the following items: - Cracking - Hardness - Proper connections Cooling System Checks • Check the engine thermostat for always being open or for the wrong heat range. 3121642 – JLG Lift – 3-91...
  • Page 132 DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks Refer to Important Preliminary Checks. Sensor Checks • Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance. 3-92 – JLG Lift – 3121642...
  • Page 133 Additional Check • Check the ECM grounds for being clean, tight, and in their proper locations. • Check the generator output voltage. • Check the vacuum hoses for kinks or leaks. • Check Transmission. 3121642 – JLG Lift – 3-93...

  • Page 134: Dtc To Spn/Fmi Cross Reference Chart

    Injector Driver 3 Open Injector Driver 3 Shorted Injector Driver 4 Open Injector Driver 4 Shorted Crank Sync Noise Crank Loss Cam Sync Noise Cam Sensor Loss Gasoline Cat Monitor 520211 Oil Pressure Low 3-94 – JLG Lift – 3121642...
  • Page 135 CAN Rx Failure 1628 CAN Address Conflict Failure 1629 Loss of TSC 1 2111 Unable to Reach Lower TPS 2112 Unable to Reach Higher TPS 2135 TPS 1/2 Simultaneous Voltages 2229 BP Pressure High 3121642 – JLG Lift – 3-95...
  • Page 136 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS NOTES: 3-96 – JLG Lift – 3121642...

  • Page 137: Hydraulics

    If leakage continues at a rate of 6-8 drops per min- installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of ute or more, cylinder repairs must be made. 3121642 – JLG Lift –...

  • Page 138: Cylinders With Single Counterbalance Valve

    Raise machine platform above stowed position approxi- leakage occurs at a rate of 6-8 drops per minute or more, mately 9 ft (2.7 m) on the 3394RT or 10 ft (3.1 m) on the the piston seals are defective and must be replaced.

  • Page 139: Right Side Wheel Test

    SURFACE IN A DIRT FREE WORK AREA. Raise machine platform above stowed position approxi- Connect a suitable auxiliary hydraulic power source to mately 9 ft (2.7 m) on the 3394RT or 10 ft (3.1 m) on the the cylinder port block fitting. 4394RT.

  • Page 140: Cylinder Barrel Support

    Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the cap screw(s) until the bushing is loose on the piston. – JLG Lift – 3121642...

  • Page 141: Cleaning And Inspection

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary. seal kit is used. See your JLG Parts Manual. 3121642 – JLG Lift –...

  • Page 142: Rod Seal Installation

    NOTE: The backup rings for the solid seal have a radius on one side. This side faces the solid seal. [See magnified insert in (See Figure 4-11.)] The split of seals and backup rings must be positioned so as not to be in alignment with each other. – JLG Lift – 3121642...

  • Page 143: Piston Seal Kit Installation

    NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and into the tapped holes in the piston.

  • Page 144: Rod Assembly Installation

    If applicable, secure the cylinder head retainer using a suitable chain wrench. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves. – JLG Lift – 3121642...

  • Page 145: Drive Pump Start-Up Procedure

    “Jog” or slowly rotate prime mover until charge pressure starts to rise. Start prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from high pressure lines through high pressure gauge ports. 3121642 – JLG Lift –...

  • Page 146: Hydraulic Component Start-Up Procedures & Recommendations

    Also reconnect the machine function(s), if discon- draw an inlet vacuum higher than it is capable of. nected earlier. Start the engine, checking to be certain the 4-10 – JLG Lift – 3121642...

  • Page 147: Hydraulic Gear Pump

    (14) and washers (9). Separate rear cover (6) from the body (13). The static seal (8) may remain either with the body or the cover. In either case, remove the static seal and discard. 3121642 – JLG Lift – 4-11...

  • Page 148: Pump Reassembly

    (3) from each bearing block and discard. Inspect bushings in each bearing block (2). Replace bearing block if bushings are heavily scored or burned. Inspect gear journals and faces. Replace if faces or jour- nals are scored or worn. 4-12 – JLG Lift – 3121642...
  • Page 149 With an adjustable wrench, check that the drive shaft scribe marks on the body and front cover. The dowel turns without evidence of a mechanical bind. pins (7) should go into the mating holes on the front cover (5). 3121642 – JLG Lift – 4-13...

