Manual de Servicio 3394RT

Service & Maintenance Manual
Models
3394RT
4394RT
Prior to S/N 0200191606

excluding S/N’s:
0200186972,
0200187002,
0200187013
3121133
October 6, 2008
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS
Relieve system pressure by cycling the applicable

A.A GENERAL
control several times with the engine stopped and
This section contains the general safety precautions ignition on, to direct any line pressure back into the
which must be observed during maintenance of the reservoir. Pressure feed lines to system components
aerial platform. It is of utmost importance that main- can then be disconnected with minimal fluid loss.
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.C MAINTENANCE
A maintenance program must be followed to ensure
that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
M O D IF I C ATI O N O F TH E M A C H I NE W I T H O U T
APPROVAL BY JLG INDUSTRIES INC., 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.
The specific precautions to be observed during
maintenance are inserted at the appropriate point in • Remove all rings, watches and jewelry when performing any
maintenance.
the manual. These precautions are, for the most
part, those that apply when servicing hydraulic and • Do not wear long hair unrestrained, or loose-fitting clothing
larger machine component parts. and neckties which are apt to become caught on or entangled
in equipment.
Your safety, and that of others, is the first consider- • Observe and obey all warnings and cautions on machine and in
ation when engaging in the maintenance of equip- service manual.
ment. Always be conscious of weight. Never attempt • Keep oil, grease, water, etc. wiped from standing surfaces and
to move heavy parts without the aid of a mechanical hand holds.
device. Do not allow heavy objects to rest in an
unstable position. When raising a portion of the • Use caution when checking a hot, pressurized coolant system.
equipment, ensure that adequate support is pro- • Never work under an elevated sizzor until platform has been
vided. safely restrained from any movement by blocking or overhead
sling, or boom safety prop has been engaged.
• Before making adjustments, lubricating or performing any
other maintenance, shut off all power controls.
SINCE THE MACHINE MANUFACTURER HAS NO • Battery should always be disconnected during replacement of
DIRECT CONTROL OVER THE FIELD INSPECTION electrical components.
AND MAINTENANCE, SAFETY IN THIS AREA RESPON-
SIBILITY OF THE OWNER/OPERATOR. • Keep all support equipment and attachments stowed in their
proper place.
• Use only approved, nonflammable cleaning solvents.
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 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
REVISION LOG
Original Issue - April 12, 2002
Revised - May 10, 2002
Revised - August 30, 2002
Revised - October 14, 2002
Revised - March 6, 2003
Revised - April 28, 2004
Revised - May 11, 2006
Revised - April 3, 2007
Revised - January 23, 2008
b – JLG Lift – 3121133

TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
A.B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
A.C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
SECTION 1 - SPECIFICATIONS
1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.7 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.8 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.12 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.13 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.14 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.6 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
SECTION 3 - CHASSIS & SCISSOR ARMS
3.1 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Level Sensor and Analyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.4 Integrated Torque/drive hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.5 Dual Fuel/LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3.6 Ford EFI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3.7 Generator - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3.8 Deutz EMR 2 (S/N 0200138634 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
3.9 Generator - Duetz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3.10 GM Engine General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
3.11 Generator - GM Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3.12 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3.13 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3.14 GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
3.15 Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
SECTION 4 - HYDRAULICS
4.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Component Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.4 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
3121133 – JLG Lift – i

TABLE OF CONTENTS
4.7 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .4-10

4.8 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.9 Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4.10 Drive Header Valve (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4.11 Drive Header Valve (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4.12 Header Valves (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4.13 dIRECTIONAL vALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4.14 pOWER dECK sANDWICH vALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4.15 Power Deck Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4.16 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
4.17 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
SECTION 5 - JLG CONTROL SYSTEM
5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Flash Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.3 Applying Silicone Dielectric Compound To Amp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.4 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.5 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6.6 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
ii – JLG Lift – 3121133

TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-3. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-2. Engine Operating Temperature Specifications - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-3. Engine Operating Temperature Specifications - GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
3-1. Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Level Sensor and Analyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-3. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-5. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-6. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-7. Integrated Torque/Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-8. Drive Motor/Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-9. Drive Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-10. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-11. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-12. Generator (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-13. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-14. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-15. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-16. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
3-17. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-18. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-19. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-20. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-25. Generator (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-26. Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
3-27. Generator (GM Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-28. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3-29. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-30. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-31. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-32. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-33. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-34. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-35. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-36. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
3-37. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3-38. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
3-39. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-40. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-41. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
3-42. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
3121133 – JLG Lift – iii

TABLE OF CONTENTS
3-43. Joystick Controller - (JLG P/N 1600308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76

3-44. Joystick Controller - (JLG P/N 1600403) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
4-1. Lift Cylinder Holding Valve and Fitting Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-2. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-3. Lift Cylinder Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-4. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-5. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-6. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-7. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-8. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-11. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-13. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-14. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-15. Main Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-16. Main Valve Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4-17. Drive Header Valve (2wd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-18. Drive Header Valve (4wd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-19. Header Valve (Fix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-20. Header Valve (Osc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-21. Directional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-22. Power Deck Sandwich Valve (Dual Deck Extension Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-23. Power Deck Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-24. Pump Pressure Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
4-25. Auxiliary Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
4-26. Steer Cylinder - Prior to S/N 137518. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4-27. Steer Cylinder - S/N 137518 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
4-28. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4-29. Lift Cylinder Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
4-30. Oscillating Axle Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
4-31. Oscillating Axle Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4-32. Leveling Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4-33. Deck Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-34. Oscillating Axle Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
5-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Analyzer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-3. Analyzer Flow Chart - SW P1.X - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
6-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
iv – JLG Lift – 3121133

TABLE OF CONTENTS
6-18. Electrical Schematic - Dual Fuel - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-21. Electrical Schematic Diesel (Prior to S/N 138634) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-24. Electrical Schematic - Dual Fuel GM - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-25. Electrical Schematic - Dual Fuel GM - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-26. Electrical Schematic Dual Fuel - GM - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-29. Electrical Schematic Diesel (S/N 138634 to Present) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . .6-28
6-32. Hydraulic Schematic 4WD - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6-40. Hydraulic Diagram - (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-41. Hydraulic Diagram - (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41
6-42. Hydraulic Diagram - (Leveling Jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
6-43. Hydraulic Diagram - Deck Extension (Single) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
6-44. Hydraulic Diagram - Deck Extension (Dual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6-45. Hydraulic Diagram - Deck Extension (Dual Megadeck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
6-46. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
6-47. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47
3121133 – JLG Lift – v

TABLE OF CONTENTS
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Deutz F3M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 GM 3.0L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 High Drive Cut-Out Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-9 Tilt Sensor Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-10 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-12 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-14 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
3-1 Tilt Sensor Harness Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-2 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-3 Torque/Drive Hub Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-4 Gearbox Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-5 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-6 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-9 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
3-10 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-11 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-12 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-13 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-14 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
3-15 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86
4-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-3 Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
5-1 Fault Code Listing - Software P1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-2 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-3 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-4 Machine Tilt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
vi – JLG Lift – 3121133

SECTION 1. SPECIFICATIONS
1.1 SPECIFICATIONS 1.2 CAPACITIES
Table 1-1. Operating Specifications
Table 1-2. Capacities
Description 3394RT 4394RT
Maximum Occupants 6
Maximum Workload Fuel Tank 31.5 gal (119 l)
(Capacity):
Single Extension: 2250 lbs (1020 kg) 1500 lbs (680 kg) Hydraulic Tank 40 gal (151 l)
Dual Extension: 2000 lbs (905 kg) 1250 lbs (565 kg)
Extension Only: 500 lbs (230 kg) 500 lbs (230 kg)
Maximum Travel Grade :
1.3 ENGINES
2 WD 35% Table 1-3. Ford LRG-425 Specifications
4WD 45%
Fuel Gasoline
Maximum Travel Grade : 3°
Oil Capacity 4.5 Quarts (4.25 L) w/Filter
Maximum Platform Height 33 ft 43 ft
Maximum Drive Speed 2 WD 3.0 mph (4.8 kph) 3.0 mph (4.8 kph) Idle RPM 1000
Maximum Drive Speed 4WD 3.5 mph (5.6 kph) 3.5 mph (5.6 kph) Low RPM 1800
LIft Up Speed (Stowed to Full High RPM 2800
Height) Alternator 40 Amp, Belt Drive
29 - 31 sec 40 - 45 sec
Lift Down Speed (Full Height Battery 112 Amphour, 950 Cold Cranking
to Stowed)
Amps, 12 VDC
Maximum Wind Speed 28 mph (12.5 m/s)
Fuel Consumption
Maximum Horizontal Manual Low RPM 3.45 GPH (13.06 lph)
Side Force: High RPM 4.60 GPH (17.41 lph)
Single Extension 335 lb force (1490 N) 300 lb force (1335 N)
Dual Extension 300 lb force (1335 N) 300 lb force (1335 N) Horsepower 54 @ 2400 RPM, full load
Single Extension (CE/AUS) 90 lb force (400 N) 90 lb force (400 N) Cooling System 16 Quarts (15.14 L)
Dual Extension (CE/AUS) 90 lb force (400 N) 90 lb force (400 N) Spark Plug AWSF-52-C
Maximum Tire Load 4400 lbs (1996 kg) Spark Plug Gap 0.044 in. (1.117 mm)
Ground Bearing Pressure 49 psi 56 psi
w/Standard tires (3.45 kg/cm2) (3.94 kg/cm2)
Table 1-4. Deutz F3M2011 Specifications
Leveling Jack Bearing 69 psi (4.9 kg/cm2)
Pressure Fuel DIesel
Wheelbase 9.67 ft (2.95 m) Oil Capacity 8.5 Quarts (8 L) w/Filter
Ground Clearance 12 in (30 cm) Low RPM 900
Maximum Hydraulic System 3000 psi (207 bar) High RPM 2800
Pressure
Alternator 95 Amp, Belt Drive
Electrical System Voltage 12 Volt
Battery 112 Amphour, 950 Cold Cranking
Inside Turning Radius 14 ft 5 in (4.39 m) Amps, 12 VDC
Outside Turning Radius 20 ft 1 in (6.12 m)
Fuel Consumption
Gross Vehicle Weight w/ One Low RPM 1.3 GPH (4.9 lph)
Extension High RPM 1.6 GPH (6.0 lph)
11,910 lbs 15,300 lbs
Note: Certain options or
(5,402 kg) (6,940 kg) Horsepower 48 @ 2800 RPM, full load
country standards increase
weight.
3121133 – JLG Sizzor – 1-1

Table 1-5. GM 3.0L Specifications 1.5 MACHINE DIMENSIONS

Fuel Gasoline or Gasoline/LP Gas
No. of Cylinders 4
Machine Height
BHP 61.75 in (1.6 m) 70.4 in (1.8 m)
(rails down)
Gasoline 83 hp @ 3000 rpm
LP 75 hp @ 3000 rpm Machine Width 7ft 10in (2.4 m)
Bore 4.0 in. (101.6 mm) Machine Length 13 ft (4 m)
Stroke 3.6 in. (91.44 mm)
Displacement 181 cu.in. (3.0 L, 2966 cc) 1.6 PRESSURE SETTINGS
Oil Capacity w/filter 4.5 qts. (4.25 L)
Table 1-7. Pressure Settings
Minimum Oil Pressure
at idle 6 psi (0.4 Bar) @ 1000 rpm Description 3394RT 4394RT
Hot 18 psi (1.2 Bar) @ 2000 rpm Main Relief 3000 psi (207 bar)
Compression Ratio 9.2:1 Steer Relief 2800 psi (193 bar)
Firing Order 1-3-4-2 Lift 2700 psi (186 bar)
Max. RPM 2800 Leveling Jack Relief 2500 psi (172 bar)
1.4 TIRES 1.7 SERIAL NUMBER LOCATIONS

Table 1-6. Tire Specifications
For machine identification, a serial number plate is affixed
Ply Inflation Wheel Nut to the machine. The plate is located at the rear of the
Size machine on the left side of the axle. In addition, should the
Rating Pressure Torque (Dry)
serial number plate be damaged or missing, the machine
12 x 16.5 170 ft lbs serial number is stamped directly under the serial number
10 90 psi (6 bar)
Pneumatic (238 Nm) plate.
12 x 16.5 Foam Fill to 170 ft lbs

10
Foam Filled 90 psi (6 bar) (238 Nm)
12 x 16.5
170 ft lbs
Pneumatic 10 90 psi (6 bar)
(238 Nm)
(Non-Marking)
12 x 16.5
Foam Fill to 170 ft lbs
Foam Filled 10
90 psi (6 bar) (238 Nm)
(Non-Marking)
33/1550 x 16.5 170 ft lbs

14 90 psi (6 bar)
Pneumatic (238 Nm)
33/1550 x 16.5 Foam Fill to 170 ft lbs

14
Foam Filled 90 psi (6 bar) (238 Nm)
33/16LLx16.1 Foam Fill to 170 ft lbs

10
Foam Filled - Sand 50 psi (3.4 bar) (238 Nm)
31 x 15.50-15 170 ft lbs

10 60 psi (4 bar) SERIAL NUMBER
Grass Master (238 Nm) PLATE SERIAL NUMBER
STAMPED
Figure 1-1. Serial Number Location
1-2 – JLG Sizzor – 3121133

1.8 SENSORS 1.9 CYLINDER SPECIFICATIONS

The machine is equipped with the following limit switches: Table 1-10. Cylinder Specifications
Elevation Switch/Rotary Position Sensor - High drive Description Bore Stroke Rod Dia
speed is cut out when platform is raised above the preset
heights listed in Table 1-8, High Drive Cut-Out Height. 4.5 in 83 in 3.5 in
Lift Cylinder
Table 1-8. High Drive Cut-Out Height (11.4 cm) (211 cm) (8.9 cm)
3 in 21.5 in 2 in
Model Feet Meters Leveling Jack Cylinder
(7.6 cm) (54.6 cm) (5 cm)
3394RT 6-9 1.8 - 2.7 Lockout Cylinder 2.5 in 6.0 in 1.75 in
(Oscillating Axle) (6.4 cm) (15.2 cm) (4.4 cm)
4394RT 7-10 2.1 - 3
Power Deck Extension 1.5 in 48 in 1 in
Tilt Alarm - An alarm sounds and a warning light is illumi- Cylinders (3.8 cm) (122 cm) (2.5 cm)
nated when the machine is operated on a slope that
exceeds the values in Table 1-9, Tilt Sensor Indicators. 2.5 in 4.6 in 1.75 in
Steer Cylinder
The lift and drive functions will cut out at these set heights. (6.4 cm) (11.2 cm) (4.4 cm)
NOTE: Alarm only sounds when above elevation.
If the machine is operated beyond the specified

slope, with the platform completely lowered, only the
1.10 MAJOR COMPONENT WEIGHTS
warning light is illuminated.
Table 1-11. Major Component Weights
Table 1-9. Tilt Sensor Indicators
Component Weight
Model Front To Back Side To Side
Fixed Platform 1070 lbs (485 kg)
5° to 26 ft (8 m) Platform Extension 440 lbs (200 kg)
3394RT
5° to full height 4° to 30 ft (9 m)
(ANSI, ANSI Export, Aus)
3° to 33 ft (10 m) Arm Assembly- (Includes Lift Cylinder)
3394RT 3600 lbs (1633 kg)
5° to 26 ft (8 m) 4394RT 4550 lbs (2064 kg)
4394RT
5° to full height 4° to 30 ft (9 m)
(ANSI, ANSI Export, Aus)
3° to 43 ft (13 m) Chassis with Pneumatic Tires
3394RT 6790 lbs (3080 kg)
3394RT/4394RT 4394RT 9080 lbs (4119 kg)
3° to full height 3° to full height
(CSA)
Chassis with Foam Filled Tires
3394RT/4394RT 3394RT 7788 lbs (3533 kg)
5° to full height 3° to full height
(CE) 4394RT 9086 lbs (4121 kg)
3121133 – JLG Sizzor – 1-3

1.11 CRITICAL STABILITY WEIGHTS 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
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS hydraulic oil, which has an SAE viscosity index of
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: 152 .
FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY. Table 1-14. Mobil DTE 13M Specs
Table 1-12. Critical Stability Weights ISO Viscosity Grade #32

Specific Gravity 0.877
Component Weight
Pour Point, Max -40°F (-40°C)
Tires Flash Point, Min. 330°F (166°C)
12 x 16.5 Pneumatic 132 lbs (60 kg)
Viscosity
12 x16.5 Foam Filled 352 lbs (160 kg)
33/1550-16.5 Pneumatic 162 lbs (73 kg) at 40° C 33cSt
33/1550-16.5 Foam Filled 410 lbs (186 kg) at 100° C 6.6 cSt
33/16LL x 16.1 Foam Filled - Sand 426 lbs (193 kg) at 100° F 169 SUS
Engine (Ford) 324 lbs (147 kg) at 210° F 48 SUS
cp at -20° F 6,200
Engine (Deutz) 441 lbs (200 kg)
Viscosity Index 140
Engine (GM) 341 lbs (155 kg)
Table 1-15. Mobil EAL 224H Specs
1.12 LUBRICATION SPECIFICATIONS
Type Synthetic Biodegradable
Table 1-13. Hydraulic Oil ISO Viscosity Grade 32/46
Specific Gravity 0.922
HYDRAULIC SYSTEM
OPERATING SAE VISCOSITY GRADE Pour Point, Max -25°F (-32°C)
TEMPERATURE RANGE Flash Point, Min. 428°F (220°C)
0°F to +23°F Operating Temp. 0°F to 180°F (-17°C to 162°C)
10W
(-18°C to -5°C) Viscosity
0°F to +210°F at 40°C 37 cSt
10W-20,10W-30
(-18°C to +100°C) at 100°C 8.4 cSt
+50°F to +210°F Viscosity Index 213
20W-20
(+10°C to +100°C) NOTE: Must be stored above 32°F (14°C)
1-4 – JLG Sizzor – 3121133

1.13 OPERATOR MAINTENANCE
1. Fuel Tank
2. Drive Hubs
3. Hydraulic Oil Tank
4. Sliding Wear Pads
5. Oil Change w/Filter - Ford
6. Oil Change w/Filter - Deutz
7. Oil Change w/Filter - GM
8. Fuel Filter - Ford
9. Fuel Filter - Deutz
10. Fuel Filter (Gasoline) - GM
11. Air Filter
12. Electronic Pressure Regulator (LP Only)
13. Fuel Filter (Propane) - GM
NOTE: Item #5 through #13 are on the opposite

side of the machine and not shown.
Figure 1-2. Operator Maintenance and Lubrication Diagram
1. Fuel Tank
TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL

MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.
NOTE: Be sure to lubricate like items on each side.
NOTE: Recommended lubricating intervals are based on

machine operations under normal conditions. For
machines used in multi-shift operations and/or
exposed to hostile environments or conditions, lubri-
cation frequencies must be increased accordingly.
Operate hydraulic functions through one complete

cycle before checking hydraulic oil level in tank. Oil
should be visible in ADD sight window on hydraulic
tank. If oil is not visible, add oil until oil is visible in • Fuel - Diesel or Gasoline
both ADD and FULL sight windows on tank. Do not • Capacity - 31.5 gal (119 l)
overfill tank.
Any time the pump coupling is removed, coat splines

of coupling with Texaco Code 1912 grease prior to
assembly.
3121133 – JLG Sizzor – 1-5

2. Drive Hub 5. Oil Change w/Filter - Ford
• Lube Point(s) - Fill Cap/Spin-on Element

(JLG P/N 7014501)
• Lube Points - Fill Plugs (4) • Capacity - 4.5 qt. (4.25 L)
• Lube - EPGL • Lube - EO
• Interval - Every 2 years or 1200 hours • Interval - 3 Months or 150 hours of operation
• Comments - Check level daily/Change in accordance
3. Hydraulic Oil with engine manual.
6. Oil Change w/Filter - Deutz
• Lube Point - Fill Cap/Fill Level

• Lube - HO (JLG P/N 7016331)
• Interval - Check oil every 10 hours of operation; • Capacity - 6.3 qt. (5.9 L) engine only
change oil every 2 years or 1200 hours of operation.
• Lube - EO
• Interval - Every Year or 600 hours of operation
4. Sliding Wear Pads
• Comments - Check level daily/Change in accordance
• Lube Points - 8 Sliding Wear Pads
with engine manual.
• Lube - MPG
• Interval - Every month or 50 hours.
1-6 – JLG Sizzor – 3121133

7. Oil Change w/Filter - GM 9. Fuel Filter - Deutz

(JLG P/N 7027965) • Lube Point(s) - Replaceable Element
• Capacity - 4.5 qt. (4.25 L) w/filter • Interval - Every Year or 600 hours of operation
• Lube - EO
10. Fuel Filter (Gasoline) - GM
• Interval - 3 Months or 150 hours of operation
• Comments - Check level daily/Change in accordance • Lube Point(s) - Replaceable Element
with engine manual. • Interval - Every 6 months or 300 hours of operation
8. Fuel Filter - Ford 11. Air Filter

• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator
12. Electronic Pressure Regulator (LP only)
• Lube Point(s) - Replaceable Element

• Interval - Every Year or 600 hours of operation

• Comments - Drain oil build up. Refer to Draining Oil
Build Up From The Propane Regulator
3121133 – JLG Sizzor – 1-7

13. Fuel Filter (Propane) - GM 5. Disconnect the electrical connection to the LPG fuel
temperature sensor in the auxiliary fuel port of the
EPR.

