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Oshkosh Corporation JLG 3394RT Service Maintenance Manual

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Service & Maintenance Manual
Models
3394RT
4394RT
S/N 0200191606 to Present
including S/N's:
0200186972,
0200187002,
0200187013
3121249
May 16, 2014

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Summary of Contents for Oshkosh Corporation JLG 3394RT

  • Page 1 Service & Maintenance Manual Models 3394RT 4394RT S/N 0200191606 to Present including S/N’s: 0200186972, 0200187002, 0200187013 3121249 May 16, 2014...

  • Page 3: Hydraulic System Safety

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. This section contains the general safety precautions which must be observed during maintenance of the aerial platform.
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - October 6, 2008 Revised - November 3, 2008 Revised - November 30, 2010 Revised - July 19, 2012 Revised - May 16, 2013 Revised - May 16, 2014 – JLG Lift – 3121249...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ..............A Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS Cylinder Repair ..............4-3 Drive Pump Start-up Procedure .
  • Page 7 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location............1-2 1-2.
  • Page 8 TABLE OF CONTENTS 3-44. Engine Tray Swing .............3-65 3-45.
  • Page 9 TABLE OF CONTENTS 4-35. Oscillating Axle Cylinder Bleeding ..........4-40 5-1.
  • Page 10 TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ............1-1 Capacities .

  • Page 11: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS SPECIFICATIONS CAPACITIES Table 1-1. Operating Specifications Table 1-2. Capacities Description 3394RT 4394RT Description 3394RT 4394RT Fuel Tank 31.5 gal (119 L) Maximum Occupants Hydraulic Tank: Maximum Workload Total Capacity 32.3 gal (122.3 L) (Capacity): Full Level 27.3 gal (103.3 L)

  • Page 12: Tires

    SECTION 1 - SPECIFICATIONS TIRES Table 1-5. Deutz F3M2011 Specifications Table 1-7. Tire Specifications Fuel DIesel Oil Capacity 8.5 Quarts (8 L) w/Filter Inflation Wheel Nut Size Low RPM Rating Pressure Torque (Dry) High RPM 2800 IN315/55D20 170 lb-ft 75 psi (5 bar) Alternator 95 Amp, Belt Drive Pneumatic...

  • Page 13: Serial Number Locations

    SECTION 1 - SPECIFICATIONS SERIAL NUMBER LOCATIONS SENSORS For machine identification, a serial number plate is affixed The machine is equipped with the following limit switches: to the machine. The plate is located at the rear of the Elevation Switch/Rotary Position Sensor - High drive machine on the center of the axle.

  • Page 14: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS CYLINDER SPECIFICATIONS 1.11 CRITICAL STABILITY WEIGHTS Table 1-11. Cylinder Specifications Description Bore Stroke Rod Dia DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS 4.5 in 83 in 3.5 in OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: Lift Cylinder (114 mm) (2.1 mm)

  • Page 15: Lubrication Specifications

    SECTION 1 - SPECIFICATIONS 1.12 LUBRICATION SPECIFICATIONS Table 1-16. Mobil 424 Specs Type Synthetic Biodegradable Table 1-14. Hydraulic Oil SAE Grade 10W-30 Hydraulic System Operating Sae Viscosity Grade Gravity, API 29.0 Temperature Range Density 7.35 lb/gal ( 0°F to +23°F Pour Point, Max -46°F (-43°C) (-18°C to -5°C)

  • Page 16: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.13 OPERATOR MAINTENANCE 1. Fuel Tank 2. Drive Hubs 3. Hydraulic Oil Tank 4. Sliding Wear Pads 5. Oil Change w/Filter - Deutz 6. Oil Change w/Filter - GM 7. Fuel Filter - Deutz 8. Fuel Filter (Gasoline) - GM 9.
  • Page 17 SECTION 1 - SPECIFICATIONS Drive Hub Engine Oil Change w/Filter - Deutz • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7016331) • Lube Points - Fill Plugs (4) • Capacity - 6.3 qt. (5.9 L) engine only • Lube - EPGL - Mobilube HD 80W-90 or equivalent •...
  • Page 18 SECTION 1 - SPECIFICATIONS Oil Change w/Filter - GM Engine Fuel Filter - Deutz D 2.9 L4 - T4F • Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) • Lube Point(s) - Replaceable Element - on engine and Pre-Filter w/pressure sensor next to fuel tank •...
  • Page 19 SECTION 1 - SPECIFICATIONS Fuel Filter (Propane) - GM • Interval - 3 Months or 150 hours of operation 4. Push in the Emergency Switch once the engine stops. • Comments - Replace filter. Refer to Propane Fuel Filter 5. Disconnect the electrical connection to the LPG fuel Replacement temperature sensor in the auxiliary fuel port of the EPR.

  • Page 20: Filter Lock Assembly

    SECTION 1 - SPECIFICATIONS INSTALLATION: 7. Once all of the oil has been drained, reinstall the LPG fuel temperature sensor and reconnect the electrical connector. 8. Open the fuel tank manual valve. BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS- ING BEFORE INSTALLING NEW SEAL.

  • Page 21: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.14 TORQUE CHARTS Figure 1-4. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121249 – JLG Lift – 1-11...
  • Page 22 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-12 – JLG Lift – 3121249...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121249 – JLG Lift – 1-13...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-14 – JLG Lift – 3121249...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121249 – JLG Lift – 1-15...
  • Page 26 SECTION 1 - SPECIFICATIONS NOTES: 1-16 – JLG Lift – 3121249...

  • Page 27: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance AND MAINTENANCE Schedule for items requiring inspection during the perfor- mance of these inspections. Reference the appropriate General areas of this manual for servicing and maintenance proce- dures.

  • Page 28: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Prior to use each day; or User or Operator User or Operator Operator and Safety Manual Inspection At each Operator change. Service and Maintenance Pre-Delivery Prior to each sale, lease, or Qualified JLG...
  • Page 29 SECTION 2 - GENERAL Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accor- When disassembling or reassembling a component, com- dance with recommended shop practices.

  • Page 30: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION 3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20°F Hydraulic System (-29°C).

  • Page 31: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. Platform Drift 1. Pinned joints should disassembled inspected if the following occurs: Measure the drift of the platform to the ground.

  • Page 32: Preventive Maintenance And Inspection Schedule

    SECTION 2 - GENERAL PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE The preventive maintenance and inspection checks are “ANNUAL MACHINE INSPECTION REPORT” FORM. listed and defined in the following table. This table is divided into two basic parts, the “AREA”...

  • Page 33: Preventive Maintenance And Safety Inspection

    SECTION 2 - GENERAL Table 2-3. Preventive Maintenance and Safety Inspection AREA INTERVAL 300 Hours 600 Hours 1200 Hours Daily Weekly (6 months) (1 year) (2 years) PLATFORM 1. Controller 1,11 2. Switches 1,11 3. Placards and Decals 4. Control Tags 5.

  • Page 34: Engine Operating Temperature Specifications - Deutz

    SECTION 2 - GENERAL Figure 2-1. Engine Operating Temperature Specifications - Deutz – JLG Lift – 3121249...

  • Page 35: Engine Operating Temperature Specifications - Gm

    SECTION 2 - GENERAL Figure 2-2. Engine Operating Temperature Specifications - GM 3121249 – JLG Lift –...
  • Page 36 SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121249...

  • Page 37: Section 3. Chassis, Platform & Scissor Arms

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS OPERATING CHARACTERISTICS Generator When the generator switch is activated, the engine RPM Leveling Jacks will increase to 2000 RPM for a 60 Hz generator or 1700 RPM for a 50 Hz generator.
  • Page 38 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS • any damage to the bead area cords of the tire Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten If a tire is damaged but is within the above noted criteria, the fasteners.