  • Page 150: Valves

    Disconnect, cap and lable all hydraulic hoses and any Re-attach valve blocks to tray with bolts. electrical harness connected to valves. Re-connect all hydraulic lines and electrical harness. Remove the valve blocks from the hydraulic tray by removing the attaching bolts. 4-14 – JLG Lift – 3121642...

  • Page 151: Main Valve

    R V 2 R V 1 M P 1 M P 2 R V 3 O R F 1 2S 2 P LG 6 O R F 2 2S 1 Figure 4-16. Main Valve Block 3121642 – JLG Lift – 4-15...

  • Page 152: Main Valve Schematic

    25 lb-ft (34.2 Nm) CL1 & CL2 (Coil) 5 lb-ft (6.8 Nm) RV1, RV2 & CV3 25 lb-ft (34.2 Nm) RV3, LS1, CV1 & CV2 20 lb-ft (27.3 Nm) Figure 4-17. Main Valve Schematic 4-16 – JLG Lift – 3121642...

  • Page 153: Flow Divider Valve

    C V 6 C V 2 5, O R 1 O R 2 F D 2 F D 1 O R 3 F D 3 C V 7 C V 8 Figure 4-18. Flow Divider Valve 3121642 – JLG Lift – 4-17...

  • Page 154: Leveling Jacks Directional Valve

    P B2 P B4 P A 4 Figure 4-19. Leveling Jacks Directional Valve Table 4-5. Leveling Jacks Directional Valve Torque Specs Item Torque 40 lb-ft (54 Nm) 23 lb-ft (31 Nm) 40 lb-ft (54 Nm) 4-18 – JLG Lift – 3121642...

  • Page 155: Powerdeck Valves

    Figure 4-21. Powerdeck Valve (Double) NOTE: All ports are SAE 04. Table 4-6. Powerdeck Valve Torque Specs Item Torque SV1, SV2 25 lb-ft (34.2 Nm) 5 lb-ft (6.8 Nm) RV1, RV2 20 lb-ft (27.3 Nm) 3121642 – JLG Lift – 4-19...

  • Page 156: Leveling Jack Valves

    Figure 4-22. Leveling Jack Valves Table 4-7. Leveling Jack Valves Torque Specs Item Torque 3 to 4.5 lb-ft (4.1 to 6.1 Nm) 18.5 to 22 lb-ft (25.1 to 29.8 Nm) 40 lb-ft (54.2 Nm) 32 lb-ft (43.4 Nm) 4-20 – JLG Lift – 3121642...

  • Page 157: Pressure Setting Procedures

    A pressure gauge must be hosed in the power deck Cold temperatures have a significant impact on pressure read- retract circuit. Tee the gauge in port 2 of the power ings. JLG Industries Inc. recommends operating the machine deck valve. until the hydraulic system has warmed to normal operating temperatures prior to checking pressures.

  • Page 158: 4.10 Gear Pump

    When oil leaks at the hose end, re-torque the hose end to 115 lb-ft ( Nm). The pump is primed and the machine is ready to start. Outlet Port, 7/8-14UNF-2B SAE #10 Inlet Port, 1-1/16-12UN-2B SAE #16 Figure 4-23. Gear Pump 4-22 – JLG Lift – 3121642...

  • Page 159: 4.11 Axial Hi 45 Pump

    Max Pressure 6525 psi (450 bar) Displacement 2.75 in³ (45 cm³) 755 mA Threshold Control Current 1640 mA Max Displacement 12 CC Charge Pump Pressure 348 psi (24 bar) Max Operating Speed 3500 rpm 3121642 – JLG Lift – 4-23...

  • Page 160: Axial Hi 45 Pump - Cross Section View

    Electric Displacement Control Shaft Charge Pump Swashplate Feedback Pin Front Bearing Rear Bearing Piston Swashplate Bearing Valve Plate Slipper Swashplate Servo Piston Shaft Seal Cylinder Block Figure 4-25. Axial HI 45 Pump - Cross Section View 4-24 – JLG Lift – 3121642...