• Comments - Replace filter. Refer to Propane Fuel Filter
Replacement
Draining Oil Build Up From The Propane

6. Remove the retainer clip for the LPG fuel tempera-
Regulator ture sensor and remove the sensor from the regula-
During the course of normal operation oils may build tor body.
inside the primary and secondary chambers of the pro-
pane pressure regulator. These oils may be a result of
poor fuel quality, contamination of the fuel supply chain,
or regional variation in the make up of the fuel. If the build
up of the oil is significant this can effect the operation of
the fuel control system. Refer to Section 1.13, Operator
Maintenance for maintenance intervals. More frequent
draining may be required if the fuel supply has been con-
taminated.
NOTICE
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM-
PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO
FLOW FREELY FROM THE REGULATOR.
NOTE: Have a small container ready to collect oil that will
1. Move the equipment to a well ventilated area. drain freely from the regulator at this point.
Ensure there are no external ignition sources.
7. Once all of the oil has been drained, reinstall the
2. Start the engine and bring to operating temperature. LPG fuel temperature sensor and reconnect the
3. With the engine running, close the manual tank electrical connector.
valve and run the engine out of fuel. 8. Open the fuel tank manual valve.
4. Push in the Emergency Switch once the engine 9. Start the engine and verify all connections are
stops. secure.
10. Dispose of any drained oil per local regulations in a
safe and proper fashion.
1-8 – JLG Sizzor – 3121133

Propane Fuel Filter Replacement INSTALLATION:
NOTICE
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-
ING BEFORE INSTALLING NEW SEAL.
1. Install the mounting plate to lock off O-ring seal.

2. Install the retaining bolt seal.
3. Install the housing seal.
4. Drop the magnet into the bottom of the filter hous-
ing.
5. Install the filter into the housing.
6. Install the retaining bolt into the filter housing.
7. Install the filter up to the bottom of the electric lock
off.
1. Electric Lock Off Solenoid 7. Electrical Connector
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).
2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring 9. Open manual shut-off valve. Start the vehicle and
4. Filter Magnet 10. Filter leak check the propane fuel system at each serviced
5. Filter Housing 11. Fuel Inlet fitting. Refer to Propane Fuel System Leak Test.
6. Seal 12. Retaining Bolt
Figure 1-3. Filter Lock Assembly Propane Fuel System Pressure Relief
REMOVAL:
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
1. Relieve the propane fuel system pressure. Refer to
312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
Propane Fuel System Pressure Relief.
SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
2. Disconnect the negative battery cable. SURE (WHERE APPLICABLE) BEFORE SERVICING THE
PROPANE FUEL SYSTEM COMPONENTS.
3. Slowly loosen the Filter housing retaining bolt and
remove it. To relieve propane fuel system pressure:
4. Pull the filter housing from the Electric lock off 1. Close the manual shut-off valve on the propane fuel
assembly. tank.
5. Locate Filter magnet and remove it. 2. Start and run the vehicle until the engine stalls.
6. Remove the filter from the housing. 3. Turn the ignition switch OFF.
7. Remove and discard the housing seal.
8. Remove and discard the retaining bolt seal.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
9. Remove and discard mounting plate to lock off O- SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
ring seal. BEFORE DISCONNECTING ANY FUEL LINE.
3121133 – JLG Sizzor – 1-9

1.14 TORQUE CHARTS
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3)
1-10 – JLG Sizzor – 3121133

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3))
3121133 – JLG Sizzor – 1-11

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

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3)
3121133 – JLG Sizzor – 1-13

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

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3)
3121133 – JLG Sizzor – 1-15

NOTES:
1-16 – JLG Sizzor – 3121133

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the Annual Machine Inspection
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe JLG recommends that an annual machine inspection be
operation, ensure that all the necessary inspections and performed by a Factory-Certified Service Technician on an
maintenance have been completed before placing the annual basis, no later than thirteen (13) months from the
machine into service. date of the prior Annual Machine Inspection. JLG Indus-
tries, Inc. recognizes a Factory-Certified Service Techni-
Preparation, Inspection, and Maintenance cian as a person who has successfully completed the JLG
Service Training School for the subject JLG product
It is important to establish and conform to a comprehen- model. Reference the machine Service and Maintenance
sive inspection and preventive maintenance program. The Manual and appropriate JLG inspection form for perfor-
following table outlines the periodic machine inspections mance of this inspection.
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for fur- Reference the JLG Annual Machine Inspection Form and
ther requirements for aerial work platforms. The frequency the Inspection and Preventative Maintenance Schedule for
of inspections and maintenance must be increased as items requiring inspection during the performance of this
environment, severity and frequency of usage requires. inspection. Reference the appropriate areas of this man-
ual for servicing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is
It is the User’s or Operator’s primary responsibility to per- important that JLG Industries, Inc. has updated ownership
form a Pre-Start Inspection of the machine prior to use information for each machine. When performing each
daily or at each change of operator. Reference the Opera- Annual Machine Inspection, notify JLG Industries, Inc. of
tor’s and Safety Manual for completion procedures for the the current machine ownership.
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per- Preventative Maintenance
forming the Pre-Start Inspection.
In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent mechanic. JLG Industries, Inc. recognizes a qualified JLG
Inspection equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train-
The Pre-Delivery Inspection and Frequent Inspection shall ing, or experience, has successfully demonstrated the
be performed by a qualified JLG equipment mechanic. ability and proficiency to service, repair, and maintain the
JLG Industries, Inc. recognizes a qualified JLG equipment subject JLG product model.
mechanic as a person who, by possession of a recog-
nized degree, certificate, extensive knowledge, training, or Reference the Preventative Maintenance Schedule and
experience, has successfully demonstrated the ability and the appropriate areas of this manual for servicing and
proficiency to service, repair, and maintain the subject maintenance procedures. The frequency of service and
JLG product model. maintenance must be increased as environment, severity
and frequency of usage requires.
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.
3121133 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Prior to use each day; or

Pre-Start Inspection User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Service and Maintenance

Pre-Delivery Prior to each sale, lease, or Qualified JLG
Owner, Dealer, or User Manual and applicable JLG
Inspection rental delivery. Mechanic
inspection form.
In service for 3 months or 150 hours,

whichever comes first; or Service and Maintenance
Qualified JLG
Frequent Inspection Out of service for a period of more than 3 Owner, Dealer, or User Manual and applicable JLG
Mechanic
months; or inspection form.
Purchased used.
Factory-Certified
Service and Maintenance
Annual Machine Annually, no later than 13 months from the Service Technician or
Owner, Dealer, or User Manual and applicable JLG
Inspection date of the prior inspection. a Qualified JLG
inspection form.
Mechanic
Preventative At intervals as specified in the Service and Qualified JLG Service and Maintenance
Owner, Dealer, or User
Maintenance Maintenance Manual. Mechanic Manual
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General 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- 3. Clean and inspect all parts during servicing or main-
dures contained in this book. tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
Safety and Workmanship clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain-
Your safety, and that of others, is the first consideration ers until they are ready to be used.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Components Removal and Installation
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising 1. Use adjustable lifting devices, whenever possible, if
a portion of the equipment, ensure that adequate support mechanical assistance is required. All slings (chains,
is provided. cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
Cleanliness lifted.
2. Should it be necessary to remove a component on

1. The most important single item in preserving the
an angle, keep in mind that the capacity of an eye-
long service life of a machine is to keep dirt and for-
bolt or similar bracket lessens, as the angle between
eign materials out of the vital components. Precau-
the supporting structure and the component
tions have been taken to safeguard against this. becomes less than 90°.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these 3. If a part resists removal, check to see whether all
items must be maintained on a scheduled basis in nuts, bolts, cables, brackets, wiring, etc., have been
order to function properly. removed and that no adjacent parts are interfering.
2-2 – JLG Lift – 3121133

SECTION 2 - GENERAL
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com- heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially dance with recommended shop practices. (See
Torque Chart Section 1.)
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been Hydraulic Lines and Electrical Wiring
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval. 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
Pressure-Fit Parts reinstalled.
When assembling pressure-fit parts, use an anti-seize or Hydraulic System

molybdenum disulfide base compound to lubricate the
mating surface. 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.
Bearings
2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
1. When a bearing is removed, cover it to keep out dirt
cleaning solvent. Lubricate components, as
and abrasives. Clean bearings in nonflammable required, to aid assembly.
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing. Lubrication
2. Discard bearings if the races and balls (or rollers) Service applicable components with the amount, type,
are pitted, scored, or burned. and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
3. If bearing is found to be serviceable, apply a light not available, consult your local supplier for an equivalent
coat of oil and wrap it in clean (waxed) paper. Do not that meets or exceeds the specifications listed.
unwrap reusable or new bearings until they are
ready to install.
Battery
Clean battery, using a non-metallic brush and a solution of
4. Lubricate new or used serviceable bearings before baking soda and water. Rinse with clean water. After
installation. When pressing a bearing into a retainer cleaning, thoroughly dry battery and coat terminals with
or bore, apply pressure to the outer race. If the bear- an anti corrosion compound.
ing is to be installed on a shaft, apply pressure to the
inner race. Lubrication and Servicing
Components and assemblies requiring lubrication and
Gaskets servicing are shown in the Lubrication Chart in Section 1.
Check that holes in gaskets align with openings in the

mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its 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.
3121133 – JLG Lift – 2-3

SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION 3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
This will allow start up at temperatures down to -20°F
Hydraulic System (-29°C). However, use of this oil will give poor perfor-
mance at temperatures above 120° (49°C). Systems
1. The primary enemy of a hydraulic system is contam- using DTE 13 oil should not be operated at tempera-
ination. Contaminants enter the system by various tures above 200°F (94°C) under any condition.
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand, Changing Hydraulic Oil
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient 1. Use of any of the recommended hydraulic oils elimi-
system warm-up or leaks in the pump supply (suc- nates the need for changing the oil on a regular
tion) lines. basis. However, filter elements must be changed
after the first 50 hours of operation and every 300
2. The design and manufacturing tolerances of the hours thereafter. If it is necessary to change the oil,
component working parts are very close, therefore, use only those oils meeting or exceeding the specifi-
even the smallest amount of dirt or foreign matter cations appearing in this manual. If unable to obtain
entering a system can cause wear or damage to the the same type of oil supplied with the machine, con-
components and generally results in faulty opera- sult local supplier for assistance in selecting the
tion. Every precaution must be taken to keep proper equivalent. Avoid mixing petroleum and syn-
hydraulic oil clean, including reserve oil in storage. thetic base oils. JLG Industries recommends chang-
Hydraulic system filters should be checked, ing the hydraulic oil annually.
cleaned, and/or replaced as necessary, at the speci-
fied intervals required in the Lubrication Chart in 2. Use every precaution to keep the hydraulic oil clean.
Section 1. Always examine filters for evidence of If the oil must be poured from the original container
metal particles. into another, be sure to clean all possible contami-
nants from the service container. Always clean the
3. Cloudy oils indicate a high moisture content which mesh element of the filter and replace the cartridge
permits organic growth, resulting in oxidation or cor- any time the system oil is changed.
rosion. If this condition occurs, the system must be
3. While the unit is shut down, a good preventive main-
drained, flushed, and refilled with clean oil.
tenance measure is to make a thorough inspection
4. It is not advisable to mix oils of different brands or of all hydraulic components, lines, fittings, etc., as
types, as they may not contain the same required well as a functional check of each system, before
additives or be of comparable viscosities. Good placing the machine back in service.
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is oper- Lubrication Specifications
ating, are recommended for use. Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
NOTE: Metal particles may appear in the oil or filters of new
multi-purpose greases usually have the qualities which
machines due to the wear-in of meshing compo-
meet a variety of single purpose grease requirements.
nents.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evalua-
Hydraulic Oil tion. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends Mobilfluid 424 hydraulic oil, which

has an SAE viscosity of 10W-30 and a viscosity
index of 152.
NOTE: Start-up of hydraulic system with oil temperatures

below -15°F (-26°C) is not recommended. If it is nec-
essary to start the system in a sub-zero environ-
ment, it will be necessary to heat the oil with a low
density, 100VAC heater to a minimum temperature of
-15°F (-26°C).
2-4 – JLG Lift – 3121133

SECTION 2 - GENERAL
2.4 CYLINDER DRIFT TEST 2.5 PINS AND COMPOSITE BEARING

Maximum acceptable cylinder drift is to be measured REPAIR GUIDELINES
using the following methods.
Filament wound bearings.
Platform Drift 1. Pinned joints should be disassembled and

inspected if the following occurs:
Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, upper boom fully a. Excessive sloppiness in joints.
extended with the rated load in the platform and power off. b. Noise originating from the joint during operation.
Maximum allowable drift is 2 in (5 cm) in 10 minutes. If the
2. Filament wound bearings should be replaced if any
machine does not pass this test, proceed with the follow-
of the following is observed:
ing.
a. Frayed or separated fibers on the liner surface.
Cylinder Drift b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their hous-
Table 2-2. Cylinder Drift ing.
Max. Acceptable Drift d. Debris embedded in liner surface.
Cylinder Bore Diameter
in 10 Minutes 3. Pins should be replaced if any of the following is
inches mm inches mm observed (pin should be properly cleaned prior to
inspection):
3 76.2 0.026 0.66
3.5 89 0.019 0.48 a. Detectable wear in the bearing area.
4 101.6 0.015 0.38 b. Flaking, pealing, scoring, or scratches on the pin
surface.
5 127 0.009 0.22
c. Rusting of the pin in the bearing area.
6 152.4 0.006 0.15
7 177.8 0.005 0.13 4. Re-assembly of pinned joints using filament wound
bearings.
Drift is to be measured at the cylinder rod with a calibrated a. Housing should be blown out to remove all dirt
dial indicator. The cylinder oil must be at ambient temper- and debris...bearings and bearing housings
ature and temperature stabilized. must be free of all contamination.
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
NOTE: This information is based on 6 drops per minute cyl- burrs, nicks, and scratches which would dam-
inder leakage. age the bearing during installation and opera-
tion.
3121133 – JLG Lift – 2-5

SECTION 2 - GENERAL
2.6 PREVENTIVE MAINTENANCE AND NOTICE

INSPECTION SCHEDULE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
The preventive maintenance and inspection checks are
“ANNUAL MACHINE INSPECTION REPORT” FORM.
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspected NOTE: This machine requires periodic safety and mainte-
and the “INTERVAL” at which the inspection is to take nance inspections by a JLG Dealer. A decal located
place. Under the “AREA” portion of the table, the various on the frame affords a place to record (stamp)
systems along with the components that make up that inspection dates. Notify dealer if inspection is over-
system are listed. The “INTERVAL” portion of the table is due.
divided into five columns representing the various inspec-
tion time periods. The numbers listed within the interval The inspection and maintenance code numbers are as fol-
column represent the applicable inspection code for lows:
which that component is to be checked.
1. Check for proper and secure installation.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that 2. Check for visible damage and legibility.
may pertain to this type of equipment nor should the lists 3. Check for proper fluid level.
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depend- 4. Check for any structural damage; cracked or broken
ing on the location and use of the machine. welds; bent or warped surfaces.
JLG Industries requires that a complete annual inspection 5. Check for leakage.
be performed in accordance with the “Annual Machine
6. Check for presence of excessive dirt or foreign
Inspection Report” form. Forms are supplied with each
material.
new machine and are also available from JLG Customer
Service. Form must be completed and returned to JLG 7. Check for proper operation and freedom of move-
Industries. 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.
2-6 – JLG Lift – 3121133

SECTION 2 - GENERAL
Table 2-3. Preventive Maintenance and Safety Inspection
AREA INTERVAL
300 Hours 600 Hours 1200 Hours
Daily Weekly
(6 months) (1 year) (2 years)
PLATFORM
1. Controller 1,11
2. Switches 1,11
3. Placards and Decals 1,2
4. Control Tags 1,2
5. Hoses and Cables 4,8
6. Wear Pads 8
7. Handrails and Chains 1,4
CHASSIS
1. Engine Oil 3 5
2. Battery 3 5
3. Air Cleaner 1 14
4. Exhaust System 1 1,5
5. Engine Mounts 1
6. Hydraulic Pump 1 5
7. Valves 1 5
8. Hydraulic Filter (See Lubrication Chart) 5,14 14
9. Hydraulic Hoses and Tubing 1 5
10. Hydraulic Oil Tank* 3 5 4
11. Hydraulic Tank Breather 6,14
12. Fuel Tank 3,5 4
13. Lift Cylinder 1,12 5,6,13 4
14. Limit Switch 1,7
15. Tilt Alarm Switch 1,7
16. Placards and Decals 1,2
17. Wheel and Tire Assemblies 1 8,9
18. Drive Motors 1,5,6
19. Drive Brakes 1,6 8
20. Drive Torque Hubs 1,3,5,6
21. Steer Cylinder 1 5,6,13 4
22. Steer Components 1 4,6 8
23. Wheel Bearings (2 Wheel Drive) 8 12
24. Sizzor Arms 1,4
25. Safety Props 1,4
26. Sliding Wear Pads 8
27. Pivot Pins/Bolts 1,4 7,8
28. Switches, Ground Control 1,11
29. Control Tags 1,2
3121133 – JLG Lift – 2-7

SECTION 2 - GENERAL
4150548 C
AMBIENT AIR
TEMPERATURE
120°F (49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F (43°C)
100°F (38°C)
90°F (32°C)
80°F (27°C)
SUMMER
ENGINE GRADE 70°F (21°C)
SAE 10W-30
SAE 10W-40
SAE 20W-50
SAE 15W-40
SAE OW-30
SAE OW-40
SAE 5W-30
SAE 5W-40
FUEL
SPECIFICATIONS 60°F (16°C)
50°F (10°C)
40°F (4°C)
30°F (-1°C)
WINTER 20°F (-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F (-12°C)
FULLY CHARGED BATTERY
0°F (-18°C)
WINTER
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE GRADE -10°F (-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER WITH -20°F (-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR GLOW KEROSENE
PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) ADDED
-30°F (-34°C)
-40°F (-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82°C) OR ABOVE
180°F (82°C)
(HYD. OIL TANK TEMP.
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE)
120°F (49°C) NOTE:

