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Service & Maintenance Manual

1. y BLEEDER BLEEDER y l Je d E 1547220 E GA 124 Hi OSCILLATING AXLE CD AGA 12431 CD 12 44 Jot H Ls X3 N Mox E A T MOM E 2 OFF orf cor BLEEDER X BLEEDER MA x 1 GFTIT2 4032 4x m 43 1 GEAR RATIO cm 1 7 in DISPLACEMENT d 0 85 in MIN DISPLACEMENT Wam XY are cay 4641221 RFA 12477 Al LFA RFB B B2 RRA pos SS E RRB A2 LRA x x3 CD x x n 4641225 x 2 AGA 12487 is cp Ai cp gt K U 3 IEW E NA _ In 77 X3 2120172 g2 LEK Ps 2 G Fo Ps Ga 18 1 L at Mov 5 e SET 5 t Mei 38003 EEN 2800 RPM 097 1 0 3 od 9 31 X J DIESEL ENGINE 2 By 65HP GAS ENGINE zer zl 4 ETA P Wah 1 35093 i 35091 SEE EM 213 1H 8 L dl Moi PT TX X2 s R H XZ Figure 6 7 Hydraulic Schematic 4WD Sheet 1 JLG Sizzor 3121133 SECTION 6 SCHEMATICS 3121133 LIFT CYLINDER Ix 4 5 BORE 3 5 ROD 83 0 STROKE STEER CYLINDER Ix 2 5 BORE LIFT 1 75 ROD 4 6 STROKE STEER SET AT CD 2700 51 SET AT 2
2. m PLAT ESTOP 801 elc YEL RED YEL RED 2 1 LACK TRIGGER NT VEL 2 9 SWITCH lt _ YFL RFD 2 10 81529 ag HI XELIRED 2 12 33 YEL RED 2 13 EE YELIRED 2 14 2 18 YEL RED 2 16 YEL RED 2 3 2 FERRE LIFT SWITCH FRONT DECK REAR DECK Sa eer SWITCH SWITCH SWITCH AUX Bee seer 16 SIT 18 POWER Sex eae UP DOWN EXT RET EXT RET 19 255 5555555 on EES 252252558 3101432 2 s 158 5 E bee 1 358 71 g 22 5 229Ca KEYSWITCH 332227 13 Ere 5 555 22225555 S2zzzcr GROUND 852555 255555 gt 2 3 1 SHIELDED 1 4 YEL RED 2 TWISTED PLATFORM HOUR METER 00000 BLACK WEL RED 2 1 2 YEL RED 2 1 1 1111 au Jg CIR BREAKER 199 LM RS a 20 12200 RED 1 1 8 5 3 8 3 55558 WHT RED 57 DUAL AXIS PIN 2 ANALOG PIN 4 HORN RED 43 1 TILT SENSOR pin 3 ORN RED 49 2 SSSR N 1 BLACK 25 25555 1 5555 IN 3 02 4 152555554555555 5 TTE OS EST ALT TITS GND 34 8 555 5525525252 LAMP 2 Lol SWE 3 J4 RECPTACLE JI RECPTACLE CA p VEL RED 2 4 IGN 45 6 BRN WHT 47 1 ALT 45 1 ENGINE OIL CHRP 5 2 GROUND ELECTRONICS L
3. 8 3Qvu9 AVS S 3Qvu9 AVS s1auajsej pajejd Ajdde jou op sanjeA 90010 959 1 310N 188 000891 2269 9686 9096 128v 00227 818 9 92 12144 862 00228 0082 0008 1 e 21 2217 008091 Ogre 0026 vaer 005921 6 6 60 6 61 0692 00082 0507 9 0798 8066 008161 190 5660 99 2 8896 001811 6 60 2106 8041 8 22 000 08161 08 61 e P 1886 Spe 008811 6666 9862 6100 1846 000701 8902 26 1 1671 6 61 00179 06811 9 1082 6986 006 01 862 812 00 242 00996 69 1 9161 2061 1891 00969 06 01 00621 e m 0192 6 60 00696 242 0 61 9972 00228 6SL 8961 BELL 8161 00856 0696 0 1 1902 1 81 00968 5610 9961 v9vL 2861 00024 voel 1801 968 6LL 005 7 09580 n e BAL 1981 1891 0069 8681 9681 5081 56 1 00 89 BELL 896 18 S801 00627 059 70 4 9661 00599 1601 6 01 8001 9861 00 65 166 858 612 696 00227 06990 000011 e 8801 00909 evel 166 226 0221 00519 516 58 169 898 00986 09090 8 696 198 0060S 86 vel 8 9 968 00897 GOL 9 5 GLb 159 00726 06050 08 60 pl gi v 9 6 00297 568 899 29 18 00917 609 vey 689 00762 02970 6 168 00 6 069 90 vey 698 00966 Ley 696 862 10 00862 06 60 00470 91 re 56 00966 695 807 086 SLS 00106 986 9 LZ ese 00815 0 66 0 0L 886 862 00952 65 144 506 00062 862 102 91 Oez 00691 09570 08290 81 ELE 590 00922 506 oez 867 08606 581 502 00 7 09220 LL Lv vez 0002 862 602 9 1 Oez 09281
4. 4 16 4 18 Oscillating Axle Valve Cartridge Torque 4 17 4 18 Lift Cylinder Valve Cartridge Torque 4 18 4 19 Steer Cylinder uei ede e retos ted oh ga ben A QUOS EUER TE alg duds 4 19 4 20 Lift Cylitider iiec DR de Were eee a DEP Ira edie 4 20 4 21 Oscillating Axle 4 21 4 22 Oscillating Axle 4 22 4 23 Leveling Jack Cylinder 1 4 23 5 1 Analyzer 5 1 5 2 Analyzer Flow Chart Sheet 1 2 2 5 16 5 3 Analyzer Flow Chart Sheet 2 2 eneen 5 17 6 1 Electrical Schematic Dual Fuel Sheet 1 6 2 6 2 Electrical Schematic Dual Fuel 2 6 3 6 3 Electrical Schematic Dual Fuel 6 4 6 4 Electrical Schematic Diesel 1 6 6 6 5 Electrical Schematic Diesel 12 6 7 6 6 Electric
5. 4 2 Cylinders Without Counterbalance Valves Steer 4 2 Cylinders With Single Counterbalance 4 2 45 Cylinder creen RIEN REA aa Een ua iu 4 2 Disassembly scii s zi e gc aan dee al ele RR s a nae 4 2 Cleaning and 4 4 Assembly e b hee mn Ret e RR ERR Rod Ros TUR Rn 4 5 4 6 Drive Pump Start up Procedure 2 4 4 8 4 7 Hydraulic Component Start Up Procedures and Recommendations 4 9 4 8 Hydraulic Gear PUMP x bre ie eg been ede quee d edes 4 10 P mp Disassembly Gre aras eL Ete e tw oi oe i 4 10 Parts Inspection ant aen Aden Bode Ee s aes 4 11 Pump Reassembly d eme oe Rx Re epe so dol M n x 4 11 4 9 Pressure Setting Procedures 4 14 Valve VENE WE P WWW das Se We T 4 14 4 10 Oscillating Axle Bleeding Procedure 4 22 SECTION 5 JLG CONTROL SYSTEM 5 1 Electronic Control 5 1 To Connect the Hand Held 5 1 Using the Analyzer inne enor eere op ergo we p eet V e
6. 1 4 PRESSURE SETTINGS Table 1 5 Pressure Settings PSI Bar Main Relief 3000 207 Steer Relief 2800 193 Lift 2700 186 Leveling Jack Relief 2500 172 3121133 JLG Sizzor SECTION 1 SPECIFICATIONS 1 6 SENSORS The machine is equipped with the following limit switches Elevation Switch Roatary Position Sensor High drive speed is cut out when platform is raised above the preset heights listed in Table 1 6 High Drive Cut Out Height Table 1 6 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 is sounds and a warning light is illu minated when the machine is operated on a slope that exceeds the values in Table 1 7 Tilt Cut Out The lift and drive functions will cut out at these set heights NOTE Alarm only sounds when above elevation SERIAL NUMBER PLATE SERIAL NUMBER STAMPED NOTE If the machine is operated beyond the specified slope with the platform completely lowered only the warning light is illuminated Figure 1 1 Serial Number Location Table 1 7 Tilt Cut Out Model Front To Back Side To Side 1 5 SERIAL NUMBER LOCATIONS For machine identification serial number plate is affixed 3394RT Australia 5 to the machine The plate is located at the rear of the machine on the left side of the axle In addition
7. 1 4 2 0 55 2 1 2 2 Service and 2 2 General Rr Leer rer en ea C PA eI Uri are Ea 2 2 Safety and Workmanship 2 2 Gleanliri8ss u 0 MAE Feu cd eb els e et 2 2 Components Removal and 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts scene eee ere denk s m ure nne 2 3 5 ee pa ee aal piat 2 3 GaSkels rra ork un DOE op RE pa h 2 3 Bolt Usage and Torque Application 2 3 Hydraulic Lines and Electrical Wiring 2 3 Elydraulic Systerms sse edt dt Ren EID es d dl 2 8 Lubricatlori IER rg 2 3 Battery 2 3 Lubrication and Servicing 2 2 3 2 3 Lubrication and Information 1 2 4 Hydra lic System 24s RITE EE ra Bb dee 2 4 Hydraulic Oil stearine ed End Oe ani nares uod Zaad 2 4 Changing Hydrauli
8. GLOW PLUG RELAY IGNITION RELAY 5 9 IE E ALTERNATOR GAS O MACHINES THROTTLE CONTROLLER GAS MACHINES ej 1 LIFT CYLINDER Ol PORT BLOCK 1e B PROP HYDRAULIC VALVE PUMPS 29 PLATFORM MODULE T LIFT DOWN VALVE FUEL BEACON HORN 2 LEVEL LIGHT ROTARY SENSOR SENSOR PORT BLOCKS Ed OSCILLATING AXLE ALARM CYLINDERS ELEVATION ND SWITCH MAIN VALVE LH E gt g m L ONCE FUEL ue rai tN IE r Olle MAGHINES D jole Q A Q GROUND CONTROL BOX Figure 6 16 Electrical Componants Installation Sheet 2 3121133 JLG Sizzor 6 19 SECTION 6 SCHEMATICS This page left blank intentionally 6 20 JLG Sizzor 3121133 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries
9. Lubrication Hydraulic Qil aa oe emet Em e eO Mobil DTE 13M Mobil EAL 224H Inspection and Cylinder Drift oec tege ante adden RR ade Preventive Maintenance and Safety Inspection ECM Diagnostic Trouble Cylinder Piston Nut Torque Specifications Holding Valve Torque Specifications Main Valve Torque Pump Pressure vena mer ee EE ee Cartridge Torque Fault Code 0 Fault Code Listing Software Version 1 14 Machine Model Adjustment Machine Configuration Programming Information Machine Configuration Programming Information Machine Tilt Configuration JLG Lift PAGE NO 3121133 SECTION 1 SPECIFICATIONS 1 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS Table 1 1 Operating Specifications Model 3394RT 4394RT Maximum Occupants 6 Maximum Workload Capacity
10. ANON ANO A O M 3 TC I3 0401 annouD L101 1 NOLIJND 11010 41145 ANIEDVI L 133HS 5 17 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 3 Machine Model Adjustment Adjustment Adjustment Range Default 3394RT Default 3394RT Default 4394RT Default 4394RT 2WD 4WD 2WD 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 DRIVEFORWARDMIN 0 35 24 24 24 24 DRIVEFORWARD MAX 0 100 70 70 70 70 DRIVEREVERSEMIN 0 35 24 24 24 24 DRIVEREVERSE MAX 0 100 70 70 70 70 MAXENGINE SPD 800 2900RPM 2800 2800 2800 2800 MID ENGINE SPD 800 2700RPM 2000 2000 2000 2000 DRIVE ELEVATED 20 50 41 41 41 41 LIFT LIFT UP ACCEL 0 1 5 0 Sec 2 2 2 2 LIFT UP DECEL 0 8 1 5 Sec 1 1 1 1 LIFT UP MIN 0 35 12 12 12 12 LIFT UP MAX 0 65 55 55 45 45 LIFT DOWN MIN 0 35 12 12 12 12 LIFT DOWN MAX 0 65 55 55 40 40 LIFT UP ENGINE SPD MAX 800 2900RPM 2800 2800 2800 2800 LIFT UP ENGINE SPD MID 800 2700RPM 2000 2000 2000 2000 STEER ENGINE SPD 800 2900RPM 2800 2800 2800 2800 GROUND LIFT UP MAX 0 65 55 55 45 45 LIFT DOWN MAX 0 65 55 55 40 40 LOAD OVERLOAD 1000 2700165 2475 2475 1650 1650 454 1225 kg 1123kg 1123kg 748 748 kg OVERLOAD 2 1000 2700
11. Cylinder Bore Diameter Max Acceptable pan 3 Pins should be replaced if any of the following is in 10 Minutes observed pin should be properly cleaned prior to inches mm inches mm inspection 3 76 2 0 026 0 66 Detectable wear the bearing area 35 89 0 019 0 48 b Flaking pealing scoring or scratches on the pin 4 101 6 0 015 0 38 surface 5 127 0 009 0 22 Rusting of the pin in the bearing area 6 152 4 0 006 0 15 4 Re assembly of pinned joints using filament wound 7 177 8 0 005 0 13 bearings Drift is to be measured at the cylinder rod with a calibrated Should De Blown MEO NE all dui dial indicator The cvlinder oil t be at ambient t _ and debris bearings and bearing housings NSP must be free of all contamination ature and temperature stabilized b Bearing pins should be cleaned with a solvent The cylinder must have the normal load which is the nor to remove all grease and oil filament wound mal platform load applied bearing are a dry joint and should not be lubri cated If the cylinder passes this test it is acceptable c Pins should be inspected to ensure it is free of fe T burrs nicks and scratches which would dam NOTE This information is based on 6 drops per minute cyl age the bearing during installation and opera inder leakage tion 3121133 JLG Lift 2 5 SECTION 2 GENERAL 2 6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection
12. SNOLLYHSTTY KVIV dl 9114 MOTD Ts 613145 OML TAART OLAY 9 NYOH UDIAL 114015 W O 103188 4 0 Lis wo SSAMLSIO SAS 19345 XW DATS Ca 193135 01 111115 09 1141915 TAS OL MIND TAS UIN 4044 1881 SNOLONDA TIV NTV 50111581 US 1881 ARI dN L AAA MON I IXA W940 YVAN I LAY MOC INA I IXA MOS INA I IXA I ATI LHA I AVAN I ATT LHA INA I AT LIT INA I ISV LUIS dT I SMT9 Sd ALY 09 I T 28041 I 2501 1904 I LATTd0Ud T XW T T MAAS DI 9114 MOTD WAALS NMOC LITT DAVIS I dS ULM CAH I A ARI I MS ONNOUD ISAL ONT 3 ISAL JSON MAING SIA ISAL WALSAS T 15105401 41141139 1010100 W 00 A ZINAA
13. 29 31sec 40 45 sec High RPM 4 60 GPH 17 41 Iph E aed to ATHE RUD Horsepower 54 2400 RPM full load aximum Wind Speed 28 mph 12 5 m s Cooling System 16 Quarts 15 14 L aximum Manual Force Reference Decalon Machine Spark Plug AWSP 52 C Spark Plug Gap 0 044 in 1 117 mm Table 1 4 Deutz F3M2011 Specifications Fuel Diesel Oil Capacity 8 5 Quarts 8 L w Filter Low RPM 900 High RPM 2800 Alternator 95 Amp Belt Drive Battery 112 Amphour 950 Cold Cranking Amps 12 VDC Fuel Consumption Low RPM 1 3 GPH 4 9 Iph High RPM 1 6 GPH 6 0 Iph Horsepower 48 2800 RPM full load JLG Sizzor SECTION 1 SPECIFICATIONS Tires Size 12x 16 5 12 x 16 5 33 1550 16 5 33 1550 16 5 33 16LLx16 1Foam 12 16 5 Pneumatic Pneumatic Foam Filled Pneumatic Foam Filled Filled Sand Non Marking Ply Rating 10 12 10 10 Inflation Pressure 9opsi 6 3kg cm 90 psi 6 3 kg cm 90 psi 6 3 kg cm Wheel Nut Torque 170 ftlbs 238 Nm Gross Machine Weight Machine Dimensions Model 3394RT 4394RT 3394RT 4394RT Single Extension No Leveling Machine Height Jacks Pneumatic Tires 5 402 NEM rails down 61 75 in 1 6m 70 4 in 1 8 DOM Machine Width 7ft10in 2 4 m Single Extension Leveling 15 140 Ibs 6 867 Machine Length 13 4 m DOM Jacks Pneumatic Tires 12 810 Ibs 5 810 kg kg Single Exten
14. 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 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