  • Page 161: General Repair Instructions

    AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAMAGE HYDRAULIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS. DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND FLUID HAS BEEN THOROUGHLY FILTERED. 3121642 – JLG Lift – 4-25...

  • Page 162: Removing The Pump

    NOTE: Be careful, do not damage solenoids and electrical connec- tions when using straps or chains to support the pump. INSPECTION: Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and grime. 4-26 – JLG Lift – 3121642...

  • Page 163: Electric Control Module

    Torque to 1.8 lb-ft (2.5 Nm). Install coil using a 12 point 26 mm socket. Torque coil Install the control module and six cap screws (D250). nut to 3.7 lb-ft (5 Nm). 3121642 – JLG Lift – 4-27...

  • Page 164: Shaft Seal, Roller Bearing & Shaft Replacement

    (J275). Press a new seal (J250) into the seal carrier. Carefully inspect the valve and pressure-balance plates. Press the seal until it is flush within 0.005 in (+0.12mm ) Scratches on these components will cause a loss of 4-28 – JLG Lift – 3121642...
  • Page 165 (see table) K300 Torque sequence K250 K400 8 mm SAE B SAE A Cover Screw K350 Cover Pad Wrench Size; Torque 17 mm; 35 lb-ft (48 Nm) B, C 19 mm; 58 lb-ft (77 Nm) 3121642 – JLG Lift – 4-29...

  • Page 166: Charge Check/Hprv

    Check for leaks. ensure proper operation. High Pressure Relief Valves (HPRVs) Charge Pressure Relief Valve L060 L068 V024 L100 / L200 22 mm 22 mm 38 ft.lbs. 81 ft.lbs. 110 Nm 52 Nm 4-30 – JLG Lift – 3121642...

  • Page 167: Pressure Limiter Valve Replacement

    Disconnect and cap the hydraulic lines on the filter (1). Remove the four bolts (2) to remove the filter from the bracket. INSTALLATION: Attach filter (1) to bracket using the four bolts (2). Uncap and reconnect the hydraulic lines to the filter. 3121642 – JLG Lift – 4-31...

  • Page 168: 4.13 Auxiliary Pump Motor

    114 - 150 in-lbs (13 - 17 Nm) Figure 4-27. Auxiliary Pump Motor • Displacement: 0.097 CU. IN/REV (1.59 CC/REV) • Delivers 1.2 min. GPM (4.5 min Liters/Min) at 1500 psi (103.4 bar) and 165 Amps maximum at 12VDC 4-32 – JLG Lift – 3121642...

  • Page 169: 4.14 Cylinder Assemblies

    Cylinder Head Wear Ring O-ring Back-up Ring O-ring Wiper Seal Wear Ring T-Seal Figure 4-28. Steer Cylinder NOTE: Apply ant-seize lube to threads of Cylinder Head (3) and torque to 200 lb-ft (271.2 Nm). 3121642 – JLG Lift – 4-33...

  • Page 170: Lift Cylinder

    Plug, O-Ring Seal Plug, O-Ring Jam Nut Ring, Back-Up Bushing Cotter Pin Setscrew Piston Cartridge, Lift Holding Solenoid Head Seal Cartridge, Lift Holding Solenoid Seal Cartridge, Check Ring, Wear Barrel Figure 4-29. Lift Cylinder 4-34 – JLG Lift – 3121642...

  • Page 171: Lift Cylinder Valve Cartridge Torque Values

    5 lb-ft (6.8 Nm) 30 lb-ft (40.7 Nm) 25 lb-ft (33.9 Nm) 40 lb-ft (54.2 Nm) 40 lb-ft (54.2 Nm) 40 lb-ft (54.2 Nm) 60 lb-ft (81.3 Nm) Figure 4-30. Lift Cylinder Valve Cartridge Torque Values 3121642 – JLG Lift – 4-35...

  • Page 172: Oscillating Axle Cylinder

    Piston Pilot Check Valve Bleeder Valve NOTE: Torque item #8 to 25-27 lb-ft (34-37 Nm) THE CYLINDER ROD CAN SLIDE OUT OF THE CYLINDER IF THE BLEEDER VALVE IS LOOSENED. Figure 4-31. Oscillating Axle Cylinder 4-36 – JLG Lift – 3121642...