110°F (43°C) AMBIENT TEMPERATURE PROLONGED OPERATION IN 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
AMBIENT AIR TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS
100°F (38°C) OF 100°F (38°C) OR ABOVE
90°F (32°C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL
MOBIL 424 10W-30
80°F (27°C)
70°F (21°C)
EXXON UNIVIS HVI 26
60°F (16°C) HYDRAULIC

50°F (10°C) SPECIFICATIONS
40°F (4°C)
°F °C
30°F (-1°C)
+32 0
20°F (-7°C) SUMMER - GRADE
FUEL
AMBIENT TEMPERATURE
10°F (-12°C) +23 -5

MOBIL DO NOT START UP HYDRAULIC SYSTEM
0°F (-18°C) DTE 13 WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10
-10°F (-23°C) HYDRAULIC OIL BELOW THIS TEMPERATURE
+5 -15
-20°F (-29°C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS AND COLD WEATHER WINTER - GRADE
-30°F (-34°C) HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
FUEL
-40°F (-40°C)
NO OPERATION BELOW THIS -13 -25
AMBIENT TEMPERATURE
-22 -30
0 10 20 30 40 50 60
% OF ADDED KEROSENE
Figure 2-1. Engine Operating Temperature Specifications - Deutz
2-8 – JLG Lift – 3121133

SECTION 2 - GENERAL
4150548 C
AMBIENT AIR
TEMPERATURE
120°F (49°C)
100°F (38°C)
90°F (32°C)
80°F (27°C)
ENGINE
SAE 10W-30
SAE 10W-40
SAE 5W-20
SAE 5W-30
SAE 5W-40
60°F (16°C)
50°F (10°C)
40°F (4°C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30°F (-1°C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20°F (-7°C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10°F (-12°C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0°F (-18°C)
-10°F (-23°C)
ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED
FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F (-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30°F (-34°C)
-40°F (-40°C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
(82°C) OR ABOVE
180°F (82°C)
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE
DEPT. FOR APPLICATION)
120°F (49°C) NOTE:

100°F (38°C) OF 100°F (38°C) OR ABOVE
MOBIL 424 10W-30
80°F (27°C)
70°F (21°C)
EXXON UNIVIS HVI 26

40°F (4°C)
30°F (-1°C)
20°F (-7°C)
10°F (-12°C)
0°F (-18°C) DTE 13 WITHOUT HEATING AIDS WITH MOBILE 424

WITHOUT HEATING AIDS AND COLD WEATHER
-40°F (-40°C)
AMBIENT TEMPERATURE
Figure 2-2. Engine Operating Temperature Specifications - Ford
3121133 – JLG Lift – 2-9

SECTION 2 - GENERAL
4150548 C
AMBIENT AIR
TEMPERATURE
120°F (49°C)
100°F (38°C)
90°F (32°C)
80°F (27°C)
ENGINE
SAE 10W-30
60°F (16°C)
50°F (10°C)
40°F (4°C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30°F (-1°C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20°F (-7°C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10°F (-12°C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0°F (-18°C)
-10°F (-23°C)
SAE 5W-30
ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED
FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F (-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30°F (-34°C)
-40°F (-40°C)
AMBIENT TEMPERATURE

HYDRAULIC OIL TANK
(82°C) OR ABOVE
180°F (82°C)
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE
DEPT. FOR APPLICATION)
120°F (49°C) NOTE:

100°F (38°C) OF 100°F (38°C) OR ABOVE
MOBIL 424 10W-30
80°F (27°C)
70°F (21°C)
EXXON UNIVIS HVI 26

40°F (4°C)
30°F (-1°C)
20°F (-7°C)
10°F (-12°C)
0°F (-18°C) DTE 13 WITHOUT HEATING AIDS WITH MOBILE 424

WITHOUT HEATING AIDS AND COLD WEATHER
-40°F (-40°C)
AMBIENT TEMPERATURE
Figure 2-3. Engine Operating Temperature Specifications - GM
2-10 – JLG Lift – 3121133

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS Power Deck
The power deck is operated through a non proportional
Leveling Jacks valve. This will not effect any other function when acti-
The machine may be equipped with auto leveling jacks. vated.
These leveling jacks are operated through one switch
unlike the traditional four switch system. The leveling
jacks are operated by a bang bang valve.
BE SURE AND RETRACT ANY POWER DECK BEFORE LOWERING
NOTE: The engine speed will drop when the leveling jacks MACHINE.
are in contact with the ground.
Generator
1. Activate the leveling jack button located on the plat-
form control box. When the generator switch is activated the engine RPM
will speed up to 2000 RPM for a 60 Hz generator or 1700
2. Extend the jacks by moving the joystick forward. RPM for a 50 Hz generator.
NOTE: Once all four jacks make contact with the ground the
When a function is selected for operation, which requires
system will go from set mode into level mode. At this
a higher engine speed than the generator, the generator
point the engine will return to idle.
will automatically shut off during the operation of the func-
tion. Once the function has stopped, the generator will be
3. The tilt indicator will go out once the machine is
active again.
level.
NOTE: If the machine is not level it will not lift. If you hit the Lift
end of stroke on any of the cylinders you cannot lift
There is a flow control valve which controls both the lift up
the machine.
and lift down speeds.
Anytime you abruptly change lift directions, there is a
NOTE: There is a limit switch on each cylinder that senses
three second delay between lift up and lift down.
when the cylinder is fully retracted when all four are
fully retracted, the stowed light in the platform control
box will light. Drive
If driving at high drive up a grade and you hit an 8° incline,
If you receive a 2/5 flash code through the system
the drive function will cut back to mid drive speed. The
fault light at the platform control station the machine
drive pump will shift back into high drive once the incline
is unable to level. You must reposition and try again.
decreases to 5°. There will be a 2 second delay before the
machine goes back into high drive.
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.
3121133 – JLG Sizzor – 3-1

3.2 CALIBRATIONS
1. Proximity Sensor
2. Rotary Angle Sensor
Figure 3-1. Limit Switch Location
Elevation Sensor Calibration 5. The bottom line on the analyzer display will show the
range of voltage the sensor must be within for
(Prior to Software P1.20) proper calibration. the actual voltage is displayed on
the bottom line to the right as shown.
NOTE: Make sure your analyzer is in ACCESS LEVEL 1.
When using the analyzer, under the DIAGNOSTIC

menu the term referring to ROTARY & PROXIMITY
sensors is ELEV SENSOR. set elev sensor:
0.50v-1.0v x-xxv
Use CALIBRATIONS menu for rotary switch adjust-
ments.
1. When mounting, make sure the rotary switch is

aligned with the bladed pin mounted on the center
link as shown in Figure 3-1., Limit Switch Location.
There must be a preload when installing the rotary
switch on the bladed pin bracket.
2. 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.
3. Make sure the deck is fully lowered. Plug in the ana-

lyzer and enter the service password (33271).
4. Go to CALIBRATIONS, then SET ELEV SENSOR and

hit enter then right arrow.
3-2 – JLG Sizzor – 3121133

6. Press the left arrow button and then enter. 2. SET 26FT ELEV (3394RT) or SET 30FT ELEV
(4394RT);
NOTE: Anytime the ground control board or if the rotary sen-
sor is replaced the rotary sensor must be reset a. Raise platform to a height of 26 feet for the
(zeroed out). 3394RT or 30 feet for the 4394RT (measured
deck to ground).
When stowed, if angle sensor is within the range of b. Enter YES on the Analyzer.
CALIB (see below), the machine should be recali- c. COMPLETE will show on the analyzer when cali-
brated. brated.
If the gap ever increases beyond 5/16 in., the switch 3. SET 30FT ELEV (3394RT) or SET 36FT ELEV
may cause intermittent operation. (4394RT);
a. Raise platform to a height of 30 feet on the
7. Completely lower the platform. Using the analyzer 3394RT or 36 feet for the 4394RT (measured
press escape and scroll through DIAGNOSTICS and deck to ground).
then go to ELEV SENSOR, press ENTER. Check to
see that the following items are reading correctly. b. Enter YES on the Analyzer.
c. COMPLETE will show on the analyzer when cali-
ANGLE SNSR 0.40 - X.XXV brated.
ZEROED 0.00V NOTE: Elevation Proximity Switch must be mounted and
functioning properly to calibrate the Elevation Sen-
ELEV CUT sor.
CALIB 0.50v - 1.0v
8. Press ESCAPE until you arrive at DIAGNOSTICS, NOTICE

then scroll over to top level menu SET ELEV SEN- FOR MACHINE TO OPERATE TO CAPACITY, BE SURE TO CALI-
SOR, press ENTER. At this point press ENTER key. If BRATE ELEVATION SENSOR AT ALL THREE POSITIONS.
everything tested properly the analyzer will read
COMPLETE. Joystick Calibration
9. Now lift the machine up. Drive speed should be (Software P1.20 & Higher)
reduced to elevated speed at the following heights;
Using the Analyzer, in Access Level 1, go to MENU: CALI-
3394RT - 6-9 ft (1.8 - 2.7m) BRATION: JOYSTICK and press ENTER.
4394RT - 7-10 ft ( 2.1 - 3m) 1. Following the analyzer screen prompts:
10. Press ESCAPE, remove analyzer and assure all a. Move the Joystick FORWARD and press ENTER.
hardware is tight. b. Allow Joystick to be in CENTER position and
press ENTER.
NOTE: If voltage is too low the analyzer will display SEN-
SOR FAILURE. If the voltage is set too high the ana- c. Move the Joytstick REVERSE and press ENTER.
lyzer will read NOT STOWED. When calibration is 2. CAL COMPLETE or CAL FAILED will display on the
attempted, once it is set within the proper limits, the analyzer.
analyzer will read COMPLETE.
3. Possible reasons if calibration failed:
Elevation Sensor Calibration a. The forward position must be a lower voltage
than reverse position.
(Software P1.20 & Higher)
b. The difference between center and forward &
Using the Analyzer, in Access Level 1, go to MENU: CALI- center and reverse must be atleast 1V.
BRATION:
Tilt Sensor Calibration:
1. SET STOW ELEV;
1. Drive the machine onto a measured level surface
a. Completely lower platform to stowed position. (±0.5° for both x and y axis).
b. Enter YES on the Analyzer.
2. Using the Analyzer, go to MENU: CALIBRATION;
c. COMPLETE will show on the analyzer when cali- TILT SENSOR. Press Enter. LEVEL VEHICLE will dis-
brated. play. Press Enter again to calibrate.
3121133 – JLG Sizzor – 3-3

3. Both axis’ raw angles need to be within ±5.0°, other- c. Tilt sensor has developed an offset shift:
wise the machine is to unlevel and the software will Remove the tilt sensor from the Ground Control
prohibit calibration. Should this occur, attempt to box, but keep both the tilt sensor and Ground
dissect the three areas of error to find the primary Control box electrically connected. Level one
contributor: axis of the tilt sensor and observe the raw read-
ing (should be within ±2.0°). Do the same for the
a. Machine mounting and/or grade: other axis. If either axis is greater than ±2.0°,
With a digital level, measure the top of the replace the tilt sensor.
Ground Control box for levelness. If unable to
get a good reading, check the box’s mounting Some possible reasons that the tilt sensor will not cali-
surface for levelness. brate are:
2 a. The surface the machine is sitting on is off level

by a few degrees (flat doesn’t imply level; park-
ing lots are often not level).
b. The tilt sensor has failed one or both of the

channels (X axis and Y axis).
1 c. Tilt sensor has moisture intrusion that has

shifted its output.
d. Water and/or corrosion in the box has corrupted

electrical connections or caused a tilt sensor or
ground control board failure (observe any
cracks in the box).
e. The Ground Control Box, as mounted on the

machine, does not allow the tilt sensor to be
1. Ground Control Box 2. Digital Level level.
For the following troubleshooting steps, a bubble level

b. Tilt sensor mounting on machine or wedged
(smaller is better) will be needed and the machine must
crooked in control box:
be on a level surface:
If the machine mounting/grade appears accept-
able, open the Ground Control box carefully. 1. On the Analyzer, go to Diagnostics/System and read
Observe whether the tilt sensor is properly the tilt angle. If either angle reports +20.0°, there is
seated. an electrical/electronic failure (tilt sensor, control
board, electrical connections).
2 a. Open the Ground Control Box.
b. Disconnect the sensor and clean any corrosion

off of the tilt sensor and control board connec-
tions.
c. Reassemble and test. If fault persists, replace tilt

sensor.
2. If the Analyzer displays angles other than +20.0°,

attempt to calibrate. If machine will not calibrate,
1 note the reason displayed on Analyzer:
a. SENSOR FAILURE – tilt sensor internal fre-

quency is out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an

1. Ground Control Box 2. Tilt Sensor offset or it is to unlevel as mounted on the
machine.
3-4 – JLG Sizzor – 3121133

3.3 LEVEL SENSOR AND ANALYZER CONNECTIONS

The level sensor is located at the ground control station. trol station on the under side of the platform control box as
Using a screwdriver, open the ground control station and shown in Figure 3-2., Level Sensor and Analyzer Connec-
locate the level sensor as shown in Figure 3-2., Level Sen- tions.
sor and Analyzer Connections.
There are two analyzer connection ports. One in the NOTE: Ensure that the level sensor is installed with the bub-
ground control station and the other at the platform con- ble towards the top side of the lower control box.
Level Sensor
Ground Control
Analyzer Connection
Platform Control
Analyzer Connection
Figure 3-2. Level Sensor and Analyzer Connections
3121133 – JLG Sizzor – 3-5

Tilt Sensor, JLG P/N 4000006:

1
2 1
3
2
1. Ground Control Box

2. Tilt Sensor (JLG P/N 4000006)
Figure 3-3. Tilt Sensor Location
Tilt Sensor Removal:

1. Tilt Sensor (JLG P/N 4000006)
NOTE: Refer to Figure 3-4., Tilt Sensor Removal for num- 2. Screw, 6-32 x 3/4
bers in parenthesis.
3. Lockwasher
1. Disconnect the batteries.
2. Open the Ground Control Box to gain access to the Figure 3-4. Tilt Sensor Removal
Tilt Sensor Assembly.
3. Remove the four Screws (2) and Lockwashers (3) to
Table 3-1. Tilt Sensor Harness Chart
remove the Tilt Sensor (1) from the Ground Control
Box. Wire Color Function Connector Pin
NOTE: Follow the above procedures in reverse order when Red VCC 1
installing the tilt sensor assembly. After installing, be Black Ground 4
sure to calibrate the tilt sensor (refer to Section 3.2,
Blue PWMX 2
Calibrations).
Yellow PWMY 3
3-6 – JLG Sizzor – 3121133

Tilt Sensor, JLG P/N 4000021:

1
1 6
2 7
2
5
4
3
1. Ground Control Box

2. Tilt Sensor Assembly (JLG P/N 1810140)
Figure 3-5. Tilt Sensor Location
NOTE: Refer to Figure 3-6., Tilt Sensor Removal for num-

bers in parenthesis. 1. Tilt Sensor (JLG P/N 4000021)
1. Disconnect the batteries. 2. Sensor Mount
2. Open the Ground Control Box to gain access to the 3. Screw, 6-32 x 1
Tilt Sensor Assembly.
4. Lockwasher
3. Remove the four Screws (3), Lockwashers (4),
5. Standoff Insulator
Standoff Insulators (5), and Washers (6) to remove
the Tilt Sensor (1) and Sensor Mount (2) from the 6. Washer, 0.313 x 0.250 Nylon
Ground Control Box.
7. Screw, M3.5 x 0.6 x 10
4. The Tilt Sensor (1) can be removed from the Sensor
Mount (2) by removing the three Screws (7). Figure 3-6. Tilt Sensor Removal
NOTE: Follow the above procedures in reverse order when
installing the tilt sensor assembly. After installing, be
sure to calibrate the tilt sensor (refer to Section 3.2, Table 3-2. Tilt Sensor Harness
Calibrations).
Wire Color Function Connector Pin
Red VCC 1
Green PWMX 2
White PWMY 3
Black Ground 4
3121133 – JLG Sizzor – 3-7

3.4 INTEGRATED TORQUE/DRIVE HUB .
The Integrated Torque/Drive Hub is an axial piston-hydrau-

lic motor with integrated, hydraulic released multi plate
parking brake and a 2-stage planetary gearbox and a dis-
connect mechanism.
To insure an optimum balancing of loads, each planetary

stage comprises of planet gears in sets. The externally
toothed wheels are case-hardened.
The hydraulically released, wet running, multi plate brake,
integrated in the hydraulic motor, is a parking brake. It is
normally closed by spring force and released when pres-
surized by hydraulic oil.
NOTICE
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK
TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO
MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE
WORKING PROPERLY.
X3
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 X
the gears are not rolling freely and should be examined for T
proper installation or defects. Some gear packages roll MA MB
with more difficulty than others. Do not be concerned if
gears seem to roll hard as long as they roll with consis-
tency.
A B
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- NOTE: JLG P/N’s: 2780263 (2WD), 2780262 (4WD)
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 Figure 3-7. Integrated Torque/Drive Hub
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, Table 3-3. Torque/Drive Hub Specs
the part must be replaced.
Gearbox
Maximum Output Speed 30.25 rpm
Maximum Output Torque 4556.5 lb ft (6177.7 Nm)
Brake
Static Brake Torque 88 lb ft (119.3 Nm)
Release Pressure 174 psi (12 bars)
Motor
Maximum Displacement 28 CCM
Minimum Displacement 14.2 CCM
Switching Pressure 145 psi min - (1450 psi) max
3-8 – JLG Sizzor – 3121133

36 34 32 26 35 37 1 10 13 15 2 24
12
33
30
28
31
29
25
27
14
8
18
19
17 11 20 16 6 4 21 22 3 7 23
1. Planet Gear 11. Tapered Roller Bearing 21. Thrust Washer 31. O-Ring
2. Planet Gear 12. Retaining Ring 22. Gear, Ring Options 32. Spring
3. Sun Gear 13. Retaining Ring 23. O-Ring 33. Shift Rod
4. Shaft Nut 14. Retaining Ring 24. Retaining Ring 34. Brake Housing
5. Planet Pin 15. Support Disk 25. Sun Gear Shaft 35. Wheel Stud
6. Support Ring 16. O-Ring 26. Input Shaft 36. Hydraulic Motor
7. Planet Carrier 17. Shaft Seal 27. Thrust Washer 37. Spring Sleeve Dowel
8. Cover 18. Screw Plug 28. Cover
9. Roller Bearing 19. Seal Ring 29. Sleeve
10. Roller Bearing 20. Bolt 30. Bolt
Figure 3-8. Drive Motor/Hub Assembly
3121133 – JLG Sizzor – 3-9

NOTICE
Table 3-4. Gearbox Maintenance Schedule
THE MAXIMUM GEAR DRIVE TOWING SPEED OF 72 RPM MUST
After 150 motor operating hours - First oil change NOT BE EXCEEDED. ENGAGE GEAR DRIVE OR SECURE
MACHINE WHEN MACHINE IS SEPARATED FROM THE TOWING
Weekly: - Inspect visually
VEHICLE.
- Check for unusual noise
- Check oil level Engaging Procedure:
Monthly: - Check the tightness of all screws
and bolts
NOTICE
Semi-annually: - Check oil quality PRIOR TO ENGAGING, THE MACHINE HAS TO BE ON LEVEL
Annually: - Change oil GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT.
(or after 1500 motor operating ENSURE AREA SURROUNDING THE DISCONNECT IS CLEANED
hours, whichever comes first) PRIOR TO OPERATION. MAKE SURE DIRT OR OTHER CONTAMI-
NANTS DO NOT ENTER THE GEAR DRIVE.
Disconnect Mechanism
The disconnect mechanism on the torque/drive hub CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING.
allows the machine to be towed. When activated, the GEAR DRIVE MAY BE HOT AND CAUSE INJURY IF RECENTLY
mechanism disconnects the gear drive and motor. OPERATED.
Disengaging Procedure:
COVER (ITEM 28) IS UNDER SPRING FORCE.