15. FRONT LEFT LEVELING JACK PRESSURE TRANSDUCER FAILURE CLEARS WHEN FAULT IS REMOVED FRONT RIGHT LEVELING JACK PRESSURE TRANSDUCER FAILURE CLEARS WHEN FAULT IS REMOVED REARLEFT LEVELING JACK PRESSURE TRANSDUCER FAILURE CLEARS WHEN FAULT IS REMOVED REAR RIGHT LEVELING JACK PRESSURE TRANSDUCER FAILURE CLEARS WHEN FAULT IS REMOVED CAN NOT LEVEL CLEARS WHEN FAULT IS REMOVED FUEL SENSOR SHORT TO BATTERY REPORTS FAULT ONLY FUEL SENSOR SHORT TO GROUND REPORTS FAULT ONLY FUEL SENSOR DISCONNECTED REPORTS FAULT ONLY OIL PRESSURE SHORT TO BATTERY CLEARS WHEN FAULT IS REMOVED OIL PRESSURE SHORT OT GROUND CLEARS WHEN FAULT IS REMOVED COOLANT TEMPERATURE SHORT TO GROUND CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 12 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 13 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 14 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 15 CLEARS WHEN FAULT IS REMOVED AJAJAJA AJ AJAJ AJIAJ AIAJ AJAJ ATIATI AJAJ AJAJ AJ A AJ A AJAJ A AJ Sel Sel NIN N NIN WY WY CO WY W W CO CO CO W CB CO CO CO CO CO A a aol C1 O FORD FAULT CODE 21 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 22 CLEARS WHEN FAULT IS REMOVED F
16. GENERATOR GENERATOR RELAY 5 OPTIONS nJ4 ar t MODULE A LEVELIN 1 ji ACK VALVE J Figure 6 15 Electrical Componants Installation Sheet 1 JLG Sizzor 3121133 SECTION 6 SCHEMATICS PLATFORM CONTROL BOX ENGINE START LPLOCK amp ASSIST SPEED yim GAS MACHINES 2 Siora 2 jomm pl g
17. IMPORTANT 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 4 8 JLG Lift 13 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 14 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 15 If applicable secure the cylinder head retainer using a suitable chain wrench 16 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 17 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable Refer to Table 4 2 Holding Valve Torque Specifications 4 6 DRIVE PUMP START UP PROCEDURE 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 IMPORTANT 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 DISABLE
18. Single Extension 2250105 1020 1500 lbs 680 Dual Extension kg kg Extension Only 2000lbs 905 1250165 565 kg kg 50016 230kg 500 Ibs 230 kg Maximum Travel Grade Grade ability See Figure 4 1 Capacities Table 1 2 Capacities Fuel Tank 31 5 1191 Hydraulic Tank 40 gal 1511 1 2 COMPONENT DATA Engines Table 1 3 Ford LRG 425 Specifications aximum Tire Load Reference Decal on Machine Ground Bearing Pressure 12x16 5 pneumatic 31x15 5 pneumatic 116 psi 8 2 kg cm 169 psi 11 9 kg cm Leveling ack Bearing Pressure 69 psi 4 9 kg cm Wheelbase 9 67 ft 2 95 m Ground Clearance 12in 30cm MaximumH ydraulic System P res sure 3000 psi 207 bar Electrical System Voltage 12 Volt Inside Turning Radius 14ft5 in 4 39 m Outside Turning Radius 20ft1 in 6 12 m 3121133 2WD 35 Fuel Gasoline 4WD 45 Oil Capacity 4 5 Quarts 4 25 L w Filter aximumTravelG rade Sideslope 3 Idle RPM 1000 See Figure 4 1 Low RPM 1800 aximum P latform Height 33 ft 43 ft High RPM 2800 aximum Drive Speed 2 WD 3 0 mph 4 8 3 0 mph 4 8 Alternator 40 Amp Belt Drive SII Spes dep kph kph Battery 112 Amphour 950 Cold Cranking 3 5 mph 5 6 3 5 mph 5 6 Amps 12 VDC kph kph Em Fuel Consumption iE LowRPM 3 45 GPH 13 06 ph
19. 2 27 HOSN3S N39AXO Q3 1V3H 3 5 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SIZZOR 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 at 40 C 40 F High temper ature causes a low resistance of 70 ohms at 130 266 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 overnight 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 press
20. ORN WHT 55 20 25 119 VALVE RR LJ YEL RED 2 1 3 5 ONT 55 2 brid 790 VALVE LJ EXTEND BED ORVAIMT 55 22 VALVE LJ EXTEND 2 BRICK ORNIMHT 55 2 n VALVE LJ RETRACT ORN MHT 55 24 ER 17980 VALVE ORN WHT 55 25 1 arg Y23 T E ED RET us OC 124 VALVE EXT GREEN 11 HAN 95 VALVE RD RET GREEN 18 bid OC 126 VALVE GREEN 19 28246 CA 121 GREEN 20 H BLACK VEL RED 2 20 25 ENT LFT STOWED BLACK SWITCH WHITE 526 STOWED BLACK SWITC WHITE STOWED BLACK WHITE 528 REAR RHT STOWED BLACK SWITCH WHITE dud 3 seg 3 d g 5 Zo 5 B8 a E t L a c REAR LEFT FRONT RIGHT PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK 1870153 F WIRE AT J3 Figure 6 6 Electrical Schematic Diesel Sheet 3 6 8 JLG Sizzor 3121133 SECTION 6 SCHEMATICS This page left blank intentionally 3121133 JLG Sizzor 6 9 SECTION 6 SCHEMATICS 6 10
21. 3121133 SECTION 6 SCHEMATICS PCPW J3 1 WHT RED 51 21 LTP 03 2 YELLOW 9 1 ATP 03 3 YELLOW 10 1 OPSN 03 4 5 QPRG GND 23 5 BLACK i DRIVE SELECT LIFT 02 SELECT HORN 03 PUSH BUTTON FRONT DECK 04 SELECT REAR DECK DRVP 42 11 ORANGE 55 5 4 505 SELECT AUTO LEVEL J2 10 55 10 4 aji 506 SELECT IGN 201 1 HRN 22 7 BLIZORN 52 3 L 501 BND JI 2 FDSP J2 9 GREEN 55 11 M 41 3 RDSP 12 8 GREEN 55 12 4 L 1 4 42 4 ORR WHT 55 1 4 012 J1 5 ENG DRV SPD 72 2 ORANGE 55 6 KoL3 1 6 COL3 SPARE 32 12 014 01 7 FSGW 12 3 H TN S 045 JI 9 APWR STRP 12 1 001 8 GENP 12 6 52 2 GENERATOR PRX 21 10 COL2 SPARE J2 5 SWITCH START AUX ENG DRV 08 POWER FUEL SEL SPEED SW H 509 16108 SI gt C N gt ORN RFD 49 4 AUX p START p SIO ENG DRV WHT RFD 57 2 i j SE WHT RED 57 3 0 gt WHI RED 51 4 ALAR iem re 555254 AW 13 1 Z77232 ANLOO 53 2 222 els Ux 85 5 APWRI J3 4 ANLGI 03 5 EJ GND J3 6 SS APWR2 23 7 en ANLG2 13 8
22. A WARNING DO NOT USE AN 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 STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK 3121133 SECTION 4 HYDRAULICS SECTION 4 HYDRAULICS 41 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 and the control valve sol
23. Below 10 F 12 C 5W 20 Below 60 F 16 C 5W 30 10 F to 90 F 23 C to 10W 30 32 Above 10 F 23 C 10W 40 or 10W 50 Above 20 F 7 C 20W 40 or 20W 50 Not recommended for severe service including high RPM operation Crankcase oil must be high quality detergent type meeting API service classification SF SH SG 3121133 Deutz F3M1011F Engine Single Viscosity Oil CD SE CD SF When Outside Temperature is Use SAE Viscosity Consistently Number 20 F to 25 F 29 C to 4 10W 30 5 F to 50 F 15 C to 10 C 20W 50 40 F to 85 F 4 C to 30 C 30 40 Above 75 F 24 C Multi Viscosity Oil CD SE CD SF This viscosity can be used at colder temperatures with engine oil preheating When Outside Temperature is Consistently 40 F to 75 F 40 C to 24 15 to 70 21 15 F to 85 F 30 C Above 5 F 21 C 5 F to 75 F 21 C to 24 26 C to 26 C to Use SAE Viscosity Number 5W 30 5W 30 5W 40 5W 40 5W 30 This viscosity can be used at colder temperatures with engine oil preheating Crankcase oil should be MIL L2104B MIL L2104C or have properties of API classification CC CD grades JLG Sizzor 1 7 SECTION 1 SPECIFICATIONS Lubrication Specifications Table 1 12 Hydraulic Oil HYDRAULIC SYSTEMOPERATING SAEVISCOSITY GRADE TEMPERATURE
24. 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 used The frequency of this inspection must be increased as environment severity and frequency of usage requires 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 Mainten
25. ROD 11 CAPSCREW JACK PLATE 12 SEAL RING LOCK 13 WIPER RING WEAR 14 RING BACK UP RING WASHER 15 T SEAL RING RETAINING 16 JACK PAD P Q N Figure 4 23 Leveling Jack Cylinder 3121133 JLG Lift 4 23 SECTION 4 HYDRAULICS This page left blank intentionally 4 24 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM 5 1 SECTION 5 JLG CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM To Connect the Hand Held Analyzer 1 Connect the four pin end of the cable supplied with the analyzer to the four position connector on the PCB in the ground control station or at the platform control station as shown in Connect the remaining end of the cable to the analyzer GROUND CONTROL ANALYZER CONNECTION PLATFORM CONTROL ANALYZER CONNECTION Figure 5 1 Analyzer Connection NOTE The cable has a four pin connector at each end of 3121133 the cable the cable cannot be connected back wards Power up the Control System by turning the lower key to the platform position and pulling both emer stop buttons on Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following MENU HELP 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 ite
26. g GND 13 9 APWR3 03 10 5 ANLG3 03 11 8 GND J3 12 WHITE GROUN ALARM BLACK WHITE HORN ALARM BLACK RED ROTARY WHITE POSITION BLACK SENSOR BLACK PROX WHITE SWITCH LIET DOWN VALVE 10 PROP LIFT LDHS JI 5 VALVE 55 GND 041 11 BLACK YI Zeer PLS J1 6 WIHLTE 5 Sez GND 01 12 BLACK 2258 2508 STEER LEFT VALVE STEER RIGHT VALVE DUMP 115 22 5 YELLOW 9 1 5 Y02 VALVE BRAKE RTS 52 6 YELLOW 10 1 5 fxy 9 VALVE LEFT OSC AX DPS J2 T RED WHT 50 1 KK LC 104 VALVE 1 LEFT OSC BRS J2 8 ORANGE 55 1 ER vna VALVE 2 RIGHT OSC AX LOSAX J2 11 ORANGE 55 3 1 15 VALVE 1 RIGHT OSC GENES 116 VALVE 2 2 SPEED ROSAX J2 12 ORANGE 55 4 1 VALVE LIFT UP D 55 106 VALVE FORWARD se SPD J2 9 ORANGF 55 3 A Yor VALVE REVERSE 855 UPS J2 10 TAN 3 1 5 fx 18 VALVE an eas 5 FWS J2 3 ORANGE 1 1 KK 109 4 gt RVS 72 4 ORANGE 8 1 t x22 XZ GEN 12 13 zzo 8 GND J2 15 BLACK 555 7 GND 42 14 BLACK 19 gt WHI 47 9 BRN ORN 53 1 FUEL GAUGE TA GLOW PLUGS 3121133 Figure 6 5 JLG Sizzor Electrical Schematic Diesel Sheet 2 6 7 SECTION 6 SCHEMATICS JI RECEPTACLE 12 E 2 s ALVE FR LJ E BLACK X 118 VALVE
27. 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 25 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 ELECTRONIC IGNITION The 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
28. should the 5 up to 30feet serial number plate be damaged or missing the machine 4394RT Australia 5 30 36 feet serial number is stamped directly under the seriel number 3 36 43 feet plate 3394RT 4394RT C SA 39 3 3121133 JLG Sizzor 1 3 SECTION 1 SPECIFICATIONS 1 7 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent centimeters cm in parentheses Table 1 8 Cylinder Specifications Description Bore Stroke RodDia Lift Cylinder 4 5 83 3 5 11 4 211 8 9 Leveling Jack 3 0 21 5 2 0 Cylinder 7 6 54 6 5 0 Lockout Cylinder 25 6 0 1 75 Oscillating Axle 6 4 15 2 4 4 Power Deck Extension Cylinders 15 48 1 0 38 1220 2 5 Steer Cylinder 25 46 1 75 6 4 11 17 4 4 1 8 MAJOR COMPONENT WEIGHTS Table 1 9 Major Component Weights Component Lb Kg Fixed Platform 1070 485 Platform Extension 440 200 Arm Assembly Includes Lift Cylinder 3394 3600 1633 4394 4550 2064 Chassis with Pneumatic Tires 3394RT 6790 3080 4394RT 9080 4119 Chassis with Foam Filled Tires 3394RT 7788 3533 4394 9086 4121 1 4 JLG Sizzor 1 9 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
29. 021 OLL 06101 021 96 08 OLL 06 21 58 89 SG GL 0506 610170 L 28 GL 0 91 06 0 09 08 00 01 09 05 0 gg 068 18110 02 out m 0 06901 08 9 SG 0 0686 SG S 05 0089 90170 vL 55 05 08 8 99 Ge 05 006 Ov ze GZ ge 0095 8 800 08 60 vc gie 05 05 05 0 S 0002 GE 82 c 0 0 51 00 9L 0 22 0086 0 02 GZ 0228 ri m vL 61 00 8 08500 210 vc 96 82 0 26 QE 22 81 50 02 6L 9L L m Ores 2500 81 8114 91 13 81 DS NI 8 1 891 0796 7980 0 82 891 091 0816 8160 0 00300 02 000200 1 ze 09 100 0060 2 Ol 27100 98 0070071 OO ze 8 510100 0 606000 08810 ze 1990070 9 70900071 2270 0 g8T NI 81 81 NI DS NI H91Vd H91Vd vauv TAM 301 201 001 3111201 an1 3111901 3111901 3111901 883816 vid 834 371 HLIM LNOHLIM 381301 40 Aud Ada 1109 SaHL 310801 310801 310801 OEL 1390S 349 dV9 IV3H 13108 9 SLAN J0VY9 0961 OMVHANN SLOAN 8 30949 3 1109 8 39 49 AVS 1104 J0VYD AVS 5 389256 dV9 0319 14 KINO SH3N31SV43 31VINO0HH9 MOTTIA 03 14 2 17 804 SANTWA Figure 1 3 Torque Chart In Lb Ft Lb For ASTM Fasteners 1 9 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS
30. 1 by prying it out with a large screw driver NOTE During disassembly take special note of the wear patterns onthe 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 Wash all part and dry thoroughly 2 Inspect front and rear bearing block replace if scor ing or uneven wear is observed 3121133 NOTE A somewhat heavier wear patteren is normal on the low pressure inlet side of the bearing blocks 2 However there should be no heavy scoring in this area 3 Remove anti extrsion seal 4 and pressure loading seal 3 from each bearing block and discard 4 Inspect bushings in each bearing block 2 replace bearing block if bushings are heavily scored or burned 5 Inspect gear journals and faces Replace if faces or journals are scored or worn 6 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
31. 20002 15 1 ORN WHT 55 KR OC 121 VALVE LJ EXTEND 2 gt BLACK CANL JI 7 950003 J5 2 ORN WAT 55 23 KK PA 12 VALVE LJ RETRACT gt lt SHIELD CAN SHIELD 1 8 0004 15 3 ORN WHT 55 24 ER VALVE 0005 75 4 ORN WHT 55 25 Ex Y23 D006 J5 5 0100 5 0 J2 4 IGN 04 1 0105 2 9 GND 24 2 ANLG4 32 10 FD EXT CAN H 04 3 0101 J2 5 VALVE FD RET CAN 24 4 0102 J2 6 VALVE RD EXT CAN SHIELD J4 5 0103 02 71 de x 15 VALVE RD RET SPARE J4 6 0007 J5 6 GREEN 18 2 KK Y26 VALVE 0008 05 1 GEEN 9 2 1 0009 5 8 GREEN 20 2 I J4 0104 J2 8 RECEPTACLE 5 10 TX 05 11 GND 5 12 J3 RECEPTACLE SEE YELIBED 2 20 SZS SZS 55955955955 525 ENT LFT STOWED BLACK SWITCH MILE Md 26 FNT RHT STOWED BLACK SWITCH WHITE ODS 27 REAR LFT STOWED BLACK SWITCH WHITE Oe 28 REAR RHT STOWED BLACK SWITCH WHITE 3 E 3 a es s H 29 q 5 9 s 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 THE SHIELD FOR EACH CABLE 18701 43 F SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 Figure 6 3 Electrical Schematic Dual Fuel Sheet 3 6 4 JLG Sizzor 3121133 SECTION 6 SCHEMATICS This page left blank intentionally 3121133 JLG Sizzor 6 5 SECTION 6 SC
