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1. Lu Lu Q Q e t e m Te Ko x lt lt Eu OE oc Cc lt Lj 27 OO tii 0 gt COs LI gt 0c Q C3 Elo i e gt as gt a l O ki lt Lu Lu Z Q Q a pr Ee e e m OO mo en fe Figure 6 42 Hydraulic Diagram Leveling Jacks 6 42 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Power Deck Manifold Valve T A OQ e O O EPB O ET EPR EPR i EF SS of Right Front Extension Cylinders Lors f C O d i ie O Left C Note ona line indicates a IN Power Deck Sandwich Valve non straight hose end Mounted on top of Main Manifold Aux Pump 3121133 Hydraulic Oil Tank C1 O s Figure 6 43 Hydraulic Diagram Deck Extension Single JLG Sizzor 6 43 SECTION 6 GENE
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3. gt e LJ cc Se w Ot m m CO 5 E me O O 9 lt _ an E Ze gt I e a gt e a O 21120 09401 020 7 IE EHI lt 8 le Do u g2 s ae SM zo To Ole EN p gm 5 o re F E 8 I ea OQ z lt lo e P ul a e i lt o E O 5 D 4 gt lt 5 f zu 20 lt 2 g Sg 5 Om d te lt m le zre 2 a E es x9 ka ala o 22 o gt oa Z zo 5b e amp ou m q gi EE LL 2 56 340 8 4 lt O O Figure 6 40 Hydraulic Diagram 2WD 6 40 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
4. PLAT ESTOP 01 LG YEL RED 2 7 2 ANALYZER mE EET TEE IGN 021 1 GND JI 2 4 3 2 TRIGGER YEL RED 2 9 COLO JI 3 SWITCH eje COLI JI 4 ae s29 XELZRED 2 11 COL2 JI 5 SIS HI YEL RED 2 COL3 01 6 YEL RED 2 13 E Pep P 1 014 41 71 z a pem COLS 1 9 E gt YFL RFD 2 15 Rd LCLK JI 8 41 10 REF PLATFORM E HARNESS RED BLU J5 10 RX X YEL BLU 25 11 TX X ORN BLU J5 12 GRD x CRSSTCSTRSSSo5959c2r7599 8 5595449995355 SAILS arie pa APE a r 525 LIFT SWITCH FRONT DECK REAR DECK 22 2 SWITCH SWITCH SWITCH AUX E rS259 38232259 5222222 Lo T 516 317 518 POWER ea 8888888552252558885 5 m Ser z b 2 UP DOWN EXT RET EXT RET 519 ze ial rn zc s 310v14323N Sr 5 zB a Sie T 5 B ooo d 3 ui Dye 5572 u TS tea g s 8 24 59 amp KEYSWITCH s 3353 2 252555 E 513 733223 33 z E BRETT ea GROUND ece296322 82z25z0 s amp YEL RED 2 3 1 00500555 55 255 me VEL RE D 2 2 ORN RED 49 1 PLATFORM 44115 I 1 717 sHIEL
5. 3 24 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Motor Assemhly 1 Press in swivel balls with tool 1 Insert shaft seal ring with tool 2 Insert control piston with spring 3 3121133 JLG Sizzor 3 25 SECTION 3 CHASSIS amp SCISSOR ARMS 2 Install rotary group with cradle Observe installation 4 Mount Seeger snap ring Opening of snap ring must position of swivel balls be on the opposite side of the control piston NOTE Slightly grease swivel balls 5 Fit pressure pins using an assembly aid Pre ten 3 Mount sleeve and pressure ring in cradle stop Insert sion the spring using a suitable device cradle stop NOTE Stick with grease CN QS 2 qo 6 Assemble piston with retaining plate Oil piston and slipper pad 3 26 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 7 Assembly aid Hold the pistons by using an o ring 9 Mount support ring 1 and quad ring 2 in pre
6. LIFT CYLINDER PORT BLOCK PROP VALVE o 9 o PLATFORM Ln MODULE LIFT DOWN VALVE 2 FUEL BEACON HORN LEVEL LIGHT ROTARY SENSOR yp SENSOR ALARM 8 9 O ELEVATION 20 SWITCH g 6 lo r3 h d FUEL n PUMP GAS MACHINES Fog gt lt GROUND CONTROL BOX Figure 6 47 Electrical Components Installation Sheet 2 3121133 JLG Sizzor 6 47 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS NOTES 6 48 JLG Sizzor 3121133 e An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 B JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 EL 612 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 USA 717 485 5161 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 El 44 0 161 654 1001
7. 4 1 4 9 Component Functional Description 4 1 4 4 Cylinder Checking 4 2 4 5 Cylinder Repaire e suu REIR 4 3 4 6 Drive Pump Start up Procedure 4 9 3121133 JLG Lift TABLE OF CONTENTS 4 7 Hydraulic Component Start Up Procedures and Recommendations 4 10 4 8 Hydraulic Gear P mp Eq Ree dor RR pleas Bg cide og ETUR 4 11 4 9 Main Valve zem RR RR eee de pue eive 4 14 4 10 Drive Header Valve 2WD sui ig rse uidi tidua an n AT EEEE ERR asa 4 16 4 11 Drive Header Valve AWD 2 2 e en bee ee mens 4 16 4 12 Header Valves AWD cR Rue EUR ec REA puna sss ER UR E eee 4 17 4 13 GIREGTIONAL VALVE uu T PH HD ee WES Sedo et tox cx E Ds 4 18 4 14 pOWER dECK sANDWICH VALVE ssssssese ee mm 4 19 4 15 Power Deck Manifold Valve m 4 19 4 16 Hydraulic PUMP in u e 4 20 4 17 Cylinder Assemblies c i her Id eee Ee Lp ELE 4 22 SECTION 5 JLG CONTROL SYSTEM 5 1 Hand Held Analyzer 2 oie tre Da Ir hr tegere aac ated pes 5 1 5 2 Flash Codes
8. 1 3 1 12 Critical Stability Weights lisse hmm 1 4 1 18 Hydraulic Oil occa ed tg x MINCE ev 1 4 1 14 Mobil DTET3M Specs yQ DERE e Bi REVERSE 1 4 1 15 Mobil EAL 224H Spe6s nere as du er E a P bse 1 4 2 1 Inspection and Maintenance 2 2 2 2 Cylinder Drift omes oe Re 2 9 2 9 Preventive Maintenance and Safety 2 7 3 1 Tilt Sensor Harness Chalt eene eel pee gp diu bags 3 6 3 2 Tilt Sensor Harness ooa eL re POE OS 3 7 3 3 Torque Drive Hub Specs 1 0 eee rs 3 8 3 4 Gearbox Maintenance 5 3 10 3 5 ECM Diagnostic Trouble 3 33 3 6 Generator Specifications 0 2 0 0 3 43 3 7 Generator Specifications mera nnn 3 57 3 8 Generator nn 3 60 3 9 LPF Fuel System Diagnosis
9. p 1641220 OSCILLATING AXLE CD A6A 12431 S oT ue Lat OP Jor i H x3 R X 19 Cop BLEEDER RUSO SP RAN BLEEDER M GE 1 LH GFTTTA 4032 4x 43 1 GEAR RATIO 1 7 in MAX DISPLACEMENT 1 g 0 85 in MIN DISPLACEMENT TAR o A x3 4641221 RFA AGA 12411 LFB LFA RFB 81 82 RRA LRB ee RRB A2 LRA X Ro S X X t X3 4641225 x X c AGA 2487 B PEE CD I f T CD SE 2 n e a 2120172 Z AUH Psy ow Co B Ps G Fa B 4 lt Mb e Mb Sem Fa pii BoA a EJ 2800 RPM nd I in R 0d 1 0 3 1 09 AM 0 31 9 4 SOHP DIESEL ENGINE 2 8 65HP GAS ENGINE LU Waa 35008 3 ry 350581 B 4 L 0 851 e I en SET lat ilh SET lag di 36000 i RE Tz xi S Pa QT X2 S Figure 6 32 Hydraulic Schematic 4WD Sheet 1 of 4 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121133 LIFT CYLINDER Ix 4 5 BORE 3 5 ROD 83 0 STROKE STEER CYLINDER 1 2 5 BORE LIFT 1 75 ROD 4 6 STROKE STEER SET AT 2800PSI Cs SET AT 2000 51 4641211 AGA 12407 2120165 43 psi 4400445 40 GALLON Figure 6 33
10. DTC Description SPN Code FMI Code 562 System Voltage Low 168 17 563 System Voltage High 168 15 601 Flash Checksum Invalid 628 13 604 RAM Failure 630 12 606 COP Failure 629 31 642 External 5V Reference Low 1079 4 643 External 5V Reference High 1079 3 685 Power Relay Open 1485 5 686 Power Relay Shorted 1485 4 687 Power Relay Short to Power 1485 3 1111 Fuel RevLimit 515 16 1112 Spark Rev Limit 515 0 1151 Closed Loop Multiplier High LPG 520206 0 1152 Closed Loop Multiplier Low LPG 520206 1 1155 Closed Loop Multiplier High Gasoline 520204 0 1156 Closed Loop Multiplier Low Gasoline 520204 1 1161 Adaptive Learn High LPG 520202 0 1162 Adaptive Learn Low LPG 520202 1 1165 LPG Cat Monitor 520213 10 1171 LPG Pressure Higher Than Expected 520260 0 1172 LPG Pressure Lower Than Expected 520260 1 1173 EPR Comm Lost 520260 31 1174 EPR Voltage Supply High 520260 3 1175 EPR Voltage Supply Low 520260 4 1176 EPR Internal Actuator Fault 520260 12 1177 EPR Internal Circuitry Fault 520260 12 1178 EPR Internal Comm Fault 520260 12 1612 RTI 1 loss 629 31 1613 RTI 2Loss 629 31 1614 RTI3Loss 629 31 1615 A D Loss 629 31 1616 Invalid Interrupt 629 31 1625 Shutdown Request 1384 31 1626 CAN Tx Failure 639 12 1627 CAN Rx Failure 639 12 1628 CAN Address Conflict Failure 639 13 1629 Loss of TSC 1 639 31 2111 Unableto Reach Lower TPS 51 7 2112 Unable to Reach Higher TPS 51 2135 TPS 1 2 Simultaneous Voltages 51 3
11. 3394RT 2WD ui 5 x x u 5 s 2 z x 5 a z o g lt zd tu ANSI USA 0 4 0 0 1 2 3 4 5 6 7 0 1 0 1 2 ANSI EXPORT 0 4 1 0 1 2 3 4 5 6 7 0 1 0 1 2 CSA 0 4 2 0 1 2 3 4 5 86 7 0 1 0 1 2 CE 0 4 3 0 1 2 3 4 5 6 7 0 1 0 1 2 AUSTRALIA 0 4 4 0 1 2 3 4 5 6 7 0 1 0 1 2 3394RT 2WD 2 5 E lt o 2 2 o E z e z i gt ANSI USA 0 1 2 0 1 2 1 ANSI EXPORT 0 1 2 0 1 2 1 CSA 0 1 2 0 1 2 1 CE 0 1 2 0 1 2 1 AUSTRALIA 0 1 2 0 1 2 1 4150390 J 5 20 JLG Lift 3121133 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 o 7 ul x x m e eo o AE B z G mr 5 m 2 a 2 5 tu ANSI USA 1 4 0 0 1 2 3 4 5 6 7 0 1 0 1 2 ANSI EXPORT 1 4 1 0 1 2 3 4 5 6 7 0 1 0 1 2 CSA 1 4 2 0 1 2 3 4 5 6 7 0 1 0 1 2 CE 1 4 3 0 1 2 3 4 5 6 7 0 1 0 1 2 AUSTRALIA 1 4 4 0 1 2 3 4 5 6 7 0 1 0 1 2 3394RT 4WD 2 5 lt o 2 2 72 5 z e z ANSI USA 0 1 2 0 1 2 1 ANSI EXPORT 0 1 2 0 1 2 1 CSA 0 1 2 0 1 2 1 CE 0 1 2 0 1 2 1 AUSTRALIA 0
12. 3 8 Os Valve Ft Ib Mn 1 Dump Valve 30 35 42 49 2 Lift Valve 25 30 35 42 3 Two Speed Valve 30 35 42 49 4 Brake Valve 30 35 42 49 5 Steer Valve 25 30 35 42 6 Lift Relief 30 35 42 49 7 Main Relief 25 30 35 42 8 Steer Relief 30 35 42 49 9 MG Port N A N A 10 MS Port N A N A 11 MP1 Port N A N A Figure 4 15 Main Valve Torque Values 4 14 JLG Lift 3121133 SECTION 4 HYDRAULICS o l LIFT SET AT C10 eooPsi gt NU i I TWP SPEED BRAKE WV Hd m m Heer 5162 al I SS PS ANA _ W mn Le 1 4 Cen PS 573 I ET 4 d DUMP VALVE MAIN RELIEF E 2 SET AT E MW AM 3000 51 1 a ne L P d KY NS C WEN Figure 4 16 Main Valve Hydraulic Schematic Pressure Setting Procedures Cold temperatures have a significant impact on pressure readings JLG Industries Inc recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior t
13. 3 45 3 14 Deutz EMR 2 Troubleshooting Flow eh 3 46 3 15 Deutz EMR 2 Vehicle Side Connection Diagram 3 47 3 16 Deutz EMR 2 Engine Side Connection Diagram Sheet 1of2 _ 3 48 3 17 Deutz EMR 2 Engine Side Connection Diagram Sheet 2of2 _ 3 49 3 18 2 Engine Plug Pin 3 50 3 19 2 Vehicle Plug Pin 3 51 3 20 EMR2 Fault Codes Sheet 1of5 3 52 3 21 2 Fault Codes Sheet 2of5 3 53 3 22 EMR2 Fault Codes Sheet 0f5 0 eet nn 3 54 3 23 2 Fault Codes Sheet4of 5 3 55 3 24 EMR2 Fault Codes Sheet 5of5 3 56 3 25 Generator Deutz Engine liiis mmn 3 57 9 26 Engirie Oil Dip Slick 2 Be tant e d Reinet UR dst ache ade red ts 3 59 3 27 Generator GM Engine liiis mmn 3 60 9 28 Electric Fuel Eock Off us asa RE 3 61 3 29 EPR Assembly i esse beoe er e s tib ro do pid eni Ad dau dees 3 62 3 30
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15. 4 29 Oscillating Axle Bleeding 4 90 Hand Held Analyzer 5 1 Analyzer Connection ee pA Tq dde dure ERU dd pe melde obs 5 1 Analyzer Flow Chart SW P1 X Sheet 1 of 3 5 14 Analyzer Flow Chart SW P1 X Sheet 2of3 5 15 Analyzer Flow Chart SW P1 X Sheet 3 of 3 5 16 Voltage Measurement DC auan mrs 6 2 Resistance Measurement 6 2 Continuity 6 3 Current Measurement 2 6 3 AMP CONNECTOR eret tine ate ound ep EU tie RE RR Rd 6 5 Connector Assembly 1 of 4 e 6 6 Connector Assembly 2 of 4 tenet 6 6 Connector Assembly 3 of 4 eh 6 7 Connector Assembly 4 of 4 hh 6 7 Connector Disassembly
16. HO RRB B1 A1 B2 A2 Figure 4 18 Drive Header Valve 4wd 4 16 JLG Lift 3121133 SECTION 4 HYDRAULICS 4 12 HEADER VALVES 4WD MCD MX3 Figure 4 19 Header Valve Fix TITI Figure 4 20 Header Valve Osc 3121133 Lift 4 17 SECTION 4 HYDRAULICS 4 13 DIRECTIONAL VALVE HYDAC usa CU 02580952 INS vender info Figure 4 21 Directional Valve Pressure Setting Procedure item Torque Cold temperatures have a significant impact on pressure 7 readings JLG Industries Inc recommends operating the PA1 40 ft lbs 54 Nm machine until the hydraulic system has warmed to normal 23ttlbs operating temperatures prior to checking pressures JLG PB1 31 Nm Industries Inc also recommends the use of a calibrated
17. Description 3394RT 4394RT Description 3394RT 4394RT Maximum Occupants 6 Maximum Workload Fuel Tank 31 5gal 1191 Capacity I Single Extension 2250105 1020kg 1500 Ibs 680 kg Hydraulic Tank 40 gal 1511 Dual Extension 2000 Ibs 905 kg 1250 Ibs 565 kg Extension Only 500 Ibs 230 kg 500 Ibs 230 kg Maximum Travel Grade 1 3 ENGINES 2WD 35 Table 1 3 Ford LRG 425 Specifications 4WD 4596 Maximum Travel Grade 3 l Gasoline Maximum Platform Height 33ft 131 Oil Capacity 4 5 Quarts 4 25 L w Filter Maximum Drive Speed 2 WD 3 0mph 4 8kph 3 0mph 4 8kph Idle RPM 1000 Maximum Drive Speed 4WD 3 5 mph 5 6 kph 3 5 mph 5 6 kph Low RPM 1800 Lift Up Speed Stowedto Full High RPM 2800 Height i ght 29 31 sec 40 45 sec Alternator 40 Amp Belt Drive Lift Down Speed Full Height Battery 112 Amphour 950 Cold Cranking to Stowed Amps 12 VDC Maximum Wind Speed 28 mph 12 5 m s Fuel Consumption Maximum Horizontal Manual Low RPM 3 45 GPH 13 06 Iph ids i 335 Ib force 1490 300 Ib force 1335 N eM SED ingle Extension orce orce Dual Extension 300 Ib force 1335N 300 Ib force 1335 N Horsepower 94 2400 RPM fullload Single Extension CE AUS 9016 400N 90lbforce 400 N Cooling System 16 Quarts 15 14 L Dual Extension CE AUS 9010 400 90lbforce 400 N Spark Plug AWSF 52 C Maximum Tire Load 4400 Ibs 1996 kg Spark Plug Gap 0
18. kumu 6 8 Connector instalation c r oes scurra ciann E m 6 9 DT DTP Contact Installation use eae a a RII HA m 6 10 DI DTP Contact Removal sp ilm RD Ree be RR UR Ee Geri s sent e UE Ren 6 10 HD HDP Contact Installation Sup RR 6 10 HD HDP Locking Contacts Into Position 6 14 HD HDP Contact Removal lt uuu kine ehh mmm 6 11 HD HDP Unlocking Contacte em 6 14 JLG Lift 3121133 TABLE OF CONTENTS 6 18 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 6 29 6 30 6 31 6 32 6 33 6 34 6 35 6 36 6 37 6 38 6 39 6 40 6 41 6 42 6 43 6 44 6 45 6 46 6 47 3121133 Electrical Schematic Dual Fuel Sheet 1 6 14 Electrical Schematic Dual Fuel Sheet 2 6 15 Electrical Schematic Dual Fuel Sheet 3 6 16 Electrical Schematic Diesel Prior to S N 138634 Sheet 1 of 3 6 18 Electrical Schematic Diesel Prior to S N 138634 Sheet 2of3 6 19 Electrical Schematic Diesel Prior to S N 138634 Sheet 3 of 3 6 20 Electrical Schematic Dual Fuel GM
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21. 2120172 2 HLX a Ps GCFa B Mb 4 ilt 2800 RPM 1 09 M 0 31 i E A 50HP DIESEL ENGINE 2 y 65HP GAS ENGINE wr eM Lo 85in N AJ T2 I X2 T4 Figure 6 36 Hydraulic Schematic 2WD Sheet 1 of 4 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121133 LIFT CYLINDER 1 4 5 BORE 3 5 ROD 83 0 STROKE STEER CYLINDER 1x 2 5 BORE LIFT 1 75 ROD 4 6 STROKE STEER SET AT 05 27005 SET AT 2800PSI E Co SET AT 3000PS 1 4641211 AGA 12407 2120165 43 psi 4400445 40 ALLCN Figure 6 37 Hydraulic Schematic 2WD Sheet 2 of 4 JLG Sizzor 6 37 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 88 ROD 1 ROD 1 5 ROD 11 125 STROKE 7 5 STROKE 8 STROKE EASI CLADDER PLUS VALVE BLOCK 1000 PSI TELE CYLINDER TILT CYLINDER LIFT CYLINDER 1 5 BORE 1 5 BORE 2 BORE 88 ROD 1 ROD 1 5 ROD 11 125 STROKE 7 5 STROKE 8 STROKE 1000 PSI EASI CLADDER PLUS VALVE BLOCK POWER DECK CYLINDER 2x 1 5 BORE 1 0 ROD 48 STROKE u POWER DECK OPTIONAL SET AT XXX PSI EPR 2 err l aii L om Be c c T ai AGA 12408 aD u POWER DECK
22. Figure 3 32 ETC throttle control device JLG Sizzor 3 63 SECTION 3 CHASSIS amp SCISSOR ARMS Engine Control Module To obtain maximum effect from the catalyst and accurate control of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control Unit ECM The ECM is a 32 bit controller which receives input data from sensors fitted to the engine and fuel sys tem and then outputs various signals to control engine operation One specific function of the controller is to maintain closed loop fuel control Closed loop fuel control is accomplished when the exhaust gas oxygen sensor HEGO mounted in the exhaust system sends a voltage signal to the controller The controller then calculates any correction that may need to be made to the air fuel ratio The controller then outputs signals to the EPR to correct the amount of fuel being supplied to the mixer At the same time the ECM may correct the throttle blade position to correct speed and load of the engine The controller also performs diagnostic functions on the fuel system and notifies the operator of malfunctions by turning on a Malfunction Indicator Light MIL mounted in the Ground Control Station and the Platform Control Sta tion Malfunctions in the system are identified by a Diag nostic Code number In addition to notifying the operator of the malfunction in the system the controller also stores the inform
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24. D ERE d LA J EIE a I MA YEL RED 2 7 4 RED 1 1 4 8 RED 1 1 4 12 WHT YEL 48 4 RE 8 RED amp START RELAY lt 90 87 87A 5 e 5 INTAKE HEATER m HEATER SOLENOID i E a RELAY RIEN Di 3 z E EE 81 8 amp ze 8 IGN HE zia E 5 POWER gt NES 30 WHT YEL 48 7 5 EN z MTB TO EMR2 ENGINE CONTROL c e 87 87A a SEE SHEET 2 FOR ENGINE gt z S 5 2 10 11 12 1314 z 5 5 r a i PLATF gt a 9 a a gt VALVE gs Y28 SIE START X o BE MOTOR ORN RED 49 198 cw K DEUTZ Lol INTAKE ORN RED 49 199 DIANOSTICS EATER mE BLACK 0 1 L PLUG ao 8 TOT J2 15 Figure 6 29 Electrical Schematic Diesel S N 138634 to Present Sheet 1 of 3 6 28 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS WHT RED 57 21 COEM 135211 YELLOW 9 1 RIBUS YELLOW 10 1 QPSN J3 4 m QPRG GND J3 5 BLACK LIF HORN 502 SELECT PUSH FRONT 03 BUTTON DECK REAR 04 SELECT DECK AUTO DRVP J2 11
25. Table 3 10 Joystick Specifications Table 3 11 Joystick Plug Loading Chart Input Voltage 4 3V 0 1V Terminal Color Function Centered Output Voltage 2 2V x 0 1V 1 Yellow Steer Right Full Positive Rev Deflection Output Voltage 4 0V x 0 1V 2 Green Steer L eft Full Negative Fwd Output Voltage 0 4V x 0 1V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 3 76 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 49 9 ohm d 15 0 ohm I TRIGGER SUPPLY RIGGER SWITCH TRIGGER SWITCHES STEER LEFT V SUPPLY STEER STEER RIGHT ROCKER SWITCHES Figure 3 44 Joystick Controller JLG P N 1600403 Table 3 12 Joystick Specifications Table 3 13 Joystick Plug Loading Chart Input Voltage 5V Terminal Color Function Centered Output Voltage 4 25V to 2 60V 1 Yellow Steer Right Reverse Voltage 4 60V to 4 80V 2 Green Steer Left Forward Voltage 0 40V to 0 60V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 3121133 JLG Sizzor 3 77 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Important Preliminary Checks Be
26. z neq 1081109 ON 0 e1e1edo y 5900 SHA Jequinu SIA eui zjneq ejeoiput 1 eui seoq A ON UBIH NYO 19 ZL Suid 550198 suyo 09 S 9194 VL punoJ5 suid lt S3A SSOJO AZ SI p lo 1 p S eui ejeoipur ay 59901 S3A JLG Sizzor Se eui oouis peisi 5 Aue epis l9 u A eui Bnidun SHA p Jamo 549 Jez Ajeuy 10911109 SHA 61 991 49 S3A p pue Jo jan ppv eui Apjeuuouqy suny 5 0 SJIE4 3 zneg 3 46 SECTION 3 CHASSIS amp SCISSOR ARMS 3 47 weibeiq uonoeuuo epis 21914A Z ZINA 91 61 8 3
27. 3 E en HOLIMS x i B zi z z E o l a lt 3 a ANALOG PIN4 TILT SENSORPIN 3 Figure 6 21 Electrical Schematic Diesel Prior to S N 138634 Sheet 1 of 3 wel a 5 p b d 107 rraga a3 g s zl E v L 2 5s revives sly HH 5 a z z a u E st st 33 Ya gt ber a 2 x 2358 838 0 2480 3 Be Ber ier JURET 6 18 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PCPW J3 1 MHI BED 57 21 b LTP 3 2 YELLOW9 1_ RTP 33 YELLOW10 1_ D QPSN J3 4 QPRG GND J3 5 BLACK DRIVE SELECT LIFT S02 SELECT HORN S03 PUSH BUTTONRONT DECK 504 SELECT REAR DECK DRVP J2 11 OBANGE 55 5 4 S05 SELECT AUTO LEVEL LFTP J2 10 TAN 55 10 4 AL S06 SELECT HRN J2 7 BLL OBN 52 3 3 alt 507 FDSP J2 9 GBEEN 55 11 J2 8 GREEN 55 12 4 ALEV J2 4 PORNAWHT 55 13 z ENG DRV SPD J2 2 OBANGE 55 6 COL3 SPARE J2 12 FSGW 2 3 48 8 APWR STRP 42 1 XHL YEL 48 9 GENP J2 6 BLU ORN52 2 GENERATO COL2 SPARE
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29. 3121133 JLG France SAS de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 D JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany F 49 0 421 69 350 20 El 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong FF 852 2639 5783 IL 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy FF 39 029 359 5210 39 029 359 5845 S JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands 4 31 0 23 565 5665 31 0 23 557 2493 JLG Polska Ul Krolewska 00 060 Warsawa Poland 48 0 914 320 245 EL 48 0 914 358 200 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland G 44 0 141 781 6700 EL 444 0 141 773 1907 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 A www jlg com JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 D
30. 3121133 JLG Sizzor 3 15 SECTION 3 CHASSIS amp 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 17 Install Sun Gear Shaft 25 14 Install the Ring Gear 22 4 18 Check axial clearance 15 Install the ring gear hex head bolts Tighten bolts to a Determine clearance between contact face of proper torque of 15 5 ft Ibs 21 Nm Sun Gear 3 and Sun Gear Shaft 25 Recom mended clearance 1 0 1 5mm 3 16 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 19 Carefully insert a new greased O ring 23 into the o 22 Install Snap Ring 24 ring groove of Ring Gear 22 20 Insert Shift Rod 33 into preassembled Cover 8 NOTE to putting into operation fill the drive with new 23 Install Plugs 18 with new Seal Rings 19 into Cover 8 21 Install preassembled Cover 8 into Ring Gear 22 3121133 JLG Sizzor 3 17 SECTION 3 CHASSIS amp SCISSOR ARMS Figure 3 9 Drive Hub Assembly 3121133 JLG Sizzor 3 18 SECTION 3 CHASSIS amp SCISSOR ARMS Motor Disassemhly 3 Disassemble guide ring 1 Mark port plate to the supporting axle 1 Seal Ring 2 Pr
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32. 3 73 3 10 Joystick Specifications nepre A E hh 3 76 3 11 Joystick Plug Loading Chart u apuyaya aaa sagu 3 76 3 12 Joystick Specifications hh 3 77 3 13 Joystick Plug Loading Chart 3 77 3 14 Symptom Diagnosis i 21 cia Reis Se eco HP Wawa Poe ane qu Es 3 78 3 15 DTC to SPN FMI Cross Reference 3 86 4 1 Cylinder Piston Nut Torque lt 4 8 4 2 Holding Valve Torque Specifications 4 8 4 9 P mp ccu PE RR E e eR 4 20 5 1 Fault Code Listing Software 1 5 6 5 2 Machine Model Adjustment m 5 17 5 3 Machine Configuration Programming Information 5 18 5 4 Machine Tilt Configuration 5 19 JLG Lift 3121133 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 4 SPECIFICATIONS 1 2 CAPACITIES Table 1 1 Operating Specifications Table 1 2 Capacities
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34. 2 If engine stumbles because of lack of gasoline place switch to LPG position until engine regains smoothness then return switch to GASOLINE posi tion 3 Close hand valve on LP gas supply by turning clock wise 3 30 JLG Sizzor Using Liquid Petroleum LP Gas A WARNING CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT MORE THAN MOMENTARILY WHEN REFUELING LPG POWERED SIZZOR LIFTS ALWAYS FOL LOW MANUFACTURERS SPECIFICATIONS AND OR APPLICABLE REGULATIONS 1 If machine is to be left overnight or longer it must be parked outside or the LPG tank removed and stored outside 2 LPGis extremely flammable No smoking 3 Only trained and authorized personnel are permitted to operate filling equipment 4 Fill LPG tanks outdoors Stay at least 50 ft 15 m from buildings motor vehicles electrical equipment or other ignition sources Stay at least 15 ft 5 m from LPG storage tanks 5 During transfer of LPG metal components can become very cold Always wear gloves when refilling or changing tanks to prevent freeze burns to skin 6 Do not store LPG tanks near heat or open flame For complete instructions on the storage of LPG fuels refer to ANSI NFPA 58 amp 505 or applicable stan dards A WARNING DO NOT USE LPG TANK THAT IS DAMAGED A DAMAGED TANK MUST BE REMOVED FROM SERVICE FROST ON THE SUR FACE OF A TANK VALVES OR FITTINGS INDICATES LEAKAGE A STRONG ODOR OF LPG FUEL CAN INDI
35. C 20 F 29 C 180 F 82 NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE HYD OIL TANK TEMP AMBIENT AIR TEMPERATURE fe 120 F 49 C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C F 18 10 F 2950 20 F 29 C 30 F 34 C 40 F 40 C 3121133 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE DEPT FOR APPLICATION NO OPERATION ABOVE THIS AMBIENT TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE HYDRAULIC SPECIFICATIONS DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE gz g p s ar E 1 EXXON UNIVIS 26 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THIS AMBIENT TEMPERATURE 30 F 34 C y 40 F 40 C NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMIT
36. Engine coolant temperature ECT sensor Intake air temperature IAT sensor Throttle position sensor Crankshaft position sensor 002g 22202 52002 200000 40090 00202 mm 122222 28928 4 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3 7 GENERATOR FORD ENGINE LVER SCREW RECPTACLE GOLD SCREW SILVER SCREW x RECPTACLE GOLD SCREW 6A 600V DIODE JLG P N 39900107 VOLTMETER o GENERATOR CONTROL BOX O BE WIRED TO PLUG PER THIS SCHEMATIC 12 VDC 220 VAC FABCO POWER CHESTER NY VOLTAGE REGULATOR MODEL PMVRI20C TIT 1 Generator 2 Ford Engine 3 Voltage Regulator Figure 3 12 Generator Ford Engine Table 3 6 Generator Specifications Description 220 Powermax Voltage 220V Continuous 2 5KW Peak 3 5 KW Amps Peak 15 Amps 3121133 JLG Sizzor 3 43 SECTION 3 CHASSIS amp SCISSOR ARMS 3 8 DEUTZ EMR 2 S N 0200138634 TO PRESENT The EMR2 consists of the sensors the control unit and the 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 The sensors attached to the engine provide the electron ics in the control unit with all the relevant physical parame ter
37. Fuel System Checks Check the fuel pressure Refer to LPG Fuel System Diagnosis Check for low fuel pressure during a moderate or full throttle acceleration If the fuel pressure drops below specification there is possibly a faulty low pressure regulator or a restriction in the fuel system 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 3121133 JLG Sizzor 3 81 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Ignition System Checks Note LPG being a gaseousfuel requires higher secondary ignition system voltages forthe equivalent gasoline operating conditions If a problem is reported on LPG and not gasoline do not discountthe possibility of a LPG only ignition system failure and test the system accordingly Check for the proper ignition voltage output with J 26792 or the equivalent Verify that the spark plugs are correct for use with LPG R42LTS Check for faulty spark plug wires Check for fouled spark plugs Additional Check Check for manifold vacuum or airinduction system leaks Check the generator output voltage Backfire DEFINITION The fuel ignites in the intake manifold or in the exhaust system making a loud popping noise
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39. 3121133 JLG Sizzor 6 17 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JLG Sizzor 15 START 21 GND 0451 LSP XL x al ol sr xu 1 38 amp 1 1 lt zo a g zr voia vr a NOI 8 GND 33 E e sr u 12 17 AN9 zg zr 1 pro oa zi a sr 02 1 TONY 96 2 NVO E 9 sr zooa auvas 61 17 uMdV y ve zr Tana zz eoa er CTSIHS NWO cei sa og zr 1ssv d1 em ema Nvo 8 zz ir 2159 ki gz er SW19 Sd1 oi zr vov ano z i 113 5 Max e zr sola oir GND k s r 1 45 001 5 9 5 s sr 9000 91 17 2 vst sooq 1 17 vo 1 2 140 3 8 11 01 17 GND t 81 20 145 a E z sr sood S 2 17 INWO INV F u a 35 1 9 Z000 p 9 10 HNWO e ir HNY o
40. SECTION 4 HYDRAULICS 4 16 HYDRAULIC PUMP 4 20 FRONT PUMP MID PUMP Figure 4 24 Pump Pressure Locations Table 4 3 Pump Pressure Item Name Pressure 1 Charge Pump Relief 320 psi 22 bar 2 Cross Relief Pressure 3000 psi 207 bar 3 G Port 4800 psi 331 bar 4 PSPort 4800 psi 331 bar 5 Coil N A 6 Cross Relief Pressure N A JLG Lift 3121133 SECTION 4 HYDRAULICS Auxiliary Pump Motor Hydraulic Schematic 1 2A Terminal Torque 84 in Ibs 9 5 Nm 2x Torque 96 120 55 11 14 Nm Check Valve Cap Torque 144 180 in Ibs 16 20 Nm 4x Torque 180 216 in Ibs 20 24 Nm 8x Torque 114 150 in Ibs 13 17 Nm BO M Figure 4 25 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 3121133 Lift 4 21 SECTION 4 HYDRAULICS 4 17 CYLINDER ASSEMBLIES ht _ Op 1 1 if YO 2 Rod 3 Cap 4 Ring Washer 7 Ring Back Up 9 Ring Wear 4 22 JLG Lift 3121133 3121133 Or Po Q ms m SECTION 4 HYDRAULICS 1 Cable Adapter 11 Flat Washer 21 Nut 2 Bolt 12 Wiper 22 Seal 3 Bracket 13 Seal 23 Ring Back Up 4 Manual Descent Cable 14 Ring Wear 24 Spacer 5 Plug O Ring 15 Seal 25 Plug O Ring 6 Jam Nut
41. SELECT 01 L ORN WHT 55 13 ORANGE 55 6 AUTO LEVEL NHI YEL 48 8 NHI YEL 48 9 BLU ORN 52 ORN RED 49 4 57 WHT RFD 51 3 SWITCH GENERATOR 508 HI START AUX POWER 09 AU p ENG DRV SPEED SW SII DRV FUEL SEL GLOW 510 ENG WHT RED 57 4 TILT ALARM ORN RED 49 3 BLACK APWRO J3 1 ANLOO J3 2 GND J3 3 APWRI J3 4 ANLGI J3 5 GND J3 6 APWR2 J3 7 ANLG2 J3 8 GND J3 9 APWR3 J3 10 ANLG3 J3 11 GND J3 12 J3 RECEPTACLE GROUN ALARM WHITE BLACK WHITE HORN ALARM BLACK RED WHITE BLACK ROTARY POSITION SENSOR PROX SWITCH LIFT DOWN VALVE RR LDHS JI 5 GND 1 1 PLS JI 6 GND JI 12 PROP LIFT VALVE R STEER VALVE YOI LEFT STEER RIGHT VALVE DUMP ME An 2 LTS RTS DPS BRS LOSAX J2 5 Lamas KR J2 6 YELLOW 10 1 2 1 RED WHI 50 1 J2 8 ORANGE 55 1 2 11 ORANGE 55 3 1 BRAKE VALVE Yo4 fxy 4 fer TESDA LEFT OSC AX VALVE 1 Y LEFT OSC VALVE 2 15 RIGHT OSC VALVE 1 YIG d saga AX RIGHT OSC AX VALVE 2 2 SPEED VALVE Ki 5 ROSAX J2 12 ORANGE 55 4 LIFT UP VALVE YoT
42. 0 1380 0 3125 0 0524 4720 18 24 22 30 3 41 e my gt x a ud a a x 0 3125 0 0580 0 3750 0 0775 0 4375 9550 55 75 63 85 80 108 0 4375 0 5000 0 1599 14400 90 122 108 146 135 183 12 0 5625 0 1820 1600 t0 149 139 188 165 224 0 5625 130 176 154 209 190 258 5 8 0 6250 0 2260 20350 170 230 180 24 240 325 olzieliziaulz slo lt o cs S gt c S s SA s Slaolo PT 33600 30 434 336 456 465 630 7 8 0 4620 485 658 660 895 0 8750 0 5090 45800 500 678 54 724 725 983 1 740 1003 706 1079 100 1491 7 68700 960 1302 1030 1396 1400 1898 0 0 8560 1155 1607 1575 2135 1 1 4 1 2500 0 9690 1360 1844 1453 1970 2000 12712 96600 1500 2034 1610 2183 2200 2983 1 5 8 1 1550 1907 2586 2625 3559 1 3750 1 3150 2165 2935 3000 4067 11 2 1 4050 2530 3430 345 4711 1 1 5000 1 5800 2844 3856 3925 5322 5000029 H NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS SAE GRADE 5 SAE GRADE 8 Figure 1 6 Torque Chart SAE Fasteners Sheet 3 of 3 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS TORQUE TENSILE CLAMP TORQUE TORQUE TORQUE ORY OR LO
43. 5 FORWARD VALVE Yo8 2SPD J2 9 UPS J2 10 FWS J2 3 RVS J2 4 GEN J2 13 GND J2 15 GND J2 14 BLACK gt 4 ORANGE 55 TAN 3 1 ORANGE 1 1 ORANGE 8 1 REVERSE VALVE d Yoo BLACK 1 0 J2 17 BLACK 19 WosN3S 1304 is LP VALVE FORD GEN 11 avol Ol6 BRN WHT 47 9 MBs 48 1 WHT YFI 48 6 BRN ORN 53 1 111 N39 0804 5 RED 1 1 3 Figure 6 19 Electrical Schematic Dual Fuel Sheet 2 of 3 3121133 JLG Sizzor 6 15 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JI RECEPTACLE SPFDTH J2 1 PFDTH JI 1 SS 42 2 FL LJ PFOTHI JI 2 SIGN J5 9 VALVE FR LJ JI 3 GND J2 3 y 118 VALVE RL LJ gt BLACK GND JI 4D 0000 J2 11 ORN WHT 55 20 m potis VALVE YEL RED 2 1 3 IGN JI 5 20001 92 12 ORN WHI 55 21 KH 120 VALVE LJ EXTEND RED CANH JI 6 70002 5 1 ORN WHT 55 22 KK Y2l VALVE LJ EXTEND 2 lt lt BLACK CANL 01 7 S D003 J5 2 ET R Y22 VALVE LJ RETRACT CAN SHIELD JI 8 0004 J5 3
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45. Operational Test Ifa visual and physical check does not locate the cause of the problem drive the vehicle with a scan tool When the prob 3 78 lem occurs an abnormal voltage or scan reading indicates the problem may bein that circuit JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Intermittent Malfunction Indicator Lamp MIL The following components can cause intermittent MIL and no DTC s A defective relay Control Module driven solenoid or a switch that can cause electrical system interference Normally the problem will occur when the faulty componentis operating Theimproper installation of electrical devices such as lights 2 way radios electric motors etc The ignition secondary voltage shorted to a ground The Malfunction Indicator Lamp MIL circuit or the Diagnostic Test Terminal intermittently shorted to ground The Control Module grounds Loss of DTC Memory To check for the loss of the DTC Memory 1 Disconnect the TMAP sensor 2 Idle the engine until the Malfunction Indicator Lamp illuminates The ECM should store a TMAP DTC The TMAP DTC should remain in the memory when the ignition is turned OFF Ifthe TMAP DTC does not store and remain the ECM is faulty No Start DEFINITION The engine cranks OK but does not start Preliminary Checks Refer to Important Preliminary Checks Control
46. Qo Ts L M Figure 6 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads Figure 6 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected If meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity 3121133 JLG Sizzor 6 3 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or co
47. gauge Pressure readings are acceptable if they are within x 596 of specified pressures 1 Activate engine and allow hydraulic system to come up to operating temperature 2 Install pressure gauge at quick connect on main valve M1 3 Energize and bottom ut the leveling jack function Adjust relief to 2800 psi 193 bar 4 De energize jack function and shut down engine Remove pressure gauge 4 18 JLG Lift 3121133 SECTION 4 HYDRAULICS 4 14 POWER DECK SANDWICH VALVE 4 15 POWER DECK MANIFOLD VALVE I Figure 4 22 Power Deck Sandwich Valve Dual Deck Extension Only item 4 Torque 1 30 35 ft lbs 41 47 Nm 2 25 30 ft lbs 34 41 Nm i EN Power Deck Optional SET AT 1500 PSI Figure 4 23 Power Deck Manifold Valve NOTE Power Deck Manifold Valve is located on the under Port s Torque EP ET 24 ft lbs 32 5 Nm EPR EPB 32 ft lbs 43 4 Nm 3121133 Lift side of the platform Dual extension decks are equipped with two Manifold Valves Single extension decks have only one Manifold Valve 4 19
48. 1 4 op gt 0 D RN NN sO 9 196 1 as o o Oo 5 a c 9 7 o g x x o o a 1 x S a 2 3 gt 10 Y o x 5 D iL 6 45 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS FUSE FOR FUTURE STARTER OPTIONS THROTTLE OIL ACTUATOR BATTERY PRESSURE SWITCH GLOW OIL PEIG TEMP SWITCH ALTERNATOR DIESEL MACHINES AC POWER gm AT PLATFORM S AUXILIARY PUMP GENERATOR CONTROL BOX o a 8 GENERATOR GENERATOR RELAY LEVELING JACK PORT BLOCKS I LEVELING