  • Page 173: Leveling Jack Cylinder

    Figure 4-32. Leveling Jack Cylinder NOTE: Apply a light coat of grease to the Cylinder Rod (3) before Apply Loctite® #242 to Capscrews (11) and torque to 30 lb- installing the Jack Pad (16). ft ( 40.7 Nm). 3121642 – JLG Lift – 4-37...

  • Page 174: Leveling Jack Torques

    SECTION 4 - HYDRAULICS H ydraulic S chem atic Item Description Torque Solenoid Directional Valve 40 lb-ft (54.2 Nm) Straight Fitting 32 lb-ft (43.4 Nm) Straight Fitting 40 lb-ft (54.2 Nm) Figure 4-33. Leveling Jack Torques 4-38 – JLG Lift – 3121642...

  • Page 175: Deck Extension Cylinder

    SECTION 4 - HYDRAULICS Locknut Spacer Tube Seal Piston Head Wiper Ring Seal Retaining Ring O-Ring O-Ring Barrel Back-up Ring Figure 4-34. Deck Extension Cylinder 3121642 – JLG Lift – 4-39...

  • Page 176: Oscillating Axle Cylinder Bleeding Procedure

    ANYTIME EITHER OF THE HOSES PLUMBING TO THE CYLINDERS ARE BROKEN Open the bleeder valve enough to get a fast stream of INTO, AIR HAS BEEN INTRODUCED INTO THE SYSTEM. THE CYLINDERS MUST oil. BE BLED. 4-40 – JLG Lift – 3121642...

  • Page 177: Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM HAND HELD ANALYZER m en u: Analyzer Dis- HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, To return home or Sub Level, and item menus access previous menu Left &...

  • Page 178: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM NOTE: The cable has a four pin connector at each end; the cable ing power up, the display will read: In platform mode, cannot be connected backwards. HELP: EVERYTHING OK, In ground mode, GROUND MODE OK...
  • Page 179 SECTION 5 - JLG CONTROL SYSTEM When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered.

  • Page 180: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Once you have gained access to level 1, and a personality item...
  • Page 181 SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to Table 5-3, Machine Configuration Programming Information and Table 5-5, Machine Model Adjustment for default settings. Password 33271 will give you access to level 1, which will permit you to change all machine personalities and/or machine setup settings.

  • Page 182: Calibrations

    Proximity Sensor (on frame inboard slide channel) Figure 5-3. Limit Switch Location a. Raise platform to a height of 30 feet on the 3394RT Elevation Sensor Calibration or 36 feet for the 4394RT (measured deck to Using the Analyzer, in Access Level 1, go to MENU: CALIBRA- ground).

  • Page 183: Joystick Calibration

    SECTION 5 - JLG CONTROL SYSTEM Joystick Calibration b. Tilt sensor mounting on machine or wedged crooked in control box: Using the Analyzer, in Access Level 1, go to MENU: CALIBRA- If the machine mounting/grade appears acceptable, TION: JOYSTICK and press ENTER.

  • Page 184: Tilt Sensor

    SECTION 5 - JLG CONTROL SYSTEM NOTE: Follow the above procedures in reverse order when install- b. Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connections. ing the tilt sensor assembly. After installing, be sure to cali- brate the tilt sensor (refer to Section 5.2, Calibrations).