NOTICE
PRIOR TO DISENGAGING, THE MACHINE MUST BE ON LEVEL For numbers in ( ), refer to Figure 3-8., Drive Motor/Hub
GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT. Assembly.
ENSURE AREA SURROUNDING THE DISCONNECT IS CLEANED
1. Remove the 2 Bolts (30) from the Cover (28) evenly.
PRIOR TO OPERATION. MAKE SURE DIRT OR OTHER CONTAMI-
NANTS DO NOT ENTER THE GEAR DRIVE. 2. Remove the Cover.
3. Rotate the Cover 180° and assemble.
4. Tighten 2 Bolts (30) with a torque wrench to 6.3 lb ft
CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING. (8.5 Nm).
GEAR DRIVE MAY BE HOT AND CAUSE INJURY IF RECENTLY
5. Slightly pull the machine with the towing vehicle to
OPERATED.
allow the spline of the Sun Gear Shaft (25) to
engage with the spline of the Input Shaft (26).
For numbers in ( ), refer to Figure 3-8., Drive Motor/Hub
Assembly.
1. Remove the 2 Bolts (30) from the Cover (28). DO NOT OPERATE THE MOTOR TO OBTAIN ENGAGEMENT.
2. Remove the Cover. 6. Check again that all bolts are tight and that all com-
ponents are returned to their original position.
3. Rotate Cover to show inside diameter.
The gear drive should now be reengaged and the
4. Press Cover sufficiently against the Shift Rod (33) to machine can be disconnected from the towing vehicle.
insert the 2 Bolts at least 2-3 threads into the Cover.
The Shift Rod is now subjected to the Spring (32)
force.
5. Install the 2 Bolts (30) and tighten until they are flush
with the Cover (28) with a torque wrench to 6.3 lb ft
(8.5 Nm).
The Sun Gear Shaft (25) and Input Shaft (26) are now dis-
connected and the machine is ready to be towed.
3-10 – JLG Sizzor – 3121133

Gearbox Disassembly 4. Remove Sun Gear Shaft (25).
For numbers in parenthesis, refer to Figure 3-8., Drive

Motor/Hub Assembly.
1. Remove Screw Plugs (18, 19) and drain oil into

appropriate container.
5. Remove complete 1st planet stage.
2. Remove Snap Ring (24).
6. Remove ring gear fastening Bolts (20), Ring Gear

(22), and O-ring (16)..
3. Remove the assembled Cover (8) with Shift Rod (33)

and O-ring (23).
3121133 – JLG Sizzor – 3-11

7. Remove Snap Rings (13). 10. Drilling Hole Sketch
8. Pull Plane Gears (1). 11. Split the Shaft Nut (4) in the area of the two drill
holes by means of a chisel, and remove from Spin-
dle (34).
9. Drill 2 holes into Shaft Nut (4) at 180° spacing

according to Drilling Hole Sketch (step 10).
NOTICE
DO NOT DAMAGE THE BEARING CAGE OF THE BEARING (11).
DO NOT TURN THE SHAFT NUT; POSSIBILITY OF SPINDLE
THREAD DAMAGE.
NOTICE
DO NOT DAMAGE THE BEARING CAGE OF TAPERED ROLLER
BEARING. CAREFULLY REMOVE METAL CHIPS.
3-12 – JLG Sizzor – 3121133

12. Remove the Support Ring (6) from the Spindle (34). 15. Repair deformed threads on the Spindle (34) in the
Components stay in Supporting Ring (6). area of the ball detend with a thread file of 1.5mm
pitch.
13. Remove Radial Shaft Seal Ring (17).
Gearbox Assembly
NOTE: Clean all parts before assembling the gearbox.
1. Make sure during assembly of the preassembled

planet gears that the larger radius on the bearing
bore is oriented towards the planet carrier.
14. Disassembly of planet gears and sun gear (1st

stage).
a. Remove Snap Rings (12) and pull Planet Gears
(2).
b. Remove Support Disks (15).
c. Remove Snap Ring (14) and lift off Planet Carrier 2. Assembly of planet gears and sun gear (1st Stage).
(7).
a. Fasten theSun Gear (3) with a new Snap Ring
(14) to the Planet Carrier (7).
b. Mount the Support Disks (15) and the planet
gears with Bearing Assembly (2, 10) heated to
approximately 189.5°F/70°C onto the planet
bolts.
3121133 – JLG Sizzor – 3-13

c. Secure the gears with new Snap Rings (12). 5. Insert the bottom part of the double Tapered Roller
Bearing (11).
NOTE: Heat Supporting Ring (6) up to approximately

189.5°F/70°C in a heating furnace. 6. Insert radial Shaft Seal Ring (17) into Supporting
Ring (6) and fill mounting space between sealing
lips with roller bearing grease.
3. Insert outer rings into heated Supporting Ring (6).
(check for proper axial seat) NOTE: Observe correct mounting position of sealing lip prior
to installing the seal ring.
4. Coat bore in Supporting Ring (6) with Loctite 573 for

Radial Shaft Seal Ring (17). 7. Install preassembled supporting ring onto Spindle
(34).
3-14 – JLG Sizzor – 3121133

8. Heat upper ring with roller cage of double Tapered b. The Loctite setting time equals 24 hours at ambi-
Roller Bearing (11) to approximately 189.5°F/70°C ent temperature of 68°F/20°C.
and mount onto Spindle (34). Allow cooling time of
approximately 15 minutes before continuing assem-
bly.
11. After proper bearing setting is completed, hammer

ball with suitable punch, 1.1 - 1.3mm into the spindle
9. De-grease threads of Spindle (34) and Shaft Nut (4). thread. Retain ball in position with expanding plug.
Then evenly apply coat of Loctite 270 to Shaft Nut
(4) threads.
12. Insert a new greased O-Ring (16) into the o-ring

groove of the Supporting Ring (6).
10. Rotate the supporitng ring repeatedly in one direc-

tion only when setting the tapered roller bearing.
a. Tighten Shaft Nut (4) by using an adequate
device with a tightening torque of 627 lb-ft (850
Nm).
3121133 – JLG Sizzor – 3-15

13. Assembly of planet gear (Main Stage): 16. Install completely pre-assembled 1st planet stage
a. Mount the planet gears with Bearing Assembly into the gear drive.
(1, 10), heated to approximately 189.5°F/70°C,
onto the planet bolts of the Spindle (34) and
secure the gears with new Snap Rings (13).
17. Install Sun Gear Shaft (25).

14. Install the Ring Gear (22).
18. Check axial clearance:

15. Install the ring gear hex head bolts. Tighten bolts to a. Determine clearance between contact face of
proper torque of 15.5 ft-lbs (21 Nm). Sun Gear (3) and Sun Gear Shaft (25). (Recom-
mended clearance 1.0 -1.5mm)
3-16 – JLG Sizzor – 3121133

19. Carefully insert a new greased O-ring (23) into the o- 22. Install Snap Ring (24).
ring groove of Ring Gear (22).
NOTE: Prior to putting into operation fill the drive with new
20. Insert Shift Rod (33) into preassembled Cover (8).
oil.
23. Install Plugs (18) with new Seal Rings (19) into
Cover (8).
21. Install preassembled Cover (8) into Ring Gear (22).
3121133 – JLG Sizzor – 3-17

Figure 3-9. Drive Hub Assembly
3-18 – JLG Sizzor – 3121133

Motor Disassembly 3. Disassemble guide ring:

1. Seal Ring
1. Mark port plate to the supporting axle.
2. Pressure Springs (quantity = 26)
3. Guide Ring
1 3
2. Remove port plate.
4. Disassemble retaining ring.
3121133 – JLG Sizzor – 3-19

5. Disassemble bearing with synchronizing plate. 8. Disassemble lamination kit.
6. Press off pressure ring with extractor. 9. Disassemble Seeger snap ring.
7. Remove pressure ring. 10. Disassemble cradle stop with 2 screws M4 x 75mm.
3-20 – JLG Sizzor – 3121133

11. Disassemble rotary group completely with cradle. 14. Disassemble shaft seal ring.
15. Insert disc. Pull off bearing ring with device.

Remove disc.
12. Disassemble control piston with spring.
13. Pull out swivel balls. 16. Disassemble bearing ring from port plate.
3121133 – JLG Sizzor – 3-21

17. Remove bearing ring (1). Disassemble spool (2). 19. Check that there are no scratches or metal deposits
on sliding surface (1), and there is no axial play (2),
(Otherwise: Pistons must be replaced in sets).
1 2
20. Check cylinder bores, splines.
18. Disassemble shuttle valve (1). Disassemble throttle

screw with throttle pin (2).
2
1 21. Check that cylinder track is free of scratches, there
are no traces of wear and no embedded foreign par-
ticles. Make sure there are no scratches on the
valve plate. (Replace ONLY in sets).
3-22 – JLG Sizzor – 3121133

22. Check splines (1) for damage or fretting; running 25. Make sure the sealing surfaces are damage free.
surfaces (2);groove cut by shaft seal (3).
3
1
23. Check that sliding surface is free of grooves (1);

cups are free of groove and there are no pittings (2).
26. Press bearing ring in port plate (with tool).
1 2
24. Make sure the seat of the shaft seal in the case has
no damage.
27. Press bearing ring in supporting axle (with tool).
3121133 – JLG Sizzor – 3-23

28. Press bearing on drive shaft. 30. Place measuring device. Ascertain tolerance. Grip
shaft with Seeger ring pincers and move up and
down. [Simulation ring 1mm + tolerance + (bearing
pretension 0.05 - 0.08) is resulting in thickness of the
synchronizing disc]. Grind synchronizing disc to
dimension.
29. Install shaft in supporting axle (1). Put in simulation

ring (2). Mount bearing with port plate , fix with 2
screws (3)
3-24 – JLG Sizzor – 3121133

Motor Assembly
1. Press in swivel balls (with tool) (1). Insert shaft seal
ring (with tool) (2). Insert control piston with spring
(3).
2
3
3121133 – JLG Sizzor – 3-25

2. Install rotary group with cradle. Observe installation 4. Mount Seeger snap ring. Opening of snap ring must
position of swivel balls. be on the opposite side of the control piston.
NOTE: Slightly grease swivel balls.
5. Fit pressure pins using an assembly aid. Pre-ten-

sion the spring using a suitable device.
3. Mount sleeve and pressure ring in cradle stop. Insert
cradle stop.
NOTE: Stick with grease.
6. Assemble piston with retaining plate. Oil piston and

slipper pad.
3-26 – JLG Sizzor – 3121133

7. Assembly aid: Hold the pistons by using an o-ring. 9. Mount support ring (1) and quad ring (2) in pressure
ring. Be careful not to excessively extend the rings.
1 2
21
10. Grease seal rings, install in supporting axle.
8. Install laminations in correct order.
3121133 – JLG Sizzor – 3-27

11. Mount retaining ring. 13. Align the two holes for fixation cylinder pin - port
plate (item 2).
Item 2
14. Mount synchronizing disc (1) and bearing (2).

12. Mount seal rings (1). Insert and line-up guide ring.
2
1
3-28 – JLG Sizzor – 3121133

15. Mount bearing ring with device. Mount spool. 17. Fill case with oil.
Mount fixation pin.
16. Fix control plate with grease at port plate.
18. Mount and screw port plate on supporting axle.
3121133 – JLG Sizzor – 3-29

3.5 DUAL FUEL/LPG SYSTEM Using Liquid Petroleum (LP) Gas
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE CLOSE FUEL VALVE ON TANK WHEN PARKING SIZZOR LIFT
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. THE FOL- MORE THAN MOMENTARILY.
LOWING INSTRUCTIONS MUST BE FOLLOWED.
WHEN REFUELING LPG POWERED SIZZOR LIFTS, ALWAYS FOL-
Changing From Gasoline to LP Gas LOW MANUFACTURERS SPECIFICATIONS AND/OR APPLICABLE
REGULATIONS.
NOTE: Before climbing onto the platform, open hand valve
on LP gas supply tank by turning valve counter- 1. If machine is to be left overnight or longer, it must be
clockwise. parked outside or the LPG tank removed and stored
outside.
19. Start engine from platform control station. 2. LPG is extremely flammable. No smoking.
20. While engine is operating, place the dual fuel switch 3. Only trained and authorized personnel are permitted
at platform control station to the LPG position. Allow to operate filling equipment.
engine to operate, without load, until engine begins
to “stumble” from lack of gasoline. At this time the 4. Fill LPG tanks outdoors. Stay at least 50 ft (15 m)
machine is allowing the LP fuel to be sent to the fuel from buildings, motor vehicles, electrical equipment
regulator. or other ignition sources. Stay at least 15 ft (5 m)
from LPG storage tanks.
Changing From LP Gas to Gasoline 5. During transfer of LPG, metal components can
1. With engine operating on LP under a no-load condi- become very cold. Always wear gloves when refilling
tion, throw LPG/GASOLINE switch at platform con- or changing tanks to prevent “freeze burns” to skin.
trol station to GASOLINE position. 6. Do not store LPG tanks near heat or open flame. For
2. If engine “stumbles” because of lack of gasoline, complete instructions on the storage of LPG fuels,
place switch to LPG position until engine regains refer to ANSI/NFPA 58 & 505 or applicable stan-
smoothness, then return switch to GASOLINE posi- dards.
tion.
3. Close hand valve on LP gas supply by turning clock-
wise. 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.
A STRONG ODOR OF LPG FUEL CAN INDICATE A LEAK.
3-30 – JLG Sizzor – 3121133

3.6 FORD EFI ENGINE • Inspect all wires and harnesses for proper connections
and routing; bent or broken connector pins; burned,
chafed, or pinched wires; and corrosion. Verify that
Performing Diagnostics harness grounds are clean and tight.
1. Verify the complaint and determine if it is a deviation • Inspect engine control module (ECM), sensors, and
from normal operation. actuators for physical damage.
2. Once the complaint has been verified, preliminary • Inspect ECM grounds for cleanliness, tightness, and
checks can be done. Conduct a thorough visual proper location.
inspection, be alert for unusual sounds or odors, • Inspect fuel system for adequate fuel level, and fuel
and gather diagnostic trouble code information. quality (concerns such as proper octane, contamina-
tion, winter/summer blend).
3. Perform a system check that will verify the proper
operation of the system in question and check for • Inspect intake air system and air filter for restrictions.
recent information updates. • Inspect battery condition and starter current draw.
4. If a diagnostic trouble code (DTC) is stored, contact If no evidence of a problem is found after visual/physical
a JLG distributor to make an effective repair. engine check has been performed, proceed to MIL DTC
retrieval procedure.
5. If no DTC is stored, select the symptom from the
symptom tables and follow the diagnostic path or EFI Diagnostics
suggestions to complete the repair.
The EFI diagnostics are designed to assist in locating a
6. After the repair has been made and validated for faulty circuit or component. When a malfunction is
proper operation, the old part should be momen- detected by the Engine Control Module (ECM), a diagnos-
tarily re-installed to verify that it was indeed the tic trouble code (DTC) is set and will be displayed on the
source of the problem. JLG Control System Analyzer. Refer to Section 6 - JLG
If no matching symptom is available, analyze the com- Control System.
plaint and develop a plan for diagnostics utilizing the wir-
CLEARING TROUBLE CODES
ing diagrams, technical assistance, and repair history.
To clear the trouble codes from the ECM, the electrical
Intermittent conditions may be resolved by using a check current running to the ECM must be shut off. To do this,
sheet to pinpoint the circuit or electrical system compo- disconnect the negative terminal from the battery for a
nent. Some diagnostic charts contain Diagnostic Aids period of approximately 15 minutes.
which give additional information about a system. Be sure
to use all of the information that is available to you. ECM and Sensors
VISUAL/PHYSICAL ENGINE INSPECTION CRANKSHAFT POSITION (CKP) SENSOR
CHECK The crankshaft position (CKP) sensor provides a signal
Perform a careful visual and physical engine inspection used by the engine control module (ECM) to calculate the
before performing any diagnostic procedure. Perform all ignition sequence. The CKP sensor initiates the reference
necessary repairs before proceeding with additional diag- pulses which the ECM uses to calculate RPM and crank-
nosis, this can often lead to repairing a problem without shaft position.
performing unnecessary steps. Use the following guide-
lines when performing a visual/physical inspection check:
• Inspect engine for modifications or aftermarket equip-

ment that can contribute to the symptom; verify that all
electrical and mechanical loads or accessory equip-
ment is "OFF" or disconnected before performing diag-
nosis.
• Inspect engine fluids for correct levels and evidence of
leaks.
• Inspect vacuum hoses for damage, leaks, cracks,
kinks and improper routing, inspect intake manifold
sealing surface for a possible vacuum leak.
• Inspect PCV valve for proper installation and operation.
3121133 – JLG Sizzor – 3-31

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
3-32 – JLG Sizzor – 3121133

Table 3-5. ECM Diagnostic Trouble Codes
Diagnostic
Trouble Description
Code
11 All Systems OK
12 Throttle Position (TP) Sensor Low Voltage
14 Manifold Absolute Pressure (MAP) Low Voltage
15 Under Minimum Map Sensor Temperature
21 Overspeed
22 Throttle Position (TP) Sensor High Voltage
23 Over maximum throttle
24 Manifold Absolute Pressure (MAP) High Voltage
25 Over Maximum Map Sensor Temperature
26 Over maximum initial Throttle Position Sensor Voltage
31 Fuel Pump Low Voltage
32 Heated Oxygen Sensor (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 – 3-33

ENGINE COOLANT TEMPERATURE (ECT) HEATED OXYGEN SENSOR

SENSOR The heated oxygen sensor is mounted in the exhaust
stream where it can monitor the oxygen content of the
The engine coolant temperature (ECT) sensor is a g ther-
exhaust gas. The oxygen present in the exhaust gas
mistor (a resistor which changes value based on tempera-
reacts with the sensor to produce a voltage output. This
ture) mounted in the engine coolant stream. Low coolant voltage should constantly fluctuate from approximately
temperature produces a high resistance of 100,000 ohms 100 mV to 900 mV. The heated oxygen sensor voltage can
at -40°C (-40°F). High temperature causes a low resis- be monitored on an IBM PC-compatible computer with
tance of 70 ohms at 130°C (266°F). The ECM supplies a 5- diagnostic software. By monitoring the voltage out-put of
volt signal to the ECT sensor through resistors in the ECM the oxygen sensor, the ECM calculates the pulse width
and measures the voltage. The signal voltage will be high command for the injectors to produce the proper combus-
when the engine is cold and low when the engine is hot. tion chamber mixture.
By measuring the voltage, the ECM calculates the engine
coolant temperature. Engine coolant temperature affects Low HO2S voltage indicates a lean mixture which will
most of the systems that the ECM controls. result in a rich command to compensate.
After engine start-up, the temperature should rise steadily High HO2S voltage indicates a rich mixture which will
to about 85°C (185°F). it then stabilizes when the thermo- result in a lean command to compensate.
stat opens. If the engine has not been run for several
hours (overnight), the engine coolant temperature and A constant voltage below 200 mV for 10 consecutive sec-
intake air temperature displays should be close to each onds will set OTC 32. A constant voltage above 650 mV
other. A fault in the engine coolant sensor circuit will set for 10 consecutive seconds will set OTC 42.
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 software
containing the correct program and calibration for the
application are required to program the ECM.
3-34 – JLG Sizzor – 3121133