  • Page 39: Drive Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Drive Assembly 1. Tire & Rim 2. Lugnuts 3. Drive Motor/Hub Assembly (Bosch Rexroth) 4. Bolt, 5/8"-11NC x 1 1/2" 5. Hardened Washer NOTE: Rear Axle Shown Figure 3-1. Drive Assembly (Bosch Rexroth ) REMOVAL: INSTALLATION: 1.
  • Page 40 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 1. Tire & Rim 2. Lugnuts 3. Drive Hub (Fairfield) 4. Bolt, 5/8"-11NC x 1 3/4" 5. Hardened Washer, 5/8" 6. Drive Motor (Sauer) 7. Nut, 1/2"-13NC 8. Hardened Washer, 1/2" NOTE: Rear Axle Shown Figure 3-2.

  • Page 41: Integrated Torque/Drive Hub

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS INTEGRATED TORQUE/DRIVE HUB (BOSCH REXROTH) The Integrated Torque/Drive Hub is an axial piston-hydrau- lic motor with integrated, hydraulic released multi plate parking brake and a 2-stage planetary gearbox and a dis- connect mechanism. To ensure an optimum balancing of loads, each planetary stage is comprised of planet gears in sets.
  • Page 42 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 32 26 35 1 10 13 15 1. Planet Gear 11. Tapered Roller Bearing 21. Thrust Washer 31. O-Ring 2. Planet Gear 12. Retaining Ring 22. Gear, Ring Options 32. Spring 3. Sun Gear 13.
  • Page 43 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-3. Gearbox Maintenance Schedule THE MAXIMUM GEAR DRIVE TOWING SPEED OF 72 RPM MUST N O T B E E X C E E D E D . E N G A G E G E A R D R I V E O R S E C U R E After 150 motor operating hours - First oil change MACHINE WHEN MACHINE IS SEPARATED FROM THE TOWING...
  • Page 44 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Gearbox Disassembly 4. Remove Sun Gear Shaft (25). For numbers in parenthesis, refer to Figure 3-4., Drive Motor/Hub Assembly. 1. Remove Screw Plugs (18, 19) and drain oil into appropriate container. 5. Remove complete 1st planet stage. 2.
  • Page 45 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7. Remove Snap Rings (13). 10. Drilling Hole Sketch 11. Split the Shaft Nut (4) in the area of the two drill 8. Pull out Plane Gears (1). holes by means of a chisel, and remove from Spin- dle (34).
  • Page 46 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Remove the Support Ring (6) from the Spindle (34). 15. Repair deformed threads on the Spindle (34) in the Components stay in Supporting Ring (6). area of the ball detend with a thread file of 1.5mm pitch.
  • Page 47 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS c. Secure the gears with new Snap Rings (12). 5. Insert the bottom part of the double Tapered Roller Bearing (11). NOTE: Heat Supporting Ring (6) to approximately 189.5° F 6. Insert radial Shaft Seal Ring (17) into Supporting (70°...
  • Page 48 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Heat upper ring with roller cage of double Tapered b. The Loctite® setting time equals 24 hours at Roller Bearing (11) to approximately 189.5° F (70° C) ambient temperature of 68° F (20° C). and mount onto Spindle (34).
  • Page 49 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 13. Assembly of planet gear (Main Stage): 16. Install completely pre-assembled 1 planet stage into the gear drive. a. Mount the planet gears with Bearing Assembly (1, 10), heated to approximately 189.5° F (70° C), onto the planet bolts of the Spindle (34) and secure the gears with new Snap Rings (13).
  • Page 50 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 20. Insert Shift Rod (33) into preassembled Cover (8). 23. Install Plugs (18) with new Seal Rings (19) into Cover (8). 21. Install preassembled Cover (8) into Ring Gear (22). 22. Install Snap Ring (24). NOTE: Prior to operating, fill the drive with new oil.
  • Page 51 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-5. Drive Hub Assembly 3121249 – JLG Lift – 3-15...
  • Page 52 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Motor Disassembly 3. Disassemble guide ring: a. Seal Ring (1) 1. Mark port plate to the supporting axle. b. Pressure Springs (2) (quantity = 26) c. Guide Ring (3) 2. Remove port plate. 4.
  • Page 53 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 5. Disassemble bearing with synchronizing plate. 8. Disassemble lamination kit. 6. Remove pressure ring with extractor. 9. Disassemble Seeger snap ring. 7. Remove pressure ring. 10. Disassemble cradle stop with 2 screws, M4 x 75mm. 3121249 –...
  • Page 54 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 11. Disassemble rotary group completely with cradle. 14. Disassemble shaft seal ring. 15. Insert disc. Pull off bearing ring with device. Remove disc. 12. Disassemble control piston with spring. 16. Disassemble bearing ring from port plate. 13.
  • Page 55 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 17. Remove bearing ring (1). Disassemble spool (2). 19. Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (Otherwise: Pistons must be replaced in sets). 20.
  • Page 56 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Check splines (1) for damage or fretting; running 25. Make sure the sealing surfaces are damage free. surfaces (2);groove cut by shaft seal (3). 23. Check that sliding surface is free of grooves (1); cups are free of grooves and there are no pittings (2).
  • Page 57 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 28. Press bearing on drive shaft. 30. Attach a measuring device. Ascertain tolerance. Grip shaft with Seeger ring pincers and move up and down. [Simulation ring 1mm + tolerance + (bearing pretension 0.05 - 0.08) is resulting in thickness of the synchronizing disc].
  • Page 58 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Motor Assembly 2. Install rotary group with cradle. Observe installation position of swivel balls. 1. Press in swivel balls (with tool) (1). Insert shaft seal NOTE: Slightly grease swivel balls. ring (with tool) (2). Insert control piston with spring (3).
  • Page 59 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Mount Seeger snap ring. Opening of snap ring must 6. Assemble piston with retaining plate. Oil piston and be on the opposite side of the control piston. slipper pad. 7. Assembly aid: Hold the pistons by using an o-ring. 5.
  • Page 60 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Install laminations in correct order. 10. Grease seal rings, install in supporting axle. 9. Mount support ring (1) and quad ring (2) in pressure ring. Be careful not to excessively extend the rings. 11.
  • Page 61 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Mount seal rings (1). Insert and line-up guide ring. 14. Mount synchronizing disc (1) and bearing (2). 15. Mount bearing ring with device. Mount spool. Mount fixation pin. 13. Align the two holes for fixation cylinder pin - port plate (item 2).
  • Page 62 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 16. Fix control plate with grease at port plate. 18. Mount and screw port plate on supporting axle. 17. Fill case with oil. 3-26 – JLG Lift – 3121249...