32. 2WD 3 43RT 4WD 0 FORD EFI D F 2 1 DEUTZ F3 0 ENGINE 2 FORD D F T2 3 DEUTZ F3 2 0 ANSI USA 3 1 ANSI EXPORT MARKET 2 CSA 0 3 CE 4 AUSTRALIA 0 NOGLOW PLUGS 1 5 SECGLOW 2 10SEC GLOW 4 3 20SEC GLOW GLOW 4 30 SEC GLOW 0 PLUGS 5 40 SEC GLOW 6 50 SEC GLOW 7 60 SEC GLOW 5 0 No Leveling Jacks not installed on vehicle LEVELING 0 JACKS 1 YES Leveling Jacks are installed on vehicle NONE Power Deck Extensions not installed on vehicle 1 FRONT Power Deck Extension is installed on the Front of the 6 vehicle 0 POWER DECK 2 DUAL Power Deck Extensions are installed on the Front and Rear ofthe vehicle 5 20 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 5 Machine Configuration Programming Information Configuration Setting Description Market Default Digit 2 4 0 NOT INSTALLED Generator is not installed on the vehicle 1 60HZ Generator is installed and engine speed set for 2000 7 when enabled 0 GEN ERA TOR 2 50HZ Generator is installed and engine speed set for 1700RPM when enabled 0 NOT INSTALLED Vehicle is not equipped with a Function Cutout device 1 DRV amp LIFT UP Vehicleis equipped with a Function Cutoutdevice 8 Drive and Lift Up will be prevented when active 0 FUNCTION CUTOUT 2 ALL FUNCTIONS Vehicle is equipped with a Function Cutout device All Functions will be
33. 81010 9101 0096 0 26 000861 506 0995 0966 002091 0062 261 Ovl 0022 00 8 0082 00061 eL zu Sree 0708 008091 6 98 0652 0962 0916 005921 6202 56 1 0901 0961 00087 0507 9 5892 0772 008161 000 591 0702 02 2 001811 05 1 9081 0921 0891 0006 08161 diet eL gel 0952 0260 008811 6092 1061 08 1 0862 000701 5061 2061 001 09 00179 09911 9 0 02 0881 00 01 0022 0191 0081 0002 00996 0061 8LLL 026 Orel 00969 06 01 Docet eL 5061 05 1 00696 0002 ESY L 0961 081 00228 S LL 6001 078 0211 00856 0696 0 1 0251 0861 00968 5 61 SSLL 0801 Obvl 0004 506 208 099 088 005 7 09580 RL zL gi 596 0021 0069 0091 0601 096 0821 00 89 0 8 m 009 008 00627 0 9 0 1 000 516 00699 0011 96 0 0001 00 69 Gel 559 068 002 00227 06990 zL 056 598 00909 066 189 089 006 00819 6 9 6 5 087 009 00986 09090 8 002 569 00606 veg 005 099 00897 028 066 0 00726 06050 m vL gii 679 689 00297 099 58 09 009 00917 G y 98 086 Oey 00762 0297 0 6 Orb 00 006 6 Gov gee 086 027 00966 OEE 992 022 00 00862 06 60 006710 9L m 00 596 00966 027 LOE 082 08E 00106 580 ove 002 092 00612 0 66 0 0L 022 00955 590 02 081 Ove 00055 061 ESL OEL 01 00691 09520 08231 8L 8 LEZ 012 00922 Ove 081 0 1 022 08606 gol SEL OLL 081 00901 09220 LL 281 691 00802 061 vgl 01 01 09281 SEL 601 06 021 0562 06020 6245 8L 91 6 0 1 SSL 00881 591 GEL OLL 051 0091 021 86 08 OLL 00911 028170 zL Lel SIL 0666 OEL 801 06 021 00901 001 08 59 06 00701 66810 000510 02 211
34. Check to see that the following items are reading correctly ANGLE SNSR 0 40 X XXV ZEROED 0 00V ELEV CUT CALIB 0 40v 1 20v 3121133 8 10 NOTE JLG Sizzor 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 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 Press ESCAPE remove analyzer and assure all hardware is tight If voltage is too low the analyzer will display SEN SOR FAILURE If the voltage is set too hig the ana lyzer will read NOT STOWED When calibration is attempted once it is set within the proper limits the analyzer will read COMPLETE 3 15 SECTION 3 CHASSIS amp SIZZOR ARMS Level Sensor and Analyzer Connections ground control station and the other at the platform con trol station on the under side of the platform control box as The level sensor is located at the ground control station shown in Figure 3 4 Level Sensor and Analyzer Connec Using a screwdriver open the ground control station and tions locate the level sensor as shown in Figure 3 4 Level Sen sor and Analyzer Connections NOTE Ensure that the level sensor is installed with the bub There are two analyzer connection ports One in the ble towards the top
35. Figure 6 13 Hydraulic Schematic 2WD Sheet 3 6 16 JLG Sizzor 3121133 SECTION 6 SCHEMATICS EASI CLADDER CYLINDER 1 5 BORE 1 ROD 7 5 STROKE B2 RIGHT FRONT FC10 20A 0 N SV08 47C 0 N 1206 08 208 0 1206 FRIO 39A 0 N 10 20 0 30 8V 10 20 N 1206 5 10 42 0 126 EASI CLADDER VALVE BLOCK LEFT FRONT SET AT CD was SET AT CD SPEED BRAKE RELEASE AGA 12472 L AGA 12407 40 GALLON Figure 6 14 Hydraulic Schematic 2WD Sheet 4 3121133 JLG Sizzor RIGHT REAR LEFT REAR 2792544D 6 17 SECTION 6 SCHEMATICS LEVELING JACK PORT BLOCKS LEVELING JACK PORT BLOCKS 6 18 FUSE FOR FUTURE OPTIONS BATTERY AUXILIARY PUMP STARTER 9i THROTTLE OIL ACTUATOR PRESSURE SWITCH GLOW PLUG OIL TEMP SWITCH ALTERNATOR DIESEL MACHINES TUT AC POWER gl AT PLATFORM 2 3 CONTROL BOX J
36. I O module and during system test when the rear right leveling jack is open cir cuit 2 6 REAR RIGHT LEVELING JACK SHORT TO Reported by the I O module and during system GROUND test when the rear right leveling jack is short to ground 2 6 REAR RIGHT LEVELING JACK SHORT TO Reported by the I O module and during system BATTERY test when the rear right leveling jack is short to battery 2 6 LEVELING JACK EXTEND VALVE OPEN CIR Reported by the I O module and during system CUIT test when the leveling jack extend valve is open circuit 5 12 Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 2 6 LEVELING JACK EXTEND VALVE SHORT TO GROUND Reported by the I O module and during system test when the leveling jack extend valve is short to ground 2 6 LEVELING JACK EXTEND VALVE SHORT TO _ Reported by the I O module and during system BATTERY test when the leveling jack extend valve is short to battery 2 6 LEVELING JACK RETRACT VALVE OPEN CIR Reported by the I O module and during system CUIT test when the leveling jack retract valve is open circuit 2 6 LEVELING JACK RETRACT VALVE SHORT TO Reported by the I O module and during system GROUND test when the leveling jack retract valve is short to ground 2 6 LEVELING JACK RETRAC
37. 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 WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A 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 work under an elevated sizzor until platform has been safely restrained from any movement by blocking or overhead sling or
38. LEFT OSC AX DPS 02 1 RED WHT 50 1 KE You VALVE I LEFT OSC AX BRS 12 8 ORANGE 55 1 VALVE 2 RIGHT OSC LOSAX 32 11 ORANGE 55 3 1 115 VALVE 1 RIGHT OSC AX EEDS 716 VALVE 42 2 SPEED ROSAX J2 12 ORANGE 55 4 1 VALVE LIFT UP 0 voe VALVE FORWARD zc 2SPD J2 9 ORANGE 55 fx VALVE REVERSE 855 E UPS 32 10 TAN 3 1 KE 108 VALVE AAR 5 FWS 2 3 ORANGE 1 1 bes 109 ven gt RVS J2 4 ORANGE 8 1 XY GEN 2 13 zze 8 GND J2 15 BLACK 555 GND 42 14 BLACK 19 L Xe z E So 2 3 ECH CE 75 BRN WHI 41 9 8 VALVE Ford S WHT YEL 48 WHI YEL 48 6 BRN ORN 53 1 3121133 FUEL ek 2 P 2 837 AUX POWER Figure 6 2 Electrical Schematic Dual Fuel Sheet 2 JLG Sizzor SECTION 6 SCHEMATICS JI RECEPTACLE 12 SPFOTH 12 1 PFDTH JI 1 PFDTHI J2 2 FL LJ PFDTHI 1 2 SIGN 25 9 T VALVE FR LJ SFDTH JI 3 GND J2 3 VALVE RL LJ BLACK GND 01 4 0000 J2 11 ORN WHT 55 20 5 19 VALVE RR LJ gt YFLIRFD 2 1 3 IGN C105 Spoor 2 12 ORN WHT 58 21 Hy 10 VALVE LJ EXTEND gt lt RFD CANH 01 6
39. 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 1 SECTION 3 CHASSIS amp SIZZOR 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 1 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 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
40. UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
41. 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 JLG Sizzor 3 11 SECTION 3 CHASSIS amp SIZZOR ARMS 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 12 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 Engine coolant temperature ECT sensor Intake air temperature IAT sensor Throttle position sensor Crankshaft position sensor 00005 77 ME otis 20700 Sagan 20 220 20025 22002 00802 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS 3 2 OPERATING CHARACTERISTICS Leveling Jacks The machine may be equi
42. change Pre Delivery Prior to each sale lease or Owner Dealer or User Qualified JLG Service and Maintenance Inspection rental delivery Mechanic Manual and applicable JLG inspection form Frequent Inspec In service for 3 months or 150 hours which Owner Dealer or User Qualified JLG Service and Maintenance tion ever comes first or Mechanic Manual and applicable JLG Out of service for a period of more than 3 inspection form months or Purchased used Annual Machine Annually no later than 13 months from the Owner Dealer or User Factory Certified Service and Maintenance Inspection date of the prior inspection Service Technician or Manual and applicable JLG a Qualified JLG inspection form Mechanic Preventative Atintervals as specified in the Service and Owner Dealer or User Qualified JLG Service and Maintenance Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES 2 At any time when fuel or lines are discon nected clear adjacent areas as well as the openings General and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to The following information is provided to assist you in the prevent entry of foreign matter use and application of servicing and maintenance proce dures contained in this book 3 Clean and inspect all parts during servicing or main Safety and Workmanship Your safety and that of others is the first consideration when engaging in
43. 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 columns 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 A IMPORTANT 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 affo
44. 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 tandum 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 holding valve is connected to
45. effect of the machine digit value is displayed along displayed or you can not adjust the personality settings with its value The above display would be selected if the machine was equipped with a ground alarm and you Machine Setup wanted it to sound when driving There are certain set tings allowed to install optional features or select the When a machine digit item is selected press the UP or machine model DOWN arrow keys to adjust its value for example When selecting the machine model to match the size of WARNING the machine the personality settings will return to default settings FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU 2 LAR MACHINE CAN RESULT IN IMPROPER OPERATION 3121133 JLG Lift 5 3 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 access to level 1 which will permit you to change all machine person ality and or machine setup settings WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE IMPORTANT IS 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 INCH
46. module 1 None FRONT LEFT LEVELING JACK AT END OF Reported when the front left leveling jack is STROKE reported to be at the end of stroke pressure None FRONT RIGHT LEVELING JACK AT END OF Reported when the front right leveling jack is STROKE reported to be at the end of stroke pressure None REAR LEFT LEVELING JACK AT END OF Reported when the rear left leveling jack is STROKE reported to be at the end of stroke pressure None REAR RIGHT LEVELING JACK AT END OF Reported whenthe rear right leveling jack is STROKE reported to be at the end of stroke pressure 2 1 Flash code 2 1 indicates issues at power up 2 1 KEYSWITCH FAULTY PLATFORM amp Reported when the ground module is reading GROUND ACTIVE TOGETHER both ground and platform modes are selected 2 by the keyswitch The control system defaults control to ground mode 5 8 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 2 2 Flash code 2 2 indicates difficultly with the platform con trols 2 2 TRIGGER SWITCH WIRING SHORTED HIGH Reports whenthe CAN message coming from IN PLATFORM CABLE the platform board and the DI on ground board conflict 2 2 TRIGGER SWITCH WIRING SHORTED LOW IN Reports when the CAN message coming from PLATFORM CABLE the platform board and the DI on gro
47. 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 inspec tions and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for further requirements for aerial work platforms The fre quency 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
48. 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 3121133 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 another 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
49. 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 157 4 0mm 2 Shaft Seal 1 JLG Lift 4 11 SECTION 4 HYDRAULICS 4 12 Shaded area represents the W 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 rring 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 onthe seal groove on the front bearing block 2 Install a new load seal and anti extrusion seal inthe groove Insert the bear ing block into the body maing sure that the load seal 3 and anti extrusion seal 4 are positioned properly ensure the outside of the W seal is exposed tothe 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 matingholes on the front cover 5 Install drive gear 12 and driven gear 11 JLG Lift Shaft Seal Drive Shaft Installation Tool Bullet Lubricate Place a small amount of g