Figure 3-10. EFI Component Location
3121133 – JLG Sizzor – 3-35

INTAKE AIR TEMPERATURE (IAT) SENSOR If the ECM detects a voltage that is significantly lower than
The intake air temperature (IAT) sensor is a thermistor the estimated MAP value for 2 or more consecutive sec-
which changes its resistance based on the temperature of onds, DTC 14 will be set. A signal voltage significantly
air entering the engine. Low temperature produces a high higher than the estimated MAP value for 2 or more con-
resistance of 100,000 ohms at -40°C (-40°F). High temper- secutive seconds will set DTC 24.
ature causes a low resistance of 70 ohms at 130°C
(266°F). The ECM supplies a 5-volt signal to the sensor
through a resistor in the ECM and monitors the signal volt-
age. The signal voltage will be high when the incoming air
is cold and low when the incoming air is hot. By measuring
the voltage, the ECM calculates the incoming air tempera-
ture. The IAT sensor signal is used to adjust spark timing
according to the incoming air density. An IBM PC-compati-
ble computer with diagnostic soft-ware can be used to dis-
play the temperature of the air entering the engine. The
temperature should read close to the ambient air tempera-
ture when the engine is cold, and rise as engine compart-
ment temperature increases. If the engine has not been
run for several hours (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.
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.
MANIFOLD ABSOLUTE PRESSURE (MAP) The ECM supplies either 5 or 12 volts to power various
SENSOR sensors or switches. The power is supplied through resis-
The manifold absolute pressure (MAP) sensor responds tances in the ECM which are so huh in value that a test
to changes in intake manifold pressure (vacuum). The light will not light when connected to the circuit. In some
MAP sensor signal voltage to the ECM varies from below 2 cases, even an ordinary shop voltmeter will not give an
volts at idle (high vacuum) to above 4 volts with the igni- accurate reading because its resistance is too low. There-
tion ON, engine not running or at wide-open throttle (low fore, a digital voltmeter with at least 10 meg ohms input
vacuum). impedance is required to ensure accurate voltage read-
ings. The ECM controls output circuits such as the fuel
The MAP sensor is used to determine the following: injectors, electronic governor, etc., by control ling the
ground or the power feed circuit through transistors or
• Engine vacuum level for engine control purposes.
other solid state devices.
• Barometric pressure (BARO)
3-36 – JLG Sizzor – 3121133

The ECM is designed to maintain exhaust emission levels • When measuring voltages, use only a digital voltmeter
to government mandated standards while providing excel- with an input impedance of at least 10 megohms.
lent operation and fuel efficiency. The ECM monitors
numerous engine functions via electronic sensors such as • Do not jump start with more than 12 volts. This could
the throttle position (TP) sensor and the heated oxygen cause damage to the electronic components.
sensor (HO2S).
• 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-
ECM INPUTS/OUTPUTS nal also changes. At a closed throttle position, the output
Inputs—Operating Conditions of the TP sensor is low. As the throttle valve opens, the
output increases so that at wide open throttle (WOT), the
• Engine Coolant Temperature output voltage should be above 4 volts.
• Crankshaft Position
The ECM calculates fuel delivery based on throttle valve
• Exhaust Oxygen Content
angle (operator demand). A broken or loose TP sensor
• Manifold Absolute Pressure may cause intermittent bursts of fuel from an injector and
unstable idle because the ECM thinks the throttle is mov-
• Battery Voltage
ing. A hard failure in the TP sensor 5-Volt reference or sig-
• Throttle Position nal circuits for greater than 2 consecutive seconds will set
either a DTC 12 or DTC 22. A hard failure with the TP sen-
• Fuel Pump Voltage
sor ground circuit for more than two consecutive seconds
• Intake Air Temperature may set DTC 22. If either DTC 12 or DTC 22 are set, the
throttle will be forced to a 6% (idle) position.
• 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.
USE OF CIRCUIT TESTING TOOLS
• Do not probe wires for testing. This can cause a volt- Do not use a test light to diagnose the engine electrical
age drop that would be critical to the operation of the
systems unless specifically instructed by the diagnostic
ECM.
procedures. A test light can put an excessive load on an
• When testing for opens and shorts, do not ground or ECM circuit and result in component damage. For volt-
apply voltage to any of the ECM's circuits unless age measurements, use only a digital voltmeter with an
instructed to do so. input impedance of at least 10 megohms.
3121133 – JLG Sizzor – 3-37

ELECTROSTATIC DISCHARGE DAMAGE A fuel injector which is stuck partly open will cause a loss
Electronic components used in the ECM are often of fuel pressure after the engine is shut down, causing
designed to carry very low voltage. Electronic compo- long crank times.
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.
FUEL METERING SYSTEM COMPONENTS
An example of charging by friction is a person sliding The fuel metering system is made up of the following
across a seat. parts:
Charge by induction occurs when a person with well-insu- • The fuel injectors
lated shoes stands near a highly charged object and
• The fuel rail
momentarily touches ground. Charges of the same polar-
ity are drained off, leaving the person highly charged with • The fuel pressure regulator/filter assembly
the opposite polarity. Static charges can cause damage,
therefore it is important to-use care when handling and • The electronic governor
testing electronic components.
• The ECM
To prevent possible electrostatic discharge damage, fol- • The crankshaft position (CKP) sensor
low these guidelines:
• The camshaft position (CMP) sensor
• Do not touch the ECM connector pins or soldered
components on the ECM board. • The fuel pump
• Do not open the replacement part package until the • The fuel pump relay
part is ready to be installed.
BASIC SYSTEM OPERATION
• Before removing the part from the package, ground
the package to a known good ground on the equip- The fuel metering system starts with the fuel in the fuel
ment. tank. The fuel is drawn up to the fuel pump through a pre-
filter. The electric fuel pump then delivers the fuel to the
• If the part has been handled while sliding across a fuel rail through an inane fuel filter. The pump is designed
seat, while sitting down from a standing position, or to provide fuel at a pressure above the pressure needed
while walking a distance, touch a known good ground by the injectors. A fuel pressure regulator in the fuel filter
before installing the part. assembly keeps fuel available to the fuel injectors at a
constant pressure. A return line delivers unused fuel back
Fuel System to the tank.
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.
3-38 – JLG Sizzor – 3121133

HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI.
Figure 3-11. Typical Fuel System
FUEL METERING SYSTEM PURPOSE The ECM monitors signals from several sensors in order
The basic function of the air/fuel metering system is to to determine the fuel needs of the engine. Fuel is deliv-
control the air/fuel delivery to the engine. Fuel is delivered ered under one of several conditions called "modes." All
to the engine by individual fuel injectors mounted in the modes are controlled by the ECM. Refer to "Open Loop
intake manifold near each intake valve. and Closed Loop Operation" for more information.
The main control sensor is the heated oxygen sensor

(H02S) located in the exhaust system. The H02S tells the
ECM how much oxygen is in the exhaust gas. The ECM
changes the air/fuel ratio to the engine by controlling the
amount of time that the fuel injector is "ON." The best mix-
ture to minimize exhaust emissions is 14.7 parts of air to 1
part of gasoline by weight, which provides the most effi-
cient combustion. Because of the constant measuring and
adjusting of the air/fuel ratio, the fuel injection system is
called a "closed loop" system.
3121133 – JLG Sizzor – 3-39

FUEL PRESSURE REGULATOR ELECTRONIC GOVERNOR AND THROTTLE

The fuel pressure regulator is a relief valve mounted in the BODY
fuel filter. It provides a constant fuel pressure of 441 kPa
In the 2.5L EFI industrial engine, throttle control is
(64 psi).
achieved by using an electronic governor which is con-
trolled by the engine control module (ECM).
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.
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.
FUEL PUMP ELECTRICAL CIRCUIT The 2-wire pigtail carries the throttle signal from the ECM
When the key is first turned "ON," the ECM energizes the to the governor. Desired engine speeds are stored in the
fuel pump relay for two seconds to build up the fuel pres- configuration program for each specific application, and
sure quickly. If the engine is not started within two sec- can be changed with the ECM calibration software. When
onds, the ECM shuts the fuel pump off and waits until the an engine speed is selected with the toggle switch, the
engine is cranked. When the engine is cranked and crank- ECM sends the appropriate signal to the governor. This is
shaft position signal has been detected by the SECM, the a pulse-width modulated (PWM) signal which cannot be
ECM supplies 12 volts to the fuel pump relay to energize read with conventional diagnostic tools such as a voltme-
the electric fuel pump. 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
An inoperative fuel pump will cause a "no-start" condition. of throttle opening. The ECM sends a signal with the
A fuel pump which does not provide enough pressure will appropriate pulse width to the governor based on the
result in poor performance. operator's choice of switch settings.
FUEL RAIL The electronic governor also acts as an idle air control
The fuel rail is mounted to the top of the engine and dis- (IAC) valve. Changes in engine load are detected by the
tributes fuel to the individual injectors. Fuel is delivered to ECM by comparing manifold absolute pressure (MAP)
the fuel inlet tube of the fuel rail by the fuel lines. 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.
3-40 – JLG Sizzor – 3121133

OPEN LOOP AND CLOSED LOOP OPERATION CAMSHAFT POSITION (CMP) SENSOR
The ECM will operate in the following two modes: The CMP sensor uses a variable reactor sensor to detect
camshaft position. The CMP signal is created as piston #1
• Open loop
is a predetermined number of degrees after top dead cen-
• Closed loop ter on the power stroke.
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°C).
• Seven minutes has elapsed since starting the engine.
After these conditions are met, the engine is said to be
operating in "closed loop." In closed loop, The ECM con-
tinuously adjusts the air/fuel ratio by responding to signals
from the HO2S (except at wide-open throttle). When the
HO2S reports a lean condition (low sensor signal voltage),
CRANKSHAFT POSITION (CKP) SENSOR
the ECM responds by increasing the "on" time of the fuel
The crankshaft position (CKP) sensor provides a signal
injectors, thus enriching the mixture. When the HO2S
used by the engine control module (ECM) to calculate the
reports a rich condition (high sensor signal Voltages the
ignition sequence. The sensor initiates the reference
ECM responds by reducing the "on" time of the fuel injec-
pulses which the ECM uses to calculate RPM and crank-
tors, thus leaning out the mixture.
shaft position.
3121133 – JLG Sizzor – 3-41

ELECTRONIC IGNITION ENGINE CONTROL MODULE (ECM)

The electronic ignition system controls fuel combustion by The ECM is responsible for maintaining proper spark and
providing a spark to ignite the compressed air/fuel w mix- fuel injection timing for all operating conditions. To provide
ture at the correct time. To provide optimum engine perfor- optimum operation and emissions, the ECM monitors the
mance, fuel economy, and control of exhaust emissions, input signals from the following components in order to
the ECM controls the spark advance of the ignition system. calculate spark timing:
Electronic ignition has the following advantages over a
• Engine coolant temperature (ECT) sensor
mechanical distributor system:
• Intake air temperature (IAT) sensor
• No moving parts
• Throttle position sensor
• Less maintenance
• Crankshaft position sensor
• Remote mounting capability
• No mechanical load on the engine
• More coil cooldown time between firing events
• Elimination of mechanical timing adjustments
• Increased available ignition coil saturation time
IGNITION COIL
The electronic ignition system uses a coil pack with one
ignition coil for each two cylinders in the engine. Each cyl-
inder is paired with its opposing cylinder in the firing order,
so that one cylinder on compression fires simultaneously
with the opposing cylinder on exhaust. The spark that
occurs in the cylinder on the exhaust stroke is referred to
as a "waste spark."
The primary coils in the coil pack are triggered by the

"Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals
from the ECM.
3-42 – JLG Sizzor – 3121133

3.7 GENERATOR - FORD ENGINE
1 2
1. Generator 2. Ford Engine 3. Voltage Regulator
Figure 3-12. Generator (Ford Engine)
Table 3-6. Generator Specifications
Description 220 Powermax

Voltage 220V
Continuous 2.5 KW
Peak 3.5 KW
Amps Peak 15 Amps
3121133 – JLG Sizzor – 3-43

3.8 DEUTZ EMR 2 (S/N 0200138634 TO The EMR2 is equipped with safety devices and measures
in the hardware and software in order to ensure emer-
PRESENT) gency running (Limp home) functions.
The EMR2 consists of the sensors, the control unit and the In order to switch the engine off, the EMR2 is switched in a
actuator. Engine-side controls as well as the JLG Control de-energized fashion over the ignition switch. A strong
System are connected by means of separate cable har- spring in the actuator presses the control rod in the de-
nesses to the EMR control unit. energized condition into the zero position. As a redun-
dancy measure, an additional solenoid serves for switch-
The sensors attached to the engine provide the electron-
ing off and this, independently of the actuator, also moves
ics in the control unit with all the relevant physical parame-
the control rod in the de-energized condition into the zero
ters In accordance with the information of the current
position.
condition of the engine and the preconditions (throttle
position etc.), the EMR2 controls an actuator that operates After the programming, that is carried out over the
the control rod of the injection pump and thus doses the ISO9141 interface, the EMR2 possesses a motor-specific
fuel quantity in accordance with the performance require- data set and this is then fixedly assigned to the engine.
ments. Included in this are the various application cases as well
as the customer’s wishes regarding a particular scope of
The exact position of the regulating rod is reported back
function.
and, if necessary, is corrected, by means of the control
rod travel sensor, situated together with the rotation mag- Each EMR2 module is matched by serial number to the
nets in a housing of the actuator. engine. Modules cannot be swapped between engines.
3-44 – JLG Sizzor – 3121133

CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE CAMSHAFT SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/

STOP; EMR2 TAKES CONTROL OF THE
ENGINE AT 700RPM
GLOW PLUG
JLG SYSTEM USES JLG ANALYZER TO

REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS-

OIL PRESSURE TEM USES THIS TO CONTROL THE ENGINE &
SENSOR FAULT REPORTING.
Figure 3-13. EMR 2 Engine Side Equipment
3121133 – JLG Sizzor – 3-45

Figure 3-14. Deutz EMR 2 Troubleshooting Flow Chart
3-46 – JLG Sizzor – 3121133

Figure 3-15. Deutz EMR 2 Vehicle Side Connection Diagram
3121133 – JLG Sizzor – 3-47

3-48
– JLG Sizzor –
Figure 3-16. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3121133
3121133
– JLG Sizzor –
Figure 3-17. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-49
Figure 3-18. EMR 2 Engine Plug Pin Identification
3-50 – JLG Sizzor – 3121133

Figure 3-19. EMR 2 Vehicle Plug Pin Identification
3121133 – JLG Sizzor – 3-51

Figure 3-20. EMR2 Fault Codes - Sheet 1 of 5
3-52 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 3-53

3-54 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 3-55

3-56 – JLG Sizzor – 3121133

3.9 GENERATOR - DUETZ ENGINE
1 2
-OR-
1. Generator (120V or 220V) 3. Voltage Regulator

2. Deutz Engine
Figure 3-25. Generator (Deutz Engine)
Description 110 Bluemax 220 Powermax

Voltage 120V 220V
Continuous 3.5 KW 2.0 KW
Peak 4.5 KW 3.0 KW
Amps Peak 37 Amps 13 Amps
3121133 – JLG Sizzor – 3-57

3.10 GM ENGINE GENERAL MAINTENANCE • Check the battery for any cracks or damage to the
case
Maintenance of the Drive Belt • Check the Positive and Negative battery cables for any
corrosion build up, rubbing or chafing, check connec-
The serpentine drive belt utilizes a spring loaded tensioner tion on the chassis to insure they are tight
which keeps the belt properly adjusted. The drive belt is • Check the entire engine wire harness for rubbing chaf-
an integral part of the cooling and charging systems and ing, cuts or damaged connections, repair if necessary
should be inspected frequently.
• Check all wire harness connectors to insure they are
When inspecting the belts check for: fully seated and locked
• Cracks or breaks • Check ignition coil and spark plug cables for harden-
ing, cracking, chafing, separation, split boot covers
• Chunking of the belt
and proper fit
• Splits • Replace spark plugs at the proper intervals as pre-
• Material hanging from the belt scribed in the engine manufacturer’s manual
• Glazing and hardening • Check to make sure all electrical components are fitted
securely
• Damaged or improperly aligned pulleys
• Check the ground and platform control stations to
• Improperly performing tensioner insure all warning indicator lights are functioning
Check the belt tensioner by pressing down on the midway
point of the longest stretch between pulleys. The belt Checking/Filling Engine Oil Level
should not depress beyond 1/2 inch (13mm). If the
depression is more than allowable adjust the tension.
AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED
NOTICE FULL MARK) CAN CAUSE AN OIL LEAK, A FLUCTUATION OR
THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE DROP IN THE OIL PRESSURE, AND ROCKER ARM "CLATTER" IN
USE OF "BELT DRESSING" OR "ANTI SLIPPING AGENTS" ON THE ENGINE.
THE DRIVE BELT.
Belt Adjustment: NOTICE

CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL
1. Remove existing belt and discard.
LEVEL. OIL LEVEL MUST BE MAINTAINED BETWEEN THE "ADD"
2. Install new belt (21mm X 1187mm). MARK AND "FULL" MARK ON THE DIPSTICK.
3. Unload spring in belt tensioner. To ensure that you are not getting a false reading, make
sure the following steps are taken to before check the oil
4. Return alternator adjustment to original position and level.
tighten bolt.
1. Stop the engine if in use.
5. Release belt tensioner.
2. Allow sufficient time (approximately 5 minutes) for
6. Check position of belt tensioner stop. the oil to drain back into the oil pan.
7. Readjust alternator position as necessary to allow 3. Remove the dipstick. Wipe with a clean cloth or
correct positon of belt tensioner stop. paper towel and reinstall. Push the dipstick all the
way into the dipstick tube.
Engine Electrical System Maintenance 4. Remove the dipstick and note the oil level.
The engine electrical system incorporates computers and
microprocessors to control the engine ignition, fuel con-
trol, and emissions. Due to the sensitivity of the computers
to good electrical connections periodic inspection of the
electrical wiring is necessary. When inspecting the electri-
cal system use the following:
• Check and clean the battery terminal connections and

insure the connections are tight
3-58 – JLG Sizzor – 3121133

5. Oil level must be between the "FULL" and "ADD" Changing The Engine Oil
marks.
NOTICE
WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER.
CHANGE OIL WHEN THE ENGINE IS WARM FROM OPERATION
AS THE OILS WILL FLOW FREELY AND CARRY AWAY MORE
IMPURITIES.
To change the oil use the following steps:

1. Start the engine and run until it reaches normal
Figure 3-26. Engine Oil Dip Stick operating temperature.
6. If the oil level is below the "ADD" mark, proceed to 2. Stop the engine.
Step 7 and 8 and reinstall the dipstick into the dip- 3. Remove the drain plug and allow the oil to drain.
stick tube.
4. Remove and discard the oil filter and its sealing ring.
7. Remove the oil filter cap from the valve rocker arm
cover. 5. Coat the sealing ring on the filter with clean engine
oil and wipe the sealing surface on the filter
8. Add the required amount of oil to bring the level up mounting surface to remove any dust, dirt and
to but not over "FULL" mark on the dipstick. debris. Tighten the filter securely (follow the filter
9. Reinstall the oil fill cap to the valve rocker cover and manufacturers instructions). Do not over tighten.
wipe away any excess oil. 6. Check the sealing ring on drain plug for any dam-
age, replace if necessary, wipe the plug with a clean
rag, and wipe the sealing surface on the pan and
reinstall the pan plug. Do not over tighten.
7. Fill the crankcase with oil.
8. Start the engine and check for oil leaks.
9. Stop the engine and check the oil level to insure the
oil level is at "FULL".
10. Dispose of the oil and filter in a safe manner.
3121133 – JLG Sizzor – 3-59