  • Page 63: Drive Hub Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.4 DRIVE HUB (FAIRFIELD) The following steps describe the proper procedure for tightening and torquing bolts or socket head cap screws in a bolt circle. Roll and Leak Testing 1. Tighten (but do not torque) bolt ”A” until snug. Always roll and leak test Drive-Hubs after assembly to make sure that the unit’s gears and sealants are working 2.
  • Page 64 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 6H 6G Figure 3-6. Drive Hub 3-28 – JLG Lift – 3121249...
  • Page 65 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-4. Drive Hub Part Description NOTE: Refer to Figure 3-6., Drive Hub. Item # Description Table 3-4. Drive Hub Part Description Dowell Pin Item # Description Coupling Spindle/Housing Assembly Input Spacer Spindle Input Spacer Seal...
  • Page 66 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Hub-Spindle Sub-Assembly Internal Gear 6 A. Cover 7 C. Spring 1 A. Spindle Carier Sub-Assembly 6 B. Cover Cap 7 D. Spacer 1 B. Seal 3 A. Carrier Housing 6 C. Bolt Input Gear 1 C.
  • Page 67 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Disassembly for Drive Hub BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU NOTE: Refer to Figure 3-7. for part location and listing. REMOVE THE O-RING. 1. Turn hub (1G) over onto its side. Remove coupling 16.
  • Page 68 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Turn hub (1G) over onto its small end. Remove two 5. Remove one spacer (3D) from inside cluster gear pipe plugs (1J) from the two pipe plug holes in the (3F). side of hub.
  • Page 69 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Set carrier housing (3A) sideways on a table. Insert a 7. Following the cluster gear, place one more thrust planet shaft (3E), roll pin hole last, into one of the washer (3B) onto planet shaft (3E) through the planet shaft holes from roll-pin-holed side of carrier opposite planet shaft hole in carrier housing (3A).
  • Page 70 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover cap (6B) onto cover (6A), aligning the pipe plug hole 1. Using the disconnect rod, push o-ring (6F) into the in the cover cap over the pipe plug hole in the cover.
  • Page 71 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 7. With the large end down, place the disconnect cap 10. Apply a light coat of "Never-Seize" to pipe plug (6H) (6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover hole in the disconnect cap over the pipe plug hole in (6A).
  • Page 72 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Apply a light coat of "Never-Seize" to two pipe plugs 6. Press seal (1B) into the small end of hub (1G). (1J) and tighten them into the two pipe plug holes in the side of the hub (1G).
  • Page 73 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Main Assembly 9. Place spacer (1H) onto spindle (1A) in hub (1G). BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL- ING THE O-RING 1. Grease o-ring (5) and place it into the counterbore in hub (1G).
  • Page 74 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Place thrust washer (11) around spindle (1A) so it 7. Place other spacer (7D) onto the smooth end of rests on the bottom of the internal gear (2). input shaft (7A). 5.
  • Page 75 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 10. Place thrust spacer (9) onto input shaft (7). the location of shoulder bolt holes on the outside of ring gear and hub. NOTE: You may lift the ring gear off the hub to align the shoulder bolt holes.
  • Page 76 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 16. Set the cover (6A) on table, interior side up. Grease 19. Place shoulder bolts (13) into the four shoulder bolt o-ring (5) and place it into the counterbore around holes in cover (6) and tighten by hand. the edge of cover (6A).
  • Page 77 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 22. Torque the shoulder bolts (13) 18 to 25 ft. lbs. (25 to 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for 34 Nm). Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 2 to 3 minutes.
  • Page 78 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP (1E) The following specialized tools are used to assemble this unit. The tool diagrams included in this manual are intended for the customer who may wish to have a tool made.
  • Page 79 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Shaft Seal Replacement 5. Install the drive motor on the hub, then release the hydraulic pressure at the brake release port. The REMOVAL coupling will remain in position. Disconnect the hydraulic power supply and reconnect the 1.
  • Page 80 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS INSPECT THE COMPONENTS 2. Using a 1/4 in hex wrench, remove plug (3). 3. Remove O-rings (4, 5, and 6). Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear, and contami- 4.
  • Page 81 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Troubleshooting Table 3-5. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply and oil supply to the motor.
  • Page 82 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced.
  • Page 83 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Using a 9/16 in internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 25. Valve Plate 26. End Cap 27. O-ring 22. Screw 28. Rear Shaft Bearing 23.
  • Page 84 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 18. Remove minimum angle stop (29) and servo spring shaft seal (34). Discard the seal. (30) from the housing. To avoid damaging the shaft during seal removal, install a large sheet metal screw into the chuck of a slide hammer.
  • Page 85 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings 44. Piston 49. Retaining Ring Figure 3-19. Swash Plate & Servo Piston 45. Slipper Retainer 50. Block Spring Washer 46.
  • Page 86 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 28. Turn the block over. Using a press, apply pressure SLIPPERS on the block spring washer (50) to compress the Inspect the running surface of the slippers. Replace any block spring. Compress the spring enough to safely piston assemblies with scored or excessively rounded remove the spiral retaining ring (51).
  • Page 87 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS BALL GUIDE AND SLIPPER RETAINER Replace swashplate if the difference in thickness from one side to the other exceeds specification. Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat.
  • Page 88 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Assembly SERVO PISTON AND MINIMUM ANGLE STOP Inspect the minimum angle stop, servo piston head, and 1. Install new O-ring (1) and piston seal (2) to the servo servo piston ball-socket for damage or excessive wear. piston (3).
  • Page 89 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3. Install the inner block spring washer (4), block 6. Install the journal bearings (13) into the housing spring (5), and outer washer (6) into the cylinder seats. Use assembly grease to keep the bearings block.
  • Page 90 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated. bearing onto shaft with lettering facing out. Lubricate Install the cylinder kit (19) onto the shaft. Install with bearing rollers.
  • Page 91 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 12. Press the rear shaft bearing (22) into the endcap. 15. Install the endcap (25) onto the housing with the Install the bearing with letters facing out. Press until endcap screws (26). Check to ensure the endcap bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) will properly seat onto the housing without interfer- above endcap surface.
  • Page 92 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing. a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and motor.
  • Page 93 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Initial Start-up Procedures 20. Install orifice poppet (30). Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage incurred 11/16 in during shipping.

  • Page 94: Front Axle

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS FRONT AXLE Steering Assembly 1. Steer Cylinder 6. Bearing 11. Washer 16. Thrust Washer 2. Screw, 3/4"D x 1 3/4" 7. Tie Rod 12. Cylinder Block 17. Bearing 3. Nut 8. End Bearing Rod 13.

  • Page 95: Axle Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Axle Assembly 1. Front Axle 4. Axle Pivot Pin 7. Bearing 2. Bolt, 5/8"-11NC x 1 1/2" 5. Thrust Washer 3. Pin Keeper 6. Thrust-Axle Washer Figure 3-33. Axle Assembly REMOVAL: ASSEMBLY: 1.
  • Page 96 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Front Axle - Tow Bar Installation (If Equipped) 1. Tow Bar Axle Mount 4. Steering Link 2. Tow Bar Steering Stops 5. Pivot Pin 3. Tow Bar 6. Tie Rod/Tow Bar Shoulder Screws Figure 3-34.

  • Page 97: Axle Lockout Cylinder

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Axle Lockout Cylinder 1. Axle Lockout Cylinder 2. Bolt, 1/2"-11NC x 2 3/4" 3. Washer Figure 3-35. Axle Lockout Cylinder REMOVAL: INSTALLATION: 1. Disable machine operation. 1. Attach cylinder to frame using four bolts (2) and washers (3).

  • Page 98: Leveling Jacks (If Equipped)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS LEVELING JACKS (IF EQUIPPED) Cylinder Removal 1. Cover 2. Bolt, 1/4"-20NC x 7/8" 3. Flatwasher 4. Tinnerman Nut 5. Jack Cover Bracket 6. Bolt, 1/2"-13NC x 3" 7. Nut 8. Leveling Jack Cylinder Figure 3-35.

  • Page 99: Leveling Jacks Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Assembly Removal NOTE: Applies to both front and rear of machine. 1. Leveling Jacks Assembly 4. Washer 7. Washer 2. Bolt, 1/2"-13NC x 1 3/8" 5. Bolt, 3/4" - 10NC x 3 1/4" 8.

  • Page 100: Platform

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS PLATFORM 1. Platform 2. Scissor Arms 3. Slide Block 4. Bolt, (metric) 10 x 200 5. Locknut, (metric) M10 x 1.5 6. Pin 7. Spacer Tube 8. Bolt, 3/8"-16NC x 1 3/8" 9.