49. 1 o 33RT2WD 33RT4WD 43RT2WD 43RT4WD 2 ENGINE FORDEFID F DEUTZF3 FORD DIF T2 DEUTZF3 2 DEUTZECM DUAL FUEL ECM GM PSI Engine 3 MARKET ANSI USA ANSI EXPORT CSA CE AUSTRALIA 4 TILT CUTOUT A O PON QO ON O ON NO Tilt Cutoutis not active Yes Tilt Cutoutis active Screen only visible to CE Market 5 GLOW PLUGS NO GLOW PLUGS 5 SECGLOW 10 SEC GLOW 20 SEC GLOW 30 SEC GLOW 40 SEC GLOW 50 SEC GLOW 60 SEC GLOW 6 LEVELING JACKS O Q GQ N O No Leveling Jacks not installed on vehicle YES Leveling Jacks are installed on vehicle 7 POWERDECK NONE Power Deck Extensions notinstalledon vehicle FRONT Power Deck Extension is installed on the Front of the vehicle DUAL Power Deck Extensions are installed on the Frontand Rear of the vehicle 8 GENERATOR NOT INSTALLED Generator is not installed on the vehicle 60HZ Generator is installed and engine speed set for 2000RPM when enabled 50HZ Generator is installed and engine speed set for 1700RPM when enabled 9 FUNCTION CUTOUT NOT INSTALLED Vehicle is not equipped with a Function Cutout device DRV amp LIFT UP Vehicle is equipped with a Function Cutout device Drive and Lift Up will be prevented when active ALL FUNCTIONS Vehicle is equipped with a Function Cutout device All Functions will be prevented when activ
50. 5 If no repairs are necessary or when repairs have been made replace counterbalance valve and care fully connect hydraulic hoses to cylinder port block 6 Ifused remove lifting device from upright or remove prop from below main boom activate hydraulic sys tem and run cylinder through one complete cycle to check for leaks Oscillating Axle Lockout Test NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure platform is fully lowered prior to beginning lockout cylinder test 1 Place a 6 inch 15 2 cm high block with ascension ramp in front of left front wheel 2 From platform control station select LOW drive speed 3 Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until left front wheel is on top of block 4 Raise machine platform approximately 9 ft 2 7 m on the 3394RT or 10 ft 3 1 m on the 4394RT 5 Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp 6 Have an assistant check to see that the left front wheel remains locked in position off the ground 7 Lower the machine platform the lockout cylinder should then release and allow wheel to rest on the ground It may be necessary to activate DRIVE to release cylinders 3121133 SECTION 4 HYDRAULICS 8 Placethe 6 inch 15 2 cm high block with
51. 91 5 XW 310143238 8 20 7010 Zi NOI 8 20 QNO 8 60 600d a QNO QE 20 1 NYD 1 60 8000 5 TONY 96 27 H NYD 9 60 1000 9 aves 61 10 UMdY 2 1303 20 010 5 80 0131 62 19 1158 0 2 ISSY 41 2010 Gn NO 5 22 1 2158 82 20 519 591 1010 2 1 EM 2 7 QN sa 5 SE 20 MdXY 4 sold 01 97 09 a r 20 H103 0010 5 E S S 9000 f aNd 3 6 000 8119 91 20 3 140 3 1 St 7000 8 1 0131 T QNO z 81 20 145 amp SM 0005 1 1 WYO d 1 9 2000 9 10 6 17 Er 1 20 1000 6 10 NOI 8 17 NOI Z et aNd 000055 QN9 QNO rn K 2 2 S9pX1 05 H103S Xud0 1 5 8 6 6 NIIS H104d 3114 ous i s o NH Ti 3 2 E 3109143938 2 d se 92 20 Lovo J amp g 5 eL H tee E EI axny 62 20 544 A 55 0807199 g lt r ouda 5 1983 ze uL E T 6T N1389 9308 T EI N3389 1001 01 9441 r2 20 09 3 z 6 7 9303 Q a e DNI 8 ND E 2 20 duH2 1 97 94 12 21 LW JELE 909 9 m SF 9 01 983 2 20 NOI Si ET ETEN H b SOND 12 20 S9N3 C TERA I b o 5114 2 QNO s X318 ay morm 51 0 LWAH 6 2 049 gt k 9 QNO 2 2 8 Eo
52. Carbon tracking Check the wiring for the following items Proper connections pinches or cuts The following symptom tables contain groups of possible causes for each symptom The order of these procedures is notimportant Ifthe scan tool readings do not indicate the problems then proceed in a logical order easiest to check or most likely to cause first Intermittent DEFINITION The problem may or m ay notturn ON the Malfunction Indicator Lamp MIL or store a Diagnostic Trouble Code DTC Preliminary Checks Refer to Important Preliminary Checks Do notuse the DTC tables If a faultis an intermittent the use of the DTC tables may result in the replacement of good parts Faulty Electrical Connections or Wiring Faulty electrical connections or wiring can cause most intermittent problems Check the suspected circuit for the following conditions Faulty fuse or circuit breaker Connectors poorly mated Terminals not fully seated in the connector backed out Terminals not properly formed or damaged Terminal to wires poorly connected Terminal tension insufficient Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension If nec essary replace all the connector terminals in the problem circuit in order to ensure the proper contact tension Checking for poor terminal to wire connections requires removing the terminal from the connector body
53. Important A closed LPG manual fuel shut off valve will create an extended crank OR no start condition Verify the excess flow valve in the LPG manual shut off valve is not tripped Check mixer module assembly for proper installation and leakage Verify proper operation of the low pressure lock off solenoids Verify proper operation of the EPR Check for air intake system leakage between the mixer and the throttle body Check the fuel system pressures Refer to the Fuel System Diagnosis Ignition System Checks Note LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operat ing conditions Check for the proper ignition voltage output with J 26792 or the equivalent Verify that the spark plugs are correct for use with LPG R42LTS Check the spark plugs for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes Heavy deposits Check for bare or shorted ignition wires Check for moisture in the distributor cap if applicable Check for loose ignition coil connections Important 1 Ifthe engine starts but then immediately stalls Check the Crankshaft Position CKP 2 Check for improper gap debris or faulty connections Engine Mechanical Checks Important The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man ifold leakage than the gasoline fuel supply system Check for the following V
54. Install the EPR refer to EPR Installation 3 68 JLG Sizzor Temperature Manifold Absolute Pressure TMAP Sensor TMAP Sensor Adapter Figure 3 40 TMAP Sensor amp Electronic Throttle Control ETC REMOVAL 1 Disconnect the TMAP electrical connector 2 Remove the two retaining bolts 3 Remove the TMAP INSTALLATION NOTE Apply a small amount of O ring lubricant before installation 1 Install in the TMAP 2 Tighten retaining bolts to 62 Ib in 7 Nm 3 Start the vehicle and check for proper operation 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Electronic Throttle Control Replacement See Figure 3 40 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 Disconnect the TMAP electrical connector Disconnect the electronic throttle control connector 6 Remove the manifold to throttle body adapter bolts and remove the throttle body mixer assembly 7 Pullthe throttle body assembly from the adapter Remove electronic throttle control device Remove the O rings gasket and discard INSTALLATION NOTICE LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO ADAPTER O RINGS 1 Install the O ring on throttle body Press it down to the bottom of the surface SLIDE O RING ON HERE 3121133 JLG Sizzor 2 3 Install the two quad seals Install one seal at a
55. J2 5 SWITCH START AUX ENG DRV 508 POWER FUEL SEL SPEED SW HI 509 IGLOW 811 AUX TART S10 ENG gt N gt ORN RED 49 4 j Se WHI BED 57 2 4 SP j WHT RED 57 3 4 Slat WHT RED 57 4 ORN RED 49 3 TILT BLACK APWRO J3 1 ANLOO J3 2 d GND 13 3 2 APWR1 J3 4 E ANLG1 J3 5 GND J3 6 lu APWR2 J3 7 ANLG2 J3 8 5 GND J3 9 APWR3 J3 10 ANLG3 J3 11 GND J3 12 HORI WHITE ALARI BLACK BED ROTARY WHITE POSITION BLACK SENSOR BLACK PROX WHITE SWITCH LIFT DOWN VALVE LDHS J1 5 L m s VALVE GND J1 11 BLACK Y11 PLS J1 6 WIHLTE Let GND J1 12 BLACK STEER LEFT VALVE STEER RIGHT Yo1 VALVE DUMP LTS J2 5 E Yo2 VALVE BRAKE RTS J2 6 YELLOW 10 1 03 VALVE LEFT OSC AX DPS J2 7 RED WHT 50 1 js VALVE 1 LEFT OSC BRS J2 8 ORANGE 55 1 LOSAX 42 11 ORANGE 55 3 1 VALVE 2 RIGHT OSC AX 3 15 VALVE 1 RIGHT OSC AX id 16 VALVE 2 2SPEED ROSAX J2 12 ORANGE 55 4 1 Y17 VALVE LIFT UP Yoe VALVE FORWARD 2SPD J2 9 ORANGE 55 2 fet fti Yo7 VALVE REVERSE UPS J2 10 TAN 3 1 KH A me VANE FWS J2 3 ORANGE 7 1 e RVS 2 4 ORANGE 8 1 Ki GEN J2 13 GND J2 15 BLACK e e e 9 GND J2 14 BLACK 19_ 53 1_ FUEL GAUGE GMAT EH Figure 6 22 Electr
56. Low Pressure Regulators rbe cece ele emn 3 62 9234 Air Fuel RIS kuma Eee ee es 3 63 3 32 throttle control n 3 63 3 33 LPG Engine Control Unit ECM RR Hm n 3 64 3 34 EOMAssembly n epe Rune ERRARE EIE panim ei WEN ED e eee 3 64 3 35 Heated Exhaust Gas Oxygen Sensor HEGO 3 64 3 36 Gasoline Fuel Pressure and Temperature Manifold Assembly 3 65 3 97 Filter Eock Assembly 21 2e diet s E eed tos dalles doe ba i I tke 3 66 3 38 Assembly icici g Ie eR Wet eee ep roi eA 3 67 3 39 Pressure Regulator Section 3 68 3 40 Sensor amp Electronic Throttle Control ETC 3 68 3 41 MixerAssemDly nis men gx PR mmodo See RC Ra E ROS 3 70 3 42 Ram RD Da Ie E UPC Rae i adis 3 72 3121133 JLG Lift iii TABLE OF CONTENTS 3 43 3 44 4 1 4 2 4 4 4 5 4 7 4 8 4 10 4 11 4 12 4 18 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 4 34 5 2 5 3 5 5 6 1 6 2 6 3 6 4 6 5 6 6 6
57. Preliminary Check Refer to Important Preliminary Checks Ignition System Checks Important LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions The ignition system must be maintained in peak condition to prevent backfire Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question Ifthe meter reads over 30 000 ohms replace the wires Check the connection at each ignition coil Check for deteriorated spark plug wire insulation Check the spark plugs The correct spark plugs for LPG are R42LTS Remove the plugs and inspect them for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes Heavy deposits Engine Mechanical Check Important TheLPG Fuel system works ona fumigation principle of fuel introduction and is more sensitive to intake man ifold leakage than a gasoline fuel supply system Checkthe engine for the following Improper valve timing Engine compression Manifold vacuum leaks Intake manifold gaskets Sticking or leaking valves Exhaust system leakage Check theintake and exhaust system for casting flash or other restrictions Fuel System Checks Perform a fuel system diagnosis Refer to LPG Fuel System Diagnosis Lack of Power Sluggishness or Sponginess DEFINITION The engine del
58. SE ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 AC GENERATOR WIRING VOLTAGE REG 1 2 3 4 5 GREEN 12 12 2 BLACK 10 GENERATOR z WHITE 10 10 BLACK 9 RED 3 12 BROWN 2 2 2 BLACK 13 3 GENERATOR BROWN 2 1 CONTROL BOX 25 L 6 RED 4 12 B RED 1 3 10 GENERATOR 87 87A RELAY a BLU ORN 52 1 30 1870190 D BLACK 2 Figure 6 31 Electrical Schematic Diesel S N 138634 to Present Sheet 3 of 3 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JES NOTES 3121133 JLG Sizzor 6 31 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 32 BLEEDER P tO BLEEDERA
59. STAMPED Figure 1 1 Serial Number Location JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS 1 8 SENSORS The machine is equipped with the following limit switches Elevation Switch Rotary Position Sensor High drive speed is cut out when platform is raised above the preset heights listed in Table 1 8 High Drive Cut Out Height Table 1 8 High Drive Cut Out Height Model Feet Meters 3394RT 6 9 1 8 2 7 4394RT 7 10 2 1 3 Tilt Alarm An alarm sounds and a warning light is illumi nated when the machine is operated on a slope that exceeds the values in Table 1 9 Tilt Sensor Indicators The lift and drive functions will cut out at these set heights NOTE Alarm only sounds when above elevation If the machine is operated beyond the specified slope with the platform completely lowered only the warning light is illuminated Table 1 9 Tilt Sensor Indicators 1 9 CYLINDER SPECIFICATIONS Table 1 10 Cylinder Specifications Description Bore Stroke Rod Dia 4 5in 83in 3 5in Liteylinder 11 4cm 211 89cm 1 21 5 2in Leveling Jack Cylinder 7 6cm 54 6cm 5cm Lockout Cylinder 2 5in 6 0in 1 75in Oscillating Axle 6 4 cm 15 2cm 4 4 cm Power Deck Extension 1 5in 48in lin Cylinders 3 8cm 122cm 2 5 2 5in 4 6in 1 75in Steer Cylinder 64cm 11 2cm 44cm 1 10 MAJO
60. Sheet 1 5 6 22 Electrical Schematic Dual Fuel GM Sheet 2of5 6 23 Electrical Schematic Dual Fuel GM Sheet 5 6 24 Electrical Schematic Dual Fuel GM 4 5 6 26 Electrical Schematic Dual Fuel GM Sheet 5 5 6 27 Electrical Schematic Diesel S N 138634 to Present Sheet 1of3 6 28 Electrical Schematic Diesel S N 138634 to Present Sheet 2 0f3 6 29 Electrical Schematic Diesel S N 138634 to Present Sheet 3of3 6 30 Hydraulic Schematic 4WD Sheet 1of4 6 32 Hydraulic Schematic 4WD Sheet 20f4 2 0 0 0 ee 6 33 Hydraulic Schematic 4WD Sheet 3 4 6 94 Hydraulic Schematic 4WD Sheet 4of4 6 35 Hydraulic Schematic 2WD Sheet 1 4 6 36 Hydraulic Schematic 2WD Sheet 2of4 6 37 Hydraulic Schematic 2WD Sheet 3 4 6 38 Hydraulic Schematic 2WD Sheet 4 4 6 39 Hydraulic Diagram 2WD 0 eR IH I ue 6 40 Hyd
61. d 905 w 5v 10 20 M 1206 Be B z n sr __ a W T i Ur T it ou u E FEE 4 A se Ho LC s em E ig odes dee BE d fos op wo eme Ll SPEED RELEASE 2 z ER 72 cole H 1 12472 T D aD CLD us P tT T D oF 6 KO te 8 A T 2792543 D 40 GALLON Figure 6 35 Hydraulic Schematic 4WD Sheet 4 of 4 3121133 JLG Sizzor 6 35 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 36 BLEEDER BLEEDERA y FS z o OSCILLATING AXLE N 9 Ert i T I I c BLEEDER BLEEDER M LRA 4 3 1 Omm x 2 f 8 RRB W LRB RRA A 4641228 X x3 CD i x x is 4641225 us em AGA 12487 1 i T
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63. rep i2 FUSE LINK RED 16 LI E RED 1 1 10 WHT LT BLU 85 STARTER m BLACK 10 LLL RED 15 30 ppc SOLENO TO PNK DR GRN 14 811 es a GROUND ALTERNATOR POWER RELAY lt 5 3 _ BRILORNOSSSI J2 35 SHT 1 TAN BLK 85 EPR PNK YEL 16 874 9 5 CONNECTOR RED 16 30 PNK TAN BLU WHT CAN 86 WHITE 12 CAN FUEL PUMP RELAY Ss BLU PNK 3 CAN ONCE 4 UNUSED 5 UNUSED BLACK 16 6 GROUND LACK Ja 14 SHT 1 BAT CABLE RED LT BLU 16 7 VBAT BAT CABLE 8 UNUSED BLACK 12 SHT 1 EPR FUSE ENGINE BLOCK LU 16 F3 PNK DR GRN 16 1870204 E Figure 6 28 Electrical Schematic Dual Fuel GM Sheet 5 of 5 3121133 JLG Sizzor 6 27 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
64. 044 in 1 117 mm Ground Bearing Pressure 49 psi 56 psi w Standard tires 3 45 kg cm 3 94 kg cm EM Table 1 4 Deutz F3M2011 Specifications Leveling Jack Bearing 69 psi 4 9 kg cm Pressure Fuel Dlesel Wheelbase 9 67 ft 2 95 m Oil Capacity 8 5 Quarts 8L w Filter Ground Clearance 12 in 30 Low RPM 900 Maximum Hydraulic System 3000 psi 207 bar High RPM 2800 dl Susana Alternator 95 Amp Belt Drive i is Battery 112 Amphour 950 Cold Cranking Inside Turning Radius 14ft5 in 4 39 m Amps 12 VDC Outside Turning Radius 20ft1 in 6 12 m Fuel Consumption Gross Vehicle Weight w One Low RPM 1 3 GPH 4 9 Iph Extension High RPM 1 6 GPH 6 0 Iph Note Certain options or dio 5 48 2800 RPM I country standards increase V 9 9 O 9SpoWer weight 3121133 JLG Sizzor 1 1 SECTION 1 SPECIFICATIONS Table 1 5 GM 3 0L Specifications 1 5 MACHINE DIMENSIONS Fuel Gasoline or Gasoline LP Gas No of Cylinders 4 BHP Gasoline 83hp 9 3000 rpm LP 75 hp 3000 rpm Bore 4 0in 101 6 mm Stroke 3 6in 91 44 mm Displacement 181 cu in 3 0L 2966 cc Oil Capacity w filter 4 5qts 4 25 L Minimum Oil Pressure Description 3394RT 4394RT Machine Height rails down 61 75in 1 6m 70 4in 1 8m Machine Width 7ft 10in 2 4 m Machine Length 13ft 4m 1 6 PRESSURE SETTING
65. 1 0 1 2 ANSI EXPORT 3 4 1 0 1 2 3 4 5 6 7 0 1 0 1 2 CSA 3 4 2 0 1 2 3 4 5 6 7 0 1 0 1 2 CE 3 4 3 0 1 2 3 4 5 6 7 0 1 0 1 2 AUSTRALIA 3 4 4 0 1 2 3 4 5 6 7 0 1 0 1 2 4394RT 4WD gt 5 S E E lt o 2 2 72 5 z e z ANSI USA 0 1 2 0 1 2 1 ANSI EXPORT 0 1 2 0 1 2 1 CSA 0 1 2 0 1 2 1 CE 0 1 2 0 1 2 1 AUSTRALIA 0 1 2 0 1 2 1 4150390 J 3121133 JLG Lift 5 23 SECTION 5 JLG CONTROL SYSTEM NOTES 5 24 JLG Lift 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 6 2 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recommended for the measurements in these procedures This section shows dia grams of a common digital VOM configured for several different circuit measurements Instructions for your VOM may vary Please consult the me
66. 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16 6 17 Joystick Controller JLG P N 1600308 3 76 Joystick Controller JLG P N 1600403 3 77 Lift Cylinder Holding Valve and Fitting 4 3 Cylinder Barrel Support su i ean EE eR ERR UR REUS asas a EROR ER RR S 4 3 Lift Cylinder Cap Screw 4 4 Cylinder Rod Support raa ect een eae alae Pea ks 4 4 Tapered Bushing Removal 4 5 Bushing Installation 2 v 22 e wah 4 5 Rod Seal Installation oka eh Sak heed weeded ae Gg SQ ard eS 4 6 Poly Pak Piston Seal Installation 2 0 0 00 00 cece eee 4 6 Wiper Seal Installation wed e owe RE Casu y bok e uia a ed 4 6 Installation of Head Seal Kit 4 6 Piston Seal Kit Installation l l ee RH Hm m 4 7 Tapered Bushing Installation 4 7 Seating the Tapered Bearing 4 7 Rod Assembly Installation liie HIA sss 4 8 Main Valve Torque Re R
67. Aney J y99U9 ureBe uo pue U3 IAS 9516 jeuuou 3ul ul amod U8uM sJeeddesip abessaw ne ajqissiuued ui jou 101222 10 44 5 J8A0d vse ais Ajddns uonduosep 1 Ayyeoo Hned viauas ou yned 9180 ure4B0Jd eJeMpJeu yun 2 3121133 JLG Sizzor 3 56 SECTION 3 CHASSIS amp SCISSOR ARMS 3 9 GENERATOR DUETZ ENGINE FABCO POWER CHESTER NY VOLT GE REGULATOR MODEL PMVRI2OC eC M 6A 600V DIODE JLG P N 3990010 SILVER SCREW AC RECPTACLE GOLD SCREW lt LVER SCREW lt 5 RECPTACLE GOLD SCREW 6 OVERLOAD VOLTMETER 12 VOC 220 VAC FABCO POWER CHESTER NY VOLTAGE REGULATOR MODEL PMVRI20C TIT GENERATOR CONTROL BOX TO BE WIRED TO PLUG PER THIS SCHEMATIC Generator 120V or 220V 3 Voltage Regulator Deutz Engine Figure 3 25 Generator Deutz Engine Table 3 7 Generator Specifications 3121133 Description 110 Bluemax 220 Powermax Voltage 120V 220V Continuous 3 5 KW 2 0 KW Peak 4 5KW 3 0KW Amps Peak 37 Amps 13 Amps JLG Sizzor 3 57 SECTION 3 CHASSIS amp S
68. DRIVE A WARNING CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING GEAR DRIVE MAY BE HOT AND CAUSE INJURY IF RECENTLY OPERATED For numbers in refer to Figure 3 8 Drive Motor Hub Assembly 1 Remove the 2 Bolts 30 from the Cover 28 2 Remove the Cover 3 Rotate Cover to show inside diameter 4 Press Cover sufficiently against the Shift Rod 33 to insert the 2 Bolts at least 2 3 threads into the Cover The Shift Rod is now subjected to the Spring 32 force 5 Install the 2 Bolts 30 and tighten until they are flush with the Cover 28 with a torque wrench to 6 3 Ib ft 8 5 Nm The Sun Gear Shaft 25 and Input Shaft 26 are now dis connected and the machine is ready to be towed 3 10 JLG Sizzor NOTICE THE MAXIMUM GEAR DRIVE TOWING SPEED OF 72 RPM MUST NOT BE EXCEEDED ENGAGE GEAR DRIVE OR SECURE MACHINE WHEN MACHINE IS SEPARATED FROM THE TOWING VEHICLE Engaging Procedure NOTICE PRIOR TO ENGAGING THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT ENSURE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION MAKE SURE DIRT OR OTHER CONTAMI NANTS DO NOT ENTER THE GEAR DRIVE A WARNING CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING GEAR DRIVE MAY BE HOT AND CAUSE INJURY IF RECENTLY OPERATED A WARNING COVER ITEM 28 IS UNDER SPRING FORCE For numbers in refer to Figure 3 8 Drive Motor Hub Assembly 1 Remove the 2 Bolts 30 from th
69. F 70 C in a heating furnace 6 Insert radial Shaft Seal Ring 17 into Supporting Ring 6 and fill mounting space between sealing lips with roller bearing grease 3 Insert outer rings into heated Supporting Ring 6 check for proper axial seat NOTE Observe correct mounting position of sealing lip prior to installing the seal ring 4 Coat bore in Supporting Ring 6 with Loctite 573 for Radial Shaft Seal Ring 17 7 Install preassembled supporting ring onto Spindle 34 3 14 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 8 Heat upper ring with roller cage of double Tapered b The Loctite setting time equals 24 hours at ambi Roller Bearing 11 to approximately 189 5 F 70 C ent temperature of 68 F 20 C and mount onto Spindle 34 Allow cooling time of approximately 15 minutes before continuing assem bly 11 After proper bearing setting is completed hammer ball with suitable punch 1 1 1 3mm into the spindle 9 De grease threads of Spindle 34 and Shaft Nut 4 thread Retain ball in position with expanding plug Then evenly apply coat of Loctite 270 to Shaft Nut 4 threads 12 Insert a new greased O Ring 16 into the o ring groove of the Supporting Ring 6 10 Rotate the supporitng ring repeatedly in one direc tion only when setting the tapered roller bearing a Tighten Shaft Nut 4 by using an adequate device with a tightening torque of 627 Ib ft 850 Nm
70. GRN RED 3 BOSCH LL YEL GRY TMAP K LT GRN 11 CONNECTOR 2 4 PINK DR GRN S 12V RELAYED POWER TAN DR GRN R AUX ANA PDI RED BLK P vs RED WHT N VS TAN BLK M AUX DIG 3 TAN RED L AUX DIG 2 LT BLUE GRY DR BLU K GOV SELECT GRY ORN J GOV SELECT 2 R DR BLU YEL H AUX ANA PUI BLACK O YEL DR BLU G AUX ANA PUI IAN 18 F AUX PWM 2 BLACK 16 E GROUND GRAY D TACH BRN WHT 16 C AUX PWM 5 24 GROUND WHT BRN 16 B AUX PWM 5 RECIRC A AUX PWM TAN 16 VEHICLE INTERFACE CONNECTORS LT BLU PN CONNECTOR LT GRN PUR 5 5V EXT 2 FPP2 ONLY LI GRN BLK R 5V RTN 2 BLU WHT P CANI BLU PNK N CANI LI GRN RED M 5V EXT BLK LT GRN L 5V RTN DR BLU ORN K PUR YEL J FPP2 IVS 6009600900 v 4 TAN BRN H FUEL SELECT AUX DIG GRN YEL 6 MIL LI BLU PNK 16 F START IN INTERRUPT TYPE DK BLU 8 E START IN AUTOCRANK ING PNK YEL 16 D FUEL PUMP BLK RED 16 C FUEL PUMP 30 87a PURPLE 16 B ALT EXCITE PINK A VSW WHITE 18 87 RED TAN 16 rn 0 START RELAY DIAGNOSTIC PNK BLK 85 CONNECTOR 4 BLK LT GRN ANA LT GRN RED 2 5V REF DR GRN 3 PC TX ORANGE 4 PC RX 5 UNUSED 6 UNUSED FUEL PUMP BLU PNK 1 CAN 4 PNK DR GRN 16 F5 PNK YEL 16 BLU WHT CANI A PNK TAN FT PINK VEA VSW RED 10 504 D E RED TAN 16 F6 RED 16 max peu um B L L AL STARTER ALTERNATOR B RED 1 RED TAN 14 F2 RED 4 N I6 F4 PNK DR GRN 16 de Beo lE A ALTERNATI OR wen PURPLE 16 IGNITION
71. H 3121133 SECTION 1 SPECIFICATIONS JLG SPECIFICATION 4150701 MAGNA 565 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE TENSILE AP TORQUE TORQUE STRESS LOCTITE 262 A y 7 7 28 o 3 ue zo _ 3 as 22 NOTE THESE TORQUE VALUES DO NOT 5000029 H APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 8 8 METRIC CLASS 10 9 25 25 27 1160 5 4 Figure 1 9 Torque Chart METRIC Fasteners Sheet 3 of 3 3121133 JLG Sizzor 1 15 SECTION 1 SPECIFICATIONS NOTES JLG Sizzor 3121133 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition For maximum service life and safe operation ensure that all the necessary inspections and maintenance have been completed before placing the machine into service Preparation Inspection and Maintenance It is important to establish and conform to a comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult your national regional or local regulat
72. Hydraulic Schematic 4WD Sheet 2 of 4 JLG Sizzor 6 33 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS CYLINDER IILI CYLINDER LIF I CYLINDER 1 5 BORE 1 5 BORE 2 BORE 88 ROD 1 ROD 1 5 ROD 11 125 STROKE 7 5 STROKE 8 STROKE EASI CLADDER PLUS VALVE BLOCK 1000 PSI ILT CYLINDER LIFT CYLINDER BORE 2 BORE ROD 1 5 ROD STROKE 8 STROKE 1 5 BORE TELE CYLINDER T T 5 88 ROD a 11 125 STROKE 5 1000 PSI EASI CLADDER PLUS VALVE BLOCK POWER DECK CYLINDER 2x 1 5 BORE 1 0 ROD 48 STROKE u POWER DECK OPTIONAL SET AT XXX PSI AGA 12408 5 POWER DECK OPTIONAL SET AT XXX PSI AGA 12408 Figure 6 34 Hydraulic Schematic 4WD Sheet 3 of 4 6 34 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS EASI CLADDER CYLINDER 5 BORE ROD 7 5 STROKE r T l al b e X FCIO 20A 0 N RIGHT FRONT RIGHT REAR LET E
73. JACK ZS PORT e BLOCKS OPTIONS T I MODULE LEVELING JACK VALVE f Il Figure 6 46 Electrical Components Installation Sheet 1 6 46 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ENGINE SPEED SENSOR LP LOCK amp ASSIST GAS MACHINES i ALTERNATOR E c GAS a cJ MACHINES HYDRAULIC PUMPS PORT BLOCKS OSCILLATING 8 J LH B O CHE Ole Jin o 5 PLATFORM CONTROL BOX IGNITION RELAY THROTTLE CONTROLLER GAS MACHINES o o
74. KE yoo RVS J2 4 GND J2 15 BLACK GND J2 14 5 BLU ORN 52 10 P GENERATOR 52211 C SEE SHEET 2 SHIELD BLACK RED 6 MODULE YEL RED 2 7 3 INTE 5 SEE SHEET 2 BRN WHT 47 9 BRN ORN 53 1 GLOW PLUG 4 C14 WHT YEL WHT YEL WHT YEL 14 AUX POWER FUEL GAUGE Figure 6 30 Electrical Schematic Diesel S N 138634 to Present Sheet 2 of 3 3121133 JLG Sizzor 6 29 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS GND J2 14 IGN POWER RELAY J2 36 L J2 37 GND J2 38 GENERATOR CONTROL SEE SHEET A B D 6 30 MODULE SEE SHEET 1 JI RECEPTACLE J2 1 41 1 Q PFDTHI J2 2 FL LJ PFDTHI JI 2 IGN J5 9 VALVE FR LJ SFDTH JI 3 s GND J2 3 BLACK yi8 VALVE RL LJ IGND JI 4 0000 92 11 ORN WHT 55 20 Yis VALVE IGN 01 5 DOO J2 12 ORN WHT 55 21 Y20 VALVE EXTEND LJ ICANH JI 6 0002 J5 1 ORN WHT 55 22 yal V
75. OPTIONAL SET AT PSI AGA 12408 CD Figure 6 38 Hydraulic Schematic 2WD Sheet 3 of 4 6 38 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 EASI CLADDER CYLINDER BORE ROD 7 5 STROKE 2 pi 82 RIGHT FRONT RIGHT REAR FCI0 20A 0 N 8V08 47C 0 N 1 206 RYO8 20A 0 N l2DG FRIO 39A 0 N CV10 20 0 N 30 SV 10 20 N 1206 SV 10 4250 H 126 ei ASI CLADDER VALVE BLOCK LEFT FRONT LEFT REAR SET AT xoesi AT ues TWO BRAKE SPEED RELEASE AGA 12412 L AGA 12407 40 GALLON 2792544D Figure 6 39 Hydraulic Schematic 2WD Sheet 4 of 4 3121133 JL G Sizzor 6 39 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
76. SAATVA Wd XXXX NG N0015 XXXX TAS 1411 WHOALVTd XXXd GNNOUD SNOISUIA WX SNIONG XXXX LUVIS HNIDNSI OM XXX AVOTA 0 01 9NIIVTH HOSNIS ATTA X QVO SHATVA W9 WAISAS XOX dN LITT 1 1049 TAS DANN 0 SNOISU3A SOLLSONOVIC SOTVLVd SOLLSONOVIG SQILSOND VIG avol SOLLSONOVIC MOSNHS ATTA SOMLSONOVIG SAATVA SOLLSONOVIC WALSAS SOLLSONOVIC 089 SQILSONDVIG SOHISONDVIG X0 ACON TH 183 WHINSSSA SISAL SOIISONDVIG ANG 4 41 ASAL WALSAS SANG C LTHHS WO 3121133 JLG Lift 5 16 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Machine Model Adjustment Model Default Values Adjustment Adjustment Range 3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD DRIVE Accel 0 1 5 0 sec 3 3 3 3 Decel 0 1 3 0 sec 1 2 1 2 1 2 1 2 Min Forward 0 35 24 24 24 24 Max Forward 0 100 56 56 56 56 Min Reverse 0 35 24 24 24 24 Max Reverse 0 100 55 55 55 55 Elev Fwd Max 20 50 41 41 41 41 Elev Rev Max 21 50 41 41 41 41 Engine 800 2900RPM 2800 2800 2800 280
77. Voltage 105 4 113 IAT High Voltage 105 3 116 ECT Higher Than Expected 1 110 15 117 ECT Low Voltage 110 4 118 ECT High Voltage 110 3 121 TPS 1 Lower Than TPS 2 51 1 122 TPS 1 Signal Voltage Low 51 4 123 TPS1 Signal Voltage High 51 3 127 IAT Higher Than Expected 2 105 0 129 BP Low Pressure 108 1 134 EGO 1 Open Inactive 724 10 154 EGO 2 Open Inactive 520208 10 171 Adaptive Learn High Gasoline 520200 0 172 Adaptive Learn Low Gasoline 520200 1 182 Fuel Temp Gasoline Low Voltage 174 4 183 Fuel Temp Gasoline High Voltage 174 3 187 Fuel Temp LPG Low Voltage 520240 4 188 Fuel Temp LPG High Voltage 520240 3 217 ECT Higher Than Expected 2 110 0 219 Max Govern Speed Override 515 15 221 TPS 2 Signal Voltage Low 51 0 222 TPS 2 Signal Low Voltage 520251 4 223 TPS 2 Signal High Voltage 520251 3 261 Injector Driver 1 Open 651 5 262 Injector Driver 1 Shorted 651 6 264 Injector Driver 2 Open 652 5 265 Injector Driver 2 Shorted 652 6 267 Injector Driver 3 Open 653 5 268 Injector Driver 3 Shorted 653 6 270 Injector Driver 4 Open 654 5 271 Injector Driver 4 Shorted 654 6 336 Crank Sync Noise 636 2 337 Crank Loss 636 4 341 Cam Sync Noise 723 2 342 Cam Sensor Loss 723 4 420 Gasoline Cat Monitor 520211 10 524 Oil Pressure Low 100 1 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 Table 3 15 DTC to SPN FMI Cross Reference Chart
78. a combination Low Pressure Regu lator and a Voice Coil Assembly The Voice coil is an elec tronic actuator which is controlled by an internal microprocessor The microprocessor provides output data to the ECM and receives input data over a CAN BUS con nection The internal microprocessor receives electrical signals from the Fuel Pressure Sensor FPS and the Fuel Temperature Pressure FTP and communicates the data to the ECM The ECM uses the FPS and FTP data to calcu late the location of the secondary lever in the LPR and sends that data back to the EPR via the CAN BUS The internal microprocessor in the EPR will then output a sig nal which causes the voice coil to move and position the secondary lever to the correct location 1 PressureRegulatorSection 4 Primary Test Port 2 Fuellnlet 5 Secondary Test Port 3 Coolant Passage 6 Voice Coil Section Figure 3 29 EPR Assembly 3 62 Low Pressure Regulator LPR The LPR is a combination vaporizer pressure regulating device The LPR is a negative pressure two stage regula tor that is normally closed when the engine is not running When the engine is cranking or running a partial vacuum is created in the fuel line which connects the regulator to the mixer This partial vacuum opens the regulator permit ting fuel to flow to the mixer Propane fuel enters the primary port of the LPR and passes through the primary jet and into the primary exchanger chamber As the propane p
79. 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 This ensures that a set ting cannot be accidentally altered To change the access level the correct password must be entered To enter the password scroll to the ACCESS LEVEL menu For exam ple MEG MENU CCESS LEVEL 2 ENTER ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 3 Repeat this process until you have entered all five digits of the password which is 33271 Once the correct password is displayed press ENTER The access level should display the following if the pass word was entered correctly 3121133 Lift 5 3 SECTION 5 JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Analyzer 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 f 3 by PERSONALIT
80. after the catalyst treatment has been com pleted in the muffler If the ECM detects that the catalytic action in the muffler is not sufficient and fuel correction cannot correct the malfunction the MIL light is illuminated in the control box and a DTC code will stored in the com puter A CAUTION THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION CONTROL DEVICE IF THE HEGO FAILS TO OPERATE REPLACE IT WITH AN OEM REPLACEMENT PART THE HEGO SENSOR IS SENSITIVE TO SILICONE OR SILICONE BASED PRODUCTS AND CAN BECOME CONTAMINATED AVOID USING SILICONE SEAL ERS OR HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR STREAM OR FUEL LINES Figure 3 35 Heated Exhaust Gas Oxygen Sensor HEGO Gasoline Multi Point Fuel Injection System The primary components of the Gasoline Multi Point Fuel Injection MPFI fuel system are the fuel tank electric fuel pump fuel pressure and temperature sensor manifold fuel filter and fuel rail 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Gasoline Fuel Pump The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by an electric fuel pump The fuel pump will receive a signal from the ECM to prime the fuel system for approximately 2 seconds prior to start Priming of the fuel system provides for a quicker start when the engine begins to crank Gasoline Pressure And Temperature Sensor Manifold This engine is equipped with a fuel injector rail that d
81. 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 insure an optimum balancing of loads each planetary stage comprises of planet gears in sets The externally toothed wheels are case hardened The hydraulically released wet running multi plate brake integrated in the hydraulic motor is a parking brake It is normally closed by spring force and released when pres surized by hydraulic oil NOTICE TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT S GEARS AND SEALANTS ARE WORKING PROPERLY Roll Test The purpose of a roll test is to determine if the unit s gears are rotating freely and properly Gears should be able to be rotated by applying a constant force to the roll checker If more drag is felt in the gears only at certain points then the gears are not rolling freely and should be examined for proper installation or defects Some gear packages roll with more difficulty than others Do not be concerned if gears seem to roll hard as long as they roll with consis tency Leak Test The purpose of the leak test is to make sure the unit is air tight The unit has a leak if the pressure gauge reading on the air checker starts to fall once the unit has been pres surized Leaks will most likely occur at main seal or wher ever o rings or gaskets are loc
82. ascension ramp in front of right front wheel 9 From platform control station select LOW drive speed 10 Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until right front wheel is on top of block 11 Raise machine platform approximately 9 ft 2 7 m on the 3394RT or 10 ft 3 1 m on the 4394RT 12 Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp 13 Have an assistant check to see that the right front wheel remains locked in position off the ground 14 Lower the machine platform the lockout cylinder should then release and allow wheel to rest on the ground It may be necessary to activate DRIVE to release cylinders 15 If the lockout cylinders do not function properly have qualified personnel correct the malfunction prior to any further operation 4 5 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting 4 WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylin
83. electronic ignition system controls fuel combustion by providing a spark to ignite the compressed air fuel w mix ture at the correct time To provide optimum engine perfor mance fuel economy and control of exhaust emissions the ECM controls the spark advance of the ignition system Electronic ignition has the following advantages over a mechanical distributor system No moving parts Less maintenance Remote mounting capability No mechanical load on the engine More coil cooldown time between firing events Elimination of mechanical timing adjustments Increased available ignition coil saturation time IGNITION COIL The electronic ignition system uses a coil pack with one ignition coil for each two cylinders in the engine Each cyl inder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark The primary coils in the coil pack are triggered by the Ignition Coil Feed 1 and Ignition Coil Feed 2 Signals from the ECM 3 42 JLG Sizzor ENGINE CONTROL MODULE ECM The ECM is responsible for maintaining proper spark and fuel injection timing for all operating conditions To provide optimum operation and emissions the ECM monitors the input signals from the following components in order to calculate spark timing