  • Page 185: 5.3 Flash Codes And Descriptions

    Reported when elevated drive is not available when communication with the DRIVE PREVENTED - ECM LOST ECM times-out. Reported when elevation prox switch is closed when the 26 ft (3394RT) or 30 ft ELEVATION SENSOR DISAGREEMENT (4394RT) voltage is reached on the elevation angle sensor. (prevents further lift up from platform controls) Flash code 2/1 indicates issues at power up.
  • Page 186 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Flash code 2/2 indicates difficultly with the platform controls. Reports when the CAN message coming from the platform board and the DI on TRIGGER SWITCH WIRING SHORTED HIGH IN PLATFORM CABLE ground board conflict.
  • Page 187 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Flash code 2/3 indicates difficultly with ground controls. FUNCTION LOCKED OUT – GROUND LIFT UP PERMANENTLY CLOSED Reported when the ground lift up switch is closed during power up.
  • Page 188 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Flash code 2/5 indicates issues that may cutout functions. ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLTAGE OUT OF...
  • Page 189 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Flash code 2/6 indicates leveling jack or power deck issues. Reported by the I/O module and during system test when the front left leveling FRONT LEFT LEVELING JACK OPEN CIRCUIT jack is open circuit.
  • Page 190 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Reported by the I/O module and during system test when the front deck retract FRONT DECK RETRACT VALVE SHORT TO GROUND valve is short to ground.
  • Page 191 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code Flash code 6/6 indicates CANbus issues. CAN BUS FAILURE Reported when there is a problem with the CANbus.
  • Page 192 SECTION 5 - JLG CONTROL SYSTEM 5-16 – JLG Lift– 3121642...
  • Page 193 SECTION 5 - JLG CONTROL SYSTEM 3121642 – JLG Lift – 5-17...
  • Page 194 SECTION 5 - JLG CONTROL SYSTEM 5-18 – JLG Lift– 3121642...

  • Page 195: Machine Configuration Programming Information

    SECTION 5 - JLG CONTROL SYSTEM NOTE: When configuring an RT, the Machine Configuration must changing the Model of the Machine Configuration will be completed before any Personality settings can be cause the Personality settings to return to default values.

  • Page 196: Machine Tilt Configuration

    SECTION 5 - JLG CONTROL SYSTEM Table 5-3. Machine Configuration Programming Information Configuration Digit Setting Description Default Number NOT INSTALLED – Load Sensing System (LSS) is not fitted to the vehicle. CUTOUT PLT – Load Sensing System (LSS) is fitted, and Platform Controls are prevented in the event of an Overload.
  • Page 197 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indi- cate the default when the option is factory installed. 3394RT 2WD ANSI USA ANSI EXPORT...
  • Page 198 SECTION 5 - JLG CONTROL SYSTEM 3394RT 4WD ANSI USA ANSI EXPORT AUSTRALIA 4150390 M 5-22 – JLG Lift– 3121642...
  • Page 199 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indi- cate the default when the option is factory installed. 4394RT 2WD ANSI USA ANSI EXPORT...
  • Page 200 SECTION 5 - JLG CONTROL SYSTEM 4394RT 4WD ANSI USA ANSI EXPORT AUSTRALIA 4150390 M 5-24 – JLG Lift– 3121642...

  • Page 201: Machine Model Adjustment

    SECTION 5 - JLG CONTROL SYSTEM Table 5-5. Machine Model Adjustment Model Default Values Adjustment Adjustment Range 3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD DRIVE Accel 0.1 - 5.0 (sec) Decel 0.1 - 3.0 (sec) Min Forward 0 - 35%...
  • Page 202 SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-26 – JLG Lift– 3121642...

  • Page 203: General Electrical Information & Schematics

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CON- TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

  • Page 204: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resis- tance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121642...

  • Page 205: Continuity Measurement

    • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating conti- nuity 3121642 – JLG Lift –...

  • Page 206: Continuity Measurement Over Long Distances

    #1 and wire #2, and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach of the jumper. – JLG Lift – 3121642...

  • Page 207: Applying Silicone Dielectric Compound To Amp Connectors

    Install a hole plug into this and/or any unused wire seal pound to the electrical connectors. that has silicone dielectric compound escaping from it. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around Figure 6-5. AMP Connector 3121642 – JLG Lift –...

  • Page 208: Assembly

    (See Figure 6-8. Connector Assembly (3 of 4)). Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)). Figure 6-9. Connector Assembly (4 of 4) – JLG Lift – 3121642...

  • Page 209: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 3121642 – JLG Lift –...

  • Page 210: Service - Voltage Reading

    This nullifies the effectiveness of the connector seals and could result in system failure. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This Figure 6-11. Connector Installation – JLG Lift – 3121642...

  • Page 211: 6.4 Working With Deutsch Connectors

    Slide tool along into the insert cavity until it engages contact and resistance is felt. Pull contact-wire assembly out of connector. Figure 6-17. HD/HDP Unlocking Contacts NOTE: Do not twist or insert tool at an angle. 3121642 – JLG Lift –...