  • Page 101: Deck Extension Cylinders Removal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Deck Extension Cylinders (if equipped) 1. Platfrom & Deck Extension 2. Deck Extension Cylinders 3. Shoulder Screw 4. Flatwasher 5. Locknut, 5/8"-11NC 6. Hanger Bracket 7. Clamp 8. Bolt, 3/8"-16NC x 4 1/2" 9.

  • Page 102: Platform Control Station

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Platform Control Station 1. Mounting Bracket 2. Bolt, 1/4"-20NC x 1/2" 3. Starwasher 7, 9 4. Console Box 5. Console Lid 6. Self Tapping Screw, #8-18 x 3/4" 7. Washer 8. Insulation Tape 9.

  • Page 103: Joystick Controller

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Joystick Controller Figure 3-40. Joystick Controller Table 3-11. Joystick Specifications Table 3-12. Joystick Plug Loading Chart Input Voltage Terminal Color Function Centered Output Voltage 4.25V to 2.60V Yellow Steer Right Reverse Voltage 4.60V to 4.80V Green Steer Left...

  • Page 104: Scissor Arms

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS SCISSOR ARMS Lift Cylinder Removal Bottom Connection Point Top Connection Point 1. Lift Cylinder 4. Nut 7. Bolt, 1/2"-13NC x 1 5/8" 2. Pin 5. Collar 8. Nut 3. Bolt, 3/8"-16NC x 3" 6.

  • Page 105: Scissor Arms Removal

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Scissor Arms Removal Scissor Arm Assembly Removal 1. Scissor Arm 4. Bolt, 3/8"-16NC x 1 1/4" 2. Slider 1. Scissor Arm 4. Nut 3. Pin 2. Pin 5. Collar Figure 3-43. Scissor Assembly Removal - Chassis 3.

  • Page 106: Side Compartment Covers

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.10 SIDE COMPARTMENT COVERS Inside: REMOVAL: Front: 2, 3, 4 5, 6, 7 2, 3, 4 6. Open the hood (8). 7. Remove the two bolts (2), washers, (3) and nuts (4) attaching the cover to the bracket (9).

  • Page 107: Ground Control Station

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.11 GROUND CONTROL STATION Ground Control Station Control Station Removal 1. Ground Control Box 2. Lid Figure 3-45. Ground Control Station DISASSEMBLY: 1. Disconnect the harnesses from the ground control box (1). 2.

  • Page 108: Fuel Tank

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.12 FUEL TANK 1. Fuel Tank 2. Fuel Lines 3. Bolt, 3/8"-16NC x 1 1/8" 3, 4, 5 4. Washer 5. Nut 6. Bolt, 3/8"-16NC x 1" 7. Washer 8. Nut 6, 7, 8 Figure 3-46.

  • Page 109: Hydraulic Tank

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.13 HYDRAULIC TANK 1. Hydraulic Tank 2. Drain Plug 3. Ground Control Box Mount 4. Bolt, 3/8"-16NC x 1" 5. Washer 6. Nut 7. Bolt, 3/8"-16NC x 1 1/8" 8. Washer 9. Nut 4, 5, 6 7, 8, 9 Figure 3-47.

  • Page 110: Battery

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.14 BATTERY 1. Battery 2. Battery Terminal (+) 3. Battery Terminal (-) 4. Bracket, Bolt, Nut & Washers 5. Fuse Mounting Block Figure 3-48. Battery Removal REMOVAL: INSTALLATION: 1. Disconnect the red battery cable from the positive 1.

  • Page 111: Dual Fuel/Lpg System

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.15 DUAL FUEL/LPG SYSTEM Using Liquid Petroleum (LP) Gas CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE MORE THAN MOMENTARILY. OTHER WITHOUT ALLOWING THE ENGINE TO STOP.

  • Page 112: Deutz Engine

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.16 DEUTZ ENGINE Deutz EMR 2 The EMR2 consists of the sensors, the control unit and the Engine Tray actuator. Engine-side controls as well as the JLG Control System are connected by means of separate cable har- nesses to the EMR control unit.

  • Page 113: Emr 2 Engine Side Equipment

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS CONTROL ROD POSITION SENSOR/ACTUATOR POWER SUPPLY COOLANT TEMPERATURE CAMSHAFT SPEED SENSOR SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS;...
  • Page 114 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3-78 – JLG Lift – 3121249...
  • Page 115 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3121249 – JLG Lift – 3-79...
  • Page 116 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3-80 – JLG Lift – 3121249...
  • Page 117 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3121249 – JLG Lift – 3-81...

  • Page 118: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-55. EMR 2 Engine Plug Pin Identification 3-82 – JLG Lift – 3121249...

  • Page 119: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Figure 3-56. EMR 2 Vehicle Plug Pin Identification 3121249 – JLG Lift – 3-83...
  • Page 120 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3-84 – JLG Lift – 3121249...
  • Page 121 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3121249 – JLG Lift – 3-85...
  • Page 122 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3-86 – JLG Lift – 3121249...
  • Page 123 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3121249 – JLG Lift – 3-87...
  • Page 124 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3-88 – JLG Lift – 3121249...

  • Page 125: Generator (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Generator (if equipped) 5, 6 3, 4 -OR- 1. Generator (120V or 220V) 4. Washer 7. Voltage Regulator 2. Deutz Engine 5. Bolt, 7/16"-14NC x 2 1/4" 3. Bolt, 5/16"-18NC x 1" 6.

  • Page 126: Exhaust System (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust System 8, 9 3, 4, 5 10, 11 1. Muffler 5. Nut 9. Washer 2. Exhaust Tail Pipe 6. Clamp 10. Bolt, 3/8"NC-16 x 1" 3. Bolt, 3/8"NC-16 x 1" 7. Exhaust Pipe 11.

  • Page 127: Air Cleaner System (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Cleaner System 1. Air Cleaner 2. Air Intake Hose 3. Clamp 4. Mounting Bracket 5. Engine Figure 3-64. Air Cleaner System (Deutz Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING.

  • Page 128: Relays (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Relays 3, 4, 5 1. Weather Proof Relay 2. Solenoid Relay 3. Bolt, NO10-24 x 0.75" 4. Locknut 7, 8, 9 5. Washer 6. Relay Mounting Bracket 7. Glow Plug Harness 8. Bolt, NO8-32 x 0.625" 9.

  • Page 129: Pump Assemblies (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pumps 1. Gear Pump 4. O-ring 7. Washer, 2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Pump Coupling 3. Washer 6. Bolt, 1/2"-13NC x 1 1/2" Figure 3-66. Pump Assemblies (Deutz Engine) 4.

  • Page 130: Pump Coupling (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pump Coupling 1. Muffler Mounting Bracket 2. Bolt, M10 x 85mm 3. Washer 4. Pump Coupling 5. Bolt, Coupling Figure 3-67. Pump Coupling (Deutz Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING.

  • Page 131: Engine Removal (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1. Deutz Engine 2. Rear Engine Mount 3. Bolt, M14 x 30mm 4. Front Engine Mount 5. Bolt, M14 x 55mm 6. Spacer Tube 5, 6 Figure 3-68. Engine Removal (Deutz Engine) 6.

  • Page 132: Radiator (Deutz Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Radiator 1. Radiator 3, 4, 5 2. Radiator Hose 3. Bolt, 3/8"-16NC x 1" 4. Washer 5. Nut 6. Bolt, 5/16"-18NC x 7/8" 7. Washer 6, 7 Figure 3-69. Radiator (Deutz Engine) INSTALLATION: 1.