84. engine Preliminary Check Refer to Important Preliminary Checks Sensor Checks Check for silicon contamination from fuel or improperly used sealant The sensor will have a white powdery coating The sensor will resultin a high but false signal voltage rich exhaust indication The ECM will reduce the amount of fuel deliv ered to the engine causing a severe driveability problem Check the Heated Exhaust Gas Oxygen Sensor HEGO performance Check the Temperature Manifold Absolute Pressure TMAP sensor response and accuracy Fuel System Checks Check for rich or lean symptom that causes the condition Drive the vehicle at the speed of the complaint Monitoring the oxygen sensors will help identify the problem Check for a sticking mixer air valve Verify proper operation of the EPR Perform a cylinder compression test Refer to Engine Mechanical in the Service Manual Check the LPR fuel pressure Refer to the LPG Fuel System Diagnosis Check mixer module assembly for proper installation and connection Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent 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 Improper gap Burned electrodes Blistered insulators Heavy deposits Check the spark plug wires by connecting an o
85. fault across the screen If there was no fault detected during power up the display will read In plattorm mode HELP EVERYTHING OK In ground mode GROUND MODE OK If ENTER is pressed again the display moves to the fol lowing display 2 3 HS HELP 1 STARTUP 2 173 C LLLA LOGGED HELP 1 STARTUP 2 1 Or last recorded fault At this point the analyzer will display the current fault if any are present You may scroll through the fault logs to view what the last fifteen faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ESC two times When a top level menu is selected a new set of menu items may be offered If for example you choose Personal ities DRIVE LIFT STEER GROUND Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus while in access level 2 Remember you may always can cel a selected menu item by pressing the ESC key 5 2 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer MENU ACCESS LEVEL 1 When the analyzer is first connected you will be in
86. frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test cor rectly Also check that the lead on the COM port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number k kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 1200 Q Example 50 mA 0 05 A 3121133 JLG Sizzor 6 1 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance 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 6 2 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement a
87. fuel 4 Push in the Emergency Switch once the engine stops 1 8 JLG Sizzor 5 Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR 6 Remove the retainer clip for the LPG fuel tempera ture sensor and remove the sensor from the regula tor body NOTE Have a small container ready to collect oil that will drain freely from the regulator at this point 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 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 3121133 SECTION 1 SPECIFICATIONS Propane Fuel Filter Replacement o qom Electric Lock Off Solenoid Mounting Plate Housing Seal Filter Magnet Filter Housing Seal 7 Electrical Connector 8 FuelOutlet 9 O ring 10 Filter 11 Fuel Inlet 12 Retaining Bolt Figure 1 3 Filter Lock Assembly REMOVAL 1 gm 3121133 Relieve the propane fuel system pressure Refer to Propane Fuel System Pressure Relief Disconnect the negative battery cable Slowly loosen the Filter housing retaining bolt and remove it Pull the filter housing from the Electric lock off assembly Locate Filter magnet and remove it Remove the filte
88. 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 De energize the circuit 2 Isolate the switch from the rest of the circuit if possible If not possible keep in mind it may affect readings 3 Access the terminals to the switch 4 Ifthe switch has two terminals a Measure resistance across the terminals b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 5 Ifthe switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise c Ifthe switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually oper ated switches except that the moving object operates the switch These switches can be tested the same way as a stan dard switch by manually op
89. of oper ation If the ECM detects an incorrect CMP signal while the engine is running DTC 53 will set If the CMP signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last fuel injection pulse and the engine will continue to nun As long as the fault is present the engine can be restarted It will run in the previously established injection sequence 3 32 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 5 ECM Diagnostic Trouble Codes Diagnostic Trouble Description Code 11 All Systems OK 12 Throttle Position TP Sensor Low Voltage 14 Manifold Absolute Pressure MAP Low Voltage 15 Under Minimum Map Sensor Temperature 21 Overspeed 22 Throttle Position TP Sensor High Voltage 23 Over maximum throttle 24 Manifold Absolute Pressure MAP High Voltage 25 Over Maximum Map Sensor Temperature 26 Over maximum initial Throttle Position Sensor Voltage 31 Fuel Pump Low Voltage 32 Heated Oxygen Sensor H02S Low Voltage 33 Engine Coolant Temperature ECT Sensor High Voltage 35 Intake Air Temperature IAT Sensor High Voltage 41 Fuel Pump High Voltage 42 Heated Oxygen Sensor H02S High Voltage 43 Engine Coolant Temperature ECT Sensor Low Voltage 45 Intake Air Temperature IAT Sensor Low Voltage 51 Low Oil Pressure 52 Crankshaft Positio
90. oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating are recommended for use Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 NOTE 2 4 Refer to Section 1 for recommendations for viscosity ranges JLG recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Start up of hydraulic system with oil temperatures below 15 F 26 C is not recommended If it is nec essary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 15 F 26 C 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 29 C However use of this oil will give poor perfor mance at temperatures above 120 49 C Systems using DTE 13 oil should not be operated at tempera tures above 200 F 94 C under any condition Changing Hydraulic Oil 1 Use of any of the recommended hydraulic oils elimi nates the need for changing the oil on a regular basis However filter elements must be changed after the fir
91. or voltage applied to the load measure voltage across the load s power terminals Also the technician can mea sure the voltage at both power terminals with respect to battery ground The difference between those two measure ments is the voltage applied to the load 3121133 JLG Sizzor 6 13 PLAT ESTOP 01 dp SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 6 SCHEMATICS 3121133 RED YEL war vi FUEL 48 3 PUMP 1 VALVE Y29 em zi YEL RED 1 BLACK YEL RED gt 33 E 26 48 4 BRN WHT 41 6 YEL RED 2 1 2231118 1 6 QNO XL
92. pin con nect the electrical connector Insert the fuel vapor line and fitting into the regulator port and lock in place with the locking pin Install both the water hoses and fittings into the reg ulator and lock in place with the locking pin remove the clamp pliers from the hoses Install the electric lock off into the regulator inlet and tighten into proper location connect the electrical connector Connect the fuel supply line and tighten until fully seated 3 67 SECTION 3 CHASSIS amp SCISSOR ARMS 8 Connect the EPR electrical connector 9 Open the manual valve 10 Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test Fuel Inlet Low Pressure die Coolant Passage fs Secondary Outlet ports i Secondary Lever and Spring Coolant Passage Secondary Outlet ports Figure 3 39 Pressure Regulator Section PRESSURE REGULATOR SECTION REMOVAL 1 Remove the EPR refer to EPR Removal Procedure 2 Remove the six 6 regulator to voice coil screws using the special tool and separate the regulator from the actuator NOTICE DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING PLATE AND DIAPHRAGM THIS WILL VOID THE WARRANTY OF THE ACTUATOR SECTION PRESSURE REGULATOR SECTION INSTALLATION 1 Install the regulator to the actuator section using the six 6 retaining screws and tighten 70 in Ibs 8 Nm 2
93. pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pressure for example to the switch These switches may need to be ener gized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Analyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for exam ple The state indicated in the control system should change Switch Wiring Low Side High Side When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power
94. prime mover at normal operating speed slowly check for forward and reverse machine operation Charge pressure should remain at 220 psi to 240 psi 15 5 bar to 16 9 bar minimum during forward or reverse opera tion Continue to cycle slowly between forward and reverse for at least five minutes Shut down prime mover remove gauges and plug ports Check reservoir level and add fluid if necessary JLG Lift 4 9 SECTION 4 HYDRAULICS 4 7 HYDRAULIC COMPONENT START UP PROCEDURES AND RECOMMENDATIONS From a hydrostatic component standpoint the goal at system start up is to put into functional operation the hydrostatic system in such a way as to preserve the designed life span of the system The following start up procedure should be adhered to whenever a new pump or motor is initially installed into a machine or a system is restarted after either a pump or motor has been removed and or replaced 4 WARNING THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND WORK FUNCTIONS DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TAKE NECES SARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE MACHINE Prior to installing the pump and or motor inspect the unit s for damage that may have been incurred during shipping and handling Make certain that all system com ponents reservoir hoses valves fittings heat exchanger etc are clean prior to filling wi
95. rod to the rod end as applicable Carefully slide the piston spacer on the rod If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved If applicable correctly place new seals and guide lock rings in the outer piston diameter groove A tube with 1 0 slightly larger than the O D of the pis ton is recommended to install the solid seal The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni fied insert in See Figure 4 11 The split of seals and backup rings are to be positioned so as not to be in alignment with each other 3121133 SECTION 4 HYDRAULICS PISTON BACKUP SPLIT SEAL RINGS NOTE 3121133 T RING SPLIT BACKUP RING SPLIT SEAL Figure 4 11 Piston Seal Kit Installation Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged Thread piston onto rod until it abuts the spacer end and install the tapered bushing When installing the tapered bushing piston and mat ing end of rod must be free of oil Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap JLG Lift screws through the drilled holes in the bushing a
96. the attaching nut A WARNING WHEN REBUILDING THE CYLINDERS APPLY LOCTITE 242 TO PISTON NUT AND SETSCREW THEN TORQUE PISTON NUT REFER TO TABLE 4 1 CYLINDER PISTON NUT TORQUE SPECIFI CATIONS NOTE The Steer Cylinder uses snap rings to secure piston 17 Prior to setscrew installation spot drill rod before installing the setscrew s which secure the piston attaching nut to the diameter groove 18 Remove the cylinder rod from the holding fixture 19 Position the cylinder barrel in a suitable holding fix ture NOTICE 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 3121133 SECTION 4 HYDRAULICS 20 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 21 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 22 If applicable secure the cylinder head retainer using a suitable chain wrench 23 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 24 lf applicable install the cartridge type holding valve and fittings in the port block using new o rings as appli
97. the fuel filter is required as indicated in Section 1 Fuel Injector Rail Fuel flows from the fuel pressure and temperature mani fold assembly to the fuel rails where the fuel is delivered to the fuel injectors The fuel rail also contains a Schrader valve which is utilized to test the regulated pressure of the fuel system Fuel Injector The fuel supply is maintained on the top of the injector from the injector rail The injector is fed a pulse signal through the wire harness which causes the injector to open During regular operating conditions the ECM con trols the opening and duration of opening of the injector During lower RPM operation the injector signals or pulses are less frequent then when the engine is operat ing at higher RPMs The engine has been calibrated to deliver the precise amount of fuel for optimum perfor mance and emission control JLG Sizzor 3 65 SECTION 3 CHASSIS amp SCISSOR ARMS 3 13 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel System Pressure Relief A CAUTION THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PER SONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRES SURE WHERE APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS To relieve propane fuel system pressure 1 Close the manual shut off valve on the propane fuel tank 2 Start and run the vehicle until the engine stalls 3 Turn the ignition sw
98. throttle WOT the output voltage should be above 4 volts The ECM calculates fuel delivery based on throttle valve angle operator demand A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the ECM thinks the throttle is mov ing A hard failure in the TP sensor 5 Volt reference or sig nal circuits for greater than 2 consecutive seconds will set either a DTC 12 or DTC 22 A hard failure with the TP sen sor ground circuit for more than two consecutive seconds may set DTC 22 If either DTC 12 or DTC 22 are set the throttle will be forced to a 6 idle position USE OF CIRCUIT TESTING TOOLS Do not use a test light to diagnose the engine electrical systems unless specifically instructed by the diagnostic procedures A test light can put an excessive load on an ECM circuit and result in component damage For volt age measurements use only a digital voltmeter with an input impedance of at least 10 megohms JLG Sizzor 3 37 SECTION 3 CHASSIS amp SCISSOR ARMS ELECTROSTATIC DISCHARGE DAMAGE Electronic components used in the ECM are often designed to carry very low voltage Electronic compo nents are susceptible to damage caused by electrostatic discharge Less than 100 volts of static electricity can cause damage to some electronic components By com parison It takes as much as 4000 volts for a person to feel the spark of a static discharge There are se
99. time to insure the seal does not roll The seal must sit flat on the throttle body INSTALL TWO QUAD CUT SEALS ON THROTTLE BODY THESE SEALS CAN NOT BE ROLLED MAKE SURE THEY SIT FLAT Attach mixer and throttle body together The two parts do not bolt together they will be secured when you mount it on the intake Notice the orientation of the air inlet and throttle body cover MIXER ATTACHES TO THROTTLE BODAY 3 69 SECTION 3 CHASSIS amp SCISSOR ARMS 4 Place gasket on intake manifold and attach mixer throttle assembly to manifold Bosch ETC Adapter Baar amp O Rings Here Figure 3 41 Mixer Assembly Gasket Here Mixer Replacement See Figure 3 41 REMOVAL 1 Remove the Throttle control device Refer to Elec tronic Throttle Body Replacement 2 Remove the four 4 bolts to the throttle control device to mixer adapter bolts 3 Remove and discard the mixer to adapter gasket INSTALLATION NOTICE COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY 1 Install Mixer to adapter gasket onto the mixer 2 Install the mixer to the throttle control device to mixer adapter and secure with the 4 retaining screws Tighten 80 Ib in 9 Nm 3 Install Throttle body Refer to Electronic Throttle Control Device Replacement 4 Start the engine and leak check all fittings and con nections 3 70 JLG Sizzor Coolant Hose Replaceme
100. traces of wear and no embedded foreign par ticles Make sure there are no scratches on the valve plate Replace ONLY in sets 3 22 JLG Sizzor 3121133 SECTION 3 CHASSIS amp 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 groove and there are no pittings 2 26 Press bearing ring in port plate with tool 1 2 A 24 Make sure the seat of the shaft seal in the case has no damage 27 Press bearing ring in supporting axle with tool 3121133 JL G Sizzor 3 23 SECTION 3 CHASSIS amp SCISSOR ARMS 28 Press bearing on drive shaft 30 Place 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 Grind synchronizing disc to dimension 29 Install shaft in supporting axle 1 Put in simulation ring 2 Mount bearing with port plate fix with 2 screws 3
101. via the low pressure fuel supply hose As the AW increases in the secondary chamber the secondary diaphragm is drawn further down forcing the secondary valve lever to open wider Resistant Idie Screw Mounting to the Throttle Body Figure 3 31 Air Fuel Mixer 3121133 Electronic Throttle Control ETC Engine speed and load control is maintained by an ETC device Speed and load control are determined by the ECM Defaults programmed into the ECM software and throttle position sensors allow the ECM to maintain safe operating control over the engine The Electronic Throttle Control device or throttle body assembly is connected to the intake manifold of the engine The electronic throttle control device utilizes an electric motor connected to the throttle shaft When the engine is running electrical signals are sent from the equipment controls to the engine ECM when the operator depresses an equipment function switch The ECM then sends an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus increasing or decreasing the air fuel flow to the engine The electronic throttle control device also incorporates two internal Throttle Position Sensors TPS which provide output signals to the ECM as to the location of the throttle shaft and blade The TPS information is used by the ECM to correct speed and load control as well as emission con trol
102. work under an elevated sizzor until platform has been safely restrained from any movement by blocking or overhead sling or boom safety prop has been engaged Before making adjustments lubricating or performing any other maintenance shut off all power controls Battery should always be disconnected during replacement of electrical components Keep all support equipment and attachments stowed in their proper place Use only approved nonflammable cleaning solvents Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue April 12 2002 Revised May 10 2002 Revised August 30 2002 Revised October 14 2002 Revised March 6 2003 Revised October 24 2003 Revised April 28 2004 Revised August 18 2004 Revised August 12 2005 Revised October 4 2005 Revised March 1 2006 Revised May 11 2006 Revised October 31 2006 Revised April 3 2007 Revised October 12 2007 Revised January 23 2008 Revised March 17 2008 Revised October 6 2008 JLG Lift 3121133 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS General EXER NO 1 8 Hydraulic System 1 a A C Maintenarce 2 eee a Ee Rer e AQ Eon Ee siet 1 a SECTION 1 SPECIFICATIONS 1 1 Specifica
103. yne4 esz dls 66 ais WOtid33 am J0148 snq JO 19 WOYUs lqeO iun Y99349 19 895 10 5 56 Durpeuiuue uonoeuuo2 Ny Y23949 juepuadap uomeoijddy snq aut paaejd aq JOUULI uoissiLusuel 10 J9Jinq Lez dais 6 6 f AVS NYO lqissod SI Snq NY9 10 19ll011u09 NV0 Lez GIs 49 01 U09 sng NVO 1095 Nv2 10413 Ldieg puer 1043 5 JO u21AS ss 5xg yna poys JO 8618 9459 1ndino ey ip Jo Y39949 eBessauu ney 10 PAYOUMS s Ad I8AUG syew y ndino ey 61p ye 12911 ajqeo n2 Joys LN uid 9 3ndino jebiga 6 W uid piouejos jJo u21IMS 1ndino uonduosep ney 89 ne ou yned uone2 2 sjndino sindul 9JeMpJeH 3 55 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS S JO 9 1 s poO 3 tz 1 99 10 NdS JO ySZ ZLS pinom paz GIS lduuex 104 ZLS ppe 19D 219 o1 enbe s GIS ALON 921 95 71 WOJU Ayney J ureBe uo pue jo uoniubi YAMS 868 pue 169 sJejaueled 10 pauejs aq 101169 o u91Ms ouaDJau3 NEJ 2245
104. 0 Mid Engine 800 2700RPM 2000 2000 2000 2000 LIFT Accel 0 1 5 0 sec 2 2 2 2 Decel 0 8 1 5 sec 1 1 1 1 Min Up 0 35 12 12 12 12 MaxUp 0 65 55 55 45 45 Min Down 0 35 12 12 12 12 MaxDown 0 65 55 55 40 40 Engine 800 2900RPM 2800 2800 2800 2800 Mid Engine 800 2700RPM 2000 2000 2000 2000 STEER Engine 800 2900RPM 2800 2800 2800 2800 POWER DECK Deck Extend 800 2900RPM 1200 1200 1200 1200 Deck Retract 800 2900RPM 1200 1200 1200 1200 GROUND Lift Up 0 65 55 55 45 45 Lift Down 0 65 55 55 40 40 LOAD Overload 1000 2700165 2415 2475 1650 1650 454 1225 kg 1123 kg 1123 kg 748 kg 748 kg 0 500 Ibs 0 0 0 0 0 227 kg Overload Dbnce 0 10 sec 3 Overload Hold 1 10 sec 5 JOYSTICK Forward Max 0 00 5 00V 0 75 0 75 0 75 0 75 Forward Min 0 00 5 00V 2 24 2 24 2 24 2 24 Reverse Min 0 00 5 00V 2 82 2 82 2 82 2 82 Reverse Max 0 00 5 00V 4 32 4 32 4 32 4 32 4150389D NOTE These settings may be changed in order to achieve optimal performance 3121133 JLG Lift 5 17 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 Table 5 3 Machine Configuration Programming Information Configuration Digit Setting Description Default Number
105. 0 hours of operation change oil every 2 years or 1200 hours of operation 4 Sliding Wear Pads Lube Points 8 Sliding Wear Pads Lube MPG Interval Every month or 50 hours 5 Oil Change w Filter Ford Lube Point s Fill Cap Spin on Element JLG P N 7014501 Capacity 4 5 qt 4 25 L e Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 6 Oil Change w Filter Deutz Lube Point s Fill Cap Spin on Element JLG P N 7016331 Capacity 6 3 qt 5 9 L engine only e Lube EO Interval Every Year or 600 hours of operation Comments Check level daily Change in accordance with engine manual 1 6 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS 9 Fuel Filter Deutz lt e Lube Point s Fill Cap Spin on Element JLG P N 7027965 Lube Point s Replaceable Element Capacity 4 5 qt 4 25 L w filter Interval Every Year or 600 hours of operation Lube EO Interval 3 Months or 150 hours of operation Filter Gasoline GM Comments Check level daily Change in accordance Lube Point s Replaceable Element with engine manual Interval Every 6 months or 300 hours of operation 8 FuelFilter Ford 11 AirFilter 3 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator 12 Ele
106. 00 1460 1979 0490 132 092 1535 2068 11 2 6 1500 1 450 7800 1940 2630 1460 19791 1755 02379 2025 12746 5000029 H NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS SAE GRADE 5 SAE GRADE 8 Figure 1 4 Torque Chart SAE Fasteners Sheet 1 of 3 1 10 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS 3121133 VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY TENSILE STRESS AREA SIZE BOLT DIA SAE GRADE 8 BOLTS amp GRADE 8 NUTS amp SOCKET HEAD CAP SCREWS 6 THRU 1 4 TORQUE DRY OR LOCTITE 263 TORQUE LUB TORQUE LOCTITE 242 08 271 TORQUE LOCTITE 262 4 540 12 1 4 9 l C 600 13 1 5 n 32 0 1380 0 00909 820 23 2 6 7 JJ 920 25 2 8 9 022 TT 8 1260 4 4 5 3 135 C 36 0 1640 0 01474 1320 43 5 3 4 10 1580 e 7 45 5 20 0 2500 0 0318 2860 14 16 108 12 3280 168 19 120 14 185 21 SQ FT LB FT LB N m FT LB FT LB 5220 25 24 20 27 25 34 30 41 7000 45 81 35 47 2 0 3750 0 0878 7900 50 68 35 47 9550 70 95 5 75 63 85 80 108 10700 80 108 60 81 12750 110 149 80 108 20 0
107. 1 2229 BP Pressure High 108 0 JL G Sizzor 3 87 SECTION 3 CHASSIS amp SCISSOR ARMS NOTES 3 88 JLG Sizzor 3121133 SECTION 4 HYDRAULICS SECTION 4 HYDRAULICS 4 1 CYLINDERS THEORY OF OPERATION Cylinders are of the double acting type The steer system incorporates a double acting cylinder A double acting cyl inder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corre sponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the cylinder rod will retract NOTE The lift cylinder is a single acting cylinder which takes hydraulic pressure to extend and gravity to retract A holding valve is used in the Lift circuit to prevent retrac tion of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 4 2 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated an
108. 1 2 0 1 2 1 4150390 J 3121133 JLG Lift 5 21 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 ui 5 x x u 5 s 2 z x 5 a z o g lt zd tu ANSI USA 2 4 0 0 1 2 3 4 5 6 7 0 1 0 1 2 ANSI EXPORT 2 4 1 0 1 2 3 4 5 6 7 0 1 0 1 2 CSA 2 4 2 0 1 2 3 4 5 86 7 0 1 0 1 2 CE 2 4 3 0 1 2 3 4 5 6 7 0 1 0 1 2 AUSTRALIA 2 4 4 0 1 2 3 4 5 6 7 0 1 0 1 2 4394RT 2WD 2 5 lt o 2 2 o E z e z i gt ANSI USA 0 1 2 0 1 2 1 ANSI EXPORT 0 1 2 0 1 2 1 CSA 0 1 2 0 1 2 1 CE 0 1 2 0 1 2 1 AUSTRALIA 0 1 2 0 1 2 1 4150390 J 5 22 JLG Lift 3121133 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 m ul 5 x x u ib g D Z x a z G 5 4 z lt ui uz 9 tu ANSI USA 3 4 0 0 1 2 3 4 5 6 7 0
109. 1133 JLG Sizzor 6 25 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS WHT LT WHT LT GRN GASOLINE LI GRN RED 0 LI GRN RED SENSOR TWR LT GRN WHT cs LT GRN WHT gt NEED a LPG TEMP BHELT GRILC C BLIILT GRIN B PNK TAN g LOCKOFF E60 1 je DR 68 08 Eso 2 DR GRN WHT E60 3 lt HI 5 PUR LT BLU 1 tps 2 6 LI BLUZDK BLU lt 1 11 6 AUX ANA PDI 8 TAN DK GRN FPP IES 9 DR BLU ORN 19 PUR YEL FPP2 1VS E AUX ANA PD2 315 AUX ANA PD3 T wur oRN CANI TERM 14 BLU PNK Eon 52 15 BLU WHT 5 16 CRANKSHAFT CAN2 ia POSITION GANZ T
110. 16 Ring Back Up 26 Bushing 7 Cotter Pin 17 Setscrew 27 Piston 8 Cartridge Lift Holding Solenoid 18 Head 28 Seal 9 Cartridge Lift Holding Solenoid 19 Seal 29 Rod 10 Cartridge Check 20 Ring Wear 30 Barrel Figure 4 28 Lift Cylinder 4 24 JLG Lift 3121133 SECTION 4 HYDRAULICS Item Ft Lbs Nm 1 25 35 2 10 12 14 17 3 35 49 4 5 7 5 30 42 Figure 4 29 Lift Cylinder Valve Cartridge Torque Values 3121133 Lift 4 25 SECTION 4 HYDRAULICS 4 26 Figure 4 30 Oscillating Axle Cylinder JLG Lift o ON N F o oN m Ring Wear T Seal Ring Wear O Ring Ring Back Up Seal Wlper Polyseal Bushing Head Rod Barrel Plug O Ring Ring Washer Capscrew Bleeder Plug O Ring Solenoid Relief Valve Bearing 3121133 SECTION 4 HYDRAULICS 3121133 Item Ft Lbs Nm 1 18 5 22 25 30 2 3 45 4 2 6 3 3 20 25 28 35 Figure 4 31 Oscillating Axle Valve Cartridge Torque Values Lift 4 27 SECTION 4 HYDRAULICS a Head Barrel Rod Jack Plate Ring Lock Ring Wear Ring Washer Ring Retaining O Ring ON YO wv Screw 11 Capscrew 12 Seal 13 Wlper 14 Ring Back Up 15 T Seal 16 Jack Pad Figure 4 32 Leve
111. 3 J2 7 ARTES x 125 VALVE RD RET SPARE J4 6 oH HA GREEN 19 Ki e w 0009 J5 8 KK 0104 J2 8 RX J5 10 TX 115 11 P J4 RECEPTACLE BLACK J3 RECEPTACLE YEL RED 2 20 25 gt gt gt gt 25 s25 82252 52055 FNT LFT STOWED 909555522588 BLACK SWITCH WHITE s E 526 FNT RHT STOWED BLACK SWITCH WHITE eS s27 REAR LFT STOWED BLACK SWITCH WHITE 9 528 REAR RHT STOWED BLACK SWITCH WHITE x x E 258 3 8 a az al c REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 AC GENERATOR WIRING VOLTAGE REG 123 45 i GREEN 12 12 2 BLACK 10 GENERATOR S WHITE 10 10 BLACK 9 RED 3 12 i BROWN 2 2 B BLACK 3 3 GENERATOR BROWN 2 CONTROL 4 BOX L s L c c 6 RED 4 12 B RED 1 3 10 e GENERATOR 87 87A a RELAY a BLU ORN 52 1 ot e BLACK 2 jJ Figure 6 26 Electrical Schematic Dual Fuel GM Sheet 3 of 5 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JES NOTES 312
112. 3 RECIRL lt e LL TEL FUEL PUMP PWM3 gt AUX B TAM AUX PWNS 89 PNK BLK 90 BLK LT GRN T AUX REC IR HE j GRY BRN CAMSHAFT T GRN RED POSITION PUR LT BLU 6 ue 4 1 TRL RFD 3 THROTTLE BLK LT GRN RED LT B TAN ORN i BRN YEL BRN LT BLU BRN WHT BRN LT GRN PNK DR GRN 16 PNK DR GRN 16 PNK DR GRN 16 PNK DR GRN 16 M X 8 D Ji Figure 6 27 Electrical Schematic Dual Fuel GM Sheet 4 of 5 6 26 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS BLK YEL BLK WHT D 600 2 BLK LT GRN PNK DK GRN C PNK DK GRN C eGo DR GRN WHT DR GRN ORN y 4 4 TAN WHT n BLK LT GRN ECT LT GREEN 4 LI
113. 5 5 Flash code 5 5 indicates a speed sensor issue SPEED SENSOR READING INVALID SPEED Reported when the speed sensor is reading a value over 4000 RPM 9 SPEED INPUT LOST Reported when the speed sensor is reading zero RPM and the oil pressure is over eight PSI 6 6 Flash code 6 6 indicates CANbus issues 10 CAN BUS FAILURE Reported when there is a problem with the CANbus LSS NOT SENDING CAN MESSAGES Reported when the LSS is configured and not seen on the CAN bus ENGINE CONTROLLER CAN COMMUNICATION LOST Reported when the engine is configured to be CAN controlled and the system is not communicating with it TWO PLATFORM MODULES DETECTED Reported when there are two platform modules connected to the control system 5 12 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X joder Communicated Displayed on Analyzer Fault Description Priority 8 Flash codes 8 indicate load cells issues 8 1 LSS CELL 1 ERROR Reported when there is a problem with cell 1 on the LSS 8 2 LSS CELL 2 ERROR Reported when there is a problem with cell 2 on the LSS 11 8 3 LSS CELL 3 ERROR Reported when there is a problem with cell 3 on the LSS 8 4 LSS CELL 4 ERROR Reported when there is a problem with cell 4 on the LSS 9 Flash codes 9 indicate LSS or memory issues 9 1 LSS WATCHDOG RESET Reported when the LSS s microprocessor watchdog has been trigger
114. 5000 0 1599 14400 120 163 90 122 16400 150 203 MO 149 18250 170 230 130 176 0 6250 0 2260 20350 20 298 170 230 180 244 18 0 6250 0 2560 23000 240 325 180 244 204 277 265 359 i MR 30100 380 515 280 380 0 7500 0 3730 33600 420 569 30 4M 9 085 0 4620 41600 600 813 460 624 485 658 660 895 45800 660 895 500 678 51500 900 1220 680 922 12 1 0000 0 6630 59700 1000 1356 740 1003 118 68700 1280 1735 960 1302 12 1 1250 0 8560 77000 140 1952 1080 1464 1 1 4 87200 1820 2468 1360 1844 1455 1970 2000 2712 96600 2000 2712 1500 2034 1610 2183 2200 2983 1 3 8 104000 2380 3227 1780 2413 1 3750 1 3150 118100 2720 3688 2040 2765 2165 2935 3000 4067 1172 6 1 500 1 450 126500 3160 4284 2360 3200 2530 3430 35 4711 1 142200 3560 4827 2660 3606 5000029 H NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS SAE GRADE 5 SAE GRADE 8 Figure 1 5 Torque Chart SAE Fasteners Sheet 2 of 3 JLG Sizzor SECTION 1 SPECIFICATIONS TPI BOLT DIA TENSILE CLAMP TORQUE ames TORQUE LOCTITE 262 0 1120 0 00604 0 1120 0 00661 JLG SPECIFICATION 4150701 MAGNA 565 SOCKET HEAD CAP SCREWS 5 16 amp ABOVE TORQUE LOCTITE 242 08 271 0 1380 0 00909 sd 0 01015 0 1640 0 1900 0070 C 0 1900 0 2500 0 0318 2860 0 2500 0 0364 3280
115. A wz non ooe 18 ZI 2304 0002 111 9 9 ili t Bul qoay yosuo7 JZ 13H u zJ yun9 5 1 xo16 Donsccucczcilczliluwosniislcilft 1 33618 queudinbe wouboip ED ei1eseqbueg updesn uosuy 81 87 1 n 00 i G B Buiapeu Smd no zJ yun16uun1JAJsuo1Jz H u9zuoyun19 u013d0 sueuqJuo1oj 19q sIp1 JuoJ1sUu90H 9304 3 49 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Designation Reserve Description Reserve Output digital 3 Digital output for solenoid Output digital 4 For heating flange optional glow plug optional Input optional Temp 1 Fuel temperature 2 Input optional Temp 2 Charge air temperature Input optional Digln 5 Coolant level oil level Output PWM2 digital 6 GND Reference potential for analog signal at pin 9 Input analog 7 Analog input for Coolant temperature sensor NTC GND Reference potential for analog signal at pin 11 Multi function input speed 2 Digln 2 Digital input se
116. ALG An Oshkosh Corporation Company Service amp Maintenance Manual Models 3394RT 4394RT Prior to S N 0200191606 excluding S N s 0200186972 0200187002 0200187013 3121133 October 6 2008 MG An Oshkosh tion Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG INDUSTRIES INC IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is pro v
117. ALVE EXTEND 2 SHIELD GANE CULT b D003 J5 2 ORN WHT 55 23 22 VALVE CAN SHIELD JI 8 0004 15 3 QRN WHT 33 24 Y28 11 RETRACT s D005 44572 ORN WHT 55 25 VALVE 0006 J5 5 ves DIOO SFDTH J2 4 IGN J4 1 DIOS J2 9 GND J4 2 ANLG4 42 10 FD EXT CAN H 024 3 DIO J2 5 VALVE FD RET CAN L 024 4 0102 12 6 Y24 VALVE RD EXT CAN SHIELD J4 5 0103 J2 7 GREEN LI 25 VALVE RD RET SPARE J4 6 0007 J5 6 TEC 126 VALVE 0008 J5 7 GREEN 19 0009 15 8 GREEN 20 0104 J2 8 RX 75 10 Tx 05 11 J4 RECEPTACLE GND J5 12 BLACK J3 RECEPTACLE nad YEL RED 2 20 Z gt gt gt gt gt ofz 25 EX Z s25 5222552552055 LFT STOWED LO 599 BLACK SWITCH WHITE Gaacccccccc e kk 26 RHT STOWED BLACK SWITCH WHITE 9 27 REAR LFT STOWED BLACK SWITCH WHITE SS EMR2 ENGINE CONTROL TO ENGINE S28 5 REAR RHT STOWED _ 28 5 lt BLACK SWITCH WHITE 8 aig La 5 5 8 233332 x x x s 5 lt 662833 E EI S S s zx 2 2 2 23 e 8 ce 8 ofa Iz 5555 a a d 829 S828 882 22238 2 55 2909 235 22222 c B 9 1312 23 4 25 24 222120 1415171918 REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER es cuarce air ENGINE EMR Pressure PRESSURE ACTUATOR Se 5 2 ox S
118. CATE A LEAK 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3 6 FORD EFI ENGINE Performing Diagnostics 1 Verify the complaint and determine if it is a deviation from normal operation 2 Once the complaint has been verified preliminary checks can be done Conduct a thorough visual inspection be alert for unusual sounds or odors and gather diagnostic trouble code information 3 Perform a system check that will verify the proper operation of the system in question and check for recent information updates 4 lf a diagnostic trouble code DTC is stored contact a JLG distributor to make an effective repair 5 If no DTC is stored select the symptom from the symptom tables and follow the diagnostic path or suggestions to complete the repair 6 After the repair has been made and validated for proper operation the old part should be momen tarily re installed to verify that it was indeed the source of the problem If no matching symptom is available analyze the com plaint and develop a plan for diagnostics utilizing the wir ing diagrams technical assistance and repair history Intermittent conditions may be resolved by using a check sheet to pinpoint the circuit or electrical system compo nent Some diagnostic charts contain Diagnostic Aids which give additional information about a system Be sure to use all of the information that is available to you VISUAL PHYSICAL ENGINE INSPECTION CHECK Perform a ca