50. 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 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 18 JLG Sizzor Using Liquid Petroleum LP Gas 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 LPG is 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
51. t 1 0 Pp 8 18 RRB OWS LRB RRA 4641228 x cp 4 X X 4641225 an 12487 CD 4 x 2120172 di 4 Ps 1 G Fa B 4 e Mbi 4 ES H 380001 2800 RPM 1 09 tH 0 31 3 50HP DIESEL ENGINE 2 A 65HP GAS ENGINE 350991 OPS 0 85 in I 7 T2 9f Figure 6 11 Hydraulic Schematic 2WD Sheet 1 JLG Sizzor 3121133 SECTION 6 SCHEMATICS LIFT CYLINDER Ix 4 5 BORE 3 5 ROD 83 0 STROKE STEER CYLINDER Ix 2 5 BORE LIFT 1 75 ROD 4 6 STROKE STEER SET AT 2700 51 SET AT 2800PS JD CED 4641211 AGA 12407 2120165 43 ps 4400445 40 ALLCN Figure 6 12 Hydraulic Schematic 2WD Sheet 2 3121133 JLG Sizzor 6 15 SECTION 6 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 T 1 5 BORE 88 ROD 14412555 1 T CYLINDER LIFT CYLINDER L 5 BORE 2 BORE ROD 1 5 ROD 8 5 STROKE 1000 PSI EASI CLADDER PLUS VALVE BLOCK POWER DECK CYLINDER 2x 1 5 BORE 1 0 ROD 48 STROKE POWER DECK OPTIONAL SET XXX PSI Sz El 12408 u POWER DECK OPTIONAL SET XXX PSI AGA 12408
52. 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 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 evidence 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
53. 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 7 SECTION 3 CHASSIS amp SIZZOR 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 several 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 momentari
54. 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 2 2 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 function properly 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 1 JLG Lift 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
55. 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 SIZZOR ARMS WARNING HIGH PRESSURE CIRCUIT OPERATING PRESSURE 65 PSI FUEL PUMP FLOW BS 6 e FUEL FILTER FROM FUEL TANK PRESSURE REGULATOR QUICK CONNECTORS Figure 3 2 Typical Fuel System FUEL METERING SYSTEM PURPOSE The basic function 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 025 located in the exhaust system The HO2S tells the ECM how much oxygen is in the exhaust gas The ECM chan
56. 10 Critcal Stability Weights Component Lb Kg Tires 12 x 16 5 Pneumatic 132 60 12x16 5 Foam Filled 352 160 33 1550 16 5 Pneumatic 162 73 33 1550 16 5 Foam Filled 410 186 33 16LL x 16 1 Foam Filled Sand 426 193 Engine Ford 525 238 Engine Deutz 675 306 31211338 SECTION 1 SPECIFICATIONS 1 10 LUBRICATION AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAIN 2 Fuel Tank Drive Hubs Hydraulic Oil Tank Sliding Wear Pads PSN Figure 1 2 Lubrication Diagram WARNING TENANCE REQUIRING THE PLATFORM TO BE ELEVATEDE Table 1 11 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a mini mum dripp ing pointof 350 F Excellent waterresistance and adhesive quali ties and being of extreme pressure type Timken OK 40 poundsminimum EPGL Extreme Pressure GearLube oil meet ing APIservice classification GL 5or MIL Spec MIL L 2105 EO Engine crankcase Oil G as APISF SG class MIL L 2104 Diesel APICC CD class MIL L 2104B MIL L 2104C HO Hydraulic Oil API service classification GL 3 e g Mobil 424 3121133 NOTE 1 Be sure to lubricate like items on each side 2 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 in
57. 121133 JLG Lift Apply Spanner Wrench Figure 4 3 Lift Cylinder Cap Screw Removal NOTE Steps 6 and 7 apply only to the steer cylinder Using a spanner wrench loosen the spanner nut retainer and remove spanner nut from cylinder bar rel 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 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 from 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 3 SECTION 4 HYDRAULICS IMPORTANT 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 9 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel SUPPORT TABLE Figure 4 4 Cylinder Rod Support Using suitable protection cl
58. 3 2 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS Table 3 1 ECM Diagnostic Trouble Codes Diagnostic Trouble Description Code 11 All Systems 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 HO2S 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 HO2S High Voltage 43 Engine Coolant Temperature ECT Sensor Low Voltage 45 Intake Air Temperature IAT Sensor Low Voltage 51 Low Oil Pressure 52 Crankshaft Position 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 3 SECTION 3 CHASSIS amp SIZZOR ARMS ENGINE COOLANT TEM
59. 3 3 EUW 10 1 5 23 4 6 OPRG GND 3 5 BLACK Tj DRIVE SELECT LIFT 02 SELECT HORN 503 PUSH BUTTON FRONT DECK 504 SELECT REAR DECK DRVP 32 11 ORANGE 55 5 L 05 SELECT AUTO LEVEL LFTP J2 10 55 10 4 L 506 SELECT IGN 01 1 HRN 72 1 8 32 507 BND 01 2 FDSP 22 9 GREEN 55 11 010 1 3 J2 8 GREEN 55 1 L KOLI J1 4 ALEV J2 4 ORN WHT 55 13 012 JI 5 ENG DRV SPD J2 2 ORANGE 55 6 003 JI 6 COL3 SPARE 22 12 KoL4 01 1 FSGW 12 3 MELDE 48 8 015 21 9 2 1 48 9 100 021 8 GENP J2 6 BLIL ORN 52 2 GENERATOR PRX 91 10 COL2 SPARE J2 5 SWITCH START AUX ENG DRV 508 POWER FUEL SEL SPEED SW HI 509 16108 511 gt gt ORN RED 49 4 AUX p E 10 ENG RV H WHI RED 51 233 WHT RED 57 S WHI RED 51 4 TILT ALARM SSSEE2 13 1 2 23 2 SZZ Ze 4 GND 03 3 SSSEES S ARI 3 4 ANLGI 03 5 SS GND J3 6 E APWR2 23 7 lt ANLG2 23 8 2 S GND 03 9 APWR3 J3 10 5 ANLG3 03 11 GND 13 12 WHITE GROUN ALARM BLACK WHITE HORN ALAR BLACK RED ROTARY WHITE POSITION BLACK SENSOR BLACK PROX WHITE SWITCH LIFT DOWN VALVE PROP LIFT 1088 1 5 VALVE 5555 GND 31 11 PLS 21 6 zsz GND JI 12 BLACK STEER LEFT VALVE STEER RIGHT Yol VALVE DUMP LTS 42 5 Y02 VALVE BRAKE RTS 02 6 YELLOW 10 1 Ly 103 VALVE
60. 5 STROKE CELL Tl de Js asi a RIGHT FRONT RIGHT REAR E lo 2190 0 Tr svos anc o v 1208 WT EASI CLADDER VALVE BLOCK slelels zlelels LEET FRONT 21321212 51825 LEFT REAR t 21905 Ier h tot 8518 soff zl 277 voit 0 52 LI Ww 1 1 T t ur 30 0X e tERtTS CD 24 RELEASE 2 idi 2 mal 7 Blo TP AGA 12472 AGA 12407 9o 9 9o 9 2 E four D 2792543 D H 40 GALLON Figure 6 10 Hydraulic Schematic 4WD Sheet 4 3121133 JLG Sizzor 6 13 SECTION 6 SCHEMATICS 6 14 BLEEDER y l OSCILLATING AXLE LT T T c1 Zx BLEEDER BLEEDER M cv ird LRA 4 3
61. 581 StL 221 691 09621 06020 62050 8L 9 6 062 012 00281 vee 881 602 0091 591 EEL 801 00911 02810 e 21 961 06681 681 91 221 691 00801 gel 801 88 221 00 01 66810 00080 0c 21 591 06101 591 01 801 09 21 SIL 26 GL 201 0506 L LLL 201 0 91 zel 56 18 801 00 01 18 89 rS GL 099 18 20 02 m vol 56 06901 801 58 GL 56 0666 GL 19 Ly 89 0089 90170 pl 89 08 8 GL 19 Ly 89 0062 rS r vt Ly 0099 8 80 0 nmm 19 09 89 m 19 000 Ly 86 Le Ly 0767 9 00 9L Le 0089 Lp ve Le vt 0225 82 c 6L 92 00 6 08500 1 0725 027 oee 9180 90 81 08 NI 0796 79600 Ed 0816 8160 0 00250 02 000200 ze 0600 0060 0L 271000 9 oopsog 90 ze 8 510100 Ov 606000 08810 ze 3 1990070 8 709000 CHO Ov 81 NI DS NI H91Vd H91Vd 2 292 892 892 Vauv HONI TAM 301 134 901 G0V01 272 111901 an1 3111901 ay01 3111901 3111901 883818 vid Ydd 3ZIS HLIM LNOHLIM diiv19 301901 HO AUG dIWV19 3111901 Aud 1109 54 1 310301 310301 310401 3143 0961 OMYHANN 349 dV9 SMAYIS 131008 9 SLNN EEUU 2 S1104 8 JGVYD AVS KINO SH3N31SV4 31VIN0HH3 MOTT3A 031114 INIZ 803 SAMVA SLAN 3 1Vd9 CEE EE DENK Figure 1 4 Torque Chart Metric Conversion For ASTM Fasteners 3121133 JLG Si
62. 800 51 3000 51 E 4641211 AGA 12407 2120165 43 psi 4400445 40 GALLON Figure 6 8 Hydraulic Schematic 4WD Sheet 2 JLG Sizzor 6 11 SECTION 6 SCHEMATICS IELE CYLINDER 1 5 BORE 88 ROD 1 125 STROKE TELE CYLINDER 1 5 BORE 88 ROD 11 125 STROKE EASI CLADDER PLUS VALVE BLOCK 6 12 IILI CYLINDER LIFI CYLINDER 1 5 BORE 2 BORE 1 ROD 1 5 ROD 7 5 STROKE 8 STROKE EASI CLADDER PLUS VALVE BLOCK 1000 PSI TILT CYLINDER LIFT CYLINDER 1 5 BORE 2 BORE 1 ROD 1 5 ROD 1 5 STROKE 8 STROKE 1000 PSI POWER DECK CYLINDER 2x 1 5 BORE 1 0 ROD 48 STROKE POWER DECK OPTIONAL SET XXX PSI ED AGA 12408 u DECK OPTIONAL SET AT XXX PSI GD AGA 12408 Figure 6 9 Hydraulic Schematic 4WD Sheet 3 JLG Sizzor 3121133 SECTION 6 SCHEMATICS EASI CLADDER CYLINDER 1 5 BORE 1 ROD 1
63. AL 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 SECTION 4 HYDRAULICS CYLINDER HEAD MALLET 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 3 Place new and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD Figure 4 10 Installation of Head Seal Kit 4 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 rod to the rod end as applicable 5 Carefully slide the piston spacer on the rod 6 If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved 7 f 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 NOTE The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni fied insert i
64. AMP BRN WHT 41 ENGOL J5 3 2 Lo2 ARN WHT 41 3 ENGTL J5 4 w BLACK 3 GND J5 5 J2 RECEPTACLE g En HEE ZT RE E 8 ENGINE TEMP Shares ES Sea eee dee LAMP sun IGN 6 1 290 av T TE U SS LAB v2 we gah ie ee sue a 103 o 1 21 EE QE Do Se OW 4 EELT ST e 5 88 92 lt T SM E9658 2225 SZ 2 22 9 088 222 5 8 J 5555852 25 2 255 55 EES LS BEACON i BRN WHT 47 6 Wer EE 5 ici RED WHT 50 2 ceo YEL RED 2 1 Z Ar a 4 BLACK t83 18 E PLATF OPT E RED VALVE ZEN A ic xy 129 E Kl YEL RED 2 1 YELIRED WHT YFI 48 4 2 z gt 113 6 2231118 26 31 33 2 Y LT Y 4 2 94 3 z Lle pni 128224 L MOTOR YWINTEE 3 T 3 2 2 4 2 1 22233 1 R MNMA J T G H JB DD B A R ENGINE CONTROL MODULE Figure 6 1 Electrical Schematic Dual Fuel Sheet 1 JLG Sizzor 3121133 SECTION 6 SCHEMATICS PCPW 03 1 WHI RED 51 21 LTP J3 2 91 RTP 4
65. AULT IS REMOVED FORD FAULT CODE UNKNOWN 4 3 CLEARS WHEN FAULT IS REMOVED BATTERY LOW 4 4 CLEARS WHEN FAULT IS REMOVED BATTERY TOO HIGH SYSTEM SHUT DOWN 4 4 REQUIRES EMS TOBE RECYCLED TO CLEAR FAULT BATTERY TOOLOW SYSTEM SHUT DOWN 4 4 CLEARS WHEN FAULT IS REMOVED SPEED SENSOR READING INVALID SPEED 5 5 CLEARS WHEN FAULT IS REMOVED SPEED INPUT LOSS 5 5 CLEARS WHEN FAULT IS REMOVED ENGINE TEMPERATURE HIGH 4 3 CLEARS WHEN FAULT IS REMOVED NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVED OIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS REMOVED 485 COMMUNICATIONS LOST 4 3 CLEARS WHEN FAULT IS REMOVED CAN BUS FAILURE 6 6 CLEARS WHEN FAULT IS REMOVED EEPROM FAILURE CHECK ALL SETTINGS 9 9 REQUIRES EMS TOBE RECYCLED TO CLEARFAULT 3121133 JLG Lift SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 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 None FUNCTION SELECTED BUT TRIGGER Reported when the trigger is not closed with SWITCH OPEN function selected and joystick out of center None RUNNING AT CUTBACK ABOVE ELEVATION Reported any time the machine is considered to be above elevation None ACCESSORY FAULT Reports when CAN faults are reported by an accessory
66. CK RET PERMANENTLY CLOSED switch is closed during power up 2 3 GROUND LIFT UP DOWN ACTIVE TOGETHER Reported when the ground lift up and lift down switches are closed atthe same time 4 2 3 GROUND FRONT DECK EXTEND RETRACT Reported when the ground front deck extend ACTIVE TOGETHER and retract switches are closed at the same time 2 3 GROUND REAR DECK EXTEND RETRACT Reported when the ground rear deck extend ACTIVE TOGETHER and retract switches are closed at the same time 2 3 NO SIGNAL FROM TILT SENSOR X AXIS Reported when sensor X axis value is not valid CHECK WIRING 2 3 NO SIGNAL FROM TILT SENSOR Y AXIS Reported when sensor Y axis value is not valid CHECK WIRING 2 3 LEVEL SENSOR FAILURE Reported when the tilt sensor frequency is out side the range of acceptable value 2 3 FUNCTION LOCKED OUT GROUND AUX Reported when the ground auxiliary power SWITCH PERMANENTLY CLOSED switch is closed during power up 2 3 FUNCTION LOCKED OUT GROUND START Reported when the ground start switch is SWITCH PERMANENTLY CLOSED closed during power up 5 10 Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Code Communicated Displayed on Analyzer Fault Description Priority 2 5 Flash code 2 5 indicates issues that may cutout func 2 5 ELEV ANGLE SENSOR FAULTY NOT MOUNTED OR VOLTAGE OUT OF RANGE Reported when the elevation rotary sensor volt age is
67. D 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 and air leaks 3121133 SECTION 4 HYDRAULICS 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 0 to 500 psi 0 to 35 bar pressure gauge in the charge pressure gauge port to monitor charge pressure during start up 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 neutra