  • Page 133: Gm Engine

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.17 GM ENGINE • Check the Positive and Negative battery cables for any corrosion build up, rubbing or chafing, Check connec- tion on the chassis to ensure they are tight. Maintenance of the Drive Belt •...

  • Page 134: Engine Oil Dip Stick

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Tray 5. Oil level must be between the "FULL" and "ADD" marks. Figure 3-43. Engine Oil Dip Stick 6. If the oil level is below the "ADD" mark, proceed to Step 7 and 8 and reinstall the dipstick into the dip- stick tube.

  • Page 135: Generator (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Generator 5, 6 3, 4 1. Generator 4. Washer 7. Voltage Regulator 2. GM Engine 5. Bolt,7/16"-14NC x 1 1/4" 3. Bolt, 5/16"-18NC x 1 1/4" 6. Washer Figure 3-71. Generator (GM Engine) INSTALLATION: 1.

  • Page 136: Gm Exhaust System (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Exhaust System 2, 3, 4 1. Tail Pipe 4. Nut 7. Exhaust Pipe 2. Bolt, 3/8"-16NC x 1" 5. Exhaust Pipe 8. Mounting Bracket 3. Washer 6. Muffler Figure 3-72. GM Exhaust System (GM Engine) INSTALLATION: 1.

  • Page 137: Air Cleaner System (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Air Cleaner System 1. Air Cleaner 2. Mounting Bracket 3. Rubber Elbow 4. Air Intake Tube 5. Sleeve 6. Air Intake Tube Figure 3-73. Air Cleaner System (GM Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING.

  • Page 138: Radiator (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Radiator 5, 6, 7 1. Radiator 2. Radiator Hose 3. Radiator Hose 4. Coolant Overflow Container 5. Bolt, 1/4"-20NC x 7/8" 6. Washer 7. Nut 9, 10, 11 8. Radiator Hose 9. Bolt, 3/8"-16NC x 1" 10.

  • Page 139: Fuel Components (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Fuel Components 1. Fuel Pump 2. Fuel Tank 3. Fuel Line - Supply from Tank 4. Fuel Line - to Fuel Filter 5. Fuel Filter 6. Fuel Line - to Fuel Pump 7.

  • Page 140: Pump Assemblies (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pumps 1. Gear Pump 4. O-ring 7. Washer 2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Coupling Flange 3. Washer 6. Bolt, 1/2"-13NC x 1 1/2" Figure 3-76. Pump Assemblies (GM Engine) INSTALLATION: 1.

  • Page 141: Pump Coupling (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Pump Coupling 1. Muffler Mounting Bracket 2. Coupling Cover 3. Coupling 4. Engine Figure 3-77. Pump Coupling (GM Engine) INSTALLATION: 1. Follow Removal Steps in reverse. ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE SERVICING.

  • Page 142: Engine Removal (Gm Engine)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Engine Removal 1. Bolt, 1/2"-13NC x 1 1/2" 2. Washer 3. Nut 4. Engine 5. Engine Tray 1, 2, 3 1, 2, 3 Figure 3-78. Engine Removal (GM Engine) 6. Slowly lift the engine up and out of the engine com- partment.

  • Page 143: Gm Engine Dual Fuel System

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.18 GM ENGINE DUAL FUEL SYSTEM lock off supply voltage is controlled by the engine control module (ECM). The Dual Fuel system allows the operator to operate the vehicle on either gasoline or LPG by positioning a selector switch on the platform control station.

  • Page 144: Low Pressure Regulators

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Low Pressure Regulator (LPR) Air Fuel Mixer The LPR is a combination vaporizer, pressure regulating The air valve mixer is an air-fuel metering device and is device. The LPR is a negative pressure, two stage regula- completely self-contained.

  • Page 145: Etc Throttle Control Device

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Electronic Throttle Control (ETC) Engine Control Module (ECM) Engine speed and load control is maintained by an ETC To obtain maximum effect from the catalyst and accurate device. Speed and load control are determined by the control of the air fuel ratio, the emission certified engine is ECM.

  • Page 146: Heated Exhaust Gas Oxygen Sensor (Hego)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Heated Exhaust Gas Oxygen Sensor (HEGO) Gasoline Fuel Pump There are two Heated Exhaust Gas Oxygen Sensors The Gasoline is stored as a liquid in the fuel tank and is (HEGO). The first HEGO is mounted in the exhaust system drawn into the fuel system by an electric fuel pump.

  • Page 147: Gm Engine Fuel System Repair

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Fuel Filter 3.19 GM ENGINE FUEL SYSTEM REPAIR After the fuel is drawn into the fuel pump, the fuel flows Propane Fuel System Pressure Relief through the gasoline fuel filter. The fuel filter will trap small particles as the fuel passes through the filter to remove debris and prevents the fuel pressure and temperature manifold and fuel injectors from becoming damaged.

  • Page 148: Filter Lock Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Propane Fuel Filter Replacement 3. Install the housing seal. 4. Drop the magnet into the bottom of the filter hous- ing. 5. Install the filter into the housing. 6. Install the retaining bolt into the filter housing. 7.
  • Page 149 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 4. Disconnect the electrical connector from the Electric 7. Connect the fuel supply line and tighten until fully Lock off. seated. 5. Remove the Electric Lock Off from the regulator. 8. Connect the EPR electrical connector. 6.

  • Page 150: Tmap) Sensor & Electronic Throttle Control (Etc)

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Temperature Manifold Absolute Pressure Electronic Throttle Control Replacement (TMAP) Sensor See Figure 3-91. REMOVAL: 1. Disconnect the negative battery cable. 2. Remove the air intake duct. 3. Release the hose clamp on the vapor fuel line and remove the vapor hose.

  • Page 151: Mixer Assembly

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 2. Install the two quad seals. Install one seal at a time 4. Place gasket on intake manifold and attach mixer/ to ensure the seal does not roll. The seal must sit flat throttle assembly to manifold.
  • Page 152 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Coolant Hose Replacement INSTALLATION: REMOVAL: 1. Drain the coolant into an appropriate container. THE CONTROLLER IS CALIBRATED FOR EACH ENGINE. VERIFY YOU HAVE THE CORRECT CONTROLLER 2. Using hose clamp pliers, disconnect both hose clamps on each hose.

  • Page 153: Gm Engine Lpg Fuel System Diagnosis

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS 3.20 GM ENGINE LPG FUEL SYSTEM Diagnostic Aids DIAGNOSIS This procedure is intended to diagnose a vehicle operat- ing on LPG. If the vehicle will not continue to run on LPG, Fuel System Description refer to Hard Start for preliminary checks.

  • Page 154: Lpf Fuel System Diagnosis

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) Were you referred to this procedure by a DTC diagnostic chart? Go to Step 3 Go to Step 2 Perform the On Board Diagnostic (OBD) System Check. Go to the Go to Step 3 Are any DTCs present in the ECM?
  • Page 155 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) 1. Turn OFF the ignition. 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. Go to Step 14 Go to Step 16 4.
  • Page 156 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-15. LPF Fuel System Diagnosis STEP ACTION VALUE(S) The fuel supply system is operating normally, if a failure of the control sole- noids is suspected. Refer to Fuel Control System Diagnosis. 1.

  • Page 157: Symptom Diagnosis

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2.
  • Page 158 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s): Lamp (MIL) • A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
  • Page 159 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Exhaust System Checks • Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure •...
  • Page 160 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Exhaust System Checks • Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure •...
  • Page 161 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Hesitation, Sag, Stumble DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condi- tion may cause the engine to stall if it's severe enough.
  • Page 162 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Lack of Power, Sluggishness, or Sponginess DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks •...
  • Page 163 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Ignition System Checks • Verify that the spark plugs are correct for use with LPG (R42LTS). • Check the spark plugs. Remove the plugs and inspect them for the following conditions: - Wet plugs - Cracks - Wear...
  • Page 164 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-16. Symptom Diagnosis Checks Action Engine Mechanical Check • Check the engine for the following: - Broken motor mounts - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes Surges/Chuggles...