119. CISSOR ARMS 3 10 GM ENGINE GENERAL MAINTENANCE Maintenance of the Drive Belt The serpentine drive belt utilizes a spring loaded tensioner which keeps the belt properly adjusted The drive belt is an integral part of the cooling and charging systems and should be inspected frequently When inspecting the belts check for Cracks or breaks Chunking of the belt Splits Material hanging from the belt Glazing and hardening Damaged or improperly aligned pulleys Improperly performing tensioner Check the belt tensioner by pressing down on the midway point of the longest stretch between pulleys The belt should not depress beyond 1 2 inch 13mm If the depression is more than allowable adjust the tension NOTICE Check the battery for any cracks or damage to the case Check the Positive and Negative battery cables for any corrosion build up rubbing or chafing check connec tion on the chassis to insure they are tight Check the entire engine wire harness for rubbing chaf ing cuts or damaged connections repair if necessary Check all wire harness connectors to insure they are fully seated and locked Check ignition coil and spark plug cables for harden ing cracking chafing separation split boot covers and proper fit Replace spark plugs at the proper intervals as pre scribed in the engine manufacturer s manual Check to make sure all electrical components are fitted securely Check the ground and platf
120. CTITE 263 LUB LOCTITE 262 rn 5 2 19 1 3 1 0 6 2 95 1 1 6 4 7 3 82 8 6 ky x jojn wily plow 1 2 3 12 35 ae e e 28 55 T 8 2 5 01 7 331 8 469 581 2 639 6 7 271 383 523 737 665 811 0 24 3 353 33 3 5 694 36 4 42 4 5 En o 1 192 20 2 5 245 22 2 5 303 3 426 1120 487 0 3680 4290 NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 8 8 METRIC CLASS 10 9 5000029_H 8 Figure 1 7 Torque Chart METRIC Fasteners Sheet 1 3 3121133 JLG Sizzor 1 13 SECTION 1 SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M3 M5 TORQUE TENSILE TORQUE TORQUE TORQUE STRESS LOCTITE 262 dut OR By AREA 2 1 4 22 Pee 4 5 47 4 8 Ls per pes Lc pepe pes 33 8 8 16 157 97 8 344 18 192 119 5 473 20 152 5 671 22 L3 T 5 39 xe a 3 5 296 0 10 3 ss se 34 5 3 ss s 3s ew 4 s ro 698 0 NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 8 8 METRIC CLASS 10 9 Figure 1 8 Torque Chart METRIC Fasteners Sheet 2 of 3 JLG Sizzor 5000029
121. Control Electric Fuel Pump Diagnostics Malfunction Indicator Lamp Data Link Connector DLC ECM SERVICE PRECAUTIONS The ECM is designed to withstand normal current draws associated with engine operation When servicing the ECM observe the following guidelines Do not overload any circuit Do not probe wires for testing This can cause a volt age drop that would be critical to the operation of the ECM When testing for opens and shorts do not ground or apply voltage to any of the ECM s circuits unless instructed to do so When measuring voltages use only a digital voltmeter with an input impedance of at least 10 megohms Do not jump start with more than 12 volts This could cause damage to the electronic components Do not employ any non standard practices such as charging the battery with an arc welder Take proper precautions to avoid static damage to the ECM Refer to Electrostatic Discharge Damage for more information THROTTLE POSITION TP SENSOR The throttle position TP sensor is a potentiometer con nected to the throttle shaft on the throttle body which is built into the electronic governor The ECM monitors the voltage on the signal line and calculates throttle position As the throttle valve angle is changed the TP sensor sig nal also changes At a closed throttle position the output of the TP sensor is low As the throttle valve opens the output increases so that at wide open
122. DED TWISTED PAIR eae BLU ORN 52 1 39 5 15 3 sie 2 EM q YEL RED 2 1 1 5153553535 ad d a 33599 E 33 3 181 CIR BREAKER 33343333 ESTOP BEEEEEE i 6 RED 1 1 9 DUAL AXIS PIN 2 WHT RED 51 1 5 ANALOG pin 4 ORN RED 49 1 zm S TILT SENSOR PIN 3 ORN RED 49 2 amp SSSSGSSESSSCS S 5 5285 PIN BLACK Qi ss 352 2X2 x S en IGN 03 0 2223222322233353 5 555555 TILTX 33 2 5 z 22177 2 dopo ALT TILTY 03 0 S 8 2 0 2902 ovon x19z2x LAMP 2 z 52995282022 amp 582255 GND 3 0 52 50257205555 z 101 2 J4 RECPTACLE CLE a YEL RED 2 4 BRN WHT 47 1 ALT 151 Y ENGINE OIL CHRP 5 2 GROUND ELECTRONICS LAMP ENGOL J5 3 102 BRN WHT 41 3 SUE NU ENGTL 45 4 BLACK 32 GND J5 5 e I J2 RECEPTACLE 3 A 3 RECTIFER dd w 8 S 8 28 S285 ENGINE TEMP CQ mw amp as 775 2557785 LAMP STATOR IGN 16 1 age Ses 9 FR 45 iei NU RX J6 2 aS 5 Sa wa Slaw gt 522 aw 06 3 S 445975 52 2 25 2 SS 285 557775 88 e G GND J6 4 2272 o 9 55 7 2 8 30 v 2 20 zz 2225 2 22 lt oux 2 5222 4 555559 Gt 5 b EFS 055 420555 g L 5 REGULATORY BRN WHT 41 1 x BEACON q SENSING AND 3 LAMP 3 F i
123. DSP J2 8 GREEN 55 12 ALEV J2 4 ORN WHT 55 13 3 ORANGE 55 6 ENG DRV SPD J2 2 COL3 SPARE J2 12 Lic vei 48 8 FSGW J2 3 APWR STRP J2 1 KE GENP J2 6 GENERATOR COL2 SPARE J2 5 SWITCH ENG DRV 08 Popi FUEL SEL SPEED SW n AUX START Hr ou DRV ORN RED 49 4 u WHT RED 57 2 WHT RED 57 3 WHT RED 57 4 ORN RED 49 3 TILT ALAR BLACK APWRO J3 1 ANLOO J3 2 GND 23 3 APWRI 03 4 ANLGI 03 5 GND J3 6 APWR2 J3 7 ANLG2 J3 8 GND J3 9 APWR3 J3 10 ANLG3 03 11 GND 23 12 GROUN WHITE ALARM BLACK WHITE HORN ALARM BLACK ROTARY POSITION SENSOR BLACK prox SWITCH ViET BONN VALVE PROP LIFT LDHS JI 5 VALVE GND JI 1D PLS JI 6 GND 01 12 BLACK STEER LEFT STEER VALVE RIGHT lt Yor VALVE DUMP LTS J2 5 YELLOW iU Yo VALVE BRAKE LEFT RTS J2 6 WED WHT 50 1 T3 VALVE 056 AX LEFT DPS J2 T ORANGE 55 1 Yo4 VALVE 1 OSC AX RIGHT BRS J2 8 ORANGE 35 3 T m4 VALVE 2 Osc AX RIGHT LOSAX J2 11 ORANGE 33 33 ga VALVE i OSC AX ROSAX J2 12 ORANGE 95 451 ORANGE 55 4 2 LR wr Gave LIFT UP ORANGE 55 4 3 Y06 VALVE FORWARD ORANGE 55 2 2SPD J2 9 SET R Yor VALVE REVERSE UPS J2 10 Y08 VALVE FWS J2 3 RANGE 1 1 yoo ORANGE 8 1 RVS J2 4 59 GND J2 15 BLACK GND 12 14 BLAC GENERATOR CONTROL BLU ORN 32 1 SEE SHEET 2 SHIELD 8 lt 7 PLATF ED 2 3 18 6 MODULE OPT 5 S
124. ECK BEFORE LOWERING MACHINE Generator When the generator switch is activated the engine RPM will speed up to 2000 RPM for a 60 Hz generator or 1700 RPM for a 50 Hz generator When a function is selected for operation which requires a higher engine speed than the generator the generator will automatically shut off during the operation of the func tion Once the function has stopped the generator will be active again Lift There is a flow control valve which controls both the lift up and lift down speeds Anytime you abruptly change lift directions there is a three second delay between lift up and lift down Drive If driving at high drive up a grade and you hit an 8 incline the drive function will cut back to mid drive speed The drive pump will shift back into high drive once the incline decreases to 5 There will be a 2 second delay before the machine goes back into high drive 3121133 JLG Sizzor 3 1 SECTION 3 CHASSIS amp SCISSOR ARMS 3 2 CALIBRATIONS 1 Proximity Sensor 2 Rotary Angle Sensor Figure 3 1 Limit Switch Location Elevation Sensor Calibration Prior to Software P1 20 NOTE Make sure your analyzer is in ACCESS LEVEL 1 3 2 When using the analyzer under the DIAGNOSTIC menu the term referring to ROTARY amp PROXIMITY sensors is ELEV SENSOR Use CALIBRATIONS menu for rotary switch adjust ments When mounting make sure the
125. EE SHEET 2 FUEL VALVE BRN WHT 47 9 wa 4 Nee m d RED WHI 50 ANC u Figure 6 25 Electrical Schematic Dual Fuel GM Sheet 2 of 5 3121133 JLG Sizzor 6 23 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS GND J2 14 IGN POWER RELAY CAN H J2 36 CAN L J2 37 GND J2 38 GENERATOR CONTROL SEE SHEET 6 24 OPT MODULE SEE SHEET 1 J RECEPTACLE PFDTH 42 1 JI 1 J2 2 FL LJ PFDTHI JI 2 IGN J5 9 alice VALVE FR LJ SFDTH JI 3 amp GND J2 3 8 VALVE RL LJ BLACK GND 21 4 0000 92 11 ORN WHT 55 20 bes fx 9 VALVE RRLJ LJ YEL RED 2 IGN JI 5 DOI J2 12 ORN WHT 55 21 KH vag VALVE RED a EXTEND LJ ORN WHT 55 22 2 CANH JI 6 o 0002 J5 1 KH r Yi VALVE EXTEND 2 BLACK 5 ORN WHT 55 23 SHIELD GANE CIA 0003 J5 2 Y22 VALVE CAN SHIELD JI 8 D004 J5 3 ORN WHT 33 24 28 LJ RETRACT s 0005 5 4 ORN WHT 55 25 VALVE 0006 J5 5 NEA DIOO SFDTH J2 4 IGN J4 1 0105 J2 9 GND J4 2 ANLG4 J2 10 FD EXT CAN H 04 3 DIO 12 5 VALVE FD RET CAN L J4 4 0102 J2 6 Y24 VALVE RD EXT CAN SHIELD J4 5 010
126. ERM 19 LT GRN RED 4 L sv EXT 20 BLK LT GRN I WHT PUR o CRANK lt 21 PUR WHI CRANK 22 WHI PUR sek CAM lt 23 GRY BRN Les 24 PUR ORN ROAD SPEED 25 RED WHT 26 RED BLK ROAD SPEED 57 ET KNOCK 5 KNOCK2 30 KNOCK2 lt gt 3 YELLOW sek COIL IA gt SPK COIL 18 2 32 SPK COIL 2 5 22 SPK COIL 2 gt 3 5 COIL 3 5 35 5 COIL 5 36 SPK COIL 4 Bd SPK COIL 48 3 ver very ect Saat AUX DI lt 4 TET 43 TAN RED AUX DIG 2 Spr AMRED AUDIS s 45 PNK TAN AUX ANA 46 DR BLU YEL AUX ANA PUR Ei EMDR BLU AUX ANA PU3I LI T FPP 2 ONLY 5V EXT 2 22 391 TTEA S 51 GRY DR BLUE Gove lt 32 GEL ORN OIL PRES FRP AUX ANA PUDI E MUTET GRN GREE pe ax 2 29 ORANGE I PULSE 1022 57 Tach 58 PR PWR 5 59 i VBAT lt 0 RED TAN GNITION INJI LS H BLU COIL INJ2 Ls _ 62 LT GRN A PNK DR GRN INJ3 LS 3 BRNYEL B XEL BLK INJ4 LS BRN WHT 8 PLUS INJS LS S se I BLACK 16 ine 15 66 IN ts lt s ELLO INJ8 Ls eRounp 92 BLACK 16 STARTER 2 T WHT LT_BLU 72 BLK WHT EGOH BLK YEL PNK DR GR EGOH 2 22 74 EGOH 35 74 Lockorr 2 72 WHT BLK rere gt TT BRN WHT PWM5 RECIRC TS MIT BRN So GRN YEL BLACK 16 52 PNK WHT DBW 2S 83 TAN ORN 84 TAN BLK FUEL PUMP RELAY 85 PNK YEL AUX PWM
127. H Z Y 30N9 1 2 8 es ze 1 0 18 w 310014238 31014238 7 or pus or 5 E 5 ponies TOM ERI 2553 25 e 2 255 iU e m ceed 5228 Sur8 9 F 4 El b o D 4 4 5 J d J lt j 999 Sr 8 SER 14 ds P 13 35 a z 334 Sis sa HOLIMS DAT a 138 9 14 M019 2222 d 3 Taaa E a 55 ES 3 582 5 ris amp d E HOLIMS 325 E 1915 EE zu B 5 a eve 2 4 Ba 2 3 2 b ee 55 25 255 ENGINE CONTROL MODULE Figure 6 18 Electrical Schematic Dual Fuel Sheet 1 of 3 JLG Sizzor AU311V8 JUAZT 6 14 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PCPW J3 1 LTP J3 2 RTP J3 3 QPSN J3 4 QPRG GND J3 5 DRVP 15 11 LFTP J2 10 HRN J2 7 FDSP J2 9 RDSP J2 8 ALEV J2 4 ENG DRV SPD J2 2 COL3 SPARE J2 12 FSGW J2 3 APWR STRP J2 1 GENP J2 6 COL2 SPARE J2 5 WHI RED 51 21 YELLOW 9 1 YELLOW 10 1 BLACK ve DRIVE SELECT 02 SELECT LIFT ORANGE 55 5 03 EIE IAN 55 10 LL BLU ORN 52 3 HORN PUSH BUTTON FRONT DECK 504 SELECT 05 Log GREEN 55 11 GREEN 55 12 REAR DECK SELECT 06 L
128. IES DRIVE ACCEL 3 05 UN C PERSONALITIES DRIVE ACCEL 3 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular per sonality If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION GROUND ALARM 1 DESCENT The effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving There are certain set tings allowed to install optional features or select the machine model When selecting the machine model to match the size of the machine the personality settings will return to default settings 5 4 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM NOTE Refer to the appropriate Machine Personality Set tings Table and the Machine Setup Table in the JLG Service Manual for the default settings Password 33271 will give you acces
129. JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Tilt Sensor JLG P N 4000021 NOTE NOTE 3121133 1 Ground Control Box 2 Tilt Sensor Assembly JLG P N 1810140 Figure 3 5 Tilt Sensor Location Refer to Figure 3 6 Tilt Sensor Removal for num bers in parenthesis Disconnect the batteries Open the Ground Control Box to gain access to the Tilt Sensor Assembly Remove the four Screws 3 Lockwashers 4 Standoff Insulators b and Washers 6 to remove the Tilt Sensor 1 and Sensor Mount 2 from the Ground Control Box The Tilt Sensor 1 can be removed from the Sensor Mount 2 by removing the three Screws 7 Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 3 2 Calibrations 1 Tilt Sensor JLG P N 4000021 2 3 4 5 6 T Figure 3 6 Tilt Sensor Removal Sensor Mount Screw 6 32 x 1 Lockwasher Standoff Insulator Washer 0 313 x 0 250 Nylon Screw M3 5 x 0 6 x 10 Table 3 2 Tilt Sensor Harness Wire Color Function Connector Pin Red VCC 1 Green PWMX 2 White PWMY 3 Black Ground 4 JLG Sizzor 3 7 SECTION 3 CHASSIS amp SCISSOR ARMS 3 4 INTEGRATED TORQUE DRIVE HUB The Integrated Torque Drive Hub is
130. JoNvEO 21 27 1000 7 5 1 N9I c NOI 2 HOTTIE 11 27 0000 S y IP QNS L I QN9 amp 2 20 S8vXL yava 6 27 QN9 E I H104S T xudo 1 2 S8yXH 5 50 9 2 10 IH1d4d INYO 3114 g ZI 1 PIU meme agaa S Heynius OT me x 4 dead 2 0 0347731 5 8 al P 1 5 E 3 m NA o 1 2 038 134 Sa a n 92 20 Lovo 5 d 22 55 xEo pz 88 552 DOC NuOTNEg ri vC dXnv 62 20 544 295 zzz E Fi 1 802 5389 ZI v 9808 2 27 19N3 n d m 4 T 6T N3385 9908 w ry Li E Jd QI v 9803 c 2 20 O9N3 a 5 T LT N3389 6 rr 9303 x WOVE al Be T RYT 8 amp 2 duH2 E 444 p TEWI 107 9d 2 20 LW 3 1 5 S9N3 3 2 2 Z3 SOND 12 20 S9N3 SS SEE TA ERE o E P 114 ov 2r QNO 3918 1 7 NH 66 20 AN9 INN E k 9 rr 2 20 8 E 5 2 90 30N9 1 20 8 m 18 1 1 034 T Bech E Looe 5 370 14239 f 310V1423N sr 9 z as 5 ma zaitte 5 Ss 2883 s7 4555 tase v z Eo aii EIE 228 555225 2774 2 2 038713 6 2 2 2552 gt SE z m a E z550 z 2856 z Te 0 0 Wovi8 5 222 52222 Seek E Bu 2 58 z SEES 225556 9zES 8 8
131. LIC SYSTEM Em WITHOUT HEATING AIDS AND COLD WEATHER a GU J HYDRAULIC OIL BELOW THIS TEMPERATURE g 4 20 WINTERS 40 F 40 C 3 NO OPERATION BELOW THIS 2 9 25 AMBIENT TEMPERATURE 22 0 C 0 10 20 30 40 50 60 OF ADDED KEROSENE Figure 2 1 Engine Operating Temperature Specifications Deutz 2 8 JLG Lift 3121133 SECTION 2 GENERAL 4150548 C NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY SAE 5W 20 SAE 5W 30 AMBIENT AIR TEMPERATURE 120 F 49 C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 70 F 21 C 60 F 16 C 50 F 10 40 F 4 C 30 F 1 C 20 F 750 10 F 12 C SAE 5W 40 EE SAE 10W 30 SAE 10W 40 ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 10 F 23 C 1 F 18
132. Module Checks If ascantoolis available Check for proper communication with both the ECM Check the fuse in the ECM battery power circuit Refer to Engine Controls Schematics Check battery power ignition power and ground circuits to the ECM Refer to Engine Control Schematics Verify voltage and or continuity for each circuit Sensor Checks Check the TMAP sensor Check the Magnetic pickup sensor RPM Fuel System Checks Important A closed LPG manual fuel shut off valve will create a no start condition Check for air intake system leakage between the mixer and the throttle body Verify proper operation of the low pressure lock off solenoids Check the fuel system pressures Refer to the LPG Fuel System Diagnosis Check for proper mixer air valve operation Ignition System Checks Note LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions Check for the proper ignition voltage output with J 26792 or the equivalent Verify that the spark plugs are correct for use with LPG R42LTS Check the spark plugs for the following conditions Wet plugs Cracks Wear Improper gap Burned electrodes Heavy deposits Check for bare or shorted ignition wires Check for loose ignition coil connections at the coil Engine Mechanical Checks Important The LPG Fuel system works ona fumigation principle of fuel introduction and is more sensitive to i
133. NGINE BLOCK HEATER ETHER INJECTION OR GLOW KEROSENE PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ADDED Voy 30 F 34 C 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE 380 F 82 C HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE Cu 120 F 490 OPERATION ABOVE THIS NOTE 110 F 43 C AMBIENT TEMPERATURE PROLONGED OPERATION IN 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES AMBIENT AIR TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 100 F 38 C OF 100 F 38 C OR ABOVE 90 F 32 C 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 3 80 F 27 C 70 F 21 C 3 60 F 16 C g Z HYDRAULIC 50 F 10 C z SPECIFICATIONS 40 F 4 C 2 o 30 F 1 C E 3G 20 F 7 C I me SUMMER GRADE 10 F 12 C E 23 5 or 19 MOP DO NOT START UP HYDRAULIC SYSTEM 5 no DTE 19 WITHOUT HEATING AIDS WITH MOBILE 424 14 10 40 F 230 HYDRAULIC OIL BELOW THIS TEMPERATURE a5 245 20 F 29 C 00 NOT START UP HYDRAU
134. NGINE DUAL FUEL SYSTEM The Dual Fuel system allows the operator to operate the vehicle on either gasoline or LPG by positioning a selector switch in the operator s platform When the operator places the selector switch in the gasoline mode the gaso line fuel pump is energized While in the gasoline mode the LPG fuel lock off is isolated and will not energize In addition the gasoline injector circuit is enabled and injec tor pulses are provided to each injector and the ECM cali bration for gasoline is also enabled When the operator selects the LPG mode the Low Pressure LPG lock off is energized and fuel from the LPG tank flows to the Elec tronic Pressure Regulator EPR The EPR receives an electronic signal to position the secondary lever for the start or run positions and when the engine begins to crank the mixer air valve will rise and fuel will begin flowing to engine During this mode the gasoline fuel pump is iso lated and will not be activated The primary components of the gasoline dual fuel system are the gasoline tank electric fuel pump and filter fuel supply line injector rail and injectors and the fuel pressure regulator The primary components of the LPG dual fuel system are the LPG fuel tank in fuel filter LPG Low Pressure lock off Electronic Pressure Regulator EPR and the fuel mixer module The LPG fuel system operates at pressures which range from 14 0 inches 355 60 mm of water column up to 312 psi 21 5 BAR Com
135. NY FUEL LINE JLG Sizzor 1 9 SECTION 1 SPECIFICATIONS 1 14 TORQUE CHARTS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY SAE GRADE 5 BOLTS amp GRADE 2 NUTS SIZE TPI BOLT DIA TENSILE TORQUE qu TORQUE roti udis SQ IN HE IN LB IN LB IN LB IN LB 40 0 120 0 00604 30 6 n 7 39 E 1311 53 555 3 3 3 3 32 on 0 00909 56 11 OP 00O 4 o 0005 60 1201 s tus S 32 0 1640 oomo so Bs 2 115 35 0 1640 0 01474 m 2 ge 1 pie 3 20 0 2500 0 0318 2020 9 0 2500 0 0364 2320 m 14 10 IBISHEIEIEIES 18 0305 0 094 7 23 19 Q6 t 16 os 0075 s 3 m 2 D pu 5 uw Li 65 8 815 185 8 m5 m 38 1 ns M 0 6250 0 260 150 251 1 165 21 18 0 6250 0 2560 16300 170 29 10 15 07 1 258 10 0 750 0 540 2130 260 51 20 351 386 16 0 0 3730 2380 30 22 938 268 1353 30 9 0 8750 0 420 290 430 581 50 3 531 4 temi 8 10000 0 660 3800 640 868 40 651 59 5 65 195 1 1 8 L 1 4 138 6 1 3750 1 1550 641
136. ORANGE 55 3 505 SELECT LEVEL LFTP J2 10 TAN 55 19 ED 506 SELECT HRN 152 7 LBLUZORN 52 2 807 posp 2 9 GREEN 55 11 n 75 GREEN 55 12 RDSP J2 8 Aley J2 4 ORN WHT 55 13 3 ANGE 55 6 ENG DRV SPD J2 2 2R f 8003 SPARE COP ID apes APWR STRP J2 1 GENP J2 6 GENERATOR START AUX COL2 SPARE J2 5 POWER SEL sena Mi AUX START sio 510 DRV ORN RED 49 4 TH WHT RED 51 2 WHT RED 51 3 WHT RED 51 4 ORN RED LOS ALAR BLACK APWRO J3 1 ANLOO 73 2 4 GND 03 3 Q J3 4 ANLGI 23 5 amp GND J3 6 APWR2 J3 7 ANLG2 J3 8 GND J3 9 gt APWR3 J3 10 ANLG3 03 11 GND 23 12 GROUN WHITE ALARM BLACK WHITE HORN ALARM BLACK RED ROTARY WHITE POSITION BLACK SENSOR BLACK PROX WHITE SWITCH LIFT DOWN VALVE PROP LIFT LDHS JI 5 VALVE GND JI 11 YI PLS JI 6 WIHLTE m GND 01 12 BLACK STEER LEFT TEER VALVE RIGHT yor VALVE DUMP LTS J2 5 YELLOW 3L ig VALVE BRAKE LEFT RTS J2 6 f X 03 VALVE OSC AX LEFT DPS J2 T ORANGE SEET KE VALVE 1 OSC AX RIGHT BRS J2 8 ORANGE 8787 KK VALVE 2 OSC AX RIGHT LOSAX J2 11 i5 VALVE 1 OSC AX 6 VALVE 2 2 SPEED noski Td NES ORANGE 55 4 1 ORANGE 55 4 2 M pe VALVE LET UP RANGE 58 3 ORANGE 554 3 KH fx 1 VALVE FORWARD 2SPD J2 9 Y07 VALVE REVERSE UPS J2 10 ORANGE 108 VALVE FWS J2 3 OMNI ONE
137. Placards and Decals 12 17 Wheel and Tire Assemblies 8 9 18 Drive Motors 1 5 6 19 Drive Brakes 1 6 20 Drive Torque Hubs 1 3 5 6 21 Steer Cylinder 5 6 13 22 Steer Components 4 6 23 Wheel Bearings 2 Wheel Drive 24 Sizzor Arms 14 25 Safety Props 14 26 Sliding Wear Pads 27 Pivot Pins Bolts 14 7 8 28 Switches Ground Control 1 11 29 Control Tags 12 3121133 JLG Lift 2 7 SECTION 2 GENERAL 4150548 C AMBIENT AIR TEMPERATURE 120 F 49 C NO OPERATION ABOVE THIS AAA AMBIENT TEMPERATURE 110 F 43 C 100 F 38 C 90 F 32 C Since 80 F 27 C ENGINE GRADE lel el a 70 F 21 C SPECIFICATIONS Duo Bl 60 F 160 Z 8 4 4 2 3 soe aoo 40 F 40 K 30 F 1 C WINTER 20 F 7 C ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10 F 12 C FULLY CHARGED BATTERY oF 1850 WINTER ENGINE WILL START AND OPERATE AT THIS TEMPERATURE GRADE 10 F 23 C WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY V FUEL V AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER y WiTH 20 F 29 C PACKAGE IE E
138. R COMPONENT WEIGHTS Table 1 11 Major Component Weights Component Weight Model Front To Back Side To Side Fixed Platform 107016 485kg 5 to 26 ft 8 m Platform Extensi 440 Ibs 200k dd pm au S tofullheight 4t030ft 9m see i 3 to 33 ft 10 m Arm Assembly Includes Lift Cylinder 3394RT 3600 Ibs 1633 kg 5 to 26 ft 8 m 4394RT 4550 lbs 2064 k ung Mum au S tofullheight 4t030ft 9m asc d j 3 to 43ft 13 m Chassis with Pneumatic Tires 3394RT 6790 Ibs 3080 kg ei 3 tofullheight 3 tofullheight 4394RT 9080 bs 4119 kg Chassis with Foam Filled Tires SPART 5 tofullheight 3 tofullheight 3394RT 7788 lbs 3533kg CE 4394RT 9086 Ibs 4121 kg 3121133 JLG Sizzor 1 3 SECTION 1 SPECIFICATIONS 1 11 CRITICAL STABILITY WEIGHTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE FILLED TIRES ENGINE DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 1 12 Critical Stability Weights Component Weight Tires 12x16 5 Pneumatic 132 Ibs 60 kg 12x16 5 Foam Filled 352 105 160 kg 33 1550 16 5 Pneumatic 162 Ibs 73 kg 33 1550 16 5 Foam Filled 410 Ibs 186 kg 33 16LL x 16 1 Foam Filled Sand 426105 193 kg Engine Ford 324 Ibs 147 kg Engine Deutz 441 Ibs 200 kg Engine GM 341 Ibs 155 kg 1 12 LUBRICATION SPECIFICATIONS NOTE Hydraulic oils must have anti we
139. RAL ELECTRICAL INFORMATION amp SCHEMATICS uel 9 ooo On O o s pue esou Sejeolpul UO x 9 ON 491 c QO 8 uolisu x3 biy ENS F O a O X WwW xny pjoylueyy JO do uo p lunolN U9IMpUES x29q _ 491 Go oe de 9 SJepur 2 uoIsue1x3 1u0J4 Oly 2 w ES gt Q 6 a em 1 4oegd 1 Figure 6 44 Hydraulic Diagram Deck Extension Dual 3121133 JLG Sizzor 6 44 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS yel 9 pue 5 UO x 9 ON 1 ssapul AD 18 amp yue uren 1 do uo U9IMDUES 1 xny 5 uoisuejxa3 40024
140. S 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL Figure 2 2 Engine Operating Temperature Specifications Ford Lift SECTION 2 GENERAL 4150548 C AMBIENT AIR TEMPERATURE a 120 F 49 C NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C ENGINE SPECIFICATIONS 8 Uh Pee 8 60 F 16 C 50 F 10 C 40 F 4 C ENGINE WILL START AND OPERATE ONLPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 30 F 1 C NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG 20 F 7 C ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F 12 C WITH THE RECOMMENDED FLUIDS AND AFULLY CHARGED BATTERY d 18 C 5 10 F 23 C ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED 5 FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER 5 20 F 29 C PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER z 5 30 34 C 40 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURE
141. S Table 1 7 Pressure Settings Description 3394RT 4394RT Main Relief 3000 psi 207 bar Steer Relief 2800 psi 193 bar Lift Leveling Jack Relief 2700 psi 186 bar 2500 psi 172 bar atidle 6 psi 0 4 Bar 1000 rpm Hot 18 psi 1 2 Bar 2000 rpm Compression Ratio 9 2 1 Firing Order 1 3 4 2 Max RPM 2800 1 4 TIRES Table 1 6 Tire Specifications Size Ply Inflation Wheel Nut Rating Pressure Torque Dry 12x16 5 17011105 Pneumatic 90 psi 6 bar 238 Nm 12x16 5 10 Foam Fill to 170ftlbs Foam Filled 90 psi 6 bar 238 Nm 12x16 5 Pneumatic 10 90psi 6bar Em Non Marking s n i Foam Fillto 170ftlbs Non Marking 90 psi 6 bar 238 Nm 33 1550x16 5 170ftlbs Pneumatic 14 90psi 6bar 038 Nm 33 1550 x 16 5 14 Foam Fill to 170 ftlbs Foam Filled 90 psi 6 bar 238 Nm 33 16LLx16 1 10 Foam Fill to 170 ftlbs Foam Filled Sand 50 psi 3 4 bar 238 Nm 31x15 50 15 i 170ftlbs Grass Master 10 60 psi 4 bar 238 Nm 1 2 1 7 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located at the rear of the machine on the left side of the axle In addition should the serial number plate be damaged or missing the machine serial number is stamped directly under the serial number plate SERIAL NUMBER PLATE SERIAL NUMBER
142. S OF 180 F 180 F 82 C 82 C OR ABOVE HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE Dk DEPT FOR APPLICATION 120 49 I NO OPERATION ABOVE THIS NOTE 110 F 43 C ANBIENTSTEMPEBATBE PROLONGED OPERATION IN 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES AMBIENT AIR TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 100 F 38 C OF 100 F 38 C OR ABOVE 90 F 32 C 2 ALL VALUES ARE ASSUMED TO AT SEA LEVEL 8 80 F 27 C 70 F 21 C 5 60 F 16 C g z HYDRAULIC 50 F 10 C 2 jg SPECIFICATIONS 40 F 4 C z o 30 F 1 C 20 F 7 C 10 F 12 C 1850 MOBIL DO NOT START UP HYDRAULIC SYSTEM DIES WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE 20 F 29 C DO NOT START UP HYDRAULIC SYSTEM 30 F 34 C WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE Figure 2 3 Engine Operating Temperature Specifications GM 2 10 JLG Lift 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 OPERATING CHARACTERISTICS Leveling Jacks The machine may be equipped with auto leveling jacks These leveling jacks are operated throug
143. SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Jog or slowly rotate the engine until charge pressure starts to rise Start the engine and run at the lowest possi ble RPM until charge pressure has been established Excess air should be bled from the system lines as close to the motors as possible NOTE With the engine on low idle crack loosen don t remove the system lines at the motor s Continue to run the engine at low idle and tighten the system lines as soon as oil is observed to leak from them When oil is observed to leak at the motor the line is full the air has been purged and the system hoses should be retightened to their specified torque 3121133 SECTION 4 HYDRAULICS 3121133 Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be as indicated in the pump model code If charge pres sure is inadequate shut down and determine the cause for improper pressure A WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down the engine and connect the external control input signal Also reconnect the machine function s if disconnected earlier Start the engine checking to be cer tain the pump remains in neutral With the engine at nor mal operating RPM slowly check for forward and reverse machine operation Charge pressure may
144. T NOILOW c 049 ZH 09 1 1 LITT AYASI NOLDNAA 114 10010 1 VOT INDSAAS ANN0Y9 NMOGLAHS T NMOGLOHS CATIVISNI I0N 0 MOLVYANAD CATIVISNI LON 0 INON 0 0N 0 WAVIV ANN0Y9 0N 0 NMOGLOHS W WAC WAMOd MOTD JAS 09 2 19014 MOTI MOTD 295 06 9 19114 MOT DAS 0p 6 19014 MOTD MOTD JAS 0 T 109114 MOTD MOTD 93S 0c 19014 MOTI I MOTD 93S 01 7 3 MOTD TANA WIVUISQV T LV 21 eA 21080 1 UIINWAN 1900 vS9 c TVA I 1 q04 7 Mc 17 TAIMON INOW T WA WIMOd SIASI SSMOVE INITAATT MOTD 95 S T 19014 MOTD SIASI 1019 1 4 ISNV T LV 1114 1 MP 1 66 1 WH3lWIN 1900 0 WAC WAMOd ON 0 SSMOVE NITIATI SONMTd MOT ON 0 19114 MOTD ON 0 W010 ISNV 0 TLV A A II 1 04 0 Mc 14 0 TAMON dNLAS SINIHOVI ANA T LASS WOW 5 15 Lift 3121133 SECTION 5 JLG CONTROL SYSTEM
145. T or 36 feet for the 4394RT measured deck to ground b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated NOTE Elevation Proximity Switch must be mounted and functioning properly to calibrate the Elevation Sen SOr NOTICE FOR MACHINE TO OPERATE TO CAPACITY BE SURE TO CALI BRATE ELEVATION SENSOR AT ALL THREE POSITIONS Joystick Calibration Software P1 20 amp Higher Using the Analyzer in Access Level 1 go to MENU CALI BRATION JOYSTICK and press ENTER 1 Following the analyzer screen prompts a Move the Joystick FORWARD and press ENTER b Allow Joystick to be in CENTER position and press ENTER c Move the Joytstick REVERSE and press ENTER 2 CAL COMPLETE or CAL FAILED will display on the analyzer 3 Possible reasons if calibration failed a The forward position must be a lower voltage than reverse position b The difference between center and forward amp center and reverse must be atleast 1V Tilt Sensor Calibration 1 Drive the machine onto a measured level surface 30 5 for both x and y axis 2 Using the Analyzer go to MENU CALIBRATION TILT SENSOR Press Enter LEVEL VEHICLE will dis play Press Enter again to calibrate JLG Sizzor 3 3 SECTION 3 CHASSIS amp SCISSOR ARMS 8 4 1 T Both axis raw angles need to be within 5 0 other wise the machine is to unlevel and the software will prohibit calibration S
146. TC 33 or DTC 43 ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY EEPROM The electrically erasable programmable read only mem ory EEPROM is a permanent memory chip that is located within the ECM The EEPROM contains the pro gram and the calibration information that the ECM needs to control engine operations If the ECM is replaced the new ECM will need to be pro grammed An IBM compatible computer and software containing the correct program and calibration for the application are required to program the ECM 3 34 JLG Sizzor HEATED OXYGEN SENSOR The heated oxygen sensor is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output This voltage should constantly fluctuate from approximately 100 mV to 900 mV The heated oxygen sensor voltage can be monitored on an IBM PC compatible computer with diagnostic software By monitoring the voltage out put of the oxygen sensor the ECM calculates the pulse width command for the injectors to produce the proper combus tion chamber mixture Low HO2S voltage indicates a lean mixture which will result in a rich command to compensate High HO2S voltage indicates a rich mixture which will result in a lean command to compensate A constant voltage below 200 mV for 10 consecutive sec onds will set OTC 32 A constant voltage above 650 mV for 10 consecuti
147. TH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 6 5 AMP Connector 3121133 JLG Sizzor 6 5 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 6 6 Connector Assembly 1 of 4 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 6 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 Ibs to be sure the retention fingers are holding the contact See Fig ure 6 7 Connector Assembly 2 of 4 3 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the lock ing latches by squeezing them inward See Figure 6 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 6 9 Connector Assembly 4 of 4 SS NSS LN 9 PULL BACK ON WIRE L RETENTION FINGERS HOLDING CONTACT Figure 6 7 Connector Assembly 2 of 4 6 6 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Fig
148. TICS SEE SHT 3 FOR ENGINE CONNECTOR w 25 58 22 ou zo MORE 5 310v143238 2599525552 5 TP esse sree zizen ano x LI 2D0 N39 a Sf 22 0128 XN 310 143938 z 81 10 9 20 void vr LI 10 NOT 896 20 2388889889 8 S 6000 E LE 20 1 NVD 1 6 8000 2 96 20 NYD 4 9 57 1000 61 10 umay ye ar 1303 35 9 v0 3uvas S w 431 L 2r 010 a 2 10 11982 0 2 ISSY 41 4433 8 20 2010 anlel 5 22 10 2158 X 82 20 SM19 Sd1 9 499 5 2 6 50 s z q 4949 01 20 v91NV z o GND Z a 2 10 1913 4833333 6 2 sold NOI S 01 IT NYS LI LHA 3 13531155 y 2r 1035 0010 5 efl P 4384333313 TE te eps soba ol ir I I 7 6 20 MdXV LHS A sau LIAE S000 6 Ir 51 1 91 20 JAIA 140 NES L1 318 CY Jg Sr 7000 8 1 1 NYJ 1 10 81 20 1451 2 I NT87G39 8 E 2 80 000 1 10 NYI ovi 1 1 INYO E NWOT s 0 P E Ss Sate 1 90 2000 o If TU 2 g ee
149. TY OF SPINDLE THREAD DAMAGE NOTICE DO NOT DAMAGE THE BEARING CAGE OF TAPERED ROLLER BEARING CAREFULLY REMOVE METAL CHIPS 3 12 JLG Sizzor 3121133 SECTION 3 CHASSIS amp 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 13 Remove Radial Shaft Seal Ring 17 Gearbox Assembly NOTE Clean all parts before assembling the gearbox 1 Make sure during assembly of the preassembled planet gears that the larger radius on the bearing bore is oriented towards the planet carrier 14 Disassembly of planet gears and sun gear 15 stage a Remove Snap Rings 12 and pull Planet Gears 2 b Remove Support Disks 15 c Remove Snap Ring 14 and lift off Planet Carrier 2 Assembly of planet gears and sun gear 1 Stage 7 a Fasten theSun Gear 3 with a new Snap Ring 14 to the Planet Carrier 7 b Mount the Support Disks 15 and the planet gears with Bearing Assembly 2 10 heated to approximately 189 5 F 70 C onto the planet bolts 3121133 JLG Sizzor 3 13 SECTION 3 CHASSIS amp SCISSOR ARMS Insert the bottom part of the double Tapered Roller Bearing 11 c Secure the gears with new Snap Rings 12 5 NOTE Heat Supporting Ring 6 up to approximately 189 5
150. Y28 VALVE 0005 15 4 ORN WHT 55 25 ER Y23 D006 J5 5 DIOO SFDTH J2 4 IGN J4 1 0105 J2 9 GND J4 2 ANLG4 42 10 FD EXT CAN H 44 3 0101 J2 5 VALVE FD RET CAN L 04 4 D102 J2 6 fxy VALVE RD EXT CAN SHIELD J4 5 D103 J2 7 LT KK 125 VALVE RD RET SPARE J4 6 0007 J5 6 expe 14 KK 126 VALVE D008 J5 7 GREEN 19 2 KH 2 0009 J5 8 J4 0104 J2 8 RECEPTACLE RX J5 10 TX J5 11 GND J5 12 J3 RECEPTACLE YELIRED 2 20 K oe o 55755 55 25 cw cee STOWED TOSTCSOSSSOSS BLACK SWITCH WHITE 5556555550565 E e 526 STOWED BLACK SWITCH WHITE e 27 REAR LFT STOWED BLACK SWITCH WHITE Ge 28 REAR RHT STOWED BLACK SWITCH WHITE d 3 dad E 4 d E 3 4 3 d 4 x k REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR 1870143 H SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 Figure 6 20 Electrical Schematic Dual Fuel Sheet 3 of 3 6 16 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JES NOTES
151. a X XVI TAR X dil X AING S XX TAA La SXX Tad WARN XVI AMA MOMSAOL DM XXXX CTHSAO dN LAIT ACON IN1015 XXXX ANALXA VOI XXXX 19918 SXX 9 AIT S XX TDV WOULSAOL SALLITVNOSYA d SALLITVNOSYAd AON 049 SHHTIVNOSdiId WA THM0d4 SALLITVNOSYAAd 1 SHILEIVNOSHd SALLTTVNOSYAd TAINA SALLITVNOSYAAd 00000 300 THAT SSADIV c LTTHS NO NO SHILIIVNOSWHd ANGI VTIATI SSADIV ANGI 11666 300 SS322V 3121133 JLG Lift 5 14 SECTION 5 JLG CONTROL SYSTEM JO Z 199US Ld MS sazAjeuy p G JSTON YANA SA DSLON YANA SAA VOT JS3 0N S3A ATTA LAXX LAS 5 ATTA LXX LAS ON WALNG SA ATTA MOIS LAS HIN S3A STIDIHSA THATT WOMLSAOL SNOLIVISTIV SNOLIVISTTV ATTA LAXX LAS SNOLIVHSTTV ATTA LAXX LAS SNOLIVTSTTV ATTA MOIS LAS SNOLIVISTIV WOSNHS LIIL SNOLIVISTIV LAAHS OL SNOLLVTSTTV ANA ZH 0S 2 HOLVATINS SNOLIDN TIV c TIV 1101 9 c 1V0