68. E TEMPERATURE HIGH This fault is not reported at this time 4 3 AIR FILTER BYPASSED This fault is not reported at this time 4 3 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 4 3 OIL PRESSURE LOW Reported when the oil pressure is below eight PSI and the engine is running for at least a few seconds 4 3 485 COMMUNICATIONS LOST Reported when a Ford engine is selected and communications with the Ford engine control lerare lost 4 3 ENGINE SHUTDOWN COMMANDED Reported when the engine is commanded to CHECK ENGINE SENSORS shutdown by the control system 4 4 Flash code 4 4 indicates a battery supply issue 4 4 BATTERY LOW Reported when the voltage on the system is below 11 volts 4 4 BATTERY TOO HIGH SYSTEM SHUTDOWN Reported when the voltage on the system is above 16 volts 4 4 BATTERY TOO LOW SYSTEM SHUTDOWN Reported when the voltage on the system is 8 below 9 volts 4 4 LSS BATTERY VOLTAGE HIGH Reported whenthe voltage on the LSS is above 34 volts 4 4 LSS BATTERY VOLTAGE LOW Reported when the voltage on the LSS is below 9 volts 5 5 Flash code 5 5 indicates a speed sensor issue 5 5 SPEED SENSOR READING INVALID SPEED Reported when the speed sensor is reading a value over 4000 RPM 8 5 5 SPEED INPUT LOST Reported when the speed sensor is reading zero RPM and the oil pressure is over eight PSI 5 14 Lift 3121133 SECTION 5 JLG CONTRO
69. EAD SEAL RING WEAR NUT SEAL RING BACK UP SPACER PLUG O RING BUSHING PISTON SEAL ROD BARREL 3121133 SECTION 4 HYDRAULICS CD 7 RING WEAR BARREL T SEAL PLUG O RING RING WEAR RING WASHER O RING CAPSCREW RING BACK UP BLEEDER SEAL WIPER PLUG O RING POLYSEAL SOLENOID BUSHING RELIEF VALVE HEAD BEARING 0 ROD N 9 m gt N Figure 4 21 Oscillating Axle Cylinder 3121133 JLG Lift 4 21 SECTION 4 HYDRAULICS LEN E OSCILLATING AXLE 74 D OSCILLATING AXLE CYLINDER Figure 4 22 Oscillating Axle Bleeding 4 10 OSCILLATING AXLE BLEEDING 4 Run pump for 10 seconds close bleeder valves PROCEDURE 5 Oscillate axle fully in the opposite direction and repeat steps 3 and 4 1 Attach 1 4 hose to bleeder valve to capture oil 2 Oscillate axle fully in one direction 3 Open the bleeder valve at the top of the retracted cylinder approx 1 2 turn and open bleeder valve at the bottom of extended cylinder approx 1 2 turn 4 22 JLG Lift 3121133 SECTION 4 HYDRAULICS 9 0 0 A GG 2 HEAD 9 O RING BARREL 10 SCREW
70. ED OUT STEERLEFT PERMANENLTY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT STEER RIGHT PERMANENLTY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GLOW PLUG SWITCH PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT AUX POWER SWITCH PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GENERATOR SWITCH PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT AUTOLEVEL SWITCH PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT JOYSTICK NOT CENTERED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT TRIGGER SWITCH PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND LIFT UP PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND LIFT DN PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND F DECK EXT PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND F DECK RET PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND REAR DECK EXT PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT GROUND REAR DECK RET PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED GROUNDLIFT UP DOWN ACTI
71. ES 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 5 4 JLG Lift 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 SECTION 5 JLG CONTROL SYSTEM 5 2 FLASH CODES AND DESCRIPTIONS Table 5 1 Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL OK REPORTS FAULT ONLY FUNCTION SELECTED BUT TRIGGER SWITCH OPEN REPORTS FAULT ONLY RUNNING AT CUTBACK ABOVE ELEVATION REPORTS FAULT ONLY STARTUP CLEARS WHEN FAULT IS REMOVED JOYSTICK MOVED BUT NO FUNCTION SELECTED CLEARS WHEN FAULT IS REMOVED TRIGGER SWITCH WIRING SHORTED HIGH IN PLATFORM CLEARS WHEN FAULT IS REMOVED TRIGGER SWITCH WIRING SHORTED LOW IN PLATFORM CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT DRIVE SELECT PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT SELECT PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT FRONT DECK PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT REAR DECK PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCKED OUT START PERMANENTLY CLOSED CLEARS WHEN FAULT IS REMOVED FUNCTION LOCK
72. HEMATICS PLAT_ESTOP 01 ale RFD TRIGGER SWITCH pl 529 HI RFD 2 16 aq YEL RED 2 12 PE YEL RED 2 13 Id YEL RFD 2 14 ELLRED 2 15 YEL RED 2 3 EU 2272 LIFT SWITCH FRONT DECK REAR DECK rd alah d di SWITCH SWITCH SWITCH AUX Saige 225252220 516 517 518 POWER uP DOWN EXT RET EXT RET P 519 Sszesssssssesyosss ON Sa AAO Sie aes 3 319V143938 Gf 2 ES Zo 5 en Ae 42003 zi 3 B 55122212 20 18 KEYSWITCH 8 2255558 552585 242225 GROUND 555_ 955555 gt YEL RED 2 3 1 23 SHIELDED FIRED 2 TWISTED PAIR PLATFORM HOUR METER 00000 L Ba 00 NEL RED 2 1 2 YEL RED 2 1 1 ze IJ Is CIR_BREAKER dd 43444445 ESTOP FOI 3 S3 44442 44238834 MS Ore as BED 1 1 8 444 3 Added D
73. ITT E d LITT 0452 MOHSAOr X01840 THOTT YIS VITIIS Dvd Ti WaMOd OLAV V WI E ANI NA NUOH Dadu 145 LHII VAALS UAMOd XIV ELA Ta Y DAAA LVS 113 ATA 14813315 Wd IXA WAA A NYOH 110437 AMALINA Wa NU LITT TS LAIT 039901 USNS TINY KIALA dl TAS SOLLSONDVIC JALNA 4 3121133 JLG Lift 5 16 SECTION 5 JLG CONTROL SYSTEM Z 199465 Jez Ajeuy 6 6 4 ST3A31 9013 CNV SSILMVNOSYAd JHL S39NVHO NYO NOA 12266 3909 u3dOHd JHL 9NIH3IN3 HALV SANAN 18 31 401 HONOHHL TIOHOS NYO NOA SAI MOHHV 3S3HL SNISS3Hd nuew dor LT OL QUYAROL UND 90015 LON TUATINA YOSNAS 21 070 31114002 JSON UHINR SHA 10535 LAS 10 pomoln Sq ans OL VMO TIND TRAR T LON YOSNAS KIL JSON VAINTSEA 308188 LIL 31414103 SISAL NIN OL WVA OL HOVE IND
74. L SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 6 6 Flash code 6 6 indicates CANbus issues 6 6 CAN BUS FAILURE Reported when there is a problem with the CANbus 10 6 6 LSS NOT SENDING CAN MESSAGES Reported when the LSS is configured and not seen on the CANbus 8 Flash codes 8 indicate load cells issues 8 1 LSS CELL 1 ERROR Reported when there is a problem with cell 1 onthe LSS 8 2 LSS CELL 2 ERROR Reported when there is a problem with cell 2 onthe LSS 11 8 3 LSS CELL 3 ERROR Reported when there is a problem with cell 3 onthe LSS 8 4 LSS CELL 4 ERROR Reported when there is a problem with cell 4 onthe LSS 9 Flash codes 9 indicate LSS or memory issues 9 1 LSS WATCHDOG RESET Reported when the LSS s microprocessor watchdog has been triggered 9 2 LSS EEPROM ERROR Reported when there is a problem with the stored memory inthe 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 off 12 set value this will be reported as a negative value 9 9 LSS INTERNAL ERROR PIN EXCITATION Reported when a pin in the LSS is reporting a voltage below 4 25 volts 9 9 LSS INTERNAL ERROR DRIVER FAULT Reported wh
75. OR 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 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 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 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 c
76. ORD FAULT CODE 23 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 24 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 25 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 26 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 31 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 32 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 33 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 34 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 35 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 36 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 41 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 42 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 43 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 44 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 45 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 46 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 51 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 52 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 53 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 54 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 55 CLEARS WHEN FAULT IS REMOVED 5 6 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing FORD FAULT CODE 56 4 3 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 57 4 3 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 61 4 3 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 62 4 3 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 63 4 3 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 64 4 3 CLEARS WHEN F
77. PERATURE 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 DTC 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 softw
78. RANGE 0 to 23 degrees F 10W 18 to 5 degrees C 0 to 210 degrees F 10W 20 10W 30 18to 100 degrees C 50 to 210 degrees F 20W 20 10 to 100 degrees NOTE Hydraulic oils must have anti wear 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 13 Mobil DTE 13M Specs ISO 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 169SUS at210 F 48 SUS cp at 20 F 6 200 Viscosity Index 140 Table 1 14 Mobil EAL 224H Specs Type Synthetic Biodegradable ISO Viscosity Grade 32 46 Specific Gravity 922 Pour Point Max 25 F 32 C Flash Point Min 428 F 220 C Operating Temp 0 to 180 F 17 to 162 C Viscosity at 40 C 37 cSt at 100 C 8 4cSt Viscosity Index 213 NOTE Must be stored above 32 F 14 C 1 8 JLG Sizzor 3121133 SECTION 1 SPECIFICATIONS 8 aqvu9 AVS S aqvu9 avs 19U9 Se pajejd Ajdde jou op sanjen
79. T VALVE SHORT TO Reported by the I O module and during system BATTERY test when the leveling jack retract valve is short to battery 2 6 FRONT DECK EXTEND VALVE OPEN CIRCUIT Reported by the I O module and during system test when the front deck extend valve is open circuit 2 6 FRONT DECK EXTEND VALVE SHORT TO Reported by the I O module and during system GROUND test when the front deck extend valve is shortto ground 2 6 FRONT DECK EXTEND VALVE SHORT TO Reported by the I O module and during system BATTERY test when the front deck extend valve is shortto battery 2 6 FRONT DECK RETRACT VALVE OPEN CIR Reported by the I O module and during system CUIT test when the front deck retract valve is open cir cuit 2 6 FRONT DECK RETRACT VALVE SHORT TO Reported by the I O module and during system GROUND test when the front deck retract valve is short to ground 2 6 FRONT DECK RETRACT VALVE SHORT TO Reported by the I O module and during system BATTERY test when the front deck retract valve is shortto battery 2 6 REAR DECK EXTEND VALVE OPEN CIRCUIT Reported by the I O module and during system test when the rear deck extend valve is open cir cuit 2 6 REAR DECK EXTEND VALVE SHORT TO Reported by the I O module and during system GROUND test when the rear deck extend valve is short to ground 2 6 REAR DECK EXTEND VALVE SHORT TO BAT Reported by the I O module and during system TERY test when the rear deck extend valve is short to bat
80. Torque Drive Hub 3 17 4 1 Lift Cylinder Holding Valve and Fitting 4 3 4 2 Cylinder Barrel Support Y a 5 48 lk ce Re a 4 3 4 3 Lift Cylinder Cap Screw Removal onee 4 3 4 4 Cylinder Rod 14 4 4 4 4 5 Tapered Bushing 2 4 4 4 6 Bushing Installation ze 1 sentent seemed ven 4 5 4 7 R d Seal Installation iie D E RE a daden Rea bid hee 4 5 4 8 Poly Pak Piston Seal Installation oenen eene 4 5 4 9 Wiper Seal Installation eenen eee eee ee 4 6 4 10 Installation of Head Seal 4 6 4 11 Piston Seal Kit RH 4 6 4 12 Tapered Bushing Installation 4 4 7 4 13 Seating the Tapered Bearing 4 7 4 14 Rod Assembly 2 4 7 4 15 Main ValveTorque 0 4 4 13 4 16 Pump Pressure Locations ua ia oenen enen eneen m eee hn 4 15 4 17 Brake Two Speed and Case Drain
81. UAL AXIS PIN 2 HHI RED 57 ANALOG 4 ORN RED 48 1 TILT SENSOR PIN 3 ORNLRED 49 2 28825 PIN BLACK See Lee et ON B IGN O0 ZI 54535555 55555 E Suc num 3 2 ue ALT TILTY 03 3 5 Sez2888 ZEZozZzojozon STE eee oes se Bae LAMP GND 3 0 amp amp 5 25525555525 950 3 J4 RECPTACLE JI RECPTACLE PU YELIRED 2 4 IGN J5 6 ARN WHT 41 1 ALT 15 1 ENGINE OIL CHRP 05 2 GROUND ELECTRONICS LAMP BRAJNHT 41 2 ENGOL 5 3 2 102 BRN WHT 41 3 ENGTL J5 4 NEA BLACK 32 GND J5 5 e RECEPTACLE 2 NC RECTIFER 4 oh A 58 NES 2 R8 ENGINE TEMP Secs 22 2 Ba cmo uo CX B HS LAMP IGN J6 D ST NE 103 46 2 Tessa AS S 5 ad 224 85 sS eE s 54 c ce moe men gt 827 gv 28 x eq Q GND 6 4 Bece S BONG ont a eee 55255202 lt Ee 55 amp 5 25 552 wo BEACON 2 BRN WHT 41 1 LAMP 1 Du 3 tod er DM NAZ S L 4 6 9 da 4 d i WHT YEL 48 4 d E ul BRN WHT 47 4 E a ne 85 45 a BR 1413 4 RED WHT 50 21 PLATE OPT WHI YEL 4817 GOVERNOR VALVE 3 ost y29 e L Ur 2 OIL PRES gt ENG TEMP SENDER SENDER qe START Jz MOTOR S m Figure 6 4 Electrical Schematic Diesel Sheet 1 JLG Sizzor