  • Page 165: Dtc To Spn/Fmi Cross Reference Chart

    SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-17. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code Crank Never Synced at Start Fuel Pump Low Voltage Fuel Pump High Voltage MAP Low Voltage MAP High Pressure IAT Higher Than Expected 1 IAT Low Voltage IAT High Voltage...
  • Page 166 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS Table 3-17. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code System Voltage Low System Voltage High Flash Checksum Invalid RAM Failure COP Failure External 5V Reference Low 1079 External 5V Reference High 1079 Power Relay Open 1485...

  • Page 167: Section 4 - Hydraulics

    SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS CYLINDERS - THEORY OF OPERATION rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving cir- cuit pressure. The relief valve is installed in the circuit Cylinders are of the double acting type.
  • Page 168 SECTION 4 - HYDRAULICS Cylinders With Single Counterbalance Valve Oscillating Axle Cylinder Test (Lockout) OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ONLY. ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 1.

  • Page 169: Cylinder Repair

    SECTION 4 - HYDRAULICS CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fix- ture. NOTE: The following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 170: Cylinder Rod Support

    SECTION 4 - HYDRAULICS tighten the cap screw(s) until the bushing is loose on the piston. 13. Remove the bushing from the piston. 7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- Figure 4-5.

  • Page 171: Rod Seal Installation

    SECTION 4 - HYDRAULICS Assembly 8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as nec- essary. NOTE: Prior to cylinder assembly, ensure that the proper 9. Inspect cylinder head inside diameter for scoring or cylinder seal kit is used.

  • Page 172: Installation Of Head Seal Kit

    SECTION 4 - HYDRAULICS Figure 4-9. Wiper Seal Installation 3. Place a new “o”ring and back-up seal in the applica- ble outside diameter groove of the cylinder head. Figure 4-11. Piston Seal Kit Installation 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as Figure 4-10.

  • Page 173: Rod Assembly Installation

    SECTION 4 - HYDRAULICS 17. Position the cylinder barrel in a suitable holding fix- ture. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

  • Page 174: Drive Pump Start-Up Procedure

    SECTION 4 - HYDRAULICS 30. After the cylinder has been reassembled, the rod Table 4-1. Cylinder Piston Nut Torque Specifications should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves. Setscrew torque Description Nut Torque Value Value...

  • Page 175: Hydraulic Component Start-Up Procedures & Recommendations

    SECTION 4 - HYDRAULICS HYDRAULIC COMPONENT START-UP “ Jog” or slowly rotate prime mover until charge pressure starts to rise. Start prime mover and run at the lowest pos- PROCEDURES & RECOMMENDATIONS sible RPM until charge pressure has been established. Excess air may be bled from high pressure lines through From a hydrostatic component standpoint, the goal at high pressure gauge ports.

  • Page 176: Hydraulic Gear Pump

    SECTION 4 - HYDRAULICS sure is inadequate, shut down and determine the cause inlet of the pump during operation in order to verify for improper pressure. that the pump is not being asked to draw an inlet vacuum higher than it is capable of. Be certain to fill the pump and/or motor housing with INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA- clean hydraulic fluid prior to start up.
  • Page 177 SECTION 4 - HYDRAULICS 3. Using light clamping pressure on the ears of the NOTE: A somewhat heavier wear pattern is normal on the front cover, secure unit in vise with shaft side down. low pressure (inlet) side of the bearing blocks (2). Remove the cap screws (14) and washers (9).
  • Page 178 SECTION 4 - HYDRAULICS 2. Clamp front cover into vise so that the ring groove is 8. Place a small amount of grease in the seal groove up. Apply a small amount of grease to the seal on the rear bearing block (2). Install a new load seal and anti extrusion seal in the groove.

  • Page 179: Valves

    SECTION 4 - HYDRAULICS VALVES 1. Main Valve 2. Flow Divider Valve 3. Outrigger Directional Valve Figure 4-15. Hydraulic Compartment REMOVAL: INSTALLATION: 1. Disconnect, cap and lable all hydraulic hoses and 1. Re-attach valve blocks to tray with bolts. any electrical harness connected to valves. 2.

  • Page 180: Main Valve Block

    SECTION 4 - HYDRAULICS Main Valve SV5, CL1 SV7, CL2 OSC AXLE 1 DUMP VALVE SV6, CL2 OSC AXLE 2 PLG6 SV1, CL2 LIFT UP SV2, CL1, CL1 STEER SV4, CL1 BRAKES SV3, CL1 2-SPD PLG6 PLG4 PLG6 ORF1 PLG6 ORF2 Figure 4-16.

  • Page 181: Main Valve Schematic

    SECTION 4 - HYDRAULICS Table 4-3. Main Valve Torque Specs Table 4-4. Porting Specs Port Size Component Torque L2, P1 & T1 SAE 10 SV1 (Lift Up) 25 lb-ft (34.2 Nm) SAE 08 SV2 (Steer) 20 lb-ft (27.3 Nm) G, P2, P3, T4 & T2 SAE 06 All Others SAE 04...

  • Page 182: Flow Divider Valve

    SECTION 4 - HYDRAULICS Flow Divider Valve 5, OR1 Figure 4-18. Flow Divider Valve 4-16 – JLG Lift – 3121249...

  • Page 183: Leveling Jacks Directional Valve

    SECTION 4 - HYDRAULICS Leveling Jacks Directional Valve PA2 PB1 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) 3121249 – JLG Lift – 4-17...

  • Page 184: Powerdeck Valve (Single)

    SECTION 4 - HYDRAULICS Powerdeck Valves SV1, CL1, CL1 Figure 4-20. Powerdeck Valve (Single) SV1, CL1, SV2, CL1, 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)

  • Page 185: Leveling Jack Valves

    SECTION 4 - HYDRAULICS Leveling Jack Valves NOTE: Applies to all four Leveling Jacks. 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)
  • Page 186 SECTION 4 - HYDRAULICS Pressure Setting Procedures decrease. (The relief valve is on the same face as the solenoid valves). Cold temperatures have a significant impact on pressure 5. Single Power Deck Relief Valve readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal a.

  • Page 187: Gear Pump

    SECTION 4 - HYDRAULICS GEAR PUMP Table 4-8. Gear Pump Specs Rotation (Viewing Drive End) Clockwise 0.878 in/rev Displacement (14.4 cc/rev) Max Rated Speed 3500 rpm 3625 psi Rated Pressure (250 bar) Minimum Speed at Rated Pressure 1000 rev/min Gear Pump Priming The gear pump is mounted with the suction hose up.

  • Page 188: Axial Hi 45 Pump

    SECTION 4 - HYDRAULICS 4.10 AXIAL HI 45 PUMP 1. Case Drain Port L2 (SAE#12) 5. Charge Pressure Filtration Port 9. Port A (SAE#16) (to inlet on filter) 2. Deutsch DT04-2P Connector 10. Charge Pump Suction Port 6. MB Gage Port (SAE#6) (SAE#16) 3.