3.11 GENERATOR - GM ENGINE
1 2
1. Generator 2. GM Engine 3. Voltage Regulator
Figure 3-27. Generator (GM Engine)
Voltage 120V
Continuous 3.5 KW
Peak 4.5 KW
Amps Peak 37 Amps
3-60 – JLG Sizzor – 3121133

3.12 GM ENGINE DUAL FUEL SYSTEM Fuel Filter

The Dual Fuel system allows the operator to operate the Propane fuel like all other motor fuels is subject to con-
vehicle on either gasoline or LPG by positioning a selector tamination from outside sources. Refueling of the equip-
switch in the operator's platform. When the operator ment’s tank and removal of the tank from the equipment
places the selector switch in the gasoline mode the gaso- can inadvertently introduce dirt and other foreign matter
line fuel pump is energized. While in the gasoline mode into the fuel system. It is therefore necessary to filter the
the LPG fuel lock-off is isolated and will not energize. In fuel prior to entering the fuel system components down-
addition the gasoline injector circuit is enabled and injec- stream of the tank. An inline fuel filter has been installed in
tor pulses are provided to each injector and the ECM cali- the fuel system to remove the dirt and foreign matter from
bration for gasoline is also enabled. When the operator the fuel. The inline filter is replaceable as a unit only. Main-
selects the LPG mode the Low Pressure LPG lock-off is tenance of the filter is critical to proper operation of the
energized and fuel from the LPG tank flows to the Elec- fuel system and should be replaced as Section 1. In
tronic Pressure Regulator (EPR). The EPR receives an severe operating condition more frequent replacement of
electronic signal to position the secondary lever for the the filter may be necessary.
start or run positions and when the engine begins to crank
the mixer air valve will rise and fuel will begin flowing to Electric Lock Off
engine. During this mode the gasoline fuel pump is iso-
lated and will not be activated. The primary components The Electric Lock Off device is an integrated assembly.
of the gasoline dual fuel system are the gasoline tank, When energized the solenoid opens the valve and allows
electric fuel pump and filter, fuel supply line, injector rail the Propane fuel to flow through the device. The valve
and injectors and the fuel pressure regulator. The primary opens during cranking and run cycles of the engine. The
components of the LPG dual fuel system are the LPG fuel lock off supply voltage is controlled by the engine control
tank, in-fuel filter, LPG Low Pressure lock-off, Electronic module (ECM).
Pressure Regulator (EPR) and the fuel mixer module. The
LPG fuel system operates at pressures which range from
14.0 inches (355.60 mm) of water column up to 312 psi
(21.5 BAR).
Components which are shared by both systems include
the Electronic Throttle Control and the ECM. The ECM
contains a dual calibration; one controls the gasoline fuel
system during gasoline operation and one controls the
LPG fuel system during LPG operation.
Figure 3-28. Electric Fuel Lock Off
3121133 – JLG Sizzor – 3-61

EPR Assembly Low Pressure Regulator (LPR)

The EPR assembly is a combination Low Pressure Regu- The LPR is a combination vaporizer, pressure regulating
lator and a Voice Coil Assembly. The Voice coil is an elec- device. The LPR is a negative pressure, two stage regula-
tronic actuator which is controlled by an internal tor that is normally closed when the engine is not running.
microprocessor. The microprocessor provides output data When the engine is cranking or running, a partial vacuum
to the ECM and receives input data over a CAN BUS con- is created in the fuel line which connects the regulator to
nection. The internal microprocessor receives electrical the mixer. This partial vacuum opens the regulator permit-
signals from the Fuel Pressure Sensor FPS and the Fuel ting fuel to flow to the mixer.
Temperature Pressure FTP and communicates the data to
Propane fuel enters the primary port of the LPR and
the ECM. The ECM uses the FPS and FTP data to calcu-
passes through the primary jet and into the primary/
late the location of the secondary lever in the LPR and
exchanger chamber. As the propane passes through the
sends that data back to the EPR via the CAN BUS. The
heat exchanger the fuel expands and creates pressure
internal microprocessor in the EPR will then output a sig-
inside the chamber. The pressure rises as the fuel
nal, which causes the voice coil to move and position the
expands when the pressure rises above 1.5 psi (10.34
secondary lever to the correct location.
kpa), sufficient pressure is exerted on the primary dia-
phragm to cause the diaphragm plate to pivot and press
against the primary valve pin thus closing off the flow of
fuel. This action causes the flow of fuel into the regulator
to be regulated.
When the engine is cranking, sufficient vacuum will be
introduced into the secondary chamber from the mixer
drawing the secondary diaphragm down onto the spring
loaded lever and opening the secondary valve allowing
vaporized fuel to pass to the mixer. This mechanical action
in conjunction with the EPR reactions causes the down-
ward action on the secondary lever causing it to open
wider allowing more fuel to flow to the mixer.
THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMIS-

SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE
1. Pressure Regulator Section 4. Primary Test Port COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT
2. Fuel Inlet 5. Secondary Test Port WITH AN OEM REPLACEMENT PART ONLY.
3. Coolant Passage 6. Voice Coil Section
Figure 3-29. EPR Assembly
Figure 3-30. Low Pressure Regulators
3-62 – JLG Sizzor – 3121133

Air Fuel Mixer Electronic Throttle Control (ETC)

The air valve mixer is an air-fuel metering device and is Engine speed and load control is maintained by an ETC
completely self-contained. The mixer is an air valve device. Speed and load control are determined by the
design, utilizing a relatively constant pressure drop to ECM. Defaults programmed into the ECM software and
draw fuel into the mixer from cranking to full load. The throttle position sensors allow the ECM to maintain safe
mixer is mounted in the air stream ahead of the throttle operating control over the engine. The Electronic Throttle
control device. Control device or "throttle body assembly" is connected to
the intake manifold of the engine. The electronic throttle
When the engine begins to crank, it draws in air with the
control device utilizes an electric motor connected to the
air valve covering the inlet, negative pressure begins to
throttle shaft. When the engine is running electrical signals
build. This negative pressure signal is communicated to
are sent from the equipment controls to the engine ECM
the top of the air valve chamber through 4 vacuum ports in
when the operator depresses an equipment function
the air valve assembly. A pressure/force imbalance begins
switch. The ECM then sends an electrical signal to the
to build across the air valve diaphragm between the air
motor on the electronic throttle control to increase or
valve vacuum chamber and the atmospheric pressure
decrease the angle of the throttle blade thus increasing or
below the diaphragm. The air valve vacuum spring is cali-
decreasing the air/fuel flow to the engine.
brated to generate from 4.0 inches (101.6 mm) of water
column at start to as high as 14.0 inches (355.60 mm) of The electronic throttle control device also incorporates
water column at full throttle. The vacuum being created is two internal Throttle Position Sensors (TPS) which provide
referred to as Air Valve Vacuum (AVV). As the air valve output signals to the ECM as to the location of the throttle
vacuum reaches 4.0 inches (101.6mm) of water column, shaft and blade. The TPS information is used by the ECM
the air valve begins to lift against the air valve spring. The to correct speed and load control as well as emission con-
amount of AVV generated is a direct result of the throttle trol.
position. At low engine speed the air valve vacuum is low
and the air valve position is low thus creating a small ven-
turi for the fuel to flow. As the engine speed increase the
AVV increases and the air valve is lifted higher thus creat-
ing a much larger venturi. This air valve vacuum is com-
municated from the mixer venture to the LPR secondary
chamber via the low pressure fuel supply hose. As the
AVV increases in the secondary chamber the secondary
diaphragm is drawn further down forcing the secondary
valve lever to open wider.
Figure 3-32. ETC throttle control device
Figure 3-31. Air Fuel Mixer
3121133 – JLG Sizzor – 3-63

Engine Control Module Heated Exhaust Gas Oxygen Sensor

To obtain maximum effect from the catalyst and accurate There are two Heated Exhaust Gas Oxygen Sensors
control of the air fuel ratio the emission certified engine is (HEGO). The first HEGO is mounted in the exhaust system
equipped with an onboard computer or Engine Control downstream of the engine. It is used to measure the
Unit (ECM). The ECM is a 32 bit controller which receives amount of oxygen present in the exhaust stream and com-
municate that to the ECM via an electrical signal. The
input data from sensors fitted to the engine and fuel sys-
amount of oxygen present in the exhaust stream indicates
tem and then outputs various signals to control engine
whether the fuel/air ratio is too rich or too lean. If the
operation. HEGO sensor signal indicates that the exhaust stream is
too rich the ECM will decrease or lean the fuel mixture dur-
One specific function of the controller is to maintain
ing engine operation, if the mixture is too lean the ECM
"closed loop fuel control". Closed loop fuel control is will richen the mixture. The ECM continuously monitors
accomplished when the exhaust gas oxygen sensor the HEGO sensor output. If a rich or lean condition is
(HEGO) mounted in the exhaust system sends a voltage present for an extended period of time, and the ECM can-
signal to the controller. The controller then calculates any not correct the condition, the ECM will set a diagnostic
correction that may need to be made to the air fuel ratio. code and turn on the MIL light in control box.
The controller then outputs signals to the EPR to correct
The second HEGO is mounted in the exhaust system after
the amount of fuel being supplied to the mixer. At the
the muffler. It measures the amount of oxygen in the
same time the ECM may correct the throttle blade position
exhaust system after the catalyst treatment has been com-
to correct speed and load of the engine. pleted in the muffler. If the ECM detects that the catalytic
action in the muffler is not sufficient and fuel correction
The controller also performs diagnostic functions on the
cannot correct the malfunction the MIL light is illuminated
fuel system and notifies the operator of malfunctions by in the control box and a DTC code will stored in the com-
turning on a Malfunction Indicator Light (MIL) mounted in puter.
the Ground Control Station and the Platform Control Sta-
tion. Malfunctions in the system are identified by a Diag-
nostic Code number. In addition to notifying the operator
of the malfunction in the system the controller also stores THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION
CONTROL DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE
the information about the malfunction in its memory.
IT WITH AN OEM REPLACEMENT PART. THE HEGO SENSOR IS
SENSITIVE TO SILICONE OR SILICONE BASED PRODUCTS AND
CAN BECOME CONTAMINATED. AVOID USING SILICONE SEAL-
ERS OR HOSES TREATED WITH SILICONE LUBRICANTS IN THE
AIR STREAM OR FUEL LINES.
Figure 3-33. LPG Engine Control Unit (ECM)
Figure 3-35. Heated Exhaust Gas Oxygen Sensor

(HEGO)
Gasoline Multi Point Fuel Injection System

(MPFI)
The primary components of the Gasoline Multi Point Fuel
Injection (MPFI) fuel system are the fuel tank, electric fuel
pump, fuel pressure and temperature sensor manifold,
Figure 3-34. ECM Assembly
fuel filter and fuel rail.
3-64 – JLG Sizzor – 3121133

Gasoline Fuel Pump Fuel Filter

The Gasoline is stored as a liquid in the fuel tank and in After the fuel is drawn into the fuel pump, the fuel flows
drawn into the fuel system by an electric fuel pump. The through the gasoline fuel filter. The fuel filter will trap small
fuel pump will receive a signal from the ECM to prime the particles as the fuel passes through the filter to remove
fuel system for approximately 2 seconds prior to start. debris and prevents the fuel pressure and temperature
Priming of the fuel system provides for a quicker start, manifold and fuel injectors from becoming damaged.
when the engine begins to crank. Maintenance of the fuel filter is required as indicated in
Section 1.
Gasoline Pressure And Temperature Sensor
Fuel Injector Rail
Manifold
Fuel flows from the fuel pressure and temperature mani-
This engine is equipped with a fuel injector rail that does fold assembly to the fuel rails where the fuel is delivered to
not have a pressure regulator or a return circuit to the fuel the fuel injectors. The fuel rail also contains a Schrader
tank. Fuel pressure for this engine is regulated by the valve which is utilized to test the regulated pressure of the
engine’s ECM. The ECM receive fuel pressure and tem- fuel system.
perature feedback from the gasoline fuel sensor manifold
and uses this information to control the ground side of the Fuel Injector
fuel pump. Fuel pressure is regulated by the ECM pulse
width modulating (PWM) the fuel pump. The fuel pressure The fuel supply is maintained on the top of the injector
and temperature sensor manifold has a return or "bleed" from the injector rail. The injector is fed a "pulse" signal
circuit that connects back to the fuel tank. This circuit is through the wire harness which causes the injector to
used to bleed off any vapor that develops in the line and open. During regular operating conditions the ECM con-
return a small amount of fuel to the tank. The fuel comes trols the opening and duration of opening of the injector.
from the fuel tank and passes through the fuel pump. Fuel During lower RPM operation the injector signals or
exits the fuel pump, passes through the filter and then "pulses" are less frequent then when the engine is operat-
enters the fuel pressure and temperature manifold assem- ing at higher RPMs. The engine has been calibrated to
bly. Fuel flows through the feed circuit and is delivered to deliver the precise amount of fuel for optimum perfor-
the fuel injector rail. Fuel that enters the bleed circuits mance and emission control.
through they bypass valve in the manifold is returned to
the fuel tank.
Figure 3-36. Gasoline Fuel Pressure and Temperature

Manifold Assembly
3121133 – JLG Sizzor – 3-65

3.13 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO

312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
SURE (WHERE APPLICABLE) BEFORE SERVICING THE
PROPANE FUEL SYSTEM COMPONENTS.
To relieve propane fuel system pressure:

1. Close the manual shut-off valve on the propane fuel
tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
1. Electric Lock Off Solenoid 7. Electrical Connector

NOTICE 2. Mounting Plate 8. Fuel Outlet
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL 3. Housing Seal 9. O-ring
SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED 4. Filter Magnet 10. Filter
BEFORE DISCONNECTING ANY FUEL LINE. 5. Filter Housing 11. Fuel Inlet
6. Seal 12. Retaining Bolt
Propane Fuel System Leak Test Figure 3-37. Filter Lock Assembly
REMOVAL
NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR 1. Relieve the propane fuel system pressure. Refer to
PROPANE FUEL SYSTEM LEAKS. Propane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
Always inspect the propane fuel system for leaks after per-
forming service. Check for leaks at the fittings of the ser- 3. Slowly loosen the Filter housing retaining bolt and
viced or replaced component. Use a commercially remove it.
available liquid leak detector or an electronic leak detec-
tor. When using both methods, use the electronic leak 4. Pull the filter housing from the Electric lock off
detector first to avoid contamination by the liquid leak assembly.
detector. 5. Locate Filter magnet and remove it.
6. Remove the filter from the housing.
7. Remove and discard the housing seal.
8. Remove and discard the retaining bolt seal.
9. Remove and discard mounting plate to lock off O-
ring seal.
INSTALLATION
NOTICE
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-
ING BEFORE INSTALLING NEW SEAL.
1. Install the mounting plate to lock off O-ring seal.

2. Install the retaining bolt seal.
3. Install the housing seal.
3-66 – JLG Sizzor – 3121133

4. Drop the magnet into the bottom of the filter hous- 5. Remove the Electric Lock Off from the regulator.
ing.
6. Remove the lock pin from the vapor fitting on the
5. Install the filter into the housing. regulator housing and remove the fitting and hose
and retain the pin.
6. Install the retaining bolt into the filter housing.
7. Remove the lock pin from the pressure sensor on
7. Install the filter up to the bottom of the electric lock the regulator housing and remove the Sensor and
off. retain the pin.
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). 8. Using a clamp pliers pinch off the hoses on the cool-
9. Open manual shut-off valve. Start the vehicle and ant lines to the regulator.
leak check the propane fuel system at each serviced 9. Remove the lock pin from both the water fittings on
fitting Refer to Propane Fuel System Leak Test. the regulator housing and remove the fittings and
hoses and retain the pin.
Electronic Pressure Regulator (EPR) 10. Disconnect the EPR electrical connector.
Assembly Replacement
11. Remove the (3) three nuts from the EPR isolators
and the EPR mounting bracket.
12. Remove the EPR from the bracket.
13. Remove the (3) three mounting isolators.
INSTALLATION
NOTICE
DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQ-
UID PIPE THREAD SEALANT WHEN INSTALLING FITTINGS.
CHECK ALL THE O-RINGS ON THE VAPOR AND WATER FIT-

TINGS FOR ANY DAMAGE REPLACE IF NECESSARY.
LUBE ALL THE O-RINGS WITH AN O-RING LUBE BEFORE

INSTALLING.
1. Pressure Regulator Section 4. Primary Test Port 1. Install the three (3) rubber isolators to the bottom of
2. Fuel Inlet 5. Secondary Test Port the EPR.
3. Coolant Passage 6. Voice Coil Section
2. Install the EPR assembly to the bracket and tighten
Figure 3-38. EPR Assembly the retaining nuts.
The EPR assembly is a made up of two separate compo- NOTE: Do not over tighten the isolators and cause a separa-
nents. The Voice Coil Section is not serviceable and can tion of the isolators.
only be replaced as an assembly. The pressure regulator
section is serviceable and will be detailed in this section. 3. Install the fuel temperature sensor into the regulator
opening and lock in place with the locking pin, con-
REMOVAL nect the electrical connector.
1. Relieve the propane fuel system pressure. Refer to 4. Insert the fuel vapor line and fitting into the regulator
Propane Fuel System Pressure Relief. port and lock in place with the locking pin.
2. Disconnect the negative battery cable. 5. Install both the water hoses and fittings into the reg-
3. Slowly remove the fuel inlet fitting at the Electric ulator and lock in place with the locking pin remove
Lock Off. the clamp pliers from the hoses.
6. Install the electric lock off into the regulator inlet and
NOTE: Residual vapor pressure will be present in the fuel
tighten into proper location, connect the electrical
system.
connector.
4. Disconnect the electrical connector to the Electric 7. Connect the fuel supply line and tighten until fully
Lock off . seated.
3121133 – JLG Sizzor – 3-67

8. Connect the EPR electrical connector. Temperature Manifold Absolute Pressure

9. Open the manual valve. (TMAP) Sensor
10. Start the vehicle and leak check the propane fuel
system at each serviced fitting Refer to Propane Fuel
System Leak Test.
Figure 3-39. Pressure Regulator Section Figure 3-40. (TMAP) Sensor & Electronic Throttle
Control (ETC)
PRESSURE REGULATOR SECTION REMOVAL
REMOVAL
1. Remove the EPR refer to EPR Removal Procedure.
1. Disconnect the TMAP electrical connector.
2. Remove the six (6) regulator to voice coil screws
using the special tool and separate the regulator 2. Remove the two retaining bolts.
from the actuator.
3. Remove the TMAP.
NOTICE INSTALLATION
DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING NOTE: Apply a small amount of O-ring lubricant before
PLATE AND DIAPHRAGM THIS WILL VOID THE WARRANTY OF installation.
THE ACTUATOR SECTION.
1. Install in the TMAP.
PRESSURE REGULATOR SECTION INSTALLATION
2. Tighten retaining bolts to 62 lb-in (7 Nm).
1. Install the regulator to the actuator section using the
six (6) retaining screws and tighten 70 in lbs (8 Nm). 3. Start the vehicle and check for proper operation.
2. Install the EPR refer to EPR Installation.
3-68 – JLG Sizzor – 3121133

Electronic Throttle Control Replacement 2. Install the two quad seals. Install one seal at a time
to insure the seal does not roll. The seal must sit flat
See Figure 3-40. on the throttle body.
REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Release the hose clamp on the vapor fuel line and
remove the vapor hose.
4. Disconnect the TMAP electrical connector.
5. Disconnect the electronic throttle control connector.
6. Remove the manifold to throttle body adapter bolts
and remove the throttle body mixer assembly.
7. Pull the throttle body assembly from the adapter.
8. Remove electronic throttle control device.
9. Remove the O-rings gasket and discard. 3. Attach mixer and throttle body together. The two
INSTALLATION parts do not bolt together; they will be secured when
you mount it on the intake. Notice the orientation of
the air inlet and throttle body cover.
NOTICE
LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO
ADAPTER O-RINGS.
1. Install the O-ring on throttle body. Press it down to

the bottom of the surface.
3121133 – JLG Sizzor – 3-69

4. Place gasket on intake manifold and attach mixer/ Coolant Hose Replacement
throttle assembly to manifold.
REMOVAL
1. Drain the coolant.
2. Using hose clamp pliers, disconnect both hose

clamps on each hose.
3. Remove the hose from each of the fittings.
INSTALLATION
NOTE: Use hose material and lengths specified by JLG.
1. Install the hose clamps to each hose and set the

clamp back on each hose to make installation eas-
Figure 3-41. Mixer Assembly ier.
2. Fit the hose to the fittings.
Mixer Replacement 3. Secure by positioning each of the clamps.
See Figure 3-41.