82. UNCTION LOCKED OUT TRIGGER SWITCH Reported whenthe trigger switch is closed dur PERMANENTLY CLOSED ing power up 2 2 JOYSTICK FAULTY STEER SWITCHES Reported when both the left and right steer ACTIVE TOGETHER switches are closed atthe same time 2 2 FUNCTION LOCKED OUT HORN SWITCH Reported whenthe horn switch is closed during PERMANENTLY CLOSED power up 3121133 JLG Lift 5 9 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 2 3 Flash code 2 3 indicates difficultly with ground con trols 2 3 FUNCTION LOCKED OUT GROUND LIFT UP Reported when the ground lift up switch is PERMANENTLY CLOSED closed during power up 2 3 FUNCTION LOCKED OUT GROUND LIFT Reported when the ground lift down switch is DOWN PERMANENTLY CLOSED closed during power up 2 3 FUNCTION LOCKED OUT GROUND FRONT Reported when the ground front deck extend DECK EXT PERMANENTLY CLOSED switch is closed during power up 2 3 FUNCTION LOCKED OUT GROUND FRONT Reported when the ground front deck retract DECKRET PREMANENTLY CLOSED Switch is closed during power up 2 3 FUNCTION LOCKED OUT GROUNDREAR __ Reported when the ground rear deck extend DECK EXT PERMANENTLY CLOSED switch is closed during power up 2 3 FUNCTION LOCKED OUT GROUND REAR Reported when the ground rear deck retract DE
83. VE TOGETHER CLEARS WHEN FAULT IS REMOVED GROUND FRONT DECK EXTEND RETRACT ACTIVE TOGETHER CLEARS WHEN FAULT IS REMOVED GROUND REAR DECK EXTEND RETRACT ACTIVE TOGETHER CLEARS WHEN FAULT IS REMOVED NO SIGNAL FROM TILT SENSOR X AXIS CHECK WIRING REPORTS FAULT ONLY NOSIGNAL FROM TILT SENSOR Y AXIS CHECK WIRING REPORTS FAULT ONLY LEVEL SENSOR FAILURE REPORTS FAULT ONLY ELEV ANGLE SENSOR FAULTY NOT MOUNTED OR VOLTAGE OUT OF RANGE CLEARS WHEN FAULT IS REMOVED ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED CLEARS WHEN FAULT IS REMOVED ELEVATION PROX SWITCH PERMANENTLY CLOSED REPORTS FAULT ONLY ELEVATION PROX SWITCH PERMANENTLY OPEN REPORTS FAULT ONLY FRONT LEFT LEVELING JACK AT END OF STROKE pw no pw pw ro ro o ro ro ro wp no we ro no pw ro no no ro ro no no ro ro ro ro o occ oa a col col rm mo rm wm pw rw rw rw rw rw rw IO IO gt lt co CLEARS WHEN FAULT IS REMOVED 3121133 JLG Lift SECTION 5 JLG CONTROL SYSTEM Table 5 1 Fault Code Listing FRONT RIGHT LEVELING JACK AT END OF STROKE CLEARS WHEN FAULT IS REMOVED REARLEFT LEVELING JACK AT END OF STROKE CLEARS WHEN FAULT IS REMOVED FRONT RIGHT LEVELING JACK AT END OF STROKE CLEARS WHEN FAULT IS REMOVED
84. ake sure the rotary switch is aligned with the bladed pin mounted on the center link as shown in Figure 3 3 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 SET ELEV SENSOR 0 0 1 20 ESC ENTER 6 Press the left arrow button and then enter 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS NOTE 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 0 05 lt or gt CALIB the machine should be recalibrated 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
85. al Schematic Diesel 3 6 8 6 7 Hydraulic Schematic 4WD Sheet 1 nnee 6 10 3121133 JLG Lift iii TABLE OF CONTENTS 6 8 6 10 6 11 6 12 6 13 6 14 6 15 6 16 Hydraulic Schematic 4WD 2 Hydraulic Schematic 4WD 13 Hydraulic Schematic 4WD Sheet 4 Hydraulic Schematic 2WD Sheet 1 Hydraulic Schematic 2WD 12 Hydraulic Schematic 2WD 13 Hydraulic Schematic 2WD 4 Electrical Componants Installation Sheet 1 Electrical Componants Installation 2 LIST OF TABLES TITLE Operating Specifications eere ee pula Ford LRG 425 Specifications Deutz F3M2011 Pressure Settings High Drive Cut Out Height Tilt en ON AN Cylinder lt Major Component Critcal Stability Weights
86. amp 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 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 13 16 17 Remove the bushing from the piston PISTON TAPERED BUSHING 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 from 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 JLG Lift Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage 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 ta
87. ance 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 the 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 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Type Frequenc Primary Service Reference yp q Responsibility Qualification Pre Start Inspec Prior to use each day or User or Operator User or Operator Operator and Safety Manual tion Ateach Operator
88. apscrews evenly and progressively in rotation to the specified torque value 8 Remove the cylinder rod from the holding fixture 3121133 JLG Lift 4 7 SECTION 4 HYDRAULICS Table 4 1 Cylinder Piston Nut Torque Specifications Description Nut Torque Setscrew p Value torque Value Lift Cylinder 400110 1001 542 12 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 48Nm Sun 1 1 8 hex 1 14 UNS thds 45 50 ftlb 61 68Nm Sun 1 1 4 hex M36 x 2 thds 150 153ftlb 204 207Nm Racine 1 1 8hex 1 1 16 12thds 50 55 ftlb 68 75 Nm Racine 1 3 8 hex 1 3 16 12 105 75 80ftlb 102 109 Nm Racine 1 7 8 hex 1 5 8 12 thds 100 110ftlb 136 149Nm 9 Push the piston onto the rod until it abuts the spacer end and install the attaching nut 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 10 Prior to setscrew installation spot drill rod before installing the setscrew s which secure the piston attaching nut to the diameter groove 11 Remove the cylinder rod from the holding fixture 12 Position the cylinder barrel in a suitable holding fix ture
89. are containing the correct program and calibration for the application are required to program the ECM 3 4 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 consecutive seconds will set OTC 42 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS 2 43 L 911614 AV TAU LYVLS AV H3MOd HOSN3S 53 ALNOSAVY 1041 4 lt _ rr c HOSN3S HIV amp EK gt bel Vo t SS 2 T JU AN U3ON3S BBN 5 212 4 JUN LVHAANAL gt Fc iNv1005 X 3H CE
90. ause 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 needs to be pressurized in order to start the 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 3121133 JLG Lift 4 9 SECTION 4 HYDRAULICS 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 gr
91. bearing dry Lubrication is not required with nickel plated pins and bearings STEEL BUSHING COMPOSITE BUSHING ARBOR 14 15 16 17 3121133 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 JLG Lift 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 special 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 WIPER SEAL CYLINDER HEAD Figure 4 7 Rod Seal Installation IMPORTANT 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 IMPORTANT WHEN INSTALLING THE WIPER SEAL ON THE LOWER TOWER LIFT CYLINDER APPLY LOCTITE 609 ON THE WIPER SE
92. 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 JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISON 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 b JLG Lift 3121133 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A General ee maaie er tete leu ee 1 Hydraulic System 1 a A C Maintenance a ee ld guia d s a kuu 1 a SECTION 1 SPECIFICATIONS 1 1 6 nan aaa ween a eek ao t go ee E ftu ost ERE 1 1 Capacities imbre ete n I uu Tu rv Se Se ee ed ad 1 1 1 2 Component Datar u us du ER pA A ea Let So bn 1 1 Engines any hadde 1 1 Ncc 1 2 Gross Machin
93. c Oil eee 2 4 Lubrication Specifications 2 4 2 4 Cylinder Drift ed eren me EE mee Beleid db pa us 2 5 on eneen den pues riu pasu ed RR DURS 2 5 3121133 JLG Lift TABLE OF CONTENTS Cylinder Drift iiri Det x ena Ds 2 5 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Preventive Maintenance and Inspection Schedule 2 6 SECTION 3 CHASSIS amp SIZZOR ARMS 3 1 Ford EFI Engine ARR RE ARRIERE ees h us Ee ER REPRE E 3 1 Performing Diagnostics 2 4 0 5 ese peer De ES aper ed 3 1 EFI DiagriostiCs Ree Rete E EUR Hera oce xoa aor ete Y apod 3 1 ECM ard Serisors ie VER qp P DE eee rer 3 1 F el System rio Re eR ae eG e Reb OP eda e uon t 3 8 3 2 Operating 3 13 Leveling Jacks Lu em een REE aed EVE es 3 13 Power Deck ume Lea Se napa 3 13 Generator Hh ye nei 3 13 Lift eR 3 13 Lose AE EA EE ae Sue ded a 3 13 3 3 Proximity and Rotary Angle Switch Installation 3 14 Level Sensor and Analyzer Connec
94. 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 A IMPORTANT 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 5 If no repairs are
95. cked 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 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 necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100 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 Ho
96. creased accordingly 1 Fuel Tank Fuel Diesel or Gasoline Capacity 31 5 gal 119 1 JLG Sizzor 1 5 SECTION 1 SPECIFICATIONS 2 Drive Hub 5 Engine Compartment Opposite Side Not Shown peut 2252 wen cmt S Lube Points Fill Plugs 4 Lube EPGL Interval Every 2 years or 1200 hours 3 Hydraulic Oil ak E Lube Point Fill Cap Fill Level Lube HO Interval Check oil every 10 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 1 6 JLG Sizzor Engine Oil Check Fill Capacity See Engine Manual Lube See Engine Manual Interval Check level daily change per manu facturer s engine manual Fuel Filter Lube Point Filter Element Interval Clean every 3 months or 150 hours change every 6 months or 300 hours 3121133 SECTION 1 SPECIFICATIONS Ford LRG425 Engine Single Viscosity Oils SF SF SE SF CC SF CD When Outside Temperature is Consistently Use SAE Viscosity Number 10 F to 60 F 10W 24 C to 16 10W 10 F to 90 F 10W 12 C to 32 C 20W 20 Above 32 F 0 C 30 Above 50 F 10 C 40 Multi Viscosity Oil SF SF SE SF CC SF CD Not recommended for severe service including high RPM operation When Outside Temperature is Consistently Use SAE Viscosity Number
97. ction when acti vated WARNING BE SURE AND RETRACT ANY POWER DECK 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 selcted for operation which requires a higher engine speed than the generator the generator will automatically shut off during the operation of the function Once the function has stopped the genrator 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 shitft 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 13 SECTION 3 CHASSIS amp SIZZOR ARMS 3 3 NOTE 1 Proximity Sensor 2 Rotary Angle Sensor Figure 3 3 Limit Switch Location PROXIMITY AND ROTARY ANGLE SWITCH INSTALLATION Make sure your analyzer is in ACCES LEVEL 1 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 m
98. d bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON 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 IMPORTANT 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 dislodged 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 TAPERED 15 If applicable install the cartridge type holding valve BUSHING and fittings in the rod port block using new o rings as applicable See Table 4 2 Holding Valve Torque Specifications BRASS SHAFT Figure 4 13 Seating the Tapered Bearing 7 Retorque the c
99. dL Service amp Maintenance Manual Model 3394RT 4394RT 3121133 October 4 2005 JLG 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 WARNING MODIFICATION OF THE MACHINE WITHOUT APPROVAL BY JLG IND 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 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 vided WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY
100. dulated 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 SIZZOR 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 HO2S it uses a pre pro grammed routine to calculate the air fuel ratio based on inputs from the TP ECT and 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 Seven minutes has elapsed since starting the engine After these conditions are met the engine is said to be
101. e 1 2 Machine Dimensions rg enmet neden beeen es 1 2 1 3 Torque Requirements na oe a enne ee ee A ee 1 2 1 4 Pressure Settings Eck ere nee ae ennen A une 1 2 1 5 serial N mber Loc tiONS er oe teren e bru er OENE wees Ee Rnd 1 3 1 6 SENSORS ars artnr Bet it DOR RE 1 3 1 7 Cylinder Specifications 1 1 4 1 8 Major Component 2 1 4 1 9 Cfitical Stability Weights rde ed 1 4 1 10 E brieattOn erp 1 5 Ford 425 Engine zie vero aerden S kuu ere og le EUN LU aa 1 7 Deutz F3M1011F Engine rr celi lb eee Ea 1 7 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General ni bote Eo er RR rbd ee 2 1 Preparation Inspection and 2 1 Pre Start Inspection novem eI re re 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 4 2 1 Preventative
102. e 1 Charge Pump Relief 320 psi 2 Cross Relief Pressure 3000 psi 3 G Port 4800 psi 4 PS Port 4800 psi 5 6 Cross Relief Pressure N A 3121133 JLG Lift 4 15 SECTION 4 HYDRAULICS Figure 4 17 Brake Two Speed and Case Drain Pressures 1 MX3 2 MX 3 MCD 4 16 JLG Lift 3121133 SECTION 4 HYDRAULICS 3121133 Table 4 3 Cartridge Torque Values Ft Lbs Nm 1 18 5 22 25 30 2 3 45 42 6 3 3 20 25 28 35 Figure 4 18 Oscillating Axle Valve Cartridge Torque Values JLG Lift 447 SECTION 4 HYDRAULICS 4 18 25 ft Ibs 35 Nm 4 5 ft lbs 7 Nm 10 12 ft Ibs 14 17 Nm 5 Ibs 42 Nm 35 ft Ibs 49 Nm Figure 4 18 Lift Cylinder Valve Cartridge Torque Values JLG Lift 3121133 SECTION 4 HYDRAULICS 7 RING BACK UP 8 O RING 9 RING WEAR 4 RING WASHER 10 RING WEAR 5 SOCKET HEAD BOLT 11 SEAL 6 WIPER 12 T SEAL Figure 4 19 Steer Cylinder 3121133 JLG Lift 4 19 SECTION 4 HYDRAULICS 4 20 CABLE ADAPTER BOLT BRACKET MANUAL DESCENT CABLE PLUG O RING JAM NUT COTTER PIN CARTRIDGE LIFT HOLDING SOLENOID CARTRIDGE LIFT HOLDING SOLENOID 10 CARTRIDGE CHECK 11 FLAT WASHER 12 WIPER 13 SEAL 14 RING WEAR 15 SEAL 1 2 3 4 5 6 7 8 9 Figure 4 20 Lift Cylinder JLG Lift RING BACK UP SETSCREW H