  • Page 189: Axial Hi 45 Pump - Cross Section View

    SECTION 4 - HYDRAULICS 1. Electric Displacement Control 6. Shaft 11. Charge Pump 2. Swashplate Feedback Pin 7. Front Bearing 12. Rear Bearing 3. Piston 8. Swashplate Bearing 13. Valve Plate 4. Slipper 9. Swashplate 14. Servo Piston 5. Shaft Seal 10.
  • Page 190 SECTION 4 - HYDRAULICS General Repair Instructions Start-Up Procedure Follow this procedure when starting-up a new pump REMOVAL: installation or when restarting an installation in which the pump has been removed and re-installed on the machine. Ensure pump has been thoroughly tested on a test stand before installing on a machine.
  • Page 191 SECTION 4 - HYDRAULICS AGE HYDRAULIC COMPONENTS. CHECK CAREFULLY FOR NOTE: Be careful, do not damage solenoids and electrical INLET LINE LEAKS. connections when using straps or chains to support DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE the pump.
  • Page 192 SECTION 4 - HYDRAULICS Electric Control Module D050 (3X) 4 mm 4 ft.lbs. (5 Nm) D250 D025A 5 mm 10 ft.lbs. D025A D050 (3X) Torque sequence 4 mm D084 4 ft.lbs. (5 Nm) D150 F100 (2X) 3 mm 1.8 ft.lbs. 2.5 Nm D300 (2X) REMOVAL:...
  • Page 193 SECTION 4 - HYDRAULICS 6. Install solenoid with three cap screws (D050) using a ing ring diameter is less than 1.53 in (38.84 mm) 4 mm internal hex wrench. Torque screws to 5 Nm (4 when installed on the shaft. lb-ft).
  • Page 194 SECTION 4 - HYDRAULICS 8. Remove the charge pump outer ring (S150), and gearset (S100). Charge pump removal/installation 9. Remove valve plate (S250) with seal (S300). Discard seal K400 8 mm INSPECTION: 10. Inspect the components for wear, scratches or pit- K100 ting.
  • Page 195 SECTION 4 - HYDRAULICS Charge Check/HPRV Charge Pressure Relief Valve Replace the charge pressure relief valve (V10) as a com- REMOVAL: plete unit. Do not attempt to repair the internal compo- 1. Using a 22 mm hex wrench, remove the HPRVs nents of the valve.

  • Page 196: Charge Pump Filter

    SECTION 4 - HYDRAULICS Pressure Limiter Valve Replacement 4.11 CHARGE PUMP FILTER NOTE: Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual components. REMOVAL: 1. Using a 14 mm wrench, remove the pressure limiter valves (L300/L400).

  • Page 197: Auxiliary Pump Motor

    SECTION 4 - HYDRAULICS 4.12 AUXILIARY PUMP MOTOR Hydraulic Schematic Item # Torque 1. UNF-2A Terminal 84 in-lbs (9.5 Nm) 2. 2x 96 - 120 in-lbs (11 - 14 Nm) 3. Check Valve Cap 144 - 180 in-lbs (16 - 20 Nm) 4.

  • Page 198: Cylinder Assemblies

    SECTION 4 - HYDRAULICS 4.13 CYLINDER ASSEMBLIES 1. Barrel Weldment 2. Rod Weldment 3. Cylinder Head 4. Wear Ring 5. O-ring 6. Back-up Ring 7. O-ring 8. Wiper 9. Seal 10. Wear Ring 11. 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).
  • Page 199 SECTION 4 - HYDRAULICS 23 22 1. Cable Adapter 11. Flat Washer 21. Nut [torque to 475 lb-ft (644 Nm)] 2. Bolt 12. Wiper 22. Seal 3. Bracket 13. Seal 23. Ring, Back-Up 4. Manual Descent Cable 14. Ring, Wear 24.

  • Page 200: Lift Cylinder

    SECTION 4 - HYDRAULICS Hydraulic Schematic Lift Cylinder Port Block Hydraulic Schematic Hydraulic Schematic Item Torque 100 lb-ft (135.6 Nm) 100lb-ft (135.6 Nm) 25 lb-ft (33.9 Nm) 10 - 12 lb-ft (13.6 - 16.3 Nm) 35 lb-ft (47.5 Nm) 5 lb-ft (6.8 Nm) 30 lb-ft (40.7 Nm) 25 lb-ft (33.9 Nm) 40 lb-ft (54.2 Nm)

  • Page 201: Oscillating Axle Cylinder

    SECTION 4 - HYDRAULICS 1. Barrel 2. Rod 3. Wiper 4. Wear Ring 5. Rod Seal 6. Plug 7. Piston Pilot 8. Check Valve 9. 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 LOOS- ENED.

  • Page 202: Leveling Jack Cylinder

    SECTION 4 - HYDRAULICS 1. Head 2. Barrel 3. Rod 4. Jack Plate 5. Ring, Lock 6. Ring, Wear 7. Ring, Washer 8. Ring, Retaining 9. O-Ring 10. Screw 11. Capscrew 12. Seal 13. WIper 14. Ring, Back-Up 15. T-Seal 16.

  • Page 203: Leveling Jack Torques

    SECTION 4 - HYDRAULICS Hydraulic Schematic 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 3121249 – JLG Lift – 4-37...

  • Page 204: Deck Extension Cylinder

    SECTION 4 - HYDRAULICS 1. Locknut 6. Spacer Tube 11. Seal 2. Piston 7. Head 12. Wiper Ring 3. Seal 8. Rod 13. Retaining Ring 4. O-Ring 9. O-Ring 5. Barrel 10. Back-up Ring Figure 4-34. Deck Extension Cylinder 4-38 –...

  • Page 205: Oscillating Axle Cylinder Bleeding

    SECTION 4 - HYDRAULICS Oscillating Axle Cylinder Bleeding Procedure 1. Oscillating Axle Cylinder 2. Bleeder Valve Figure 4-35. Oscillating Axle Cylinder Bleeding 1. Start the engine. NOTE: A fast stream of oil will exhaust the air out of the hoses and cylinder better than a slow stream of oil. 2.
  • Page 206 SECTION 4 - HYDRAULICS NOTES: 4-40 – JLG Lift – 3121249...

  • Page 207: Section 5 - Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub To return home or access Level, and item menus previous menu Left &...
  • Page 208 SECTION 5 - JLG CONTROL SYSTEM play will scroll the fault across the screen. If there was no NOTE: The cable has a four pin connector at each end; the fault detected during power up, the display will read: cable cannot be connected backwards. In platform mode, HELP: EVERYTHING OK, In ground mode, GROUND MODE OK 2.
  • Page 209 SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- Analyzer: word was entered correctly: 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 pass- word to advance to a lower level.
  • Page 210 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 is selected, press the UP or DOWN arrow keys to adjust its value, for example: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-...
  • Page 211 SECTION 5 - JLG CONTROL SYSTEM NOTE: Refer to Table 5-3, Machine Configuration Program- ming Information and Table 5-5, Machine Model IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- Adjustment for default settings. TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- Password 33271 will give you access to level 1, CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.

  • Page 212: Calibrations

    SECTION 5 - JLG CONTROL SYSTEM CALIBRATIONS 1. Scissor Arm Assembly 3. Rotary Angle Sensor 2. Proximity Sensor (on frame inboard slide channel) Figure 5-3. Limit Switch Location Elevation Sensor Calibration 3. SET 30FT ELEV (3394RT) or SET 36FT ELEV (4394RT);...
  • Page 213 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: CALI- If the machine mounting/grade appears accept- BRATION: JOYSTICK and press ENTER. able, open the Ground Control box carefully.

  • Page 214: Tilt Sensor Location

    SECTION 5 - JLG CONTROL SYSTEM an electrical/electronic failure (tilt sensor, control 4. The Tilt Sensor (1) can be removed from the Sensor board, electrical connections). Mount (2) by removing the three Screws (7). a. Open the Ground Control Box. NOTE: Follow the above procedures in reverse order when installing the tilt sensor assembly.