Vapor Hose Replacement
REMOVAL REMOVAL
1. Remove the Throttle control device Refer to Elec- 1. Using hose clamp pliers disconnect both hose
tronic Throttle Body Replacement. clamps.
2. Remove the four (4) bolts to the throttle control 2. Remove the vapor hose from each fitting.
device to mixer adapter bolts. INSTALLATION
3. Remove and discard the mixer to adapter gasket.
NOTICE
INSTALLATION THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO
NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPEC-
NOTICE IFIED PARTS.
COVER THROTTLE BODY ADAPTER OPENING TO PREVENT
1. Install hose clamps and set back on each hose.
DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY.
2. Reinstall the vapor hose to each fitting.
1. Install Mixer to adapter gasket onto the mixer.
3. Reset clamps.
2. Install the mixer to the throttle control device to
4. Start engine and check for leaks.
mixer adapter and secure with the 4 retaining
screws. Tighten 80 lb-in (9 Nm).
3. Install Throttle body. Refer to Electronic Throttle

Control Device Replacement.
4. Start the engine and leak check all fittings and con-
nections.
3-70 – JLG Sizzor – 3121133

Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor

REMOVAL Replacement
1. Disconnect Negative battery cable. REMOVAL
2. Remove controller from mounting bracket. 1. Disconnect Negative battery cable.
3. Push connector lock back to unlock connector. 2. Disconnect the O2 sensor electrical connector.
4. Unplug controller and remove. 3. Using an O2 Sensor socket, remove the O2 Sensor
and discard.
INSTALLATION
INSTALLATION
NOTICE
THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY NOTICE
YOU HAVE THE CORRECT CONTROLLER BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH
ANTI-SEIZE COMPOUND GM P/N 5613695 OR EQUIVALENT.
1. Plug connector into controller. AVOID GETTING COMPOUND ON THE SENSOR TIP.
2. Push lock into place. 1. Install O2 sensor. Tighten to 30 lb-ft (41 Nm).
3. Mount controller into mounting bracket. 2. Start engine.
4. Reconnect the battery cable. 3. Check for any DTC codes and clear.
5. Start engine. 4. Verify engine is in closed loop and no warning lights
6. Check for any DTC codes and clear. are illuminated.
7. Verify engine is in closed loop and no warning lights

are illuminated.
3121133 – JLG Sizzor – 3-71

3.14 GM ENGINE LPG FUEL SYSTEM Diagnostic Aids

DIAGNOSIS This procedure is intended to diagnose a vehicle operat-
ing on LPG. If the vehicle will not continue to run on LPG,
refer to Hard Start for preliminary checks. Before proceed-
Fuel System Description ing with this procedure, verify that the vehicle has a suffi-
cient quantity of fuel and that liquid fuel is being delivered
to the LPR. Also, ensure that the manual shut off valve on
the LPG tank is fully opened and that the excess flow valve
has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs)
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light
Diagnostic Scan Tool
• Diagnostic Display tool.
Figure 3-42. EPR Assembly
Pressure Gauges
• IMPCO ITK-2 Test kit
To maintain fuel and emission control on the LPG fuel sys-
• Water Column Gauge / Manometer (GM 7333-6 or
tem the Engine Control Units (ECM) relies on numerous
equivalent).
engine sensor and output data from the Electronic Pres-
sure Regulator (EPR). The ECM will then determine the • 0-10 PSI Gauge
target fuel calibration and command the EPR to reposition Test Description
the voice coil to the proper position which, subsequently
reposition the secondary lever in the pressure regulator to The numbers below refer to step numbers on the diagnos-
maintain proper control. The EPR and ECM will continue tic table.
to communicate back and forth during normal operation. 5. This step determines if the LPR requires replacement.
In the event that the EPR fails to communicate or the Com- 6. This step determines if the problems are in the mechan-
munications Area Network (CAN) cable fails to transmit ical side of the Pressure Regulator or the Electronic Voice
data the regulator will operate in an open loop configura- Coil.
tion. As the air valve vacuum in the mixer venturi is com-
10. This step determines if the Mixer requires replace-
municated to the secondary chamber of the regulator the
ment.
secondary diaphragm will be drawn in a downwards
motion. This downward motion will cause the secondary 14. This step determines if the Lock Off requires replace-
lever to open thus allowing more fuel to enter the mixer. ment.
17. This step determines if the Fuel Filter requires replace-
In the (LPR) the fuel is vaporized and the pressure
ment.
reduced in two stages. The first stage reduces the pres-
sure to approximately 1.0 to 3.0 psi (6.8 to 20.6 kPa). The
second stage reduces the pressure to approximately neg-
ative 1.5" of water column.
The fuel is then drawn from the secondary chamber of the

LPR by the vacuum generated by air flowing through the
mixer. This vacuum signal is also used to generate lift for
the mixer air valve. This vacuum signal is most commonly
referred to as air valve vacuum. In the mixer, the fuel mixes
with the air entering the engine. This air/ fuel mixture is
then drawn into the engine for combustion.
3-72 – JLG Sizzor – 3121133

Table 3-9. LPF Fuel System Diagnosis
STEP ACTION VALUE(S) YES NO

1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2
2 Perform the On Board Diagnostic (OBD) System Check. -- Go to the Go to Step 3
Are any DTCs present in the ECM? applicable DTC Table
3 Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual -- Go to Step 4 --
valve is open and the tank quick connect is fully engaged
Does the vehicle have fuel?
4 1. Connect a water column gauge or a manometer to the secondary test port of -- Go to Step 5 Go to Step 8
the low pressure regulator (LPR).
2. Start the engine and allow it to reach operating temperature.
Does the engine start and run?
5 With the engine idling, observe the pressure reading for the LPR secondary -1.0" to Go to Step 25 Go to Step 6
pressure. -2.0" w.c
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range?
6 1. Disconnect the EPR electrical connectors. NOTE: This action will cause a -1.0" to Go to Fuel Control Go to Step 7
DTC to be set by the ECM -2.0" w.c System Diagnosis
2. With the engine idling observe the pressure reading on the secondary test
port.
Is the fuel pressure WITHIN the specified range?
7 1. Inspect the air intake stream between the mixer assembly and the throttle -- Go to Step 26 Go to Step 22
body for leaks.
2. Inspect the fuel hose connection between the LPR and mixer assembly for
damage or leakage.
3. Inspect any vacuum hoses for leaks
Was a problem found and corrected?
8 1. Connect a water column gauge or a manometer to the secondary test port of -- Go to Step 12 Go to Step 9
the low pressure regulator (LPR).
2. Crank the engine and observe the pressure reading for the LPR secondary
pressure.
Does the fuel pressure indicate a vacuum is present?
9 1. Remove Air induction hose to the mixer -- Go to Step 11 Go to Step 10
2. Observe the air valve for movement while the engine is cranking. Note: Move-
ment of the air valve will be minimal at cranking speeds.
Does the air valve move when the engine is cranked?
10 1. Inspect the air intake stream to the mixer assembly and the throttle body for -- Go to Step 26 Go to Step 24
vacuum leaks.
2. Inspect the vacuum hoses from the mixer for proper connection and condition.
Was a problem found and repaired?
11 Inspect the fuel hose connection between the LPR and the mixer assembly for -- Go to Step 26 Go to Step 12
damage or leakage.
Was a problem found and repaired?
12 1. Connect a 0-10 psi gauge to the primary test port of the low pressure regulator 1- 3 PSI Go to Step 22 Go to Step 13
(LPR).
2. Crank the engine and observe the pressure reading for the LPR primary pres-
sure.
Is the fuel pressure ABOVE the specified value?
3121133 – JLG Sizzor – 3-73


13 1. Turn OFF the ignition. -- Go to Step 14 Go to Step 16
2. Disconnect the LPL connector.
3. Install a test light between the pins of the LPL connector.
4. Crank the engine. The test light should illuminate.
Does the test light illuminate?
14 Using a DVOM, check the resistance of the low pressure lock-off (LPL). 12Ω - 16Ω Go to Step 15 Go to Step 23
Is the resistance within the specified range?
15 1. Turn the ignition OFF. -- Go to Step 23 Go to Step 17
2. Close the manual shut-off valve on the LPG tank.
CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Per-
form this step in a well ventilated area.
3. Loosen the fuel inlet hose fitting at the inlet of the LPL.
Was fuel present when the fitting was loosened?
16 1. Turn OFF the ignition. -- Go to Step 20 Go to Step 21
2. Connect the test light to chassis ground and probe pin A of the LPL connector.
3. Crank the engine. The test light should illuminate.
Does the test light illuminate?
17 1. Remove the LPG fuel filter / LPL. -- Go to Step 19 Go to Step 18
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG fuel filter onto a clean surface.
4. Inspect the contents of the LPG fuel filter for an excessive amount of foreign
material or water. If necessary, locate and repair the source of contamination.
5. Verify the LPG fuel filter is not restricted or plugged.
Was a problem found?
18 The fuel supply system or hoses are plugged or restricted, locate and repair the -- Go to Step 26 --
problem.
Is the action complete?
19 Replace the fuel filter. Refer to Fuel Filter Replacement. -- Go to Step 26 --
20 Repair the open in the lock-off ground circuit. -- Go to Step 26 --
21 Repair the open in the lock-off power circuit. -- Go to Step 26 --
22 Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator -- Go to Step 26 --
Replacement.
23 Replace the lock-off. Refer to Lock-off Replacement. -- Go to Step 26 --
24 Replace the mixer assembly. Refer to Fuel Mixer Replacement. -- Go to Step 26 --
3-74 – JLG Sizzor – 3121133


25 The fuel supply system is operating normally, if a failure of the control solenoids is -- System OK --
suspected. Refer to Fuel Control System Diagnosis.
1. Install the test plug in the LPR secondary chamber.

2. If you were sent to this routine by another diagnostic chart, return to the previ-
ous diagnostic procedure.
26 1. Disconnect all test equipment -- System OK --
2. Install the primary and secondary test port plugs.
3. Start the engine.
4. Using SNOOP or equivalent, leak check the test port plugs.
3121133 – JLG Sizzor – 3-75

3.15 JOYSTICK CONTROLLER
Figure 3-43. Joystick Controller - (JLG P/N 1600308)
Table 3-10. Joystick Specifications Table 3-11. Joystick Plug Loading Chart
Input Voltage 4.3V (±0.1V) Terminal Color Function
Centered Output Voltage 2.2V (±0.1V) 1 Yellow Steer Right
Full Positive (Rev) Deflection Output Voltage 4.0V (±0.1V) 2 Green Steer Left
Full Negative (Fwd) Output Voltage 0.4V (±0.1V) 3 Brown Pot Wiper
4 Red Handle Common
5 N/A Not Connected
6 White/Red Pot (+)
7 Violet Trigger Switch
8 Blue Trigger Supply
9 White/Black Pot (-)
3-76 – JLG Sizzor – 3121133

Figure 3-44. Joystick Controller - (JLG P/N 1600403)
Table 3-12. Joystick Specifications Table 3-13. Joystick Plug Loading Chart
Input Voltage 5V Terminal Color Function

Centered Output Voltage 4.25V to 2.60V 1 Yellow Steer Right
Reverse Voltage 4.60V to 4.80V 2 Green Steer Left
Forward Voltage 0.40V to 0.60V 3 Brown Pot Wiper
4 Red Handle Common
5 N/A Not Connected
6 White/Red Pot (+)
7 Violet Trigger Switch
8 Blue Trigger Supply
9 White/Black Pot (-)
3121133 – JLG Sizzor – 3-77

Table 3-14. Symptom Diagnosis
Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks
are very important. The checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check 1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich.
IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at
that time.
Visual and Physical Checks ²Check all ECM system fuses and circuit breakers.
²Check the ECM ground for being clean, tight and in its proper location.
²Check the vacuum hoses for splits, kinks and proper connections.
²Check thoroughly for any type of leak or restriction.
²Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
²Check for proper installation of the mixer module assembly.
²Check for air leaks at the mixer assembly.
²Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
²Check the wiring for the following items:
- Proper connections, pinches or cuts.
²The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is
not important. If the scan tool readings do not indicate the problems, then proceed in a logical order, easiest to check or
most likely to cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks ²Refer to Important Preliminary Checks.
²Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good
parts.
Faulty Electrical Connections or ²Faulty electrical connections or wiring can cause most intermittent problems.
Wiring ²Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
²Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If nec-
essary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension.
²Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the prob-
lem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.
3-78 – JLG Sizzor – 3121133

Checks Action
Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s):
Lamp (MIL) ²A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally,
the problem will occur when the faulty component is operating.
²The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
²The ignition secondary voltage shorted to a ground.
²The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
²The Control Module grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the
TMAP DTC does not store and remain, the ECM is faulty
No Start
DEFINITION: The engine cranks OK²²but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
²Check for proper communication with both the ECM
²Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
²Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage
and/or continuity for each circuit.
Sensor Checks ²Check the TMAP sensor.
²Check the Magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
²Check for air intake system leakage between the mixer and the throttle body.
²Verify proper operation of the low pressure lock-off solenoids.
²Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
²Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating
conditions.
²Check for the proper ignition voltage output with J 26792 or the equivalent.
²Verify that the spark plugs are correct for use with LPG (R42LTS)
²Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
²Check for bare or shorted ignition wires.
²Check for loose ignition coil connections at the coil.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
ifold leakage than the gasoline fuel supply system.
²Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
3121133 – JLG Sizzor – 3-79

Checks Action
Exhaust System Checks ²Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
²Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
Hard Start
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
²Make sure the vehicle' s operator is using the correct starting procedure.
Sensor Checks ²Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the
ambient air temperature on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than
the ambient air temperature on a cold engine, check for high resistance in the coolant sensor circuit. Refer to DTC 111
²Check the Crankshaft Position (CKP) sensor.
²Check the Throttle position (TPS) sensor.
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
²Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
²Check mixer module assembly for proper installation and leakage.
²Verify proper operation of the low pressure lock-off solenoids.
²Verify proper operation of the EPR
²Check for air intake system leakage between the mixer and the throttle body.
²Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operat-
ing conditions.
²Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
²Check for bare or shorted ignition wires.
²Check for moisture in the distributor cap if applicable.
²Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, Check the Crankshaft Position (CKP).
2. Check for improper gap, debris or faulty connections.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
²Check for the following:
- Vacuum leaks
- Low compression
- Bent pushrods
- Worn rocker arms
²Check the intake and exhaust manifolds for casting flash.
3-80 – JLG Sizzor – 3121133

Checks Action
²Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the
GM Base Engine Service Manual
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM.
The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Ignition System Checks ²Start the engine.
²Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring as you
apply water.
²Check for proper ignition output voltage with spark tester J 26792.
²Check for a cylinder misfire.
²Remove the spark plugs in these cylinders and check for the following conditions:
²Insulation cracks
²Wear
²Improper gap
²Burned electrodes
²Heavy deposits
²Visually/Physically inspect the secondary ignition for the following:
²Ignition wires for arcing, cross-firing and proper routing
²Ignition coils for cracks or carbon tracking
Engine Mechanical Checks ²Perform a cylinder compression check.
²Check the engine for the following:
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs.
²Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks ²Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
²Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
²EMI on the reference circuit can cause a missing condition.
²Monitoring the engine RPM with a scan tool can detect an EMI.
²A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
²If the problem exists, check the routing of the secondary wires and the ground circuit.
Hesitation, Sag, Stumble
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition
may cause the engine to stall if it' s severe enough.
Fuel System Checks ²Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
²Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification,
there is possibly a faulty low pressure regulator or a restriction in the fuel system.
²Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
²Check LPL electrical connection
²Check the mixer air valve for sticking or binding.
²Check the mixer module assembly for proper installation and leakage.
²Check the EPR electrical connections.
3121133 – JLG Sizzor – 3-81

Checks Action
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating
conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system
failure and test the system accordingly.
²Check for faulty spark plug wires
²Check for fouled spark plugs.
Additional Check ²Check for manifold vacuum or air induction system leaks
²Check the generator output voltage.
Backfire
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check ²Refer to Important Preliminary Checks.
Ignition System Checks Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent
gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
²Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent.
²Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over
30,000 ohms, replace the wires.
²Check the connection at each ignition coil.
²Check for deteriorated spark plug wire insulation.
²Check the spark plugs. The correct spark plugs for LPG are (R42LTS)
²Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Engine Mechanical Check Important! The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
ifold leakage than a gasoline fuel supply system.
²Check the engine for the following:
- Engine compression
- Manifold vacuum leaks
- Intake manifold gaskets
- Sticking or leaking valves
- Exhaust system leakage
²Check the intake and exhaust system for casting flash or other restrictions.
Fuel System Checks ²Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
Lack of Power, Sluggishness, or Sponginess
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal.
²Refer to the LPG Fuel system OBD System Check
²Compare the customer' s vehicle with a similar unit. Make sure the customer has an actual problem. Do not compare the
power output of the vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel
characteristics
²Remove the air filter and check for dirt or restriction.
²Check the vehicle transmission Refer to the OEM transmission diagnostics.
3-82 – JLG Sizzor – 3121133

Checks Action
Fuel System Checks ²Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
²Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
²Check for proper installation of the mixer module assembly.
²Check all air inlet ducts for condition and proper installation.
²Check for fuel leaks between the LPR and the mixer.
²Verify that the LPG tank manual shut-off valve is fully open.
²Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks ²Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper opera-
tion of the MAP sensor.
²Check for proper operation of the TPS sensor.
- Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following:
²Engine compression
²Valve timing
²Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check ²Check the ECM grounds for being clean, tight, and in their proper locations.
²If all procedures have been completed and no malfunction has been found, review and inspect the following items:
²Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
²Check the scan tool data.
Poor Fuel Economy
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this
vehicle at one time, as previously shown by an by refueling records.
²Check the air cleaner element (filter) for dirt or being plugged.
²Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
²Check the operators driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are the tires at the correct air pressure?
- Are excessively heavy loads being carried?
- Is their often rapid acceleration?
²Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
²Suggest that a different operator use the equipment and record the results.
Fuel System Checks ²Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
²Check the fuel system for leakage.
Sensor Checks ²Check the Temperature Manifold Absolute Pressure (TMAP) sensor.
Ignition System Checks ²Verify that the spark plugs are correct for use with LPG (R42LTS)
²Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
²Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
3121133 – JLG Sizzor – 3-83