152. a e s SS Y 8y 131 1HM e M eS a g 038 i 01 NYD a s 2 01318 Bd L m es S3 ole EE sis EE HOLIMS i da z3 s EE as SG ou B EE bl 715 PON iy E HOLIMS Sa E x 18 15 5 o zz Boo E E 2 2 038 134 ERES 9 dz d zzzz E r 8 po E 2 z 5 zo 5 2 255 amp VAZ we LA LE NA Be X LL m 1 1 we T az ii lO O lO 2 1 2 038 13 555 258 555 553 sss e SNE Z N S Z N wowla LHS JLG Sizzor 3121133 Figure 6 24 Electrical Schematic Dual Fuel GM Sheet 1 of 5 6 22 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PCPW 13 1 57 21 YELLOW 9 1 LTP 03 2 RTP 03 3 YELLOW 0 1 DRIVE OPSN J3 4 L PRO GND BLACK SELECT LIFT HORN 502 SELECT PUSH FRONT 503 BUTTON DECK REAR 504 SELECT DECK AUTO J2 ORANGE 53 5 805 SELECT LEVEL J2 10 35 10 A 506 SELECT J2 7 LBLUZORN 52 3 801 FDSP J2 9 GREEN 55 11 3 R
153. acuum leaks Improper valve timing Low compression Bent pushrods Worn rocker arms Broken or weak valve springs Worn camshaft lobes Checkthe intake and exhaust manifolds for casting flash 3 80 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Exhaust System Checks Check the exhaust system for a possible restriction Inspectthe exhaust system for damaged or collapsed pipes Inspectthe 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 Cuts Out Misses DEFINITION A surging or jerking that follows engine speed usually more pronounced as the engine load increases whichis not normally feltabove 1500 RPM The exhaust has a steady spitting sound atidle low speed or hard acceleration for the fuel starvation that can cause the engine to cut out Preliminary Checks Refer to Important Preliminary Checks Ignition System Checks Start the engine Wet down the secondary ignition system with water from a spray bottle and look listen for arcing or misfiring as you apply water Check for proper ignition output voltage with spark tester J 26792 Check for a cylinder misfire Verify that the spark plugs are correct for use with LPG R42LTS Remove the spark plugs i
154. and lt 5 6 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 1 cC 6 1 6 2 Multimeter Basics 2 ek e RR LEE 6 1 6 3 Applying Silicone Dielectric Compound Amp 6 5 6 4 Working With Deutsch 6 10 6 5 SWILChSS sided eot acide eate ode dete Maar le a Re 6 12 6 6 Schemalies y uu reo Pe eer nee eu Page ele esae dtc ite eoe die ER e 6 14 ii JLG Lift 3121133 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Serial Number Location Palio na RR RA ei Ra 1 2 1 2 Operator Maintenance and Lubrication 1 5 1 3 Filter Lock Assembly eins fics ea ee EE v E E Se Shed le wl dus 1 9 1 4 Torque Chart SAE Fasteners Sheet 1 1 10 1 5 Torque Chart SAE Fasteners Sheet 2 1 11 1 6 Torque Chart SAE Fasteners Sheet 3 1 12 1 7 Torque Chart METRIC Fasteners Sheet 1 of 1 13 1 8 Torque Chart METRIC Fasteners Sheet 2 3 1 14 1 9 Torqu
155. and dis card 5 Lift out the rear bearing block 2 drive gear 12 and driven gear 11 6 Separate body 13 from front cover 5 Dowel pins 7 and the front static seal 8 may remain with either the body 13 or the front cover 5 In either case remove the static seal and discard 7 usually the front bearing block 2 will remain in the body 13 so invert the body and lift out the bearing block 8 Invert front cover 5 with shaft seal up Remove the shaft seal 1 by prying it out with a large screw driver JLG Lift 4 11 SECTION 4 HYDRAULICS NOTE During disassembly take special note of the wear patterns on the bearing blocks 2 and body 13 Relate these patterns to the inlet and outlet sides of the pump The large port whether in the body 13 or the rear cover 6 corresponds to the inlet side of the pump The inlet side of the body can be identified by the gear contact pattern in the gear bore The bear ing block will have somewhat heavier wear patterns on the inlet side Parts Inspection 1 2 NOTE 4 12 Wash all part and dry thoroughly Inspect front and rear bearing block replace if scor ing or uneven wear is observed A somewhat heavier wear pattern is normal on the low pressure inlet side of the bearing blocks 2 However there should be no heavy scoring in this area Remove anti extrusion seal 4 and pressure loading seal 3 from each bearing block an
156. and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct excessive wear or damage Replace as necessary a Thoroughly clean hole steel bushing of burrs dirt etc to facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod barrel must be replaced c Lubricate inside of steel bushing with WD40 prior to bearing installation d Using an arbor of the correct size carefully press the bearing into steel bushing Install pin into the Gar Max bearing dry Lubrication is not required with nickel plated pins and bearings STEEL BUSHING COMPOSITE BUSHING ARBOR 14 15 16 17 Lift Figure 4 6 Bushing Installation Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary 4 5 SECTION 4 HYDRAULICS Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly 1 A s
157. ar qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity index of 152 Table 1 14 Mobil DTE 13M Specs IS0 Viscosity Grade 32 Specific Gravity 0 877 Pour Point Max 40 F 40 C Flash Point Min 330 F 166 C Viscosity at 40 C 33cSt at 100 C 6 6 cSt at 100 F 169 SUS at 210 F 48 SUS at 20 F 6 200 Viscosity Index 140 Table 1 15 Mobil EAL 224H Specs Type Synthetic Biodegradable Table 1 13 Hydraulic Oil ISO Viscosity Grade 32 46 HYDRAULIC SYSTEM Specific Gravity 0 922 OPERATING SAE VISCOSITY GRADE Pour Point Max 25 F 32 C TEMPERATURE RANGE Flash Point Min 428 F 220 C O F to 23 F Operating Temp O F to 180 F 17 C to 162 C o o 10W 18 C to 5 C Viscosity 0 F to 210 F at 40 C 37 cSt w i 10W 20 10W 30 18 C to 100 C at 100 C 8 4 cSt 50 Fto 210 F 20 20 Viscosity Index 213 10 C to 100 C 1 NOTE Must be stored above 32 F 14 C 1 4 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS 1 13 OPERATOR MAINTENANCE 2 1 FuelTank 2 DriveHubs 3 Hydraulic Oil Tank 4 Sliding Wear Pads 5 Oil Change w Filter Ford 6 Oil Change w Filter Deutz 7 Oil Change w Filter GM 4 8 FuelFilter Ford 9 Fuel Fi
158. asses through the heat exchanger the fuel expands and creates pressure inside the chamber The pressure rises as the fuel expands when the pressure rises above 1 5 psi 10 34 kpa sufficient pressure is exerted on the primary dia phragm to cause the diaphragm plate to pivot and press against the primary valve pin thus closing off the flow of fuel This action causes the flow of fuel into the regulator to be regulated When the engine is cranking sufficient vacuum will be introduced into the secondary chamber from the mixer drawing the secondary diaphragm down onto the spring loaded lever and opening the secondary valve allowing vaporized fuel to pass to the mixer This mechanical action in conjunction with the EPR reactions causes the down ward action on the secondary lever causing it to open wider allowing more fuel to flow to the mixer A WARNING THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMIS SIONS CONTROL DEVICE AND CANNOT BE REBUILT IF THE COIL ASSEMBLY FAILS TO OPERATE PROPERLY REPLACE IT WITH AN OEM REPLACEMENT PART ONLY Fuel Inlet Low Pressure NN Coolant Passage Secondary a Outlet ports NSS Coolant AER Passage Secondary SON FS Lever and Or Spring Secondary Outlet ports Figure 3 30 Low Pressure Regulators JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Air Fuel Mixer The air valve mixer is an air fuel mete
159. ated The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where o rings or gaskets meet the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced NOTE JLG P N s 2780263 2WD 2780262 AWD Figure 3 7 Integrated Torque Drive Hub Table 3 3 Torque Drive Hub Specs Gearbox Maximum Output Speed 30 25 rpm Maximum Output Torque 4556 5 lb ft 6177 7 Nm Brake Static Brake Torque 88 lb ft 119 3 Nm Release Pressure 174psi 12 bars Motor Maximum Displacement 28 CCM Minimum Displacement 14 2CCM Switching Pressure 145 psi min 1450 psi max 3 8 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 32 26 35 37 1101315 2 24 ss Mf zz m NA 2112220 7 32 l fai TM oe SS GL LEG EA AERE 22 Z A AS lt SU a lt s 2172 V HEA ES 28 INGE im STA 1UZZEI 7 ZZ JA lt II IN U Gu Y Vj C l 2722222 i A 2 LA REY 7 NS IN 11 20 16 6 421 22 3 1 Planet Gear 11 Tapered Roll
160. atform modes are selected by the keyswitch The control system defaults control to ground mode 5 6 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X SE Communicated Displayed on Analyzer Fault Description Priority 2 2 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 FORM CABLE board and the DI on ground board conflict TRIGGER SWITCH WIRING SHORTED LOWINPLAT Reports when the CAN message coming from the platform FORM CABLE board and the DI on ground board conflict FUNCTION LOCKED OUT DRIVE SELECT PERMA Reported when drive selectis closed during power up NENTLY CLOSED FUNCTION LOCKED OUT LIFT SELECT PERMA Reported when lift selectis closed during power up NENTLY CLOSED FUNCTION LOCKED OUT FRONT DECK SELECT PER Reported when front deck select is closed during power up MANENTLY CLOSED FUNCTION LOCKED OUT REAR DECK SELECT PER Reported when rear deck selectis closed during power up MANENTLY CLOSED FUNCTION LOCKED OUT START PERMANENTLY Reported when the start switch is closed during power up CLOSED FUNCTION LOCKED OUT STEER LEFT PERMA Reported whenthe left steer switch is closed during power up NENTLY CLOSED FUNCTION LOCKED OUT STEER RIGHT PERMA Reported wh
161. ation about the malfunction in its memory RPM J gt THROTTLE CONTROL ENGINE TEMP gt SPARK TIMING OIL PRESSURE gt GAUGE CONTROL AIR TEMP ECU AUXILIARY OUTPUTS gt VOICE COIL CONTROL BATTERY FUEL TEMP HEGO gt FUEL PRESS THROTTLE POS gt EPR Figure 3 33 LPG Engine Control Unit ECM Figure 3 34 ECM Assembly 3 64 JLG Sizzor Heated Exhaust Gas Oxygen Sensor There are two Heated Exhaust Gas Oxygen Sensors HEGO The first HEGO is mounted in the exhaust system downstream of the engine It is used to measure the amount of oxygen present in the exhaust stream and com municate that to the ECM via an electrical signal The amount of oxygen present in the exhaust stream indicates whether the fuel air ratio is too rich or too lean If the HEGO sensor signal indicates that the exhaust stream is too rich the ECM will decrease or lean the fuel mixture dur ing engine operation if the mixture is too lean the ECM will richen the mixture The ECM continuously monitors the HEGO sensor output If a rich or lean condition is present for an extended period of time and the ECM can not correct the condition the ECM will set a diagnostic code and turn on the MIL light in control box The second HEGO is mounted in the exhaust system after the muffler It measures the amount of oxygen in the exhaust system
162. by the 1 0 module and during system test when the 6 rear left leveling jack is open circuit REAR LEFT LEVELING JACK SHORT TO GROUND Reported by the 1 0 module and during system test when the rear left leveling jack is shortto ground REAR LEFT LEVELING JACK SHORT TO BATTERY Reported by the 1 0 module and during system test when the rear left leveling jack is shortto battery REAR RIGHT LEVELING JACK OPEN CIRCUIT Reported by the 1 0 module and during system test when the rear right leveling jack is open circuit REAR RIGHT LEVELING JACK SHORT TO GROUND Reported by the I O module and during system test when the rear right leveling jack is shortto ground REAR RIGHT LEVELING JACK SHORT TO BATTERY Reported by the I O module and during system test when the rear right leveling jack is shortto battery LEVELING JACK EXTEND VALVE OPEN CIRCUIT Reported by the I O module and during system test when the leveling jack extend valve is open circuit 5 10 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X phon Communicated Displayed on Analyzer Fault Description Priority 2 6 LEVELING JACK EXTEND VALVE SHORT TO GROUND Reported by the 1 0 module and during system test when the leveling jack extend valve is shortto ground LEVELING JACK EXTEND VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the leveling jack ex
163. cable Refer to Table 4 2 Holding Valve Torque Specifications 4 6 DRIVE PUMP START UP PROCEDURE NOTICE THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND DRIVE FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN AND OTHER PERSONNEL TAKE NECESSARY SAFETY PRECAU TIONS BEFORE MOVING THE MACHINE Prior to installing pump and or motor inspect unit s for damage incurred during shipping and handling Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with hydraulic fluid Fill reservoir with recommended hydraulic fluid which should be passed through a 10 micron nominal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to components which may result in unexpected machine movement The inlet line leading from the reservoir to the pump should be filled prior to start up Check inlet line for prop erly tightened fittings and make sure it is free of restric tions an
164. cond engine speed crankshaft optional and speed signal optional GND Reference potential for analog signal at pin 13 Input speed 1 Digital input first engine speed camshaft STG PWM output signal for actuator coil STG PWM output signal for actuator coil Screen Screening regulating rod travel sensor for lines 17 18 19 RF General connection for reference and measuring coil RF REF Analog input reference signal of the reference coil RF MESS Analog input measuring signal of the measuring coil GND Reference potential for signal at pin 21 Input analog 4 digital 9 Analog input 4 sensor signal oil pressure sensor or digital input 9 5 V REF 5 V Reference voltage for signal at pin 21 max 15 mA GND Reference potential for signal at pin 24 Input analog 2 digital 7 Analog input 2 sensor signal charge air or digital input 7 5 V LDA 5 V Reference potential for signal at pin 24 max 15 mA 1 For continuous power lt 4A 2 Corresponds to special function fuel temperature compensation at the EMR 0211 2571 Figure 3 18 EMR 2 Engine Plug Pin Identification 3 50 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Designation U Batt Description Negative pole at battery clamp 31 GND Reference potential for signal Output digital 2 PWM or digital
165. ctronic Pressure Regulator LP only Lube Point s Replaceable Element Interval Every Year or 600 hours of operation Interval 3 Months or 150 hours of operation Comments Drain oil build up Refer to Draining Build Up From The Propane Regulator 3121133 JLG Sizzor 1 7 SECTION 1 SPECIFICATIONS 13 Fuel Filter Propane GM Interval 3 Months or 150 hours of operation Comments Replace filter Refer to Propane Fuel Filter Replacement Draining Oil Build Up From The Propane Regulator During the course of normal operation oils may build inside the primary and secondary chambers of the pro pane pressure regulator These oils may be a result of poor fuel quality contamination of the fuel supply chain or regional variation in the make up of the fuel If the build up of the oil is significant this can effect the operation of the fuel control system Refer to Section 1 13 Operator Maintenance for maintenance intervals More frequent draining may be required if the fuel supply has been con taminated NOTICE FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM PERATURE BEFORE DRAINING THIS WILL ALLOW THE OILS TO FLOW FREELY FROM THE REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and bring to operating temperature 3 With the engine running close the manual tank valve and run the engine out of
166. d The frequency of this inspection must be increased as environment severity and frequency of usage requires 3121133 Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection JLG recommends that an annual machine inspection be performed by a Factory Certified Service Technician on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Indus tries Inc recognizes a Factory Certified Service Techni cian as a person who has successfully completed the JLG Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for perfor mance of this inspection Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of th
167. d MAP sensors The system remains in open loop until the following condi tions are met The HO2S has a varying voltage output showing that it is hot enough to operate properly this depends on temperature The ECT has reached 160 F 71 C Seven minutes has elapsed since starting the engine After these conditions are met the engine is said to be operating in closed loop In closed loop The ECM con tinuously adjusts the air fuel ratio by responding to signals from the HO2S except at wide open throttle When the HO2S reports a lean condition low sensor signal voltage the ECM responds by increasing the on time of the fuel injectors thus enriching the mixture When the HO2S reports a rich condition high sensor signal Voltages the ECM responds by reducing the on time of the fuel injec tors thus leaning out the mixture CAMSHAFT POSITION CMP SENSOR The CMP sensor uses a variable reactor sensor to detect camshaft position The CMP signal is created as piston 1 is a predetermined number of degrees after top dead cen ter on the power stroke CRANKSHAFT POSITION CKP SENSOR The crankshaft position CKP sensor provides a signal used by the engine control module ECM to calculate the ignition sequence The sensor initiates the reference pulses which the ECM uses to calculate RPM and crank shaft position JL G Sizzor 3 41 SECTION 3 CHASSIS amp SCISSOR ARMS ELECTRONIC IGNITION The
168. d air leaks 3121133 Be certain to fill pump and or motor housing with clean hydraulic fluid prior to start up Fill housing by pouring fil tered oil into upper case drain port Install a O to 500 psi 0 to 35 bar pressure gauge in the charge pressure gauge port to monitor charge pressure during start up It is recommended that the external control input signal electrical connections be disconnected at the pump con trol until after initial start up This will allow the pump to remain in its neutral position Jog or slowly rotate prime mover until charge pressure starts to rise Start prime mover and run at the lowest pos sible RPM until charge pressure has been established Excess air may be bled from high pressure lines through high pressure gauge ports A WARNING DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION 0 DEGREES SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be approximately 220 psi 15 5 bar minimum If charge pressure is incorrect shut down and determine cause for improper pressure A WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down prime mover and connect external control input signal start prime mover checking to be certain pump remains in neutral with
169. d 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 journals are scored or worn Inspect body for wear and scoring If gear contact wear on low pressure side inlet exceeds 0 005 in 127mm depth replace body If the body is usable lightly wipe and remove burr s with suitable de burr ing tool Pump Reassembly 1 Place the front cover 5 on a flat plate with the steal shaft seal bore up Install new shaft seal 1 Press seal until it is 0 157 in 4 0mm below front surface Pack the area between the double lip of the seal with Lubriplate or and equivalent grease Face of Pilot Diameter A57 4 0mm Shaft Seal 1 JLG Lift 3121133 SECTION 4 HYDRAULICS 3121133 Shaded area represents the W uer Discharge Pressure Clamp front cover into vise so that the ring groove is up Apply a small amount of grease tot he seal groove and install a new seal ring 8 into the groove Apply lubriplate or equivalent to outer surface of drive shaft installation tool Insert tool bullet into shaft seal from seal ring groove side of front cover Place a small amount of grease on the seal groove on the front bearing block 2 Install a new load seal and anti extrusion seal in the groove Insert the bear ing block into the body making sure that the load seal 3 and anti
170. d the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing 3121133 rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is al
171. der Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3121133 Lift If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings Figure 4 1 Lift Cylinder Holding Valve and Fitting Removal 4 Place the cylinder barrel into a suitable holding fix ture PROTECTED ROD CLAMP SUPPORT Figure 4 2 Cylinder Barrel Support 4 8 SECTION 4 HYDRAULICS Apply Spanner Wrench Figure 4 3 Lift Cylinder Cap Screw Removal NOTE Steps 6 and 7 apply only to the steer cylinder 5 Using a spanner wrench loosen the spanner nut retainer and remove spanner nut from cylinder bar rel NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 6 Being careful not to mar the surface of the rod use a punch or wooden dowel and hammer to drive the rod guide about one inch down into the cylinder 9 bore Using a screw driver carefully push one end of the round retaining ring back towards the inside of the cylinder and then slip the screwdriver tip under that end Pull the ring out of the groove toward the wall mouth Once one end of the retaining ring is free fr
172. ding valve is connected to the manual descent valve which is connected to a cable which when pulled manually opens the lift down port of the valve and allows the platform to be lowered in the event hydraulic power is lost JLG Lift 4 1 SECTION 4 HYDRAULICS 4 4 CYLINDER CHECKING PROCEDURE NOTE Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected Cylinders Without Counterbalance Valves Steer Cylinder 1 Using all applicable safety precautions activate engine and fully extend cylinder to be checked Shut down engine 2 Carefully disconnect hydraulic hoses from retract port of cylinder There will be some initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further drainage from the retract port 3 Activate engine and extend cylinder 4 If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repair must be made 5 With cylinder fully retracted shut down engine and carefully disconnect hydraulic hose from cylinder extend port 6 Activate engine and retract cylinder Check extend port for leakage 7 f extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port than activate cylinder thro
173. e 5 18 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 3 Machine Configuration Programming Information Configuration Digit Setting Description Default Number 0 NOT INSTALLED Load Sensing System LSS is not fitted to the vehicle 1 CUTOUT PLT Load Sensing System LSS is fitted and Platform Controls are pre vented in the event of an Overload Ground Controls remain functional This is the default 10 setting for CE machines 0 LOAD 2 CUTOUT ALL Load Sensing System LSS is fitted Platform and Ground Controls are prevented in the event of an Overload NOTE Certain market selections will alter default setting 0 NOT INSTALLED Vehicle alarm will function for Overload if LOAD enabled 1 DESCENT Vehicle alarm will function for Overload if LOAD enabled and during Lift 11 Down motion GROUND ALARM m 2 MOTION Vehicle alarm will function for Overload if LOAD enabled during Drive motion and during Lift motion NOTE Certain market selections will alter default setting 2 0 NO The engine will not be automatically shutdown 1 SHUTDOWN The engine will automatically shutdownin the eventofhigh engine coolant 1 ENGINE SHUTDOWN temperature low oil pressure or a temperature sensor or oil pressure sensor fault 4150390 J Table 5 4 Machine Tilt Configuration Model Market Limits Lift Up and Drive prevented when El
174. e Chart METRIC Fasteners Sheet 3 1 15 2 1 Engine Operating Temperature Specifications Deutz 2 8 2 2 Engine Operating Temperature Specifications Ford 2 9 2 3 Engine Operating Temperature Specifications 2 10 3 1 Limit Switch Location EL aque eu ev 3 2 3 2 Level Sensor and Analyzer Connections 3 5 3 3 Tilt Sensor Location sss u Rr s EL Ee a s Pour e e 3 6 3 4 Tilt Sensor Removal cem Deo ue m REOR CERTUM CR Gea Rae ele dee 3 6 3 5 Tilt Sensor Location nanese de qudm 3 7 3 6 Tilt Sensor Removal r Ee usya aska ae eee ETE sampa a P RE eee 3 7 3 7 Integrated Torque Drive Hub 3 8 3 8 Drive Motor Hub Assembly 3 9 3 9 Drive Hub Assembly ote Woda rv QUEE 3 18 3 10 EFI Component Location mmm 3 35 9 11 Typical Fuel System Dan date Re Raton d anaes Mand edipi pn edt ce 3 39 3 12 Generator Ford e nh 9 49 3 13 2 Engine Side
175. e Cover 28 evenly 2 Remove the Cover 3 Rotate the Cover 180 and assemble 4 Tighten 2 Bolts 30 with a torque wrench to 6 3 Ib ft 8 5 Nm 5 Slightly pull the machine with the towing vehicle to allow the spline of the Sun Gear Shaft 25 to engage with the spline of the Input Shaft 26 A WARNING DO NOT OPERATE THE MOTOR TO OBTAIN ENGAGEMENT 6 Check again that all bolts are tight and that all com ponents are returned to their original position The gear drive should now be reengaged and the machine can be disconnected from the towing vehicle 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Gearbox Disassembly 4 Remove Sun Gear Shaft 25 For numbers in parenthesis refer to Figure 3 8 Drive Motor Hub Assembly 1 Remove Screw Plugs 18 19 and drain oil into appropriate container 6 Remove ring gear fastening Bolts 20 Ring Gear 22 and O ring 16 3 Remove the assembled Cover 8 with Shift Rod 33 and O ring 23 3121133 JLG Sizzor 3 11 SECTION 3 CHASSIS amp SCISSOR ARMS 7 Remove Snap Rings 13 10 Drilling Hole Sketch 1 Split the Shaft Nut 4 in the area of the two drill holes by means of a chisel and remove from Spin dle 34 9 Drill 2 holes into Shaft Nut 4 at 180 spacing according to Drilling Hole Sketch step 10 NOTICE DO NOT DAMAGE THE BEARING CAGE OF THE BEARING 11 DO NOT TURN THE SHAFT NUT POSSIBILI
176. e Regulator Replacement Is the action complete Go to Step 26 23 Replace the lock off Refer to Lock off Replacement Is the action complete Go to Step 26 24 Replace the mixer assembly Refer to Fuel Mixer Replacement Is the action complete Go to Step 26 3 74 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 9 LPF Fuel System Diagnosis STEP ACTION VALUE S YES NO 25 Thefuelsupply systemis operating normally ifa failure ofthe control solenoids is System OK suspected Refer to Fuel Control System Diagnosis 1 Install the test plug in the LPR secondary chamber 2 Ifyou were senttothis routine by another diagnostic chart return to the previ ous diagnostic procedure Is the action complete 26 1 Disconnectall test equipment System OK 2 Install the primary and secondary test port plugs 3 Startthe engine 4 Using SNOOP or equivalent leak check the test port plugs Is the action complete 3121133 JLG Sizzor 3 75 SECTION 3 CHASSIS amp SCISSOR ARMS 3 15 JOYSTICK CONTROLLER POT 50 ohm 2W POT WIPER POT 150 ohm 2W CENTER TAP TRIGGER SUPPLY TRIGGER S CHES TRIGGER SWITCH SWITCHES TEER LEFT SUPPLY STEER ROCKER SWITCHES EER RIGHT Figure 3 43 Joystick Controller JLG P N 1600308
177. e current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires JLG Lift 24 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc Pun Reference q y Responsibility Qualification i Priorto use each day or Pre Start Inspection Ateach Operator change User or Operator User or Operator Operator and Safety Manual Pre Delivery Prior to each sale lease or Qualified JLG Service and Mai tenan e Owner Dealer or User Manual and applicable JLG Inspection rental delivery Mechanic i inspection form In service for 3 months or 150 hours whichever comes first or Qualified JLG Service and Maintenance Frequent Inspection Outofservice fora period of more than 3 Owner Dealer or User Mechanic Manualandapplicable JLG months or insp
178. ection form Purchasedused Factory Certified Service and Maintenance Annual Machine Annually no later than 13 months from the Service Technician or i Ls Owner Dealer or User Manual and applicable JLG Inspection date ofthe prior inspection a Qualified JLG i inspection form Mechanic Preventative Atintervalsas specifiedinthe Service and Qualified JLG Service and Maintenance Owner Dealer or User Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this book Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to funct
179. ed 9 2 LSS EEPROM ERROR Reported when there is a problem with the stored memory in the LSS 9 3 LSS HAS NOT BEEN CALIBRATED Reported when the LSS is configured but not calibrated 9 9 LSS NEEDS TO BE RE CALIBRATED Reported when the LSS is configured and reporting a value that is less than half of the offset value this will be reported as a 12 negative value LSS INTERNAL ERROR PIN EXCITATION Reported when a pin inthe LSS is reporting a voltage below 4 25 volts LSS INTERNAL ERROR DRIVER FAULT Reported whenthe 55 detects this internal error LSS INTERNAL ERROR DRDY MISSING FROM A D Reported when the LSS detects this internal error EEPROM FAILURE CHECK ALL SETTINGS Reported when the memory in the ground or platform module has become corrupt 4150588D 3121133 JLG Lift 5 13 SECTION 5 JLG CONTROL SYSTEM XVI ATH OLLSAOL SXX 2v01 A XXX ATH MOWSAOL IDNA YAO JO 119916 Ld MS Heu Jez jeuy E G AMA XX ADJV VOT X NA LAIT ACON ANNOY XXXX ANIONG OVALA WAA Jd XXXX IN TAR ANIONG TAR Wd UXXXX IN XX XVI AJA ATTA 3IARIG 4 ANION XX XVIN ATTA X NMOC 11 XVI TANG X NMOC XHSdHAH TAING X dN XVN L
180. ehicle assumed to be at full height ELEV ANGLE SENSOR NOT DETECTING CHANGE Reported when elevation angle sensor voltage does not change for 5 sec during lift up gt 2096 Vehicle assumed to be at full height Fault cleared only in valid stowed position 3121133 JLG Lift 5 9 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X Pd Communicated Displayed on Analyzer Fault Description Priority 2 6 Flash code 2 6 indicates leveling jack or power deck issues FRONT LEFT LEVELING JACK OPEN CIRCUIT Reported by the I O module and during system test when the front left leveling jack is open circuit FRONT LEFT LEVELING JACK SHORT TO GROUND Reported by the 1 0 module and during system test when the front left leveling jack is short to ground FRONT LEFT LEVELING JACK SHORT TO BATTERY Reported by the 1 0 module and during system test when the front left leveling jack is shortto battery FRONT RIGHT LEVELING JACK OPEN CIRCUIT Reported by the 1 0 module and during system test when the front right leveling jack is open circuit FRONT RIGHT LEVELING JACK SHORT TO GROUND Reported by the 1 0 module and during system test when the front right leveling jack is short to ground FRONT RIGHT LEVELING JACK SHORT TOBATTERY Reported by the 1 0 module and during system test when the front right leveling jack is shortto battery REAR LEFT LEVELING JACK OPEN CIRCUIT Reported
181. enthe right steer switch is closed during power NENTLY CLOSED up 3 FUNCTION LOCKED OUT AUX POWER SWITCH PER Reported when the auxiliary switch is closed during power up MANENTLY CLOSED FUNCTION LOCKED OUT GENERATOR SWITCH PER Reported when the generator switch is closed during power up MANENTLY CLOSED FUNCTION LOCKED OUT AUTOLEVEL SWITCH PER Reported when the leveling jack select switch is closed during MANENTLY CLOSED power up TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Reported when trigger is closed forten seconds and no func tion selected FUNCTION LOCKED OUT JOYSTICK NOT CENTERED Reported when joystick is not centered while selecting a func tion FUNCTION LOCKED OUT TRIGGER SWITCH PERMA Reported when the trigger switch is closed during power up NENTLY CLOSED JOYSTICK FAULTY STEER SWITCHES ACTIVE Reported when both the left and right steer switches are closed TOGETHER atthe same time FUNCTION LOCKED OUT HORN SWITCH PERMA Reported when the horn switch is closed during power up NENTLY CLOSED JOYSTICK CALIBRATION FAULTY Reported when joystick calibration is improper Platform P1 6 or later only 3121133 JLG Lift 5 7 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X Communicated Displayed on Analyzer Fault Description Priority 2 9 Flash code 2 3 indicates difficultly with gro
182. er Bearing 21 Thrust Washer 31 O Ring 2 Planet Gear 12 Retaining Ring 22 Gear Ring Options 32 Spring 3 Sun Gear 13 Retaining Ring 23 O Ring 33 Shift Rod 4 Shaft Nut 14 Retaining Ring 24 Retaining Ring 34 Brake Housing 5 Planet Pin 15 Support Disk 25 Sun Gear Shaft 35 Wheel Stud 6 Support Ring 16 O Ring 26 Input Shaft 36 Hydraulic Motor 7 Planet Carrier 17 Shaft Seal 27 Thrust Washer 37 Spring Sleeve Dowel 8 Cover 18 Screw Plug 28 Cover 9 Roller Bearing 19 Seal Ring 29 Sleeve 10 Roller Bearing 20 Bolt 30 Bolt Figure 3 8 Drive Motor Hub Assembly 3121133 JLG Sizzor 3 9 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 4 Gearbox Maintenance Schedule After 150 motor operating hours Firstoil change Weekly Inspectvisually Checkfor unusual noise Checkoil level Monthly Checkthe tightness of all screws and bolts Semi annually Checkoil quality Annually Changeoil orafter 1500 motor operating hours whichever comes first Disconnect Mechanism The disconnect mechanism on the torque drive hub allows the machine to be towed When activated the mechanism disconnects the gear drive and motor Disengaging Procedure PRIOR TO DISENGAGING THE MACHINE MUST BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT ENSURE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION MAKE SURE DIRT OR OTHER CONTAMI NANTS DO NOT ENTER THE GEAR
183. erating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows 1 Remove prox switch from its mount 2 Reconnect harness if it was disconnected for step a and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehicle or control system documentation on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed 6 12 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Automatic Switches If the switch is actuated automatically by temperature or