103. eatest amount of lubrication to the internal components NOTE 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 NOTE 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 WARNING DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION 0 DEGREES 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 a
104. en the LSS detects this internal error 9 9 LSS INTERNAL ERROR DRDY MISSING Reported when the LSS detects this internal FROM A D error 9 9 EEPROM FAILURE CHECKALLSETTINGS Reported when the memory in the ground platform module has become corrupt 4150588 A 3121133 JLG Lift 5 15 SECTION 5 JLG CONTROL SYSTEM es 133HS OL R SQ nue een ans jens NA LIIT 9945 HEYD Jez Ajeuy 2 6 941614 INA 1 3NDNH NMO WW ASUAATA NMOC NIN 41 XV VMO 411 NIK dil LIIT aw 190 11655 QHOMSSVd 16 HO1VH3dO 3HL 1631 031525 NNH OL H3QHO NI 3 LON GAddINOA Al x 3 LON TANA DATAS TANA Wa041yld IN1019 1 534710 INV1009 AMIE 3DIATIS 1166 TAT MAO YY AXA WAA UU LTA MAO LI IXA VOR 14 AXE MOVE IXA WOVE T WOVE WOVE 99 WOVE LU LI MVL LT LI AD ISON 9801 4044 NG L
105. enoid 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 also avoided by relieving
106. ges 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 under one of several conditions called modes modes are controlled by the ECM Refer to Open Loop and Closed Loop Operation for more information JLG Sizzor 3 9 SECTION 3 CHASSIS amp SIZZOR 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 identical 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 f
107. ginning disassembly scribe match marks on the body 13 and covers 5 and 6 to insure that the pump will be reassembled inthe same manner as it was shipped fromt he 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 Seperate rear cover 6 from the body 13 The static seal 8 may remain either with the body or the cover In either case remove the static seal and dis card 4 10 JLG Lift 3121133 SECTION 4 HYDRAULICS 5 Lift out the rear bearing block 2 drive gear 12 and driven gear 11 6 Seperate 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
108. he 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 thoroughly 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 che
109. l position 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 WARNING 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 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 with fluid 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 WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA T
110. lbs 1000105 1000105 1000 lbs 1000 lbs 454 1225 kg 454 kg 454 kg 454 kg 454 kg ACC Y 0 500 lbs 0 0 0 0 0 227 kg OVERLOAD DEBOUNCE 0 10sec 3 3 3 3 OVERLOAD HOLD 1 10sec 5 5 5 5 4150389 NOTE These settings may change order to achieve opti mal performance on a machine by machine basis 5 18 JLG Lift 3121133 SECTION 5 JLG CONTROL SYSTEM the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default NOTE When configuring an RT scissors machine the machine configuration must be completed before any personality settings can be changed Changing Table 5 4 Machine Configuration Programming Information Configuration Digit Number Description Default Num ber 1 0 3394RT 2WD 1 Model 1 3394RT 4WD 2 4394RT 2WD 3 4394RT 4WD 2 0 FORD EFI D F 0 Engine 1 DEUTZF3 3 0 60 Time in seconds the glow plugs are on Only available if DEUTZ is the engine configured 5 Glow Plug 4 0 CEW O CUT Tiltangle is 3 side to side 5 front to back 1 Tilt 1 ANSI AUSTRALIAN w CUT Cutout lift up and drive if tilted and elevated to the following angles and heights 3394RT sidetoside S upto26feet 4 26 30feet 3 30 33feet 4394RT sidetoside S upto30feet 4 30 36feet 3 36 43 feet 3394RT amp 4394RT frontto back 5 to full height Degree values are nominal Light activates at the
111. ly 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 through the fuel pressure regulator before being returned to the fuel tank 3 8 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
112. m 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 the analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read JLG Lift 5 1 SECTION 5 JLG CONTROL SYSTEM In platform mode HELP EVERYTHING OK In ground mode GROUND MODE OK ENTER is pressed again the display moves to the fol lowing display 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 pe
113. n 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 4 6 NOTE JLG Lift SPLIT SEAL PISTON BACKUP RINGS 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 3121133 SECTION 4 HYDRAULICS screws through the drilled holes in the bushing and into the tapped holes in the piston PISTON 74 TAPERED BUSHING CAP SCREWS Figure 4 12 Tapered Bushing Installation 5 Tighten the capscrews evenly and progressively in rotation to the specified torque value 6 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 tapere
114. nd 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 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 WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA 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 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 be
115. necessary or when repairs have been made replace counterbalance valve and care fully connect hydraulic hoses to cylinder port block 6 If used 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 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 IMPORTANT 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 WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3121133 SECTION 4 HYDRAULICS 3 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 TABLE Figure 4 2 Cylinder Barrel Support 3
116. nent 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 Chart JLG Lift 3121133 SECTION 2 GENERAL 2 4 CYLINDER DRIFT TEST 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 6 cm in 10 minutes If the machine does not pass this test proceed with the follow ing Cylinder Drift Table 2 2 Cylinder Drift 2 5 PINS AND COMPOSITE BEARING 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 or 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
117. ode 2 6 indicates leveling jack or power deck issues 2 6 FRONT LEFT LEVELING JACK OPEN CIRCUIT Reported by the I O module and during system test when the front left leveling jack is open cir cuit 2 6 FRONT LEFT LEVELING JACK SHORT TO Reported by the I O module and during system GROUND test when the front left leveling jack is short to ground 2 6 FRONT LEFT LEVELING JACK SHORT TO Reported by the I O module and during system BATTERY test when the front left leveling jack is short to battery 2 6 FRONT RIGHT LEVELING JACK OPEN CIR Reported by the I O module and during system CUIT test when the front right leveling jack is open cir cuit 2 6 FRONT RIGHT LEVELING JACK SHORT TO Reported by the I O module and during system GROUND test when the front right leveling jack is short to ground 2 6 FRONT RIGHT LEVELING JACK SHORT TO Reported by the I O module and during system BATTERY test when the front right leveling jack is shortto battery 2 6 REARLEFTLEVELINGJACKOPENCIRCUIT Reported by the I O module and during system test when the rear left leveling jack is open cir cuit 2 6 REAR LEFT LEVELING JACK SHORT TO Reported by the I O module and during system GROUND test when the rear left leveling jack is short to ground 2 6 REAR LEFT LEVELING JACK SHORT TO BAT Reported by the I O module and during system TERY test when the rear left leveling jack is shortto battery 2 6 REAR RIGHT LEVELING JACK OPEN CIRCUIT Reported by the
118. ontto Back 5 to Full Height Side to Side 3 to Full Height AUSTRALIA Same as ANSI USA ANSI USA Lift Up and Drive prevented when Elevated and Tilted beyond the following limits 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 ANSI USA CSA Lift Up and Drive prevented when Elevated and Tilted beyond the following limits 33RT 2WD 33RT4WD Frontto Back 3 to Full Height Sideto Side 3 to Full Height CE TiltLamp energized when Tilted beyond the following limits Frontto Back 5 to Full Height Side to Side 3 to Full Height AUSTRALIA Same as ANSI USA 5 22 JLG Lift 3121133 SECTION 6 SCHEMATICS 3121133 SECTION 6 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 pre sented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 6 2 TROUBLESHOOTING It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems The first rule for troubleshooting any circuit that is hydrau licall
119. outside the range of acceptable values 2 5 ELEV ANGLE SENSOR HAS NOT BEEN CALI BRATED Reported when the rotary calibration value 2 5 ELEVATION PROX SWITCH PERMANENTLY CLOSED Reported when the elevation rotary sensor is reporting above elevation and the elevation proximity switch is still closed 2 5 ELEVATION PROX SWITCH PERMANENTLY OPEN Reported when the elevation rotary sensor is reporting stowed and the elevation proximity switch is open 2 5 FRONT LEFT LEVELING JACK PRESSURE Reported when the front left leveling jack pres TRANSDUCER FAILURE sure reading is well below OPSI 2 5 FRONT RIGHT LEVELING JACK PRESSURE Reported when the front right leveling jack pres TRANSDUCER FAILURE sure reading is well below OPSI 2 5 REAR LEFT LEVELING JACK PRESSURE Reported when the rear left leveling jack pres TRANSDUCER FAILURE sure reading is well below OPSI 2 5 REAR RIGHT LEVELING JACK PRESSURE Reported when the rear right leveling jack pres TRANSDUCER FAILURE sure reading is well below OPSI 2 5 PLATFORM OVERLOAD Reported when the overload is setup and the LSS is reading the platform is overloaded 3121133 JLG Lift SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 2 6 Flash c
120. pering 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 3121133 SECTION 4 HYDRAULICS 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 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
121. pped with auto leveling jacks These leveling jacks are operated through 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 fun
122. prevented when active 0 NOT INSTALLED Load Sensing System LSS is notfitted to the vehicle 1 CUTOUT PLT Load Sensing System LSS is fitted and Platform 9 Controls are prevented in the eventof an Overload Ground Con LOAD trols remain functional This is the default setting for CE machines 0 0 2 CUTOUT ALL Load Sensing System LSS is fitted Platform and Ground Controls are prevented in the event of an Overload 0 NOT INSTALLED Vehicle alarm will function for Overload if LOAD enabled 10 1 DESCENT Vehicle alarm will function for Overload if LOAD 2 2 GROUND enabled and during Lift Down motion ALARM 2 MOTION Vehicle alarm will function for Overload if LOAD enabled during Drive motion and during Lift motion ANSI USA ANSI EXPORT CSA CE AUSTRALIA ANSI USA ANSI 43RT2WD 43RT 4110 CSA CE AUSTRALIA 3121133 JLG Lift 5 21 SECTION 5 JLG CONTROL SYSTEM Table 5 6 Machine Tilt Configuration Model Market Limits ANSI USA Lift Up and Drive prevented when Elevated and Tilted beyond the following limits Frontto Back 45 to Full Height Side to Side 5 to 26 Feet 44 to 30 Feet 3 to Full Heightv ANSI EXPORT Sameas ANSIUSA CSA Lift Up and Drive prevented when Elevated and Tilted beyond the following limits 33RT 2WD 4WD Frontto Back 3 to Full Height Side to Side 3 to Full Height CE TiltLamp energized when Tilted beyond the following limits Fr
123. r Cleaner 14 4 Exhaust System wl c 5 Engine Mounts 6 Hydraulic Pump 7 Valves 8 Hydraulic Filter See Lubrication Chart 5 14 9 Hydraulic Hoses and Tubing 10 Hydraulic Oil Tank 11 Hydraulic Tank Breather 6 14 12 Fuel Tank 3 5 13 Lift Cylinder 1 12 5 6 13 14 Limit Switch 1 7 15 Tilt Alarm Switch 16 Placards and Decals 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 12 24 Sizzor Arms 25 Safety Props 26 Sliding Wear Pads 27 Pivot Pins Bolts 7 8 28 Switches Ground Control 29 Control Tags 3121133 JLG Lift 2 7 SECTION 2 GENERAL 2 8 This page left blank intentionally JLG Lift 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS SECTION 3 CHASSIS amp SIZZOR ARMS 3 1 FORD EFI ENGINE Inspect all wires and harnesses for proper connections 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 info
124. rds 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 a Check 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 1 2 4 Control Tags 1 2 5 Hoses and Cables 4 8 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Engine Oil 2 Battery 3 Ai