  • Page 215: Flash Codes And Descriptions

    SECTION 5 - JLG CONTROL SYSTEM 5.3 FLASH CODES AND DESCRIPTIONS Table 5-2. Fault Code Listing - Software P1.X Fault Flash Communicated (Displayed on Analyzer) Fault Description Priority Code No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
  • Page 216 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. TRIGGER SWITCH WIRING SHORTED HIGH IN PLAT- Reports when the CAN message coming from the platform board FORM CABLE and the DI on ground board conflict.
  • Page 217 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 PERMA- Reported when the ground lift up switch is closed during power NENTLY CLOSED FUNCTION LOCKED OUT –...
  • Page 218 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 Reported when the elevation rotary sensor voltage is outside the VOLTAGE OUT OF RANGE range of acceptable values.
  • Page 219 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 FRONT LEFT LEVELING JACK OPEN CIRCUIT left leveling jack is open circuit.
  • Page 220 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 FRONT DECK RETRACT VALVE SHORT TO GROUND deck retract valve is short to ground.
  • Page 221 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 5/5 indicates a speed sensor issue. Reported when the speed sensor is reading a value over 4000 SPEED SENSOR READING INVALID SPEED RPM.
  • Page 222 SECTION 5 - JLG CONTROL SYSTEM 5-16 – JLG Lift– 3121249...
  • Page 223 SECTION 5 - JLG CONTROL SYSTEM 3121249 – JLG Lift – 5-17...
  • Page 224 SECTION 5 - JLG CONTROL SYSTEM 5-18 – JLG Lift– 3121249...

  • Page 225: Machine Configuration Programming Information

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

  • Page 226: 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 pre- vented in the event of an Overload.
  • Page 227 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 3394RT 2WD ANSI USA ANSI EXPORT AUSTRALIA 3394RT 2WD ANSI USA ANSI EXPORT...
  • Page 228 SECTION 5 - JLG CONTROL SYSTEM NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 3394RT 4WD ANSI USA ANSI EXPORT AUSTRALIA 3394RT 4WD ANSI USA ANSI EXPORT...
  • Page 229 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 4394RT 2WD ANSI USA ANSI EXPORT AUSTRALIA 4394RT 2WD ANSI USA ANSI EXPORT...
  • Page 230 SECTION 5 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 4394RT 4WD ANSI USA ANSI EXPORT AUSTRALIA 4394RT 4WD ANSI USA ANSI EXPORT...

  • Page 231: 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% Max Forward 0 -100% Min Reverse...
  • Page 232 SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-26 – JLG Lift– 3121249...

  • Page 233: Section 6 - General Electrical Information & Schematics

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, tech- nically qualified guidance should be obtained before proceeding with any maintenance.

  • Page 234: Voltage Measurement (Dc)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together. (See multimeter’s operation manual) Resistance should read a short circuit (very low resis- tance)

  • Page 235: Continuity Measurement

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC) • Some meters require a separate button press to • Set up the meter for the expected current range enable audible continuity testing •...
  • Page 236 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness.

  • Page 237: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. •...

  • Page 238: Connector Assembly (1 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Pro- ceed as follows: Figure 6-6. Connector Assembly (1 of 4) 1.

  • Page 239: Connector Assembly (3 Of 4)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-8. Connector Assembly (3 of 4) Figure 6-9. Connector Assembly (4 of 4) 3121249 – JLG Lift –...

  • Page 240: Connector Disassembly

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7.

  • Page 241: Connector Installation

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system.

  • Page 242: Working With Deutsch Connectors

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 6-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

  • Page 243: Hd/Hdp Locking Contacts Into Position

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 6-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 6-16.

  • Page 244: Switches

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 6.5 SWITCHES Basic check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1.
  • Page 245 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener- gized to actuate.

  • Page 246: Schematics

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SCHEMATICS Figure 6-18. Electrical Schematic - Deutz - Sheet 1 of 2 6-14 – JLG Lift – 3121249...
  • Page 247 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-18., Electrical Schematic - Deutz - Sheet 1 of 2 3121249 – JLG Lift – 6-15...

  • Page 248: Electrical Schematic - Deutz - Sheet 2 Of 3

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103487 B Figure 6-19. Electrical Schematic - Deutz - Sheet 2 of 2 6-16 – JLG Lift – 3121249...
  • Page 249 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-17...

  • Page 250: Electrical Schematic - Gm - Sheet 1 Of 5

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20. Electrical Schematic - GM - Sheet 1 of 3 6-18 – JLG Lift – 3121249...
  • Page 251 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-20., Electrical Schematic - GM - Sheet 1 of 3 3121249 – JLG Lift – 6-19...

  • Page 252: Electrical Schematic - Gm - Sheet 2 Of 5

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-21. Electrical Schematic - GM - Sheet 2 of 3 6-20 – JLG Lift – 3121249...
  • Page 253 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-21...

  • Page 254: Electrical Schematic - Gm - Sheet 3 Of 5

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-22. Electrical Schematic - GM - Sheet 3 of 3 6-22 – JLG Lift – 3121249...
  • Page 255 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103488 B Figure 6-22., Electrical Schematic - GM - Sheet 3 of 3 3121249 – JLG Lift – 6-23...

  • Page 256: Hydraulic Schematic - Sheet 1 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-23. Hydraulic Schematic - Sheet 1 of 2 6-24 – JLG Lift – 3121249...

  • Page 257: Hydraulic Schematic - Sheet 2 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001106835_D Figure 6-24. Hydraulic Schematic - Sheet 2 of 2 3121249 – JLG Lift – 6-25...

  • Page 258: Hydraulic Diagram

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001106834_F Figure 6-25. Hydraulic Diagram 6-26 – JLG Lift – 3121249...

  • Page 259: Hydraulic Diagram (Powerdeck - Single)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-26. Hydraulic Diagram (Powerdeck - Single) 3121249 – JLG Lift – 6-27...

  • Page 260: Hydraulic Diagram (Powerdeck - Dual)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-27. Hydraulic Diagram (Powerdeck - Dual) 6-28 – JLG Lift – 3121249...

  • Page 261: Hydraulic Diagram (Powerdeck - Mega)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 6-28. Hydraulic Diagram (Powerdeck - Mega) 3121249 – JLG Lift – 6-29...

  • Page 262: Hydraulic Diagram (Leveling Jacks)

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001103552_B Figure 6-29. Hydraulic Diagram (Leveling Jacks) 6-30 – JLG Lift – 3121249...
  • Page 263 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121249 – JLG Lift – 6-31...

  • Page 264: Electrical Components Installation - Sheet 1 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS STARTER THROTTLE ENGINE ACTUATOR CONTROL (DEUTZ) BATTERY FUSE PRESSURE BLOCK SWITCH GLOW TEMP PLUG SWITCH IGNITION RELAY HEADLIGHTS ALTERNATOR (DIESEL ENGINE MACHINES) LIGHTS HARNESS RELAY (DEUTZ) CIRCUIT BREAKER PLATFORM TAILLIGHTS WORKLIGHTS AC POWER POWER AT PLATFORM DECK...

  • Page 265: Electrical Components Installation - Sheet 2 Of 2

    SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PLATFORM CONTROL ENGINE SPEED GLOW LP LOCK & ASSIST SENSOR PLUG (GAS MACHINES) RELAY START RELAY GLOW PLUGS IGNITION RELAY ALTERNATOR (GAS MACHINES) LIFT CYLINDER PORT BLOCK PROP VALVE HYDRAULIC PUMPS PLATFORM LIFT ELEVATION DOWN...
  • Page 266 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 6-34 – JLG Lift – 3121249...
  • Page 268 3121249 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I.

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