184. essure Springs quantity 26 3 Guide Ring 2 Remove port plate 3121133 JLG Sizzor 3 19 SECTION 3 CHASSIS amp SCISSOR ARMS 5 Disassemble bearing with synchronizing plate 8 Disassemble lamination kit 6 Press off pressure ring with extractor 9 Disassemble Seeger snap ring 7 Remove pressure ring 10 Disassemble cradle stop with 2 screws M4 x 75mm 3 20 JLG Sizzor 3121133 SECTION 3 CHASSIS amp 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 13 Pull out swivel balls 16 Disassemble bearing ring from port plate 3121133 JLG Sizzor 3 21 SECTION 3 CHASSIS amp 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 Check cylinder bores splines C 18 Disassemble shuttle valve 1 Disassemble throttle C 5 CO screw with throttle pin 2 21 Check that cylinder track is free of scratches there are no
185. evated and Tilted beyond the following limits ANSIUSA Frontto Back 2 5 to Full Height Side to Side 5 to 26 Feet 4 to 30 Feet 3 to Full Height ANSI EXPORT Same as ANSI USA 33RT 2WD Lift Up and Drive prevented when Elevated and Tilted beyond the following limits 33RT 4WD CSA Frontto Back 3 to Full Height Side to Side 3 to Full Height Tilt Lamp energized when Tilted beyond the following limits CE Frontto Back 5 to Full Height Side to Side 3 to Full Height AUSTRALIA Same as ANSI USA Lift Up and Drive prevented when Elevated and Tilted beyond the following limits ANSIUSA Frontto Back 5 to Full Height Side to Side 5 to 30 Feet 4 to 36 Feet 3 to Full Height ANSI EXPORT Same as ANSIUSA 33RT 2WD Lift Up and Drive prevented when Elevated and Tilted beyond the following limits 33RT CSA Front to Back 3 to Full Height Side to Side 3 to Full Height Tilt Lamp energized when Tilted beyond the following limits CE Frontto Back 5 to Full Height Side to Side 3 to Full Height AUSTRALIA Same as ANSI USA 4150390 J NOTE Vehicle Tilt Configuration based on Model and Market Settings 3121133 JLG Lift 5 19 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
186. extrusion seal 4 are positioned properly ensure the outside of the W seal is exposed to the discharge pressure Apply a small amount of grease tot he dowel pins 7 and install them into the body 13 Set the body 13 onto the front cover 5 matching the scribes marks on the body and front cover The dowel pins 7 should go into the mating holes on the front cover 5 Install drive gear 12 and driven gear 11 10 11 12 JLG Lift Shaft Seal Drive Shaft 4 Installation Tool Bullet Lubricate Place a small amount of grease in seal groove on the rear bearing block 2 Install a new load seal and anti extrusion seal in groove Insert the bearing block into the body making sure that the load seal and anti extrusion seal are positioned properly Ensure outside of the W seal is exposed to the dis charge pressure Apply a small amount of grease tot he seal groove in the rear cover 6 and install a new seal ring 8 into the groove Set the rear cover 6 onto the body 13 matching the scribes marks on the body and rear cover Insert he cap screw 14 and washers 9 torque to 42 46 ft Ib 57 62 Nm On models equipped with keyed drive shaft install drive key 10 With an adjustable wrench Check that the drive shaft turns without evidence of a mechanical bind 4 13 SECTION 4 HYDRAULICS 4 9 MAIN VALVE 11 OO
187. ff valve on the LPG tank CAUTION When disconnecting LPG fuel lines liquid LPG may be present Per form this step in a well ventilated area 3 Loosen the fuel inlet hose fitting at the inlet of the LPL Was fuel present when the fitting was loosened Go to Step 23 Go to Step 17 1 Turn OFF the ignition 2 Connect the test light to chassis ground and probe pin A of the LPL connector 3 Crank the engine The test light should illuminate Does the test light illuminate Go to Step 20 Goto Step 21 1 Remove the LPG fuel filter LPL 2 Removethe filter from the LPL 3 Empty the contents of the inlet side ofthe LPG fuel filter onto a clean surface 4 Inspectthe contents of the LPG fuel filter for an excessive amount of foreign material or water If necessary locate and repairthe source of contamination 5 Verify the LPG fuel filter is not restricted or plugged Was a problem found Goto Step 19 Goto Step 18 The fuel supply system or hoses are plugged or restricted locate and repair the problem Is the action complete Go to Step 26 Replace the fuel filter Refer to Fuel Filter Replacement Is the action complete Go to Step 26 20 Repair the openin the lock off ground circuit Is the action complete Go to Step 26 21 Repair the open in the lock off power circuit Is the action complete Go to Step 26 22 Replace the low pressure regulator LPR Refer to Low Pressur
188. for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while pump motor is running 12 Check for proper lubrication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 16 Check Inspection Decal for current inspection stamp JLG Lift 3121133 SECTION 2 GENERAL Table 2 3 Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 300 Hours 6 months 600 Hours 1 year 1200 Hours 2 years PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 12 4 Control Tags 12 5 Hoses and Cables 48 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Engine Oil 2 Battery 3 Air Cleaner 4 Exhaust System c 1 5 5 Engine Mounts 6 Hydraulic Pump 7 Valves 8 Hydraulic Filter See Lubrication Chart 9 Hydraulic Hoses and Tubing 10 Hydraulic Oil Tank 11 Hydraulic Tank Breather 12 Fuel Tank 3 5 13 Lift Cylinder 1 12 14 Limit Switch 17 15 Tilt Alarm Switch 16
189. fore 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 There are no Diagnostic Trouble Codes DTCs stored or a DTC exists but without a MIL Several of the following symptom procedures call for a careful visual and physical check The visual and physical checks are very important The checks can lead to correcting a problem without further checks that may save valuable time LPG Fuel System Check 1 Verify the customer complaint 2 Locatethe correct symptom table 3 Checkthe items indicated under that symptom 4 Operate the vehicle under the conditions the symptom occurs Verify HEGO switching between lean and rich IMPORTANT Normal HEGO switching indicates the LPG fuel systemis in closed loop and operating correctly at thattime Visual and Physical Checks Checkall ECM system fuses and circuit breakers Check the ECM ground for being clean tight and in its proper location Check the vacuum hoses for splits kinks and proper connections Check thoroughly for any type of leak or restriction Check for air leaks at all the mounting areas of the intake manifold sealing surfaces Check for proper installation of the mixer module assembly Check for air leaks at the mixer assembly Check the ignition wires for the following conditions Cracking Hardness Proper routing
190. gine is cranking Note Move mentofthe air valve will be minimal at cranking speeds Does the air valve move when the engine is cranked 10 1 Inspectthe air intake stream to the mixer assembly and the throttle body for Goto Step 26 Goto Step 24 vacuum leaks 2 Inspectthe vacuum hoses from the mixer for proper connection and condition Was a problem found and repaired 11 Inspectthe fuel hose connection between the LPR and the mixer assembly for Goto Step 26 Goto Step 12 damage or leakage Was a problem found and repaired 12 1 Connecta0 10 psi gauge to the primary test port of the low pressure regulator 1 3PSI Goto Step 22 Go to Step 13 LPR 2 Crank the engine and observe the pressure reading for the LPR primary pres sure Is the fuel pressure ABOVE the specified value 3121133 JLG Sizzor 3 73 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 9 LPF Fuel System Diagnosis STEP ACTION VALUE S YES NO 1 Turn OFF the ignition 2 Disconnectthe LPL connector 3 Install a test light between the pins of the LPL connector 4 Crank the engine The test light should illuminate Does the testlight illuminate Go to Step 14 Go to Step 16 Using a DVOM check the resistance of the low pressure lock off LPL Is the resistance within the specified range 120 160 Goto Step 15 Goto Step 23 1 Turn the ignition OFF 2 Close the manual shut o
191. h 4 If there is a problem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire procedure 6 4 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WI
192. h one switch unlike the traditional four switch system The leveling jacks are operated by a bang bang valve NOTE The engine speed will drop when the leveling jacks are in contact with the ground 1 Activate the leveling jack button located on the plat form control box 2 Extend the jacks by moving the joystick forward NOTE Once all four jacks make contact with the ground the system will go from set mode into level mode At this point the engine will return to idle 3 The tilt indicator will go out once the machine is level NOTE If the machine is not level it will not lift If you hit the end of stroke on any of the cylinders you cannot lift the machine NOTE There is a limit switch on each cylinder that senses when the cylinder is fully retracted when all four are fully retracted the stowed light in the platform control box will light If you receive a 2 5 flash code through the system fault light at the platform control station the machine is unable to level You must reposition and try again The jacks are operational extend or retract if the machine is in the stowed position The proximity sensor and rotary sensor together must sense that the machine is stowed A failure of either sensor will prevent the jacks from being activated Power Deck The power deck is operated through a non proportional valve This will not effect any other function when acti vated A WARNING BE SURE AND RETRACT ANY POWER D
193. he flow of oil a vacuum reading should be taken at the inlet of the pump during operation in order to verify 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 clean hydraulic fluid prior to start up Fill the housing by pouring filtered oil into the upper case drain port NOTE It is highly recommended to use the highest possible case drain port this ensures that the housing con tains as much oil as possible and offers the greatest amount of lubrication to the internal components In initial start up conditions it may be convenient to fill the housing just prior to installing the case drain line Component especially motor location may be such that access to the case drain port after installa tion is not realistic Make certain that the oil being used to fill the compo nent housing is as clean as possible and store the fill container in such a way as to prevent it from becoming contaminated Install a 60 bar or 1000 psi pressure gauge in the charge pressure gauge port in order to monitor the charge pres sure during start up It is recommended that the external control input signal electrical connections for EDC be disconnected at the pump control until after initial start up This will ensure that the pump remains in its neutral position 4 WARNING DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION 0 DEGREES
194. hly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1 JLG Lift 2 3 SECTION 2 GENERAL 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 NOTE The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied intervals required in the Lubrication Chart in Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean
195. hmmeter to the ends of each wire in question If the meter reads over 30 000 ohms replace the wires Additional Checks Important The LPG Fuel system works ona fumigation principle of fuel introduction and is more sensitive to intake man ifold leakage than the gasoline fuel supply system Check for vacuum leaks Vacuum leaks can cause a higher than normal idle and low throttle angle control command Checkthe ECM grounds for being clean tight and in their proper locations Checkthe battery cables and ground straps They should be clean and secure Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality Engine Mechanical Check Checkthe engine for the following Broken motor mounts mproper valve timing Lowcompression Bentpushrods Wornrockerarms Brokenorweak valve springs Worncamshaftlobes Surges Chuggles erator pedal DEFINITION The engine has a power variation under a steady throttle or cruise The vehicle feels as ifitspeeds up and slows down with no change in the accel Preliminary Checks Sensor Checks Refer to Important Preliminary Checks Check Heated Exhaust Gas Oxygen Sensor HEGO performance 3 84 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Fuel System Checks Check for Rich or Lean symptom that causes the condition Drive the vehicle a
196. hould this occur attempt to dissect the three areas of error to find the primary contributor a Machine mounting and or grade With a digital level measure the top of the Ground Control box for levelness If unable to get a good reading check the box s mounting surface for levelness Ground Control Box 2 Digital Level b Tilt sensor mounting on machine or wedged crooked in control box If the machine mounting grade appears accept able open the Ground Control box carefully Observe whether the tilt sensor is properly seated 2 Tilt Sensor Ground Control Box JLG Sizzor c Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected Level one axis of the tilt sensor and observe the raw read ing should be within 2 0 Do the same for the other axis If either axis is greater than 2 0 replace the tilt sensor Some possible reasons that the tilt sensor will not cali brate are a The surface the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level b The tilt sensor has failed one or both of the channels X axis and Y axis c Tilt sensor has moisture intrusion that has shifted its output d Water and or corrosion in the box has corrupted electrical connections or caused a tilt sensor or grou
197. hrough the fuel pressure regulator before being returned to the fuel tank 3 38 JLG Sizzor A fuel injector which is stuck partly open will cause a loss of fuel pressure after the engine is shut down causing long crank times FUEL METERING SYSTEM COMPONENTS The fuel metering system is made up of the following parts The fuel injectors The fuel rail The fuel pressure regulator filter assembly The electronic governor The ECM The crankshaft position CKP sensor The camshaft position CMP sensor The fuel pump The fuel pump relay BASIC SYSTEM OPERATION The fuel metering system starts with the fuel in the fuel tank The fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail through an inane fuel filter The pump is designed to provide fuel at a pressure above the pressure needed by the injectors A fuel pressure regulator in the fuel filter assembly keeps fuel available to the fuel injectors at a constant pressure A return line delivers unused fuel back to the tank 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS A WARNING HIGH PRESSURE CIRCUIT OPERATING PRESSURE 65 PSI d FUEL PUMP es g FLOW A RETURN 6 TO TANK e FUEL FILTER FROM FUEL TANK PRESSURE REGULATOR QUICK CONNECTORS Figure 3 11 Typical Fuel System FUEL METERING SYSTEM PURPOSE The basic functi
198. ical Schematic Diesel Prior to S N 138634 Sheet 2 of 3 3121133 JLG Sizzor 6 19 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS J1 RECEPTACLE Q PFDTH J2 1 PFDTH J1 1 PFDTH J2 2 FLLJ J1 2 H IGN 45 9 VALVE FRLJ SFDTH J1 3 IB GND J2 3 BLACK CY 18 VALVE RLLJ BLACK GND J1 4 to DOOD J2 11 OBN WHT 55 20 K Y19 VALVE RR LJ YEL RED 2 7 3 IGN J1 5 DOO1 J2 12 ORN WHT 55 21 5 X 20 VALVE LJ EXTEND 1 RED ___ CANH J1 6 DOO J5 1 ORN WHT 55 22 Y Yet VALVE LJ EXTEND 2 BLACK _ CANL J1 7 SI poos J5 2 ORBN WHT 55 23 Ka Y22 VALVE LJ RETRACT SHIELD CAN SHIELD 1 8 DO04 J5 3 ORN WHT 55 24 v 28 VALVE 0005 J5 4 ORN WHT 55 25 Ki 8 DOO6 J5 5 DIOO SFDTH J2 4 IGN J4 1 DIO5 J2 9 GND J4 2 4 2 10 FD EXT CAN H J4 3 DIO1 J2 5 VALVE FD RET CAN L J4 4 DIO2 J2 6 Y4 VALVE RD EXT CAN SHIELD J4 5 0103 J2 7 GREEN17 2 Yes VALVE RD RET SPARE J4 6 DOO7 J5 6 GREEN 18 2 1 x Ye6 VALVE 0008 J5 7 GREEN 19 2 ke Yo7 0009 45 8 GREEN 20 2 J4 DIO4 J2 8 RECEPTACLE RX 5 10 TX 5 11 GND J5 12 BLACK J3 RECEPTACLE gt gt gt g
199. ided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3121133 Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss A C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND ISA SAFETY VIOLATION No smoking is mandatory never refuel during electrical storms ensure that fuel cap is closed and secure at all other times Remove all rings watches and jewelry when performing any maintenance Do not wear long hair unrestrained or loose fitting clothing and neckties which are apt to become caught on or entangled in equipment Observe and obey all warnings and cautions on machine and in service manual Keep oil grease water etc wiped from standing surfaces and hand holds Use caution when checking a hot pressurized coolant system Never
200. idence of a problem is found after visual physical engine check has been performed proceed to MIL DTC retrieval procedure EFI Diagnostics The EFI diagnostics are designed to assist in locating a faulty circuit or component When a malfunction is detected by the Engine Control Module ECM a diagnos tic trouble code DTC is set and will be displayed on the JLG Control System Analyzer Refer to Section 6 JLG Control System CLEARING TROUBLE CODES To clear the trouble codes from the ECM the electrical current running to the ECM must be shut off To do this disconnect the negative terminal from the battery for a period of approximately 15 minutes ECM and Sensors CRANKSHAFT POSITION CKP SENSOR The crankshaft position CKP sensor provides a signal used by the engine control module ECM to calculate the ignition sequence The CKP sensor initiates the reference pulses which the ECM uses to calculate RPM and crank shaft position JLG Sizzor 3 31 SECTION 3 CHASSIS amp SCISSOR ARMS CAMSHAFT POSITION CMP SENSOR AND SIGNAL The camshaft position CMP sensor sends a CMP signal to the ECM The ECM uses this signal as a sync pulse to trigger the injectors in the proper sequence The ECM uses the CMP signal to indicate the position of the 41 pis ton during its power stroke The CMP uses a Hall Effect sensor to measure piston position This allows the ECM to calculate true sequential fuel injection SFI mode
201. igure 3 19 EMR 2 Vehicle Plug Pin Identification 3 51 SECTION 3 CHASSIS amp SCISSOR ARMS Josuas JO SHUI ne 32947 pauinba ji pue Josuas y9 49 9 q83 Josues y99U9 S JO 1394S s poO ZHIN3 Oz 1 997 10 NdS JO 6 9 Gz AIS lduiex 104 ZLS ppe 196 OL zs enbe s 15 3LON Si pareroosse au 1051195 34 JO ANEL YM pouu SN1U 9101500 10 991 9 S3JIY A 104 uo Joyenioe ejqeo J 998 49 pue Jojemoe x29u spol xeu BUWIS Gid X29049 paads y98u9 1 1 Y99349 e qeo Jo Lous 6 9 1051195 BuipuodsaJJ00 18 1 neJ 991 JO Y29349 peeds 1998110911 onJ 961819 oJnjejodujo 18 009 65814 004 JO SS83X8 si seM paads 061 eunsseJd Ho uo1Ass peeds ss 5xg peuinba a2ejday oue pue uomnoauuoo 189 Y29949 uome1edo ouaDaula ul 1 peydnuaqui uonaeuuoo ajqe s s nduii jeuonippy pajrej OYIEL Josues poedg paJinbai 838 9 pue Josuas y99u9 uonoauuoo 789 Y29949 33uB sID 29U you Josuas Jl JJo youms 1 10SU9S uw uoneJado
202. ilter with clean engine oil and wipe the sealing surface on the filter mounting surface to remove any dust dirt and debris Tighten the filter securely follow the filter manufacturers instructions Do not over tighten Check the sealing ring on drain plug for any dam age replace if necessary wipe the plug with a clean rag and wipe the sealing surface on the pan and reinstall the pan plug Do not over tighten Fill the crankcase with oil Start the engine and check for oil leaks Stop the engine and check the oil level to insure the oil level is at FULL Dispose of the oil and filter in a safe manner 3 59 SECTION 3 CHASSIS amp SCISSOR ARMS 3 11 GENERATOR GM ENGINE E 120 VAC FABCO POWER CHESTER NY VOLTAGE REGULATOR MODEL PMVRI2OC oy 3 60 JLG P N 3990010 TN N 6A 600V DIOD LVER SCREW RECPTACLE ie SILVER SCREW lt AC RECPTACLE 7 GOLD SCREW VOLTMETER AL GENERATOR CONTROL BOX TO BE WIRED TO PLUG PER THIS SCHEMATIC 1 Generator 2 GM Engine 3 Voltage Regulator Figure 3 27 Generator GM Engine Table 3 8 Generator Specifications Voltage 120V Continuous 3 5 KW Peak 4 5 KW Amps Peak 37 Amps JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 3 12 GM E
203. ing delivered to the LPR Also ensure that the manual shut off valve on the LPG tank is fully opened and that the excess flow valve has not been activated Tools Required 7 16 Open end wrench for test port plugs DVOM GM J 39200 Fluke 88 or equivalent 12 volt test light Diagnostic Scan Tool Diagnostic Display tool Pressure Gauges MPCO ITK2 Test kit Water Column Gauge Manometer GM 7333 6 or equivalent 0 10 PSI Gauge Test Description The numbers below refer to step numbers on the diagnos tic table 5 This step determines if the LPR requires replacement 6 This step determines if the problems are in the mechan ical side of the Pressure Regulator or the Electronic Voice Coil 10 This step determines if the Mixer requires replace ment 14 This step determines if the Lock Off requires replace ment 17 This step determines if the Fuel Filter requires replace ment 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 9 LPF Fuel System Diagnosis STEP ACTION VALUE S YES NO 1 Were you referred to this procedure by a DTC diagnostic chart Goto Step 3 Go to Step 2 2 Perform the On Board Diagnostic OBD System Check Gotothe Goto Step 3 Are any DTCs presentin the ECM applicable DTC Table 3 Verifythatthe LPG fuel tank has a minimum of 1 4 tank of fuel that the manual Goto Step4 valveis open andthe tank quick connectis fully engaged Doesthe vehicle ha
204. ing items are reading correctly ANGLE SNSR 0 40 X XXV ZEROED 0 00V ELEV CUT CALIB 0 50v 1 0v 8 Press ESCAPE until you arrive at DIAGNOSTICS then scroll over to top level menu SET ELEV SEN SOR press ENTER At this point press ENTER key If everything tested properly the analyzer will read COMPLETE 9 Now lift the machine up Drive speed should be reduced to elevated speed at the following heights 3394RT 6 9 ft 1 8 2 7m 4394RT 7 10 ft 2 1 3m 10 Press ESCAPE remove analyzer and assure all hardware is tight NOTE If voltage is too low the analyzer will display SEN SOR FAILURE If the voltage is set too high the ana lyzer will read NOT STOWED When calibration is attempted once it is set within the proper limits the analyzer will read COMPLETE Elevation Sensor Calibration Software P1 20 amp Higher Using the Analyzer in Access Level 1 go to MENU CALI BRATION 1 SET STOW ELEV a Completely lower platform to stowed position b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated 3121133 2 SET 26FT ELEV 3394RT or SET 30FT ELEV 4394RT a Raise platform to a height of 26 feet for the 3394RT or 30 feet for the 4394RT measured deck to ground b Enter YES on the Analyzer c COMPLETE will show on the analyzer when cali brated 3 SET 30FT ELEV 3394RT or SET 36FT ELEV 4394RT a Raise platform to a height of 30 feet on the 3394R
205. ion properly 2 2 JLG Lift 1 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering 3121133 SECTION 2 GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on ano
206. ions for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased use
207. is in closed loop and no warning lights are illuminated Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL 1 2 3 Disconnect Negative battery cable Disconnect the O2 sensor electrical connector Using an O2 Sensor socket remove the O2 Sensor and discard INSTALLATION NOTICE BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH ANTI SEIZE COMPOUND GM P N 5613695 OR EQUIVALENT AVOID GETTING COMPOUND ON THE SENSOR TIP 1 JLG 8220 Install O2 sensor Tighten to 30 Ib ft 41 Nm Start engine Check for any DTC codes and clear Verify engine is in closed loop and no warning lights are illuminated 3 71 SECTION 3 CHASSIS amp SCISSOR ARMS 3 14 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Fuel System Description Pressure Regulator Section p ES Fuel Inlet Coolant Passage ui U Test Port 7 pe Secondary Test Port Voice Coil Section Figure 3 42 EPR Assembly To maintain fuel and emission control on the LPG fuel sys tem the Engine Control Units ECM relies on numerous engine sensor and output data from the Electronic Pres sure Regulator EPR The ECM will then determine the target fuel calibration and command the EPR to reposition the voice coil to the proper position which subsequently reposition the secondary lever in the pressure regulator to maintain proper control The EPR and ECM will continue to communicate back a
208. itch OFF NOTICE RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE Propane Fuel System Leak Test A CAUTION NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PROPANE FUEL SYSTEM LEAKS Always inspect the propane fuel system for leaks after per forming service Check for leaks at the fittings of the ser viced or replaced component Use a commercially available liquid leak detector or an electronic leak detec tor When using both methods use the electronic leak detector first to avoid contamination by the liquid leak detector 3 66 Propane Fuel Filter Replacement 1 ElectricLockOffSolenoid 7 Electrical Connector 2 Mounting Plate 8 Fuel Outlet 3 Housing Seal 9 O ring 4 Filter Magnet 10 Filter 5 Filter Housing 11 Fuellnlet 6 Seal 12 Retaining Bolt Figure 3 37 Filter Lock Assembly REMOVAL 1 o o o Relieve the propane fuel system pressure Refer to Propane Fuel System Pressure Relief Disconnect the negative battery cable Slowly loosen the Filter housing retaining bolt and remove it Pull the filter housing from the Electric lock off assembly Locate Filter magnet and remove it Remove the filter from the housing Remove and discard the housing seal Remove and discard the retaining bolt seal Remove and discard mounting plate to lock off O ring sea
209. ivers less than expected power Thereis little or no increase in speed when partially applying the accelerator pedal Preliminary Checks Referto Important Preliminary Checks Refertothe LPG Fuel system OBD System Check Comparethe customer s vehicle with a similar unit Make sure the customer has an actual problem Do not compare the power output of the vehicle operating on 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 82 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Fuel System Checks Check for a restricted fuel filter contaminated fuel or improper fuel pressure Refer to LPG Fuel System Diagnosis Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent Check for proper installation of the mixer module assembly Check all air inlet ducts for condition and proper installation Check for fuel leaks between the LPR and the mixer Verify that the LPG tank manual shut off valve is fully open Verify that liquid fuel not vapor is being delivered to the LPR Sensor Checks Check the Heated Exhaust Gas Oxygen Sensor HEGO for contamination and performance Check for proper opera tion ofthe MAP sensor Check for prope
210. l INSTALLATION 1 2 3 JLG Sizzor NOTICE BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS ING BEFORE INSTALLING NEW SEAL Install the mounting plate to lock off O ring seal Install the retaining bolt seal Install the housing seal 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Drop the magnet into the bottom of the filter hous ing Install the filter into the housing Install the retaining bolt into the filter housing Install the filter up to the bottom of the electric lock off Tighten the filter retaining bolt to 106 in Ibs 12 Nm Open manual shut off valve Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test Electronic Pressure Regulator EPR Assembly Replacement Pressure Regulator Section 4 Primary Test Port Fuel Inlet 5 Secondary Test Port Coolant Passage 6 Voice Coil Section Figure 3 38 EPR Assembly The EPR assembly is a made up of two separate compo nents The Voice Coil Section is not serviceable and can only be replaced as an assembly The pressure regulator section is serviceable and will be detailed in this section REMOVAL 1 NOTE 3121133 Relieve the propane fuel system pressure Refer to Propane Fuel System Pressure Relief Disconnect the negative battery cable Slowly remove the fuel inlet fitting at the Electric Lock Off Residual vapor pressure will be pre
211. l filter regulator assembly A standard fuel filter does not regulate pressure and could cause engine problems or component damage FUEL PUMP ELECTRICAL CIRCUIT When the key is first turned ON the ECM energizes the fuel pump relay for two seconds to build up the fuel pres sure quickly If the engine is not started within two sec onds the ECM shuts the fuel pump off and waits until the engine is cranked When the engine is cranked and crank shaft position signal has been detected by the SECM the ECM supplies 12 volts to the fuel pump relay to energize the electric fuel pump An inoperative fuel pump will cause a no start condition A fuel pump which does not provide enough pressure will result in poor performance FUEL RAIL The fuel rail is mounted to the top of the engine and dis tributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines 3 40 JLG Sizzor ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2 5L EFI industrial engine throttle control is achieved by using an electronic governor which is con trolled by the engine control module ECM The electronic governor consists of a throttle body an electronically actuated throttle plate and a built in throttle position TP sensor There are two pigtails that exit the governor body The 3 wire pigtail connects the TP sensor to the ECM Refer to Throttle Position TP Sensor for more infor
212. l below OPSI REAR LEFT LEVELING JACK PRESSURE TRANS Reported when the rear left leveling jack pressure reading is DUCER FAILURE well below OPSI REAR RIGHT LEVELING JACK PRESSURE TRANS Reported when the rear right leveling jack pressure reading is DUCER FAILURE well below OPSI PLATFORM OVERLOAD Reported when the overload is setup and the LSS is reading the platform is overloaded FRONT LEFT LEVELING JACK STOW SWITCH PERMA Reported when the FRONT LEFT Leveling Jack Stow Switch is 5 NENTLY CLOSED closedandthe FRONT LEFT pressuretransducer reads Set pressure FRONT RIGHT LEVELING JACK STOW SWITCH PER Reported whenthe FRONT RIGHT Leveling Jack Stow Switch MANENTLY CLOSED is closed and FRONT RIGHT pressure transducer reads Set pressure REAR LEFT LEVELING JACK STOW SWITCH PERMA Reported whenthe REAR LEFT Leveling Jack Stow Switch is NENTLY CLOSED closed and the REAR LEFT pressure transducer reads Set pressure REAR RIGHT LEVELING JACK STOW SWITCH PERMA Reported when the REAR RIGHT Leveling Jack Stow Switch is NENTLY CLOSED closed and the REAR RIGHT pressure transducer reads Set pressure ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when elevation height calibration has not been per formed oris notlogical increasing voltages from stowed Vehicle assumed to be at full height ELEV ANGLE SENSOR FAULTY NOT MOUNTED OR Reported when elevation angle sensor is outside the 0 30V to VOLTAGE OUT OF RANGE 4 85V range V
213. lated part If bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 3121133 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 dance with recommended shop practices See Torque Chart Section 1 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroug
214. ling Jack Cylinder 4 28 JLG Lift 3121133 SECTION 4 HYDRAULICS 3121133 ao gt gt O Locknut Piston Seal O Ring Barrel 6 Spacer Tube 11 Seal 7 Head 12 Wiper Ring 8 Rod 13 Retaining Ring 9 O Ring 10 Back up Ring Figure 4 33 Deck Extension Cylinder Lift 4 29 SECTION 4 HYDRAULICS Oscillating Axle Bleeding Procedure OSCILLATING AXLE BLEEDER OSCILLATING AXLE CYLINDER Figure 4 34 Oscillating Axle Bleeding 1 Attach 1 4 hose to bleeder valve to capture oil 4 Run pump for 10 seconds close bleeder valves 2 Oscillate axle fully in one direction 5 Oscillate axle fully in the opposite direction and 3 Open the bleeder valve at the top of the retracted repeat steps 3 and 4 cylinder approx 1 2 turn and open bleeder valve at the bottom of extended cylinder approx 1 2 turn 4 30 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM SECTION 5 JLG CONTROL SYSTEM 5 1 HAND HELD ANALYZER MENU Analyzer Display HELP PRESS ENTER Escape Key Enter Key To return home or access 4 Storesandselects Top Level Sub previous menu Level and item menus Left amp Right Arrow Keys Usedto move between Top Level Sub Level and item menus Up amp Down Arrow Keys Value Selector Figure 5 1 Hand Held Analyzer To Connect the Hand Held Analyzer PCB in the gro
215. lter Deutz 10 Fuel Filter Gasoline GM 3 11 AirFilter 12 Electronic Pressure Regulator LP Only 13 Fuel Filter Propane GM NOTE Item 5 through 13 are on the opposite side of the machine and not shown Figure 1 2 Operator Maintenance and Lubrication Diagram A WARNING TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Be sure to lubricate like items on each side NOTE Recommended lubricating intervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubri cation frequencies must be increased accordingly Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank Oil should be visible in ADD sight window on hydraulic tank If oil is not visible add oil until oil is visible in both 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 3121133 JLG Sizzor Fuel Tank Fuel Diesel or Gasoline e Capacity 31 5 gal 119 I 1 5 SECTION 1 SPECIFICATIONS 2 Drive Hub pe Lube Points Fill Plugs 4 Lube EPGL Interval Every 2 years or 1200 hours 3 Hydraulic Oil Lube Point Fill Cap Fill Level Lube HO Interval Check oil every 1