125. rease in seal groove onthe rear bearing block 2 Install a new load seal and anti extrsion seal in groove Insert the bearing block into the body making sure that the load seal and anti extrusion seal are postioned properly Ensure outside of the W seal is exposed to the discharge pressure Apply a small amount of grease tot he seal groove int he 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 ont he 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 3121133 SECTION 4 HYDRAULICS Table 4 3 Main Valve Torque Values 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 Rrelief 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 ValveTorque Values 3121133 JLG Lift 4 13 SECTION 4 HYDRAULICS 4 9 PRESSURE SETTING PROCEDURES Main Valve Cold tempera
126. respective angles the alarm only activates when elevated 2 CSA W CUTOUT Cutout lift up and drive iftilted and elevated required for CSA market Tiltangle 3 5 0 No 0 Leveling Jacks 1 Yes 6 0 None 0 Power Deck 1 Front 2 Dual 7 0 No 0 Generator 1 Yes 8 0 None 0 Function Cutout 1 Drive amp Lift Up Allows Lift Down 2 All functions Note The function cutout input functionality is disabled whenever LSS is enabled 9 0 Not Installed 0 Load 1 Cutout PLT Prevents all lift and drive if overloaded in platform mode Ground control operates normally 2 Cutout ALL Prevents all Liftand drive if overloaded no matter which control station is active Note Also knownas LSS Load Sense System 3121133 JLG Lift 5 19 SECTION 5 JLG CONTROL SYSTEM Table 5 4 Machine Configuration Programming Information 10 0 None 1 Ground Alarm 1 Descent 2 Motion 4150390E NOTE When configuring an RT the Machine Configuration NOTE Shaded entries are not available for the selected must be completed before any Personality settings Market 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 5 Machine Configuration Programming Information Configuration Setting Description Market Default Digit 0 1 2 3 4 0 33RT2WD 1 1 4WD 1 MODEL 2 43RT
127. rmation 3 Perform a system check that will verify the proper operation of the system in question and check for recent information updates 4 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 careful 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
128. rsonality 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 Changing the Access Level of the Hand Held Analyzer When the analyzer is first connected you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a pass word to advance to a lower level 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 Me MENU ACCESS LEVEL 2 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 SECTION 5 JLG CONTROL SYSTEM GROUND ALARA 1 00 1011 MENU ACCESS LEVEL 1 MENU GROUND ALARM ACCESS LEVEL 1 1 MOTION Repeat the above steps if the correct access level is not The
129. ses ud 5 1 ii JLG Lift 3121133 TABLE OF CONTENTS 5 2 Changing the Access Level of the Hand Held Analyzer 5 2 Machine Setups se EM ellie vd eae E edere ass Qa 5 3 Flash Codes and Descriptions 5 5 SECTION 6 SCHEMATICS 6 1 General casas luu kunay as man pet tele a basa matu 6 1 6 2 Troubleshooting 2 id adha wane Oh 6 1 6 3 Hydraulic Circuit 1 6 1 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Serial Number 1 3 1 2 L brication DIagrarm x nne a den en odd Bede en 1 5 1 3 Torque Chart In Lb Ft Lb For ASTM Fasteners 1 9 1 4 Torque Chart Metric Conversion For ASTM 1 10 1 5 Torque Chart N m For Metric Class 1 11 3 1 EFi Component hi 3 5 3 2 Typical Fuel System una senen eal yaa erna ede e ARR de 3 9 3 3 Limit Switch Location 0 1 3 14 3 4 Level Sensor and Analyzer Connections 3 16 3 5 Integrated
130. side of the lower control box LEVEL SENSOR GROUND CONTROL ANALYZER CONNECTION PLATFORM CONTROL ANALYZER CONNECTION Figure 3 4 Level Sensor and Analyzer Connections 3 16 JLG Sizzor 3121133 SECTION 3 CHASSIS amp SIZZOR ARMS 3 4 INTEGRATED TORQUE DRIVE HUB The Integrated Torque Drive Hub is an axial piston hydrau lie 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 IMPORTANT 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 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 be examined for proper installation or defects Some gear packages roll with more difficulty than o
131. sion DOM o Leveling Jacks Foam Filled Tires 12 910 Ibs 5 856 kg 15 240 Ibs 6 913 kg DOM Single Extension Leveling acks Foam Filled Tires 13 810 Ibs 6 264 kg 15 140 Ibs 6 867 kg DOM Dual Extension No Leveling acks Pneumatic Tires 12 350 Ibs 5 602 kg 15 680 Ibs 7 112 kg DOM Dual Extension Leveling acks Pneumatic Tires 13 250 Ibs 6 010 kg 15 580 Ibs 7 067 kg acks Foam Filled DOM Dual Extension No Leveling Tires 13 350 Ibs 6 055 kg 15 680 Ibs 7 112 kg acks Foam Filled DOM Dual Extension Leveling Tires 14 250 Ibs 6 464 kg 15 580 Ibs 7 067 kg acks Foam Filled AUS Single Extension No Leveling Tires CE 12 900 Ibs 5 851 kg 15 140 Ibs 6 913 kg Single Extension Leveling Tires CE acks Foam Filled AUS 13 800 Ibs 6 260 kg 15 140 Ibs 6 867 kg acks Foam Filled AUS Dual Extension No Leveling Tires CE 13 440 Ibs 6 096 kg 15 680 Ibs 7 112 kg acks Foam Filled AUS Dual Extension Leveling Tires CE 14 240 Ibs 6 460 kg 16 580 Ibs 7 521 kg 1 3 TORQUE REQUIREMENTS All wheel lugs must be torqued at 170 ft Ibs 238 Nm every 50 hours NOTE When maintenance becomes necessary or a fas tener has loosened refer to Torque Chart to deter mine proper torque value
132. t 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 SIZZOR 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 77 8 20800 Sagan go 220 20025 20000 00802 ECM 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 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
133. tery 2 6 REAR DECK RETRACT VALVE OPEN CIRCUIT Reported by the I O module and during system test when the rear deck retract valve is open cir cuit 2 6 REAR DECK RETRACT VALVE SHORT TO Reported by the I O module and during system GROUND test when the rear deck retract valve is shortto ground 2 6 REAR DECK RETRACT VALVE SHORT TO BAT Reported by the I O module and during system TERY test when the rear deck retract valve is shortto battery 3121133 JLG Lift 5 13 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Fault Code Listing Software Version 1 14 Fault Flash Communicated Displayed on Analyzer Fault Description Priority Code 4 3 Flash code 4 3 indicates engine issues 4 3 FUEL SENSOR SHORT TO BATTERY Reported when the fuel sensor is reading a value that is much too high 4 3 FUEL SENSOR SHORT TO GROUND Reported when the fuel sensor is reading ground 4 3 FUEL SENSOR DISCONNECTED Reported when the fuel sensor is reading a value that is too high 4 3 OIL PRESSURE SHORT TO BATTERY Reported when the oil pressure sensor is read ing a value that is too high 4 3 OIL PRESSURE SHORT TO GROUND Reported when the oil pressure sensor is read ing a value that is too low 4 3 COOLANT TEMPERATURE SHORT TO Reported whenthe coolanttemperature sensor GROUND is reading a value that is too low 4 3 FORD FAULT CODE Reported by the Ford engine 7 4 3 ENGIN
134. 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 through one complete cycle and
135. thers 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 located 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 Figure 3 5 Integrated Torque Drive Hub 3121133 JLG Sizzor 3 17 SECTION 3 CHASSIS amp SIZZOR 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 1 Start engine from platform control station 2 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
136. tions 3 16 3 4 Integrated Torque drive 3 17 Tester renate ver gatver 3 17 Leak Test ener ne vex ER ER ende gar a 3 17 3 5 Dual Fuel EPG SyStelm qe oed dit ed edet en Bain 3 18 Changing From Gasoline to LP 3 18 Changing From LP Gas to 3 18 Using Liquid Petroleum LP 3 18 SECTION 4 HYDRAULICS 4 1 Cylinders Theory of 4 1 4 2 Valves Theory of 4 1 Solenoid Control Valves Bang Bang 4 1 Relief Valves siie Ta oett ere ope ys aed detener eir edes 4 1 Crossover Relief 4 1 4 3 Component Functional Description 4 1 Piston Hydraulic 2 2 2 4 1 Gear Hydraulic 1 4 1 Manual 1 1 4 1 44 Cylinder Checking
137. tures 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 to 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 4 14 JLG Lift Install pressure gauge at the MP1 port Adjust both Steer Section Crossover Relief s all the way in Adjust Main Relief Cartridge out several turns Activate engine and allow hydraulic system to come up to operating temperature 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 Leveling Jacks Valve If Equipped Activate engine and allow hydraulic system to come up to operating temperature Install pressure gauge at quick connect on main valve M1 Energize and bottom ut the leveling jack function Adjust relief to 2800 psi 193 bar De energize jack function and shut down engine Remove pressure gauge 3121133 SECTION 4 HYDRAULICS FRONT PUMP MID PUMP Figure 4 16 Pump Pressure Locations Table 4 3 Pump Pressure Valve Pressur
138. uel 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 10 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 information 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 mo
139. und board conflict 2 2 FUNCTION LOCKED OUT DRIVE SELECT Reported when drive selectis closed during PERMANENTLY CLOSED power up 2 2 FUNCTION LOCKED OUT LIFT SELECT PER Reported when lift select is closed during MANENTLY CLOSED power up 2 2 FUNCTION LOCKED OUT FRONT DECK Reported when front deck selectis closed dur SELECT PERMANENTLY CLOSED ing power up 2 2 FUNCTION LOCKED OUT REAR DECK Reported when rear deck select is closed dur SELECT PERMANENTLY CLOSED ing power up 2 2 FUNCTION LOCKED OUT START PERMA Reported when the start switch is closed during NENTLY CLOSED power up 2 2 FUNCTION LOCKED OUT STEER LEFT PER Reported when the left steer switch is closed 3 MANENTLY CLOSED during power up 2 2 FUNCTION LOCKED OUT STEER RIGHT Reported when the right steer switch is closed PERMANENTLY CLOSED during power up 2 2 FUNCTION LOCKED OUT AUX POWER Reported when the auxiliary switch is closed SWITCH PERMANENTLY CLOSED during power up 2 2 FUNCTION LOCKED OUT GENERATOR Reported when the generator switch is closed SWITCH PERMANENTLY CLOSED during power up 2 2 FUNCTION LOCKED OUT AUTOLEVEL Reported whenthe leveling jack select switch is SWITCH PERMANENTLY CLOSED closed during power up 2 2 TRIGGER CLOSED TOO LONG WHILE IN NEU Reported when trigger is closed for ten sec TRAL onds and no function selected 2 2 FUNCTION LOCKED OUT JOYSTICK NOT Reported when joystick is not centered while CENTERED selecting a function 2 2 F
140. ure 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 6 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 in 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 no
141. wever use of this oil will give poor per formance at temperatures above 120 F 49 C Sys tems using DTE 13 oil should not be operated at temperatures above 200 F 94 C under any condi tion Changing Hydraulic Oil 1 Use of any of the recommended hydraulic oils elim inates the need for changing the oil on a regular basis However filter elements must be changed after the first 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 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 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 compo
142. 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 related part If a 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 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 t
143. y operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 6 3 HYDRAULIC CIRCUIT CHECKS The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a systematic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits JLG Sizzor 6 1 SECTION 6 SCHEMATICS 6 2
144. zzor 1 10 SECTION 1 SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 8 8 METRIC BOLTS amp CLASS 10 9 METRIC BOLTS amp CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS SIZE PITCH TENSILE STRESS AREA TORQUE TORQUE DRY OR LOCTITE 263 LOCTITE 242 OR 271 DRY OR LOCTITE LOCTITE po 242 OR 263 211 LOCTITE LUB 262 610 22 2 5 303 189 0 832 624 665 915 24 3 353 220 0 1060 792 845 1170 27 3 459 286 0 1540 1160 1240 1690 30 3 5 561 349 5 2100 1570 1680 2310 33 3 5 694 432 5 2600 2140 2280 2860 36 4 817 509 0 3660 2750 2930 4020 42 4 5 1120 698 0 5860 4400 4690 6440 Note These torque values do not apply to cadmium plated fasteners METRIC CLASS 8 8 CLASS 10 9 Figure 1 5 Torque Chart N m For Metric Class Fasteners 3121133 JLG Sizzor 1 11 SECTION 1 SPECIFICATIONS This page left blank intentionally 1 12 JLG Sizzor 3121133 SECTION 2 GENERAL 3121133 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

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