  • Page 212: 6.5 Switches

    Another type of limit switch used by JLG is the inductive selected. proximity switch, also referred to as a "prox switch". Induc- tive proximity switches are actuated only by ferrous metal 1.

  • Page 213: Automatic Switches

    Also, the technician can measure the voltage at both power ter- minals with respect to battery ground. The difference between those two measurements is the voltage applied to the load. 3121642 – JLG Lift – 6-11...

  • Page 214: Electrical Components Installation

    (W /O JA CK OPTION) (W /O POW ER DECK) (W / POW ER DECK) LEVELING JA CK PORT OPTIONS BL OCKS MODULE LEVELING JA CK V A L VE Figure 6-18. Electrical Components Installation 6-12 – JLG Lift – 3121642...
  • Page 215 V A L VE SPLICE SPLICE GROUND SPLICE MA IN V A L VE DEUTZ GROUND IGNITION SPLICE DIA NOSTICS CONTROL PL UG (DIESEL) IGNITION SPLICE (GA S) GROUND SPLICE (DIESEL) Figure 6-18., Electrical Components Installation 3121642 – JLG Lift – 6-13...

  • Page 216: Schematics

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SCHEMATICS Figure 6-19. Electrical Schematic - Diesel 6-14 – JLG Lift – 3121642...
  • Page 217 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103487_G-Sht. 1 of 3 Figure 6-19., Electrical Schematic - Diesel 3121642 – JLG Lift – 6-15...
  • Page 218 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-19., Electrical Schematic - Diesel 6-16 – JLG Lift – 3121642...
  • Page 219 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103487_G-Sht. 2 of 3 Figure 6-19., Electrical Schematic - Diesel 3121642 – JLG Lift – 6-17...
  • Page 220 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-19., Electrical Schematic - Diesel 6-18 – JLG Lift – 3121642...
  • Page 221 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103487_G-Sht. 3 of 3 Figure 6-19., Electrical Schematic - Diesel 3121642 – JLG Lift – 6-19...

  • Page 222: Electrical Schematic - Dual Fuel

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20. Electrical Schematic - Dual Fuel 6-20 – JLG Lift – 3121642...
  • Page 223 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488_D-Sht. 1 of 4 Figure 6-20., Electrical Schematic - Dual Fuel 3121642 – JLG Lift – 6-21...
  • Page 224 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20., Electrical Schematic - Dual Fuel 6-22 – JLG Lift – 3121642...
  • Page 225 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488_D-Sht. 2 of 4 Figure 6-20., Electrical Schematic - Dual Fuel 3121642 – JLG Lift – 6-23...
  • Page 226 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20., Electrical Schematic - Dual Fuel 6-24 – JLG Lift – 3121642...
  • Page 227 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488_D-Sht. 3 of 4 Figure 6-20., Electrical Schematic - Dual Fuel 3121642 – JLG Lift – 6-25...
  • Page 228 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20., Electrical Schematic - Dual Fuel 6-26 – JLG Lift – 3121642...
  • Page 229 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488_D-Sht. 4 of 4 Figure 6-20., Electrical Schematic - Dual Fuel 3121642 – JLG Lift – 6-27...

  • Page 230: Hydraulic Schematic

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21. Hydraulic Schematic 6-28 – JLG Lift – 3121642...
  • Page 231 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21., Hydraulic Schematic 3121642 – JLG Lift – 6-29...
  • Page 232 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21., Hydraulic Schematic 6-30 – JLG Lift – 3121642...
  • Page 233 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21., Hydraulic Schematic 3121642 – JLG Lift – 6-31...

  • Page 234: Hydraulic Schematic (Ce)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22. Hydraulic Schematic (CE) 6-32 – JLG Lift – 3121642...
  • Page 235 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22., Hydraulic Schematic (CE) 3121642 – JLG Lift – 6-33...
  • Page 236 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22., Hydraulic Schematic (CE) 6-34 – JLG Lift – 3121642...
  • Page 237 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22., Hydraulic Schematic (CE) 3121642 – JLG Lift – 6-35...
  • Page 238 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 6-36 – JLG Lift – 3121642...
  • Page 240 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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