216. mation The 2 wire pigtail carries the throttle signal from the ECM to the governor Desired engine speeds are stored in the configuration program for each specific application and can be changed with the ECM calibration software When an engine speed is selected with the toggle switch the ECM sends the appropriate signal to the governor This is a pulse width modulated PWM signal which cannot be read with conventional diagnostic tools such as a voltme ter A 12 volt signal is pulsed on and off at a high rate of speed The width of the on pulse determines the amount of throttle opening The ECM sends a signal with the appropriate pulse width to the governor based on the operator s choice of switch settings The electronic governor also acts as an idle air control IAC valve Changes in engine load are detected by the ECM by comparing manifold absolute pressure MAP with throttle position When the ECM detects a change in engine load it can adjust idle speed by changing the PWM signal to the governor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 OPEN LOOP AND CLOSED LOOP OPERATION The ECM will operate in the following two modes Open loop Closed loop When the engine is first started the system is in open loop operation In open loop the ECM ignores the signal from the heated oxygen sensor 25 it uses a pre pro grammed routine to calculate the air fuel ratio based on inputs from the TP ECT an
217. n CKP Sensor Extra Missing Pulses 53 Camshaft Position Sensor CMP Sensor Illegal Pattern 54 Engine Control Module ECM Fault Illegal Operation 55 Engine Control Module ECM Fault Illegal Interruption 56 Engine Control Module ECM Fault COP Computer Operating Properly Failure 61 System Voltage Low 62 System Voltage High 3121133 JLG Sizzor 3 33 SECTION 3 CHASSIS amp SCISSOR ARMS ENGINE COOLANT TEMPERATURE ECT SENSOR The engine coolant temperature ECT sensor is a g ther mistor a resistor which changes value based on tempera ture mounted in the engine coolant stream Low coolant temperature produces a high resistance of 100 000 ohms at 40 C 40 F High temperature causes a low resis tance of 70 ohms at 130 C 266 F The ECM supplies a 5 volt signal to the ECT sensor through resistors in the ECM and measures the voltage The signal voltage will be high when the engine is cold and low when the engine is hot By measuring the voltage the ECM calculates the engine coolant temperature Engine coolant temperature affects most of the systems that the ECM controls After engine start up the temperature should rise steadily to about 85 C 185 F it then stabilizes when the thermo stat opens If the engine has not been run for several hours overnight the engine coolant temperature and intake air temperature displays should be close to each other A fault in the engine coolant sensor circuit will set D
218. n making repairs The ECM supplies either 5 or 12 volts to power various sensors or switches The power is supplied through resis tances in the ECM which are so huh in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low There fore a digital voltmeter with at least 10 meg ohms input impedance is required to ensure accurate voltage read ings The ECM controls output circuits such as the fuel injectors electronic governor etc by control ling the ground or the power feed circuit through transistors or other solid state devices 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 The ECM is designed to maintain exhaust emission levels to government mandated standards while providing excel lent operation and fuel efficiency The ECM monitors numerous engine functions via electronic sensors such as the throttle position TP sensor and the heated oxygen sensor HO2S 00005 152202 O 25252 amp 20000 280000 20 00a 50022 22007 00002 INPUTS OUTPUTS Inputs Operating Conditions Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery Voltage Throttle Position Fuel Pump Voltage Intake Air Temperature Camshaft Position Outputs System Controlled Fuel Control Idle Air
219. n these cylinders and check for the following conditions Insulation cracks Wear Improper gap Burned electrodes Heavy deposits Visually Physically inspect the secondary ignition for the following Ignition wires for arcing cross firing and proper routing Ignition coils for cracks or carbon tracking Engine Mechanical Checks Perform a cylinder compression check Checkthe engine for the following Improper valve timing Bent pushrods Worn rocker arms Worn camshaftlobes Broken or weak valve springs Checkthe intake and exhaust manifold passages for casting flash Fuel System Checks Check the fuel system plugged fuel filter low fuel pressure etc Refer to LPG Fuel System Diagnosis Check the condition of the wiring to the low pressure lock off solenoid Additional Check Check for Electromagnetic Interference EMI EMI on the reference circuit can cause a missing condition Monitoring the engine RPM with a scan tool can detect an EMI A sudden increase in the RPM with little change in the actual engine RPM indicates EMI is present Ifthe problem exists check the routing of the secondary wires and the ground circuit 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 condition may cause the engine to stall ifi s severe enough Preliminary Checks Refer to Important Preliminary Checks
220. nd into the tapped holes in the piston PISTON TAPERED BUSHING CAP SCREWS Figure 4 12 Tapered Bushing Installation Tighten the capscrews evenly and progressively in rotation to the specified torque value After the screws have been torqued tap the tapered bushing with a hammer 16 to 24 oz and brass shaft approximately 3 4 in diameter as follows a Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON TAPERED BUSHING BRASS SHAFT Figure 4 13 Seating the Tapered Bearing 7 Retorque the capscrews evenly and progressively in rotation to the specified torque value 8 Remove the cylinder rod from the holding fixture 4 7 SECTION 4 HYDRAULICS 9 Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 4 11 10 Position the cylinder barrel in a suitable holding fix ture NOTICE 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 11 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or di
221. nd control board failure observe any cracks in the box e The Ground Control Box as mounted on the machine does not allow the tilt sensor to be level For the following troubleshooting steps a bubble level smaller is better will be needed and the machine must be on a level surface 1 On the Analyzer go to Diagnostics System and read the tilt angle If either angle reports 20 0 there is an electrical electronic failure tilt sensor control board electrical connections a Open the Ground Control Box b Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connec tions c Reassemble and test If fault persists replace tilt sensor If the Analyzer displays angles other than 20 0 attempt to calibrate If machine will not calibrate note the reason displayed on Analyzer a SENSOR FAILURE tilt sensor internal fre quency is out of range replace sensor b NOT LEVEL tilt sensor has either developed an offset or it is to unlevel as mounted on the machine 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3 3 LEVEL SENSOR AND ANALYZER CONNECTIONS The level sensor is located at the ground control station trol station on the under side of the platform control box as Using a screwdriver open the ground control station and shown in Figure 3 2 Level Sensor and Analyzer Connec locate the level sensor as shown in Figure 3 2 Level Sen tions sor and Analyzer C
222. nd forth during normal operation In the event that the EPR fails to communicate or the Com munications Area Network CAN cable fails to transmit data the regulator will operate in an open loop configura tion As the air valve vacuum in the mixer venturi is com municated to the secondary chamber of the regulator the secondary diaphragm will be drawn in a downwards motion This downward motion will cause the secondary lever to open thus allowing more fuel to enter the mixer In the LPR the fuel is vaporized and the pressure reduced in two stages The first stage reduces the pres sure to approximately 1 0 to 3 0 psi 6 8 to 20 6 kPa The second stage reduces the pressure to approximately neg ative 1 5 of water column The fuel is then drawn from the secondary chamber of the LPR by the vacuum generated by air flowing through the mixer This vacuum signal is also used to generate lift for the mixer air valve 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 3 72 JLG Sizzor Diagnostic Aids This procedure is intended to diagnose a vehicle operat ing on LPG If the vehicle will not continue to run on LPG refer to Hard Start for preliminary checks Before proceed ing with this procedure verify that the vehicle has a suffi cient quantity of fuel and that liquid fuel is be
223. nger by moving it away from the contact with a screwdriver 7 Hold the rear seal in place as removing the contact may displace the seal HD30 HDP20 Series Assembly Figure 6 14 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 6 10 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 LOCKING FINGERS CONTACT CONTACT INSERTION c UNLOCKED POSITION CONTACT LOCKED IN POSITION 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 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 12 Slide tool along into the insert cavity until it engages contact and resistance is felt 13 Pull contact wire assembly out of connector TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 6 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121133 JLG Sizzor 6 11 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 5 SWITCHES Basic check The following check determines if the switch is
224. ns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries 2 6 NOTICE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM NOTE This machine requires periodic safety and mainte nance inspections by a JLG Dealer A decal located on the frame affords a place to record stamp inspection dates Notify dealer if inspection is over due The inspection and maintenance code numbers are as fol lows 1 Check for proper and secure installation 2 Check for visible damage and legibility 3 Check for proper fluid level 4 Check for any structural damage cracked or broken welds bent or warped surfaces Check
225. nt REMOVAL 1 Drain the coolant 2 Using hose clamp pliers disconnect both hose clamps on each hose 3 Remove the hose from each of the fittings INSTALLATION NOTE Use hose material and lengths specified by JLG 1 Install the hose clamps to each hose and set the clamp back on each hose to make installation eas ier 2 Fitthe hose to the fittings 3 Secure by positioning each of the clamps Vapor Hose Replacement REMOVAL 1 Using hose clamp pliers disconnect both hose clamps 2 Remove the vapor hose from each fitting INSTALLATION NOTICE THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED DO NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPEC IFIED PARTS 1 Install hose clamps and set back on each hose 2 Reinstall the vapor hose to each fitting 3 Reset clamps 4 Start engine and check for leaks 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS Engine Control Module Replacement REMOVAL 1 2 3 4 Disconnect Negative battery cable Remove controller from mounting bracket Push connector lock back to unlock connector Unplug controller and remove INSTALLATION NOTICE THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY YOU HAVE THE CORRECT CONTROLLER 1 3121133 o0 N Plug connector into controller Push lock into place Mount controller into mounting bracket Reconnect the battery cable Start engine Check for any DTC codes and clear Verify engine
226. ntake man ifold leakage than the gasoline fuel supply system Check for the following Vacuum leaks Improper valve timing Low compression Bent pushrods Worn rocker arms Broken or weak valve springs Worn camshaft lobes 3121133 JLG Sizzor 3 79 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Exhaust System Checks Check the exhaust system for a possible restriction Inspectthe exhaust system for damaged or collapsed pipes Inspectthe muffler for signs of heat distress or for possible internal failure Check for possible plugged catalytic converter Refer to Restricted Exhaust System Diagnosis Hard Start DEFINITION The engine cranks OK but does not start for a long time The engine does eventually run or may start butimmediately dies Preliminary Checks Refer to Important Preliminary Checks Make sure the vehicle s operator is using the correct starting procedure Sensor Checks Fuel System Checks Check the Engine Coolant Temperature sensor with the scan tool Compare the engine coolant temperature with the ambient air temperature ona cold engine IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine check for high resistance in the coolant sensor circuit Refer to DTC 111 Check the Crankshaft Position CKP sensor Check the Throttle position TPS sensor
227. ntinuity Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accurate mea surement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 42 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 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect battery terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 Onone side jumper from contact of wire 41 and wire 42 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measure ment If still no continuity repair wires or consult schematic for other wires to use for test Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 throug
228. o checking pressures JLG Industries Inc also recommends the use of a calibrated gauge Pressure readings are acceptable if they are within x 596 of specified pressures 1 Install pressure gauge at the MP1 port 2 Adjust both Steer Section Crossover Relief s all the way in 3 Adjust Main Relief Cartridge out several turns 4 Activate engine and allow hydraulic system to come up to operating temperature 3121133 Lift 5 Bottom out Steer function Adjust Main Relief to 3000 psi 207 bar Bottom out Steer Right and Steer Left functions and adjust each Steer Crossover Relief to 2800 psi 193 bar Bottom out Lift Up functions and adjust Lift Pressure to 2700 psi 186 bar De energize Lift function shut down motor and dis connect pressure gauge 4 15 SECTION 4 HYDRAULICS 4 10 DRIVE HEADER VALVE 2WD A1 B1 JI A 5 waoscH REXROTH V 1800918425 LII d O Figure 4 17 Drive Header Valve 2wd item Torque 45 50 ft lbs 1 FSDH XAN 61 68 Nm 25 30 ft lbs 2 CXAD XCN 34 41 Nm 4 11 DRIVE HEADER VALVE 4WD LRA Ne S L LFB RFA CO
229. oes not have a pressure regulator or a return circuit to the fuel tank Fuel pressure for this engine is regulated by the engine s ECM The ECM receive fuel pressure and tem perature feedback from the gasoline fuel sensor manifold and uses this information to control the ground side of the fuel pump Fuel pressure is regulated by the ECM pulse width modulating PWM the fuel pump The fuel pressure and temperature sensor manifold has a return or bleed circuit that connects back to the fuel tank This circuit is used to bleed off any vapor that develops in the line and return a small amount of fuel to the tank The fuel comes from the fuel tank and passes through the fuel pump Fuel exits the fuel pump passes through the filter and then enters the fuel pressure and temperature manifold assem bly Fuel flows through the feed circuit and is delivered to the fuel injector rail Fuel that enters the bleed circuits through they bypass valve in the manifold is returned to the fuel tank Return Bleed Port Bleed Return Circuit Fuel Feed Circuit Figure 3 36 Gasoline Fuel Pressure and Temperature Manifold Assembly 3121133 Fuel Filter After the fuel is drawn into the fuel pump the fuel flows 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 Maintenance of
230. om the groove the remainder can be easily pried free using ones fingers or pliers SPANNER NUT RETAINING RING 7 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable 4 4 JLG Lift With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel ROD SUPPORT SUPPORT TABLE Figure 4 4 Cylinder Rod Support Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Step 11 applies only to the steer cylinder Loosen and remove nut which attaches the piston to the rod and remove the piston Loosen and remove the cap screw s if applicable which attach the tapered bushing to the piston 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 3121133 SECTION 4 HYDRAULICS 13 14 15 16 17 Remove the bushing from the piston PISTON TAPERED BUSHING CAP SCREWS Figure 4 5 Tapered Bushing Removal Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings Remove piston spacer if applicable from the rod Remove the rod fr
231. om the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 3121133 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary 10 11 12 13 NOTE Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality
232. on of the air fuel metering system is to control the air fuel delivery to the engine Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve The main control sensor is the heated oxygen sensor 25 located in the exhaust system The HO2S tells the ECM how much oxygen is in the exhaust gas The ECM changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mix ture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most effi cient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system 3121133 The ECM monitors signals from several sensors in order to determine the fuel needs of the engine Fuel is deliv ered under one of several conditions called modes All modes are controlled by the ECM Refer to Open Loop and Closed Loop Operation for more information JLG Sizzor 3 39 SECTION 3 CHASSIS amp SCISSOR ARMS FUEL PRESSURE REGULATOR The fuel pressure regulator is a relief valve mounted in the fuel filter It provides a constant fuel pressure of 441 kPa 64 psi If the pressure is too low poor performance and a DTC 32 will set If the pressure is too high excessive odor and or a DTC 42 will result When replacing the fuel filter be sure to use an identica
233. onnections There are two analyzer connection ports One in the NOTE Ensure that the level sensor is installed with the bub ground control station and the other at the platform con ble towards the top side of the lower control box Level Sensor Ground Control Analyzer Connection Analyzer Connection Figure 3 2 Level Sensor and Analyzer Connections 3121133 JLG Sizzor 3 5 SECTION 3 CHASSIS amp SCISSOR ARMS Tilt Sensor JLG P N 4000006 1 Ground Control Box 2 Tilt Sensor JLG P N 4000006 Figure 3 3 Tilt Sensor Location Tilt Sensor Removal NOTE Refer to Figure 3 4 Tilt Sensor Removal for num bers in parenthesis 1 Disconnect the batteries 2 Open the Ground Control Box to gain access to the Tilt Sensor Assembly 3 Remove the four Screws 2 and Lockwashers 3 to remove the Tilt Sensor 1 from the Ground Control Box NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 3 2 Calibrations 1 Tilt Sensor JLG P N 4000006 2 Screw 6 32 x 3 4 3 Lockwasher Figure 3 4 Tilt Sensor Removal Table 3 1 Tilt Sensor Harness Chart Wire Color Function Connector Pin Red 1 Black Ground 4 Blue PWMX 2 Yellow PWMY 3 3 6
234. orm control stations to insure all warning indicator lights are functioning Checking Filling Engine Oil Level AN OVERFILLED CRANKCASE OIL LEVEL OVER THE SPECIFIED FULL MARK CAN CAUSE AN OIL LEAK A FLUCTUATION OR THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE DROP IN THE OIL PRESSURE AND ROCKER ARM CLATTER IN USE OF BELT DRESSING OR ANTI SLIPPING AGENTS ON THE ENGINE THE DRIVE BELT Belt Adjustment 1 Remove existing belt and discard 2 Install new belt 21mm X 1187mm 3 Unload spring in belt tensioner 4 Return alternator adjustment to original position and tighten bolt 5 Release belt tensioner 6 Check position of belt tensioner stop 7 Readjust alternator position as necessary to allow correct positon of belt tensioner stop Engine Electrical System Maintenance The engine electrical system incorporates computers and microprocessors to control the engine ignition fuel con trol and emissions Due to the sensitivity of the computers to good electrical connections periodic inspection of the electrical wiring is necessary When inspecting the electri cal system use the following Check and clean the battery terminal connections and insure the connections are tight 3 58 NOTICE CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL OIL LEVEL MUST BE MAINTAINED BETWEEN THE ADD MARK AND FULL MARK ON THE DIPSTICK To ensure that you are not getting a false reading make sure the following
235. output various functions Input output DigInOut Fault lamp and diagnostic button Output PWM 1 Dig 1 PWM or digital output various functions Multi function input Genset applications gear shift motor brake Input digital 10 velocity Speed signal tacho input NC Not occupied NC Not occupied L line Serial ISO 9141 interface K line Serial ISO 9141 interface CAN high Interface for CAN Bus CAN low Interface for CAN Bus U Batt Positive pole for battery clamp 15 Output digital 5 Digital output various functions Output digital 7 Frequency Frequency PWM or digital output various functions Ground Reference potential for signal at pins 18 19 and 21 Input digital 1 PWM 1 PWM 1 or digital input 1 various functions Multi function input Digln 4 Performance curve switching genset applications Multi function input digital 8 analog 3 Hand hand throttle genset applications Digital 8 or analog input 3 Input digital 2 PWM 2 PWM 2 or digital input 2 various functions Screen Screening e g for lines hand throttle or PWG GND Reference potential for signal at pin 24 Input analog 1 digital 6 Analog input 1 pedal value sensor PWG or digital input 6 5 V REF JL G Sizzor 5 V Reference voltage for signal at pin 24 F
236. pecial tool is used to install a new rod seal into the applicable cylinder head gland groove SEAL TOOL 1 7004275 1 1 2 7004276 2 7002826 CYLINDER 4 HEAD Figure 4 7 Rod Seal Installation WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION WHEN INSTALLING THE WIPER SEAL ON THE LOWER TOWER LIFT CYLINDER APPLY LOCTITE 609 ON THE WIPER SEAL IN THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE SEAL 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable cylinder head gland groove PISTON REF Figure 4 8 Poly Pak Piston Seal Installation 4 6 CYLINDER HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head Figure 4 9 Wiper Seal Installation n Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD O RING BACKUP RING NOTE JLG Lift Figure 4 10 Installation of Head Seal Kit Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the
237. ponents which are shared by both systems include the Electronic Throttle Control and the ECM The ECM contains a dual calibration one controls the gasoline fuel system during gasoline operation and one controls the LPG fuel system during LPG operation Fuel Filter Propane fuel like all other motor fuels is subject to con tamination from outside sources Refueling of the equip ment s tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system It is therefore necessary to filter the fuel prior to entering the fuel system components down stream of the tank An inline fuel filter has been installed in the fuel system to remove the dirt and foreign matter from the fuel The inline filter is replaceable as a unit only Main tenance of the filter is critical to proper operation of the fuel system and should be replaced as Section 1 In severe operating condition more frequent replacement of the filter may be necessary Electric Lock Off The Electric Lock Off device is an integrated assembly When energized the solenoid opens the valve and allows the Propane fuel to flow through the device The valve opens during cranking and run cycles of the engine The lock off supply voltage is controlled by the engine control module ECM Figure 3 28 Electric Fuel Lock Off JLG Sizzor 3 61 SECTION 3 CHASSIS amp SCISSOR ARMS EPR Assembly The EPR assembly is
238. pressure Are excessively heavy loads being carried Is their often rapid acceleration Suggest to the owner to fill the fuel tank and to recheck the fuel economy Suggest that a different operator use the equipment and record the results Fuel System Checks Check the LPR fuel pressure Refer to LPG Fuel System Diagnosis Check the fuel system for leakage Sensor Checks Check the Temperature Manifold Absolute Pressure TMAP sensor 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 Improper gap Burned electrodes Heavy deposits Check the ignition wires for the following items Cracking Hardness Proper connections 3121133 JLG Sizzor 3 83 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 14 Symptom Diagnosis Checks Action Cooling System Checks Additional Check Checkthe engine thermostat for always being open or for the wrong heat range Check the transmission shift pattern Refer to the OEM Transmission Controls section the Service Manual Check for dragging brakes Rough Unstable or Incorrect Idle Stalling DEFINITION The engine runs unevenly atidle If severe enough the engine or vehicle may shake The engine idle speed may vary in RPM Either condition may be severe enough to stall the
239. r Rh 4 14 Main Valve Hydraulic 5 4 15 Drive Header Valve e Rr Rep RR ERE sa 4 16 Drive Header Valve 4wd essas sraa ee n mm hme 4 16 Header Valve FiX o oi rive eese Mex b Pe eise 4 17 Header Valve ens ER wee oad 4 17 Directional Valve ucu s ANS eR PEE VENUE E d qs 4 18 Power Deck Sandwich Valve Dual Deck Extension Only 4 19 Power Deck Manifold Valve siasa 4 19 Pump Pressure Locations s iig gu e ka n kr hne 4 20 Auxiliary Purrip Motor vu pomo wa pr aet pO aan be add Dacha dades 4 21 Steer Cylinder Prior to S N 137518 4 22 Steer Cylinder S N 137518 to Present 4 23 Lift Cylinder shea icis Re ee TR ps eA itys ma uma kutimuq Ree ates 4 24 Lift Cylinder Valve Cartridge Torque 4 25 Oscillating Axle RII I 4 26 Oscillating Axle Valve Cartridge Torque 4 27 Leveling Jack 4 28 Deck Extension
240. r from the housing Remove and discard the housing seal Remove and discard the retaining bolt seal Remove and discard mounting plate to lock off O ring seal INSTALLATION NOTICE BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS ING BEFORE INSTALLING NEW SEAL 1 Install the mounting plate to lock off O ring seal Install the retaining bolt seal Install the housing seal Drop the magnet into the bottom of the filter hous ing Install the filter into the housing Install the retaining bolt into the filter housing Install the filter up to the bottom of the electric lock off Tighten the filter retaining bolt to 106 in Ibs 12 Nm Open manual shut off valve Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test Propane Fuel System Pressure Relief A CAUTION THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PER SONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRES SURE WHERE APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS To relieve propane fuel system pressure 1 Close the manual shut off valve on the propane fuel tank Start and run the vehicle until the engine stalls Turn the ignition switch OFF A CAUTION RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING A
241. r operation of the TPS sensor Exhaust System Checks Check the exhaust system for a possible restriction Inspect the exhaust system for damaged or collapsed pipes Inspectthe muffler for signs of heat distress or for possible internal failure Check for possible plugged catalytic converter Engine Mechanical Check Check the engine for the following Engine compression Valve timing Improper or worn camshaft Refer to Engine Mechanical in the Service Manual Additional Check Check the ECM grounds for being clean tight and in their proper locations Check the generator output voltage If all procedures have been completed and no malfunction has been found review and inspect the following items Visually and physically inspect all electrical connections within the suspected circuit and or systems Check the scan tool data Poor Fuel Economy DEFINITION Fuel economy as measured by refueling records is noticeably lower than expected Also the economy is noticeably lower than it was on this vehicle at one time as previously shown by an by refueling records Preliminary Checks Refer to Important Preliminary Checks Check the air cleaner element filter for dirt or being plugged Visually Physically check the vacuum hoses for splits kinks and proper connections Check the operators driving habits for the following items Is there excessive idling or stop and go driving Are the tires at the correct air
242. r separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface 3 Pins should be replaced if any of the following is observed pin should be properly cleaned prior to inspection a Detectable wear in the bearing area b Flaking pealing scoring or scratches on the pin surface c Rusting of the pin in the bearing area 4 Re assembly of pinned joints using filament wound bearings a Housing should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination b Bearing pins should be cleaned with a solvent to remove all grease and oil filament wound bearing are a dry joint and should not be lubri cated c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and opera tion JLG Lift 2 5 SECTION 2 GENERAL 2 6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five colum
243. raulic Diagram 4WD u U i sa uwunku RH ue 6 41 Hydraulic Diagram Leveling lt 6 42 Hydraulic Diagram Deck Extension Single 6 43 Hydraulic Diagram Deck Extension 6 44 Hydraulic Diagram Deck Extension Dual 6 45 Electrical Components Installation Sheet 1 6 46 Electrical Components Installation Sheet 2 6 47 JLG Lift TABLE OF CONTENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Operating Specifications sr re spekei uu tenet ees 1 1 1 2 Capacities uu uw IE RERUM EL Seis Sie TREE PER HEROS 1 1 1 3 Ford LRG 425 Specifications 0 2 ete teens 1 1 1 4 Deutz F3M2011 Specifications 1 1 1 5 GM 3 0L Specificatioris oe tag Phe ao Ex RE El Sl Pee ae oda 1 2 1 6 Tire Specifications ns rq TERIS PvE iu DER REQUE Rp 1 2 1 7 Pressure Settings x scura Ag ee eee a 1 2 1 8 High Drive Cut Out Height 1 3 1 9 Tilt Sensor Indieators t tn Pad d tee uel eat 1 3 1 10 Cylinder Specifications ss eene Ro ee eoe Rd E E Ie ROSE hn 1 3 1 11 Major Component
244. reful visual and physical engine inspection before performing any diagnostic procedure Perform all necessary repairs before proceeding with additional diag nosis this can often lead to repairing a problem without performing unnecessary steps Use the following guide lines when performing a visual physical inspection check Inspect engine for modifications or aftermarket equip ment that can contribute to the symptom verify that all electrical and mechanical loads or accessory equip ment is OFF or disconnected before performing diag nosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routing inspect intake manifold sealing surface for a possible vacuum leak Inspect PCV valve for proper installation and operation 3121133 Inspect all wires and harnesses for proper connections and routing bent or broken connector pins burned chafed or pinched wires and corrosion Verify that harness grounds are clean and tight Inspect engine control module ECM sensors and actuators for physical damage Inspect ECM grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamina tion winter summer blend Inspect intake air system and air filter for restrictions Inspect battery condition and starter current draw If no ev
245. ring device and is completely self contained The mixer is an air valve design utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load The mixer is mounted in the air stream ahead of the throttle control device When the engine begins to crank it draws in air with the air valve covering the inlet negative pressure begins to build This negative pressure signal is communicated to the top of the air valve chamber through 4 vacuum ports in the air valve assembly A pressure force imbalance begins to build across the air valve diaphragm between the air valve vacuum chamber and the atmospheric pressure below the diaphragm The air valve vacuum spring is cali brated to generate from 4 0 inches 101 6 mm of water column at start to as high as 14 0 inches 355 60 mm of water column at full throttle The vacuum being created is referred to as Air Valve Vacuum AVV As the air valve vacuum reaches 4 0 inches 101 6mm of water column the air valve begins to lift against the air valve spring The amount of AVV generated is a direct result of the throttle position At low engine speed the air valve vacuum is low and the air valve position is low thus creating a small ven turi for the fuel to flow As the engine speed increase the AW increases and the air valve is lifted higher thus creat ing a much larger venturi This air valve vacuum is com municated from the mixer venture to the LPR secondary chamber
246. rotary switch is aligned with the bladed pin mounted on the center link as shown in Figure 3 1 Limit Switch Location There must be a preload when installing the rotary switch on the bladed pin bracket There are 3 mounting screws that hold the switch onto the center link mounting lug make sure they are snug not loose so you are able to rotate the rotary switch Make sure the deck is fully lowered Plug in the ana lyzer and enter the service password 33271 Go to CALIBRATIONS then SET ELEV SENSOR and hit enter then right arrow JLG Sizzor 5 The bottom line on the analyzer display will show the range of voltage the sensor must be within for proper calibration the actual voltage is displayed on the bottom line to the right as shown A S LEE SET ELEV SENSOR 0 50V 1 0V X XXV a 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 6 Press the left arrow button and then enter NOTE Anytime the ground control board or if the rotary sen sor is replaced the rotary sensor must be reset zeroed out When stowed if angle sensor is within the range of CALIB see below the machine should be recali brated If the gap ever increases beyond 5 16 in the switch may cause intermittent operation 7 Completely lower the platform Using the analyzer press escape and scroll through DIAGNOSTICS and then go to ELEV SENSOR press ENTER Check to see that the follow
247. s This nullifies the effectiveness of the connector seals and could result in system failure WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST gt BOTH BE VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 6 11 Connector Installation 3121133 JLG Sizzor 6 9 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedge lock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 6 13 DT DTP Contact Removal 5 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 6 To remove the contacts gently pull wire backwards while at the same time releasing the locking fi
248. s In accordance with the information of the current condition of the engine and the preconditions throttle position etc the EMR2 controls an actuator that operates the control rod of the injection pump and thus doses the fuel quantity in accordance with the performance require ments The exact position of the regulating rod is reported back and if necessary is corrected by means of the control rod travel sensor situated together with the rotation mag nets in a housing of the actuator 3 44 JLG Sizzor The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emer gency running Limp home functions In order to switch the engine off the EMR2 is switched in a de energized fashion over the ignition switch A strong spring in the actuator presses the control rod in the de energized condition into the zero position As a redun dancy measure an additional solenoid serves for switch ing off and this independently of the actuator also moves the control rod in the de energized condition into the zero position After the programming that is carried out over the 1809141 interface the EMR2 possesses a motor specific data set and this is then fixedly assigned to the engine Included in this are the various application cases as well as the customer s wishes regarding a particular scope of function Each EMR2 module is matched by serial number to the engine Modules cannot be
249. s to level 1 which will permit you to change all machine person ality and or machine setup settings 4 WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE The flash code is indicated on the face of the platform control box as shown SYSTEM FAULT 1705189A NOTE Flash codes are also displayed on the handheld ana lyzer For descriptions see Table 5 1 Fault Code Listing 3121133 NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS 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 Lift 5 5 SECTION 5 JLG CONTROL SYSTEM 5 2 FLASH CODES AND DESCRIPTIONS Table 5 1 Fault Code Listing Software P1 X E Communicated Displayed on Analyzer Fault Description Priority None 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 FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Reported when the trigger is not closed with function selected and joystick out of cen
250. sent in the fuel system Disconnect the electrical connector to the Electric Lock off 5 Remove the Electric Lock Off from the regulator 6 Remove the lock pin from the vapor fitting on the regulator housing and remove the fitting and hose and retain the pin 7 Remove the lock pin from the pressure sensor on the regulator housing and remove the Sensor and retain the pin 8 Using a clamp pliers pinch off the hoses on the cool ant lines to the regulator 9 Remove the lock pin from both the water fittings on the regulator housing and remove the fittings and hoses and retain the pin 10 Disconnect the EPR electrical connector 11 Remove the 3 three nuts from the EPR isolators and the EPR mounting bracket 12 Remove the EPR from the bracket 13 Remove the 3 three mounting isolators INSTALLATION NOTICE DO NOT USE TEFLON TAPE ON ANY FUEL FITTING USE A LIQ UID PIPE THREAD SEALANT WHEN INSTALLING FITTINGS CHECK ALL THE O RINGS ON THE VAPOR AND WATER FIT TINGS FOR ANY DAMAGE REPLACE IF NECESSARY LUBE ALL THE O RINGS WITH AN O RING LUBE BEFORE INSTALLING 1 NOTE JLG Sizzor Install the three 3 rubber isolators to the bottom of the EPR Install the EPR assembly to the bracket and tighten the retaining nuts Do not over tighten the isolators and cause a separa tion of the isolators Install the fuel temperature sensor into the regulator opening and lock in place with the locking
251. slightly decrease during forward or reverse operation Continue to cycle slowly between for ward and reverse for at least five minutes Shut down engine remove gauges and plug ports Check reservoir level and add filtered fluid if needed The machine is now ready for operation 4 8 HYDRAULIC GEAR PUMP Overhaul pump only in a clean dust free location using clean tools and equipment dirt and grit will damage the highly machined surfaces and will result in leakage or pre mature failure of the pump Scribe match marks Before beginning disassembly scribe match marks on the body 13 and covers 5 and 6 to insure that the pump will be reassembled in the same manner as it was shipped from the factory If the body or rear cover is replaced dur ing overhaul scribe a match mark on the new part in the same location as on the part it replaced Pump Disassembly 1 Clean outside of pump with a good grade solvent and dry thoroughly 2 On models with a splined drive shaft proceed to step 3 On models with a keyed drive shaft remove drive key 10 from drive shaft Using a file or stone remove burrs from shaft end of keyway 3 Using light clamping pressure on the ears of the front cover secure unit in vise with shaft side down remove cap screws 14 and washers 9 4 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
252. slodged 12 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 13 Secure the cylinder head gland using the washer ring and socket head bolts SPACER HEAD ASSY CYLINDER BARREL PISTON ASSY WASHER RING Figure 4 14 Rod Assembly Installation 14 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 15 If applicable install the cartridge type holding valve and fittings in the rod port block using new o rings as applicable See Table 4 2 Holding Valve Torque Specifications 4 8 JLG Lift Table 4 1 Cylinder Piston Nut Torque Specifications Description Nut Torque Setscrew p Value torque Value 400 ftlb 100inlb Lift Cylinder 542 Nm 12 Nm Lockout Cylinder N A N A Steer Cylinder N A N A Table 4 2 Holding Valve Torque Specifications Description Torque Value Sun 7 8 hex M20 x 1 5 thds 30 35 ftlb 41 48 Nm Sun 1 1 8 hex 1 14 UNS thds 45 50ftlb 61 68 Nm Sun 1 1 4 hex M36 x 2thds 150 153ftlb 204 207Nm Racine 1 1 8 hex 1 1 16 12 thds 50 55 ftlb 68 75Nm Racine 1 3 8 hex 1 3 16 12 thds 75 80 ftlb 102 109Nm Racine 1 7 8 hex 1 5 8 12 thds 100 110ftlb 136 149Nm 16 Push the piston onto the rod until it abuts the spacer end and install
253. so avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral relief s are provided for each side of the circuit 4 3 COMPONENT FUNCTIONAL DESCRIPTION Piston Hydraulic Pump The Rexroth tandem piston pump is attached to and driven by the engine The pump is a 28 cc piston pump that powers the drive motors Gear Hydraulic Pump The Bosch rexroth gear pump is piggy backed to the piston pump and operates all machine functions except drive The gear pump is a 14 cc pump which pumps 14 5 GPM Manual Descent Valve The manual descent valve is located on top of the holding valve on the lift cylinder The holding valve is a normally closed solenoid valve and holds the platform in place when raised When activated the valve opens to permit lift down The hol
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255. ssure ring Be careful not to excessively extend the rings 2 10 Grease seal rings install in supporting axle 8 Install laminations in correct order 3121133 JLG Sizzor 3 27 SECTION 3 CHASSIS amp SCISSOR ARMS 11 Mount retaining ring 13 Align the two holes for fixation cylinder pin port plate item 2 3 28 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 15 Mount bearing ring with device Mount spool 17 Fill case with oil Mount fixation pin 3121133 JLG Sizzor 3 29 SECTION 3 CHASSIS amp SCISSOR ARMS 3 5 DUAL FUEL LPG SYSTEM IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP THE FOL LOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas NOTE Before climbing onto the platform open hand valve on LP gas supply tank by turning valve counter clockwise 19 Start engine from platform control station 20 While engine is operating place the dual fuel switch at platform control station to the LPG position Allow engine to operate without load until engine begins to stumble from lack of gasoline At this time the machine is allowing the LP fuel to be sent to the fuel regulator Changing From LP Gas to Gasoline 1 With engine operating on LP under a no load condi tion throw LPG GASOLINE switch at platform con trol station to GASOLINE position
256. ssure sensoris reading a valuethatis too low COOLANT TEMPERATURE SHORT TO GROUND Reported when the coolant temperature sensor is reading a value thatis too low FORD FAULT CODE Reported by the Ford engine 1 ENGINE TEMPERATURE HIGH This faultis not reported atthis time AIR FILTER BYPASSED This fault is not reported atthis time NO ALTERNATOR OUTPUT Reported when the engine is running for at least a few seconds and the alternator input is on the ground board is high OIL PRESSURE LOW Reported when the oil pressure is below eight PSI and the engine is running for at least a few seconds 485 COMMUNICATIONS LOST Reported when a Ford engine is selected and communications with the Ford engine controller are lost ENGINE SHUTDOWN COMMANDED CHECK ENGINE Reported when the engine is commanded to shutdown by the SENSORS control system WRONG ENGINE SELECTED Reported when CAN ECM is detected and not configured DEUTZ ECM FAULT CODE Reported when the Deutz Engine Controller is giving a fault 4 4 Flash code 4 4 indicates a battery supply issue BATTERY LOW Reported when the voltage on the system is below 11 volts BATTERY TOO HIGH SYSTEM SHUTDOWN Reported when the voltage on the system is above 16 volts 8 BATTERY TOO LOW SYSTEM SHUTDOWN Reported when the voltage on the system is below 9 volts LSS BATTERY VOLTAGE HIGH Reported when the voltage on the LSS is above 34 volts LSS BATTERY VOLTAGE LOW Reported when the voltage on the LSS is below 9 volts
257. st 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifi cations appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually 2 Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Char
258. steps are taken to before check the oil level 1 Stop the engine if in use 2 Allow sufficient time approximately 5 minutes for the oil to drain back into the oil pan 3 Remove the dipstick Wipe with a clean cloth or paper towel and reinstall Push the dipstick all the way into the dipstick tube 4 Remove the dipstick and note the oil level JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 5 Oil level must be between the FULL and ADD marks FULL MARK ADD MARK Figure 3 26 Engine Oil Dip Stick If the oil level is below the ADD mark proceed to 2 Step 7 and 8 and reinstall the dipstick into the dip 3 stick tube 4 Remove the oil filter cap from the valve rocker arm cover 5 Add the required amount of oil to bring the level up to but not over FULL mark on the dipstick Reinstall the oil fill cap to the valve rocker cover and wipe away any excess oil 6 7 8 9 10 JLG Sizzor Changing The Engine Oil NOTICE WHEN CHANGING THE OIL ALWAYS CHANGE THE OIL FILTER CHANGE OIL WHEN THE ENGINE IS WARM FROM OPERATION AS THE OILS WILL FLOW FREELY AND CARRY AWAY MORE IMPURITIES To change the oil use the following steps 1 Start the engine and run until it reaches normal operating temperature Stop the engine Remove the drain plug and allow the oil to drain Remove and discard the oil filter and its sealing ring Coat the sealing ring on the f
259. swapped between engines 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS 3121133 Engine side equipment CONTROL ROD POSITION SENSOR ACTUATOR COOLANT TEMPERATURE SENSOR CAMSHAFT SPEED SENSOR OIL PRESSURE SENSOR Set and vehicle side equipment EMR 2 Control uni GLOW PLUG 42 24 y POWER SUPPLY JLG SYSTEM HANDLES ENGINE START STOP EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE CAN BUS JLG SYS TEM USES THIS TO CONTROL THE ENGINE amp FAULT REPORTING Figure 3 13 EMR 2 Engine Side Equipment JLG Sizzor 3 45 SECTION 3 CHASSIS amp SCISSOR ARMS peoejde4 CHA eur SHA gues 1 seoq peoejdeJ speeu piou os 1 8 5 pue 1 5 u L ON Heyo HIN3 1 anba Aejas 1 eui uedo ue Buneoipui syne lt lt ON y uo gt SI YOUMS eui si 1 815 uBu y Hes ueg i UJe qoJd e eyeolpul onsouDeip eui seoq ON zjneq esn lt SHA 3121133 alemyos onsoubeiq doydeq jp uuoo jueumnredeq
260. t JLG Lift 3121133 SECTION 2 GENERAL 2 4 CYLINDER DRIFT TEST 2 5 PINS AND COMPOSITE BEARING Maximum acceptable cylinder drift is to be measured using the following methods Platform Drift Measure the drift of the platform to the ground Lower booms if equipped slightly elevated upper boom fully extended with the rated load in the platform and power off Maximum allowable drift is 2 in 5 cm in 10 minutes If the machine does not pass this test proceed with the follow ing Cylinder Drift Table 2 2 Cylinder Drift Cylinder Bore Diameter i T inches mm inches mm 3 76 2 0 026 0 66 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 152 4 0 006 0 15 7 177 8 0 005 0 13 3121133 Drift is to be measured at the cylinder rod with a calibrated dial indicator The cylinder oil must be at ambient temper ature and temperature stabilized The cylinder must have the normal load which is the nor mal platform load applied Ifthe cylinder passes this test it is acceptable NOTE This information is based on 6 drops per minute cyl inder leakage REPAIR GUIDELINES Filament wound bearings 1 Pinned joints should be disassembled and inspected if the following occurs a Excessive sloppiness in joints b Noise originating from the joint during operation 2 Filament wound bearings should be replaced if any of the following is observed a Frayed o
261. t REAR DECK EXTEND VALVE SHORT TO GROUND Reported by the 1 0 module and during system test when the rear deck extend valve is shortto ground REAR DECK EXTEND VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the rear deck extend valve is shortto battery REAR DECK RETRACT VALVE OPEN CIRCUIT Reported by the 1 0 module and during system test when the rear deck retract valve is open circuit REAR DECK RETRACT VALVE SHORT TO GROUND Reported by the 1 0 module and during system test when the rear deck retract valve is shortto ground REAR DECK RETRACT VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the rear deck retract valve is shortto battery 3121133 JLG Lift 5 11 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X Communicated Displayed on Analyzer Fault Description Priority 4 3 Flash code 4 3 indicates engine issues FUEL SENSOR SHORT TO BATTERY Reported whenthe fuel sensor is reading a value that is much too high FUEL SENSOR SHORT TO GROUND Reported when the fuel sensor is reading ground FUEL SENSOR DISCONNECTED Reported when the fuel sensor is reading a value that is too high OIL PRESSURE SHORT TO BATTERY Reported whenthe oil pressure sensoris reading a valuethatis too high OIL PRESSURE SHORT TO GROUND Reported whenthe oil pre
262. t gt gt 2 x 823823223823 YEL RED 2 20 50555550555 S25 2952P 5 5 2 ENT LFT STOWED 2966905995996 BLACK SWITCH WHITE wig 93 SS BS S26 FNT RHT STOWED BLACK SWITCH WHITE XS S27 REAR LFT STOWED BLACK SWITCH WHITE 28 REAR RHT STOWED BLACK SWITCH WHITE B c B C B A REARRIGHT REARLEFT FRONTRIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCE ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE THE SHIELD FOR EACH CABLE 1870153 G SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 Figure 6 23 Electrical Schematic Diesel Prior to S N 138634 Sheet 3 of 3 6 20 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JES NOTES 3121133 JLG Sizzor 6 21 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMA
263. t the IAT sensor tempera ture and engine coolant temperature should read close to each other A failure in the IAT sensor circuit will set DTC 35 or DTC 45 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR The manifold absolute pressure MAP sensor responds to changes in intake manifold pressure vacuum The MAP sensor signal voltage to the ECM varies from below 2 volts at idle high vacuum to above 4 volts with the igni tion ON engine not running or at wide open throttle low vacuum The MAP sensor is used to determine the following Engine vacuum level for engine control purposes Barometric pressure BARO 3 36 JLG Sizzor If the ECM detects a voltage that is significantly lower than the estimated MAP value for 2 or more consecutive sec onds DTC 14 will be set A signal voltage significantly higher than the estimated MAP value for 2 or more con secutive seconds will set DTC 24 ENGINE CONTROL MODULE ECM The ECM controls the following Fuel metering system Ignition timing On board diagnostics for engine functions The ECM constantly observes the information from vari ous sensors The ECM controls the systems that affect engine performance The ECM performs the diagnostic function of the system It can recognize operational prob lems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTCs DTCs identify the problem areas to aid the technician i
264. t the speed of the complaint Monitoring the oxygen sensors will help identify the problem Check the fuel pressure while the condition exists Refer to LPG Fuel System Diagnosis Verify proper fuel control solenoid operation Verify that the LPG manual shut off valve is fully open Check the in line fuel filter for restrictions Ignition System Checks Additional Check Check for the proper ignition output voltage using the spark tester J26792 or the equivalent 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 Improper gap Burned electrodes Heavy deposits Checkthe Crankshaft Position CKP sensor Checkthe ECM grounds for being clean tight and in their proper locations Checkthe generator output voltage Checkthe vacuum hoses for kinks or leaks Check Transmission 3121133 JLG Sizzor 3 85 SECTION 3 CHASSIS amp SCISSOR ARMS 3 86 Table 3 15 DTC to SPN FMI Cross Reference Chart DTC Description SPN Code FMI Code 16 Crank Never Syncedat Start 636 8 91 Fuel Pump Low Voltage 94 4 92 Fuel Pump High Voltage 94 3 107 MAP Low Voltage 106 4 108 MAP High Pressure 106 16 111 IAT Higher Than Expected 1 105 15 112 IAT Low
265. tend valve is shortto battery LEVELING JACK RETRACT VALVE OPEN CIRCUIT Reported by the 1 0 module and during system test when the leveling jack retract valve is open circuit LEVELING JACK RETRACT VALVE SHORT TO GROUND Reported by the I O module and during system test when the leveling jack retract valve is shortto ground LEVELING JACK RETRACT VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the leveling jack retract valve is shortto battery FRONT DECK EXTEND VALVE OPEN CIRCUIT Reported by the 1 0 module and during system test when the front deck extend valve is open circuit FRONT DECK EXTEND VALVE SHORT TO GROUND Reported by the 1 0 module and during system test when the front deck extend valve is shortto ground FRONT DECK EXTEND VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the front deck extend valve is shortto battery FRONT DECK RETRACT VALVE OPEN CIRCUIT Reported by the 1 0 module and during system test when the 6 front deck retract valve is open circuit FRONT DECK RETRACT VALVE SHORT TO GROUND Reported by the 1 0 module and during system test when the front deck retract valve is shortto ground FRONT DECK RETRACT VALVE SHORT TO BATTERY Reported by the 1 0 module and during system test when the front deck retract valve is shortto battery REAR DECK EXTEND VALVE OPEN CIRCUIT Reported by the 1 0 module and during system test when the rear deck extend valve is open circui
266. ter RUNNING AT CUTBACK ABOVE ELEVATION Reported any time the machine is considered to be above ele vation ACCESSORY FAULT Reports when CAN faults are reported by an accessory mod ule FRONT LEFT LEVELING JACK AT END OF STROKE Reported when the frontleftleveling jackis reported to be atthe end of stroke pressure FRONT RIGHT LEVELING JACK AT END OF STROKE Reported when the front right leveling jack is reported to be at the end of stroke pressure 1 REAR LEFT LEVELING JACK AT END OF STROKE Reported when the rear left leveling jack is reported to be atthe end of stroke pressure REAR RIGHT LEVELING JACK AT END OF STROKE Reported when the rear right leveling jack is reported to be at the end of stroke pressure LEVELING JACK SET PREVENTED ECM LOST Reported when autoleveling is not available when communica tion with the ECM times out GENERATOR PREVENTED ECMLOST Reported when generator is not available when communica tion with the ECM times out DRIVE PREVENTED ECM LOST Reported when elevated drive is not available when communi cation with the ECM times out ELEVATION SENSOR DISAGREEMENT Reported when elevation prox switch is closed when the 26 ft 3394RT or 30 ft 4394RT voltage is reached on the elevation angle sensor prevents further lift up from platform controls 2 1 Flash code 2 1 indicates issues at power up KEYSWITCH FAULTY PLATFORM GROUND ACTIVE Reported when the ground module is reading both ground and 2 TOGETHER pl
267. ter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed con nector by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading
268. th fluid Fill the reservoir with recommended hydraulic fluid This fluid should be passed through a 10 micron nominal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to the components which may result in unexpected vehicle machine move ment NOTE If a pump or motor is being replaced due to internal damage the remaining units pump or motors need to be inspected for damage and contamination and the entire hydraulic system will need to be flushed and the fluid replaced Failure to do so may cause considerable damage to the entire system The inlet line leading from the reservoir to the pump must be filled prior to start up Check the inlet line for property tightened fittings and make sure it is free of restrictions and air leaks NOTE In most cases the reservoir is above the pump inlet so that the pressure head created by the higher oil level helps to keep the inlet pressures within an acceptable range and prevent high vacuum levels However due to hose routing or low reservoir loca tions there may be air trapped within this line It is important to assure that the air is bled from this line This can be accomplished by loosening the hose at the fitting closest the pump When oil begins to flow the line is full the air has been purged and the fitting can be retightened to its specified torque If the tank 4 10 JLG Lift needs to be pressurized in order to start t
269. the tilt sensor frequency is outside the range of acceptable value FUNCTION LOCKED OUT GROUND AUX SWITCH PER Reported when the ground auxiliary power switch is closed MANENTLY CLOSED during power up FUNCTION LOCKED OUT GROUND START SWITCH Reported when the ground start switch is closed during power PERMANENTLY CLOSED up 5 8 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing Software P1 X NE Communicated Displayed on Analyzer Fault Description Priority 2 5 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 VOLTAGE OUT OF RANGE the range of acceptable values ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported whenthe rotary calibration value does not exist ELEVATION PROX SWITCH PERMANENTLY CLOSED Reported when the elevation rotary sensor is reporting above elevation andthe elevation proximity switch is still closed ELEVATION PROX SWITCH PERMANENTLY OPEN Reported when the elevation rotary sensor is reporting stowed and the elevation proximity switch is open FRONT LEFT LEVELING JACK PRESSURE TRANS Reported when the front left leveling jack pressure reading is DUCER FAILURE well below OPSI FRONT RIGHT LEVELING JACK PRESSURE TRANS Reported when the front right leveling jack pressure reading is DUCER FAILURE wel
270. ther Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 If bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its re
271. tions aee ee eidcm Cp ERE p o dec atit sara toa ete o d dad 1 1 1 2 Capacities a Sa ete edd 1 1 1 3 ENQINGS e PTT 1 1 1 4 TOS seid da ee ects eo red HE i etica or aic mage Pa eR 1 2 1 5 Machine Dimensions eiae ee pasos isq a Plagas 1 2 1 6 Pressure Setlirigs ak oe dae WER 1 2 1 7 Serial Number Locations ep cisien aqa hr 1 2 1 8 bt we cede u 1 3 1 9 Cylinder Specifications llis 1 3 1 10 Major Component Weights mh 1 3 1 11 Critical Stability Weights ei u eee teens 1 4 1 12 Lubrication Specifications sss orere CAS S au asa Qasa ara aku 1 4 1 13 Operator Maintenance 1 5 1 14 T tq e Charts sik EM P kha Le RES 1 10 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 2 2 Service and 2 2 2 8 Lubrication and Information III 2 4 2 4 Cylinder Drift Test x AER RU d bain Se e 2 5 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Preventi
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273. ugh one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Cylinders With Single Counterbalance Valve NOTICE OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system 2 Shut down hydraulic system and allow machine to sit for 10 15 minutes If machine is equipped with bang bang or proportional control valves turn igni tion switch to on move control switch or lever for applicable cylinder in each direction then turn igni tion switch to off If machine is equipped with hydraulic control valves move control lever for applicable cylinder in each direction This is done to relieve pressure in the hydraulic lines 4 2 JLG Lift Carefully remove hydraulic hoses from appropriate cylinder port block 3 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counterbalance valve is defective and must be replaced 4 To check piston seals carefully remove the counter balance valve from the retract port After initial dis charge there should be no further leakage from the ports If leakage occurs at a rate of 6 8 drops per minute or more the piston seals are defective and must be replaced
274. und control station or at the platform control station as shown in Connect the remaining 1 Connect the four pin end of the cable supplied with end of the cable to the analyzer the analyzer to the four position connector on the Ground Control Platform Controll Analyzer Connection Analyzer Connection Figure 5 2 Analyzer Connection 3121133 Lift 5 1 SECTION 5 JLG CONTROL SYSTEM NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Control System by turning the lower key to the platform position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following i B He ENU E Wu LP 3 I H PRESS ENTER HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACCESS LEVEL PERSONALITIES MACHINE SETUP ACTIVATE TESTS CALIBRATION If you press ENTER at the HELP PRESS ENTER display and a fault is present during power up the analyzer dis play will scroll the
275. und controls FUNCTION LOCKED OUT GROUND LIFT UP PERMA Reported whenthe ground liftup switch is closed during power NENTLY CLOSED up FUNCTION LOCKED OUT GROUND LIFT DOWN PER Reported when the ground lift down switch is closed during MANENTLY CLOSED power up FUNCTION LOCKED OUT GROUND FRONT DECK EXT Reported when the ground front deck extend switch is closed PERMANENTLY CLOSED during power up FUNCTION LOCKED OUT GROUND FRONT DECK RET Reported when the ground front deck retract switch is closed PREMANENTLY CLOSED during power up FUNCTION LOCKED OUT GROUND REAR DECK EXT Reported when the ground rear deck extend switch is closed PERMANENTLY CLOSED during power up FUNCTION LOCKED OUT GROUND REAR DECKRET Reported when the ground rear deck retract switch is closed PERMANENTLY CLOSED during power up GROUND LIFT UP DOWN ACTIVE TOGETHER Reported when the ground lift up and lift down switches are closed atthe same time 4 GROUND FRONT DECK EXTEND RETRACT ACTIVE Reported whenthe ground front deck extend and retract TOGETHER switches are closed atthe same time GROUND REAR DECK EXTEND RETRACT ACTIVE Reported when the ground rear deck extend and retract TOGETHER switches are closed atthe same time NO SIGNAL FROM TILT SENSOR X AXIS CHECK WIR Reported when sensor X axis value is not valid ING NO SIGNAL FROM TILT SENSOR Y AXIS CHECK WIR Reported when sensor Y axis value is not valid ING LEVEL SENSOR FAILURE Reported when
276. ure 6 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH 4 nd Wk Sat IT LL Y Figure 6 9 Connector Assembly 4 of 4 3121133 JLG Sizzor 6 7 SECTION 6 GENERAL ELECTRICAL INFORMATION amp 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 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed a Figure 6 10 Connector Disassembly NOTE The wedge lock should never be removed from the housing for insertion or removal of the contacts Wedge Lock 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 6 8 JLG Sizzor 3121133 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Service Voltage Reading A CAUTION 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 The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strand
277. ve Maintenance and Inspection 2 6 SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 Operating Characteristics liliis 3 1 3 2 Calibrations P EA 3 2 3 3 Level Sensor and Analyzer Connections 3 5 3 4 Integrated Torque drive 9 8 3 5 Dual F el EPG Syst m E eO We et s bete s 3 30 3 6 Ford EFI Engine oed ete aed e t qe 3 31 3 7 Generator Ford Engine Jsu asua uui hr 9 49 3 8 Deutz EMR 2 S N 0200138634 to 3 44 9 9 Generator Duetz hh 3 57 3 10 GM Engine General 3 58 3 11 Generator GM Engine 3 60 3 12 GM Engine Dual Fuel System 3 64 3 13 GM Engine Fuel System 3 66 3 14 GM Engine LPG Fuel System Diagnosis 3 72 3 15 Joystick Controller SS E ense vovg 3 76 SECTION 4 HYDRAULICS 4 1 Cylinders Theory of 4 1 4 2 Valves Theory of
278. ve fuel 4 1 Connectawater column gauge or a manometer to the secondary test port of Goto Step5 Goto Step 8 the low pressure regulator LPR 2 Startthe engine and allow itto reach operating temperature Does the engine start and run 5 With the engine idling observe the pressure reading for the LPR secondary 1 0 to Go to Step 25 Goto Step 6 pressure 2 0 w c Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range 6 1 Disconnectthe EPR electrical connectors NOTE This action will cause a 1 0 to Go to Fuel Control Goto Step 7 DTC to be set by the ECM 2 0 w c System Diagnosis 2 With the engine idling observe the pressure reading on the secondary test port Is the fuel pressure WITHIN the specified range 7 1 Inspect the air intake stream between the mixer assembly and the throttle Goto Step 26 Goto Step 22 body for leaks 2 Inspect the fuel hose connection between the LPR and mixer assembly for damage or leakage 3 Inspect any vacuum hoses for leaks Was a problem found and corrected 8 1 Connecta water column gauge or a manometer to the secondary test port of Goto Step 12 Goto Step9 thelow pressure regulator LPR 2 Crankthe engine and observe the pressure reading for the LPR secondary pressure Does the fuel pressure indicate a vacuum is present 9 1 Remove Air induction hose to the mixer Goto Step 11 Goto Step 10 2 Observe the air valve for movement while the en
279. ve seconds will set OTC 42 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS uoneoo 43 0 9 31N l4 AV I3 18V1S AV TH8 H3MOd HOSN3S 3 31fT1OS8V G IOJINVIA 3409 4 1 T FD Be HOLIMS HOSN3S N39AXO Q3 1V3H 3 35 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SCISSOR ARMS INTAKE AIR TEMPERATURE IAT SENSOR The intake air temperature IAT sensor is a thermistor which changes its resistance based on the temperature of air entering the engine Low temperature produces a high resistance of 100 000 ohms 40 C 40 F High temper ature causes a low resistance of 70 ohms at 130 C 266 F The ECM supplies a 5 volt signal to the sensor through a resistor in the ECM and monitors the signal volt age The signal voltage will be high when the incoming air is cold and low when the incoming air is hot By measuring the voltage the ECM calculates the incoming air tempera ture The IAT sensor signal is used to adjust spark timing according to the incoming air density An IBM PC compati ble computer with diagnostic soft ware can be used to dis play the temperature of the air entering the engine The temperature should read close to the ambient air tempera ture when the engine is cold and rise as engine compart ment temperature increases If the engine has not been run for several hours overnigh
280. veral ways for a person to become statically charged The most common methods of charging are by friction and induction An example of charging by friction is a person sliding across a seat Charge by induction occurs when a person with well insu lated shoes stands near a highly charged object and momentarily touches ground Charges of the same polar ity are drained off leaving the person highly charged with the opposite polarity Static charges can cause damage therefore it is important to use care when handling and testing electronic components To prevent possible electrostatic discharge damage fol low these guidelines Do not touch the ECM connector pins or soldered components on the ECM board Do not open the replacement part package until the part is ready to be installed Before removing the part from the package ground the package to a known good ground on the equip ment If the part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part Fuel System FUEL INJECTOR The Electronic Fuel Injection EFI fuel injector is a sole noid operated device controlled by the ECM The ECM energizes the solenoid which opens a valve to allow fuel delivery The fuel is injected under pressure in a conical spray pat tern at the opening of the intake valve Excess fuel not used by the injectors passes t

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