Checks Action
Cooling System Checks ²Check the engine thermostat for always being open or for the wrong heat range
Additional Check ²Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
²Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition
may be severe enough to stall the engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks ²Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The
sensor will result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel deliv-
ered to the engine causing a severe driveability problem.
²Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
²Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks ²Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the
oxygen sensors will help identify the problem.
²Check for a sticking mixer air valve.
²Verify proper operation of the EPR.
²Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
²Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
²Check mixer module assembly for proper installation and connection.
Ignition System Checks ²Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
²Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over
30,000 ohms, replace the wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
²Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
²Check the ECM grounds for being clean, tight, and in their proper locations.
²Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor
readings to be skewed resulting in poor idle quality.
Engine Mechanical Check ²Check the engine for the following:
- Broken motor mounts
- Low compression
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes
Surges/Chuggles
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accel-
erator pedal.
Sensor Checks ²Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
3-84 – JLG Sizzor – 3121133

Checks Action
Fuel System Checks ²Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring
the oxygen sensors will help identify the problem.
²Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
²Verify proper fuel control solenoid operation.
²Verify that the LPG manual shut-off valve is fully open.
²Check the in-line fuel filter for restrictions.
Ignition System Checks ²Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor.
Additional Check ²Check the ECM grounds for being clean, tight, and in their proper locations.
²Check the vacuum hoses for kinks or leaks.
²Check Transmission
3121133 – JLG Sizzor – 3-85

Table 3-15. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

16 Crank Never Synced at Start 636 8
91 Fuel Pump Low Voltage 94 4
92 Fuel Pump High Voltage 94 3
107 MAP Low Voltage 106 4
108 MAP High Pressure 106 16
111 IAT Higher Than Expected 1 105 15
112 IAT Low Voltage 105 4
113 IAT High Voltage 105 3
116 ECT Higher Than Expected 1 110 15
117 ECT Low Voltage 110 4
118 ECT High Voltage 110 3
121 TPS 1 Lower Than TPS 2 51 1
122 TPS 1 Signal Voltage Low 51 4
123 TPS 1 Signal Voltage High 51 3
127 IAT Higher Than Expected 2 105 0
129 BP Low Pressure 108 1
134 EGO 1 Open/Inactive 724 10
154 EGO 2 Open/Inactive 520208 10
171 Adaptive Learn High Gasoline 520200 0
172 Adaptive Learn Low Gasoline 520200 1
182 Fuel Temp Gasoline Low Voltage 174 4
183 Fuel Temp Gasoline High Voltage 174 3
187 Fuel Temp LPG Low Voltage 520240 4
188 Fuel Temp LPG High Voltage 520240 3
217 ECT Higher Than Expected 2 110 0
219 Max Govern Speed Override 515 15
221 TPS 2 Signal Voltage Low 51 0
222 TPS 2 Signal Low Voltage 520251 4
223 TPS 2 Signal High Voltage 520251 3
261 Injector Driver 1 Open 651 5
262 Injector Driver 1 Shorted 651 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1
3-86 – JLG Sizzor – 3121133

Table 3-15. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

562 System Voltage Low 168 17
563 System Voltage High 168 15
601 Flash Checksum Invalid 628 13
604 RAM Failure 630 12
606 COP Failure 629 31
642 External 5V Reference Low 1079 4
643 External 5V Reference High 1079 3
685 Power Relay Open 1485 5
686 Power Relay Shorted 1485 4
687 Power Relay Short to Power 1485 3
1111 Fuel Rev Limit 515 16
1112 Spark Rev Limit 515 0
1151 Closed Loop Multiplier High LPG 520206 0
1152 Closed Loop Multiplier Low LPG 520206 1
1155 Closed Loop Multiplier High Gasoline 520204 0
1156 Closed Loop Multiplier Low Gasoline 520204 1
1161 Adaptive Learn High LPG 520202 0
1162 Adaptive Learn Low LPG 520202 1
1165 LPG Cat Monitor 520213 10
1171 LPG Pressure Higher Than Expected 520260 0
1172 LPG Pressure Lower Than Expected 520260 1
1173 EPR Comm Lost 520260 31
1174 EPR Voltage Supply High 520260 3
1175 EPR Voltage Supply Low 520260 4
1176 EPR Internal Actuator Fault 520260 12
1177 EPR Internal Circuitry Fault 520260 12
1178 EPR Internal Comm Fault 520260 12
1612 RTI 1 loss 629 31
1613 RTI 2 Loss 629 31
1614 RTI 3 Loss 629 31
1615 A/D Loss 629 31
1616 Invalid Interrupt 629 31
1625 Shutdown Request 1384 31
1626 CAN Tx Failure 639 12
1627 CAN Rx Failure 639 12
1628 CAN Address Conflict Failure 639 13
1629 Loss of TSC 1 639 31
2111 Unable to Reach Lower TPS 51 7
2112 Unable to Reach Higher TPS 51
2135 TPS 1/2 Simultaneous Voltages 51 31
2229 BP Pressure High 108 0
3121133 – JLG Sizzor – 3-87

NOTES:
3-88 – JLG Sizzor – 3121133

SECTION 4. HYDRAULICS
4.1 CYLINDERS - THEORY OF OPERATION rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir-
Cylinders are of the double acting type. The steer system cuit pressure. The relief valve is installed in the circuit
incorporates a double acting cylinder. A double acting cyl- between the pump outlet (pressure line) and the cylinder
inder is one that requires oil flow to operate the cylinder of the circuit, generally as an integral part of the system
rod in both directions. Directing oil (by actuating the corre- valve bank. Relief pressures are set slightly higher than
sponding control valve to the piston side of the cylinder) the load requirement, with the valve diverting excess
forces the piston to travel toward the rod end of the barrel, pump delivery back to the reservoir when operating pres-
extending the cylinder rod (piston attached to rod). When sure of the component is reached.
the oil flow is stopped, movement of the rod will stop. By
directing oil to the rod side of the cylinder, the piston will Crossover Relief Valves
be forced in the opposite direction and the cylinder rod
Crossover relief valves are used in circuits where the actu-
will retract.
ator requires an operating pressure lower than that sup-
NOTE: The lift cylinder is a single acting cylinder which plied to the system. When the circuit is activated and the
takes hydraulic pressure to extend and gravity to required pressure at the actuator is developed, the cross-
retract. over relief diverts excess pump flow to the reservoir. Indi-
vidual, integral relief’s are provided for each side of the
A holding valve is used in the Lift circuit to prevent retrac- circuit.
tion of the cylinder rod should a hydraulic line rupture or a
leak develop between the cylinder and its related control 4.3 COMPONENT FUNCTIONAL
valve. DESCRIPTION
4.2 VALVES - THEORY OF OPERATION Piston Hydraulic Pump
Solenoid Control Valves (Bang-Bang) The Rexroth tandem piston pump is attached to and
driven by the engine. The pump is a 28 cc piston pump
Control valves used are four-way three-position solenoid that powers the drive motors.
valves of the sliding spool design. When a circuit is acti-
vated and the control valve solenoid energizes, the spool Gear Hydraulic Pump
is shifted and the corresponding work port opens to per-
mit oil flow to the component in the selected circuit, with The Bosch rexroth gear pump is “piggy-backed” to the
the opposite work port opening to reservoir. Once the cir- piston pump, and operates all machine functions except
cuit is deactivated (control returned to neutral), the valve drive. The gear pump is a 14 cc pump which pumps 14.5
spool returns to neutral (center) and oil flow is then GPM.
directed through the valve body and returns to reservoir. A
typical control valve consists of the valve body, sliding Manual Descent Valve
spool, and two solenoid assemblies. The spool is The manual descent valve is located on top of the holding
machine fitted in the bore of the valve body. Lands on the valve on the lift cylinder. The holding valve is a normally
spool divide the bore into various chambers, which, when closed solenoid valve, and holds the platform in place
the spool is shifted, align with corresponding ports in the when raised. When activated, the valve opens to permit lift
valve body open to common flow. At the same time other down. The holding valve is connected to the manual
ports would be blocked to flow. The spool is spring- descent valve, which is connected to a cable which, when
loaded to center position, therefore when the control is pulled, manually opens the lift down port of the valve and
released, the spool automatically returns to neutral, pro- allows the platform to be lowered in the event hydraulic
hibiting any flow through the circuit. power is lost.
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 – JLG Lift – 4-1

4.4 CYLINDER CHECKING PROCEDURE Carefully remove hydraulic hoses from appropriate
cylinder port block.
NOTE: Cylinder check must be performed anytime a system
3. There will be initial weeping of hydraulic fluid, which
component is replaced or when improper system
can be caught in a suitable container. After the initial
operation is suspected.
discharge, there should be no further leakage from
the ports. If leakage continues at a rate of 6-8 drops
Cylinders Without Counterbalance Valves - per minute or more, the counterbalance valve is
Steer Cylinder defective and must be replaced.
4. To check piston seals, carefully remove the counter-

1. Using all applicable safety precautions, activate
balance valve from the retract port. After initial dis-
engine and fully extend cylinder to be checked. Shut
charge, there should be no further leakage from the
down engine.
ports. If leakage occurs at a rate of 6-8 drops per
2. Carefully disconnect hydraulic hoses from retract minute or more, the piston seals are defective and
port of cylinder. There will be some initial weeping of must be replaced.
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be 5. If no repairs are necessary or when repairs have
no further drainage from the retract port. been made, replace counterbalance valve and care-
fully connect hydraulic hoses to cylinder port block.
3. Activate engine and extend cylinder.
6. If used, remove lifting device from upright or remove
4. If cylinder retract port leakage is less than 6-8 drops prop from below main boom, activate hydraulic sys-
per minute, carefully reconnect hose to port and tem and run cylinder through one complete cycle to
retract cylinder. If leakage continues at a rate of 6-8 check for leaks.
drops per minute or more, cylinder repair must be
made. Oscillating Axle Lockout Test
5. With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder NOTICE
extend port. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
6. Activate engine and retract cylinder. Check extend ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
port for leakage. IMPROPER SYSTEM OPERATION IS SUSPECTED.
7. If extend port leakage is less than 6-8 drops per NOTE: Ensure platform is fully lowered prior to beginning
minute, carefully reconnect hose to extend port, lockout cylinder test.
than activate cylinder through one complete cycle
and check for leaks. If leakage continues at a rate of 1. Place a 6 inch (15.2 cm) high block with ascension
6-8 drops per minute or more, cylinder repairs must ramp in front of left front wheel.
be made.
2. From platform control station, select LOW drive
Cylinders With Single Counterbalance Valve speed.
3. Place DRIVE control switch to FORWARD position

NOTICE and carefully drive the machine up ascension ramp
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION until left front wheel is on top of block.
ONLY.
4. Raise machine platform approximately 9 ft (2.7 m)
on the 3394RT or 10 ft (3.1 m) on the 4394RT.
1. Using all applicable safety precautions, activate
hydraulic system. 5. Place DRIVE control switch to REVERSE position
and carefully drive the machine off the block and
2. Shut down hydraulic system and allow machine to
ramp.
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn igni- 6. Have an assistant check to see that the left front
tion switch to on, move control switch or lever for wheel remains locked in position off the ground.
applicable cylinder in each direction, then turn igni-
tion switch to off. If machine is equipped with 7. Lower the machine platform; the lockout cylinder
hydraulic control valves, move control lever for should then release and allow wheel to rest on the
applicable cylinder in each direction. This is done to ground. It may be necessary to activate DRIVE to
relieve pressure in the hydraulic lines. release cylinders.
4-2 – JLG Lift – 3121133

8. Place the 6 inch (15.2 cm) high block with ascension 3. If applicable, remove the cartridge-type holding
ramp in front of right front wheel. valve and fittings from the cylinder port block. Dis-
card o-rings.
9. From platform control station, select LOW drive
speed.
10. Place DRIVE control switch to FORWARD position

and carefully drive the machine up ascension ramp
until right front wheel is on top of block.
11. Raise machine platform approximately 9 ft (2.7 m)

on the 3394RT or 10 ft (3.1 m) on the 4394RT.
12. Place DRIVE control switch to REVERSE position

and carefully drive the machine off the block and
ramp.
13. Have an assistant check to see that the right front

wheel remains locked in position off the ground.
14. Lower the machine platform; the lockout cylinder

should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to
Figure 4-1. Lift Cylinder Holding Valve and Fitting
release cylinders.
Removal
15. If the lockout cylinders do not function properly,
have qualified personnel correct the malfunction 4. Place the cylinder barrel into a suitable holding fix-
prior to any further operation. ture.
4.5 CYLINDER REPAIR

NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
Disassembly
NOTICE
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source Figure 4-2. Cylinder Barrel Support
to the cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
SURE.
2. Operate the hydraulic power source and extend the

cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli-
cable.
3121133 – JLG Lift – 4-3

NOTICE
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
8. With the barrel clamped securely, apply pressure to

the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
Figure 4-3. Lift Cylinder Cap Screw Removal
NOTE: Steps 6 and 7 apply only to the steer cylinder.
5. Using a spanner wrench, loosen the spanner nut

retainer, and remove spanner nut from cylinder bar-
rel.
6. Being careful not to mar the surface of the rod, use a Figure 4-4. Cylinder Rod Support
punch or wooden dowel and hammer to drive the
rod guide about one inch down into the cylinder 9. Using suitable protection, clamp the cylinder rod in
bore. Using a screw driver, carefully push one end of a vise or similar holding fixture as close to the piston
the round retaining ring back towards the inside of as possible.
the cylinder and then slip the screwdriver tip under NOTE: Step 11 applies only to the steer cylinder.
that end. Pull the ring out of the groove toward the
wall mouth. Once one end of the retaining ring is 10. Loosen and remove nut which attaches the piston to
free from the groove, the remainder can be easily the rod, and remove the piston.
pried free using ones fingers or pliers. 11. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.
12. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.
7. Attach a suitable pulling device to the cylinder rod

port block end or cylinder rod end, as applicable.
4-4 – JLG Lift – 3121133

13. Remove the bushing from the piston. 9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.
10. Inspect threaded portion of head for damage. Dress

threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs

and sharp edges. Dress applicable surfaces as nec-
essary.
12. Inspect cylinder head outside diameter for scoring

or other damage and ovality and tapering. Replace
as necessary.
13. If applicable, inspect rod and barrel bearings for

signs of correct excessive wear or damage. Replace
as necessary.
Figure 4-5. Tapered Bushing Removal
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
14. Screw the piston CCW, by hand, and remove the b. Inspect steel bushing for wear or other damage.
piston from cylinder rod. If steel bushing is worn or damaged, rod/barrel
15. Remove and discard the piston o-rings, seal rings, must be replaced.
and backup rings. c. Lubricate inside of steel bushing with WD40
prior to bearing installation.
16. Remove piston spacer, if applicable, from the rod.
d. Using an arbor of the correct size, carefully
17. Remove the rod from the holding fixture. Remove press the bearing into steel bushing.
the cylinder head gland and retainer plate, if applica-
ble. Discard the o-rings, back-up rings, rod seals, NOTE: Install pin into the Gar-Max bearing dry. Lubrication
and wiper seals. is not required with nickel plated pins and bearings.
Cleaning and Inspection STEEL

COMPOSITE
BUSHING
BUSHING
1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,

or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
ARBOR
3. Inspect threaded portion of rod for excessive dam-
age. Dress threads as necessary.
Figure 4-6. Bushing Installation
4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary. 14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
5. Inspect threaded portion of barrel for damage. Dress surface with Scotch Brite or equivalent.
threads as necessary.
15. If applicable, inspect port block fittings and holding
6. Inspect piston surface for damage and scoring and valve. Replace as necessary.
for distortion. Dress piston surface or replace piston
as necessary. 16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary. 17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as nec-
essary.
3121133 – JLG Lift – 4-5

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.
Figure 4-9. Wiper Seal Installation
3. Place a new “o”ring and back-up seal in the applica-

ble outside diameter groove of the cylinder head.
Figure 4-7. Rod Seal Installation
NOTICE
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA- Figure 4-10. Installation of Head Seal Kit
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION. 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
WHEN INSTALLING THE WIPER SEAL ON THE LOWER (TOWER)
along the rod to the rod end, as applicable.
LIFT CYLINDER, APPLY LOCTITE #609 ON THE WIPER SEAL IN
THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE 5. Carefully slide the piston spacer on the rod.
SEAL. 6. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side fac-
2. Use a soft mallet to tap a new wiper seal into the ing the O-ring is grooved.)
applicable cylinder head gland groove. Install a new
7. If applicable, correctly place new seals and guide
wear ring into the applicable cylinder head gland-
lock rings in the outer piston diameter groove. (A
groove.
tube, with I.D. 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 in (See Figure 4-11.))The split of seals
and backup rings are to be positioned so as not to be
in alignment with each other.
Figure 4-8. Poly-Pak Piston Seal Installation
4-6 – JLG Lift – 3121133

screws) through the drilled holes in the bushing and

into the tapped holes in the piston.
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;
Figure 4-11. Piston Seal Kit Installation
a. Place the shaft against the cylinder rod and in
1. Using suitable protection, clamp the cylinder rod in contact with the bushing in the spaces between
a vise or similar holding fixture as close to piston as the capscrews.
possible.
b. Tap each space once; this means the tapered
2. Carefully thread the piston on the cylinder rod hand bushing is tapped 3 times as there are 3 spaces
tight, ensuring that the o-ring and back-up rings are
between the capscrews.
not damaged or dislodged.
3. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and mat-

ing end of rod must be free of oil.
4. Assemble the tapered bushing loosely into the pis-

ton and insert JLG capscrews (not vendor cap-
Figure 4-13. Seating the Tapered Bearing
7. Retorque the capscrews evenly and progressively in

rotation to the specified torque value.
8. Remove the cylinder rod from the holding fixture.
3121133 – JLG Lift – 4-7

9. Place new guide locks and seals in the applicable

outside diameter grooves of the cylinder piston.
Table 4-1. Cylinder Piston Nut Torque Specifications
(See Figure 4-11.)
10. Position the cylinder barrel in a suitable holding fix- Nut Torque Setscrew
Description
ture. Value torque Value
400 ft lb 100 in lb
NOTICE Lift Cylinder
(542 Nm) (12 Nm)
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD Lockout Cylinder N/A N/A
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES. Steer Cylinder N/A N/A
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 Table 4-2. Holding Valve Torque Specifications
and seal ring are not damaged or dislodged.
Description Torque Value
12. Continue pushing the rod into the barrel until the cyl-
inder head gland can be inserted into the barrel cyl- Sun - 7/8 hex M20 x 1.5 thds 30 - 35 ft lb 41 - 48 Nm
inder.
Sun - 1-1/8 hex 1 - 14 UNS thds 45 - 50 ft lb 61 - 68 Nm
13. Secure the cylinder head gland using the washer
ring and socket head bolts. Sun - 1-1/4 hex M36 x 2 thds 150 - 153 ft lb 204 - 207 Nm
Racine - 1-1/8 hex 1-1/16 - 12 thds 50 - 55 ft lb 68 - 75 Nm
16. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut.
WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #242 TO

Figure 4-14. Rod Assembly Installation PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT.
REFER TO TABLE 4-1, CYLINDER PISTON NUT TORQUE SPECIFI-
CATIONS
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. NOTE: The Steer Cylinder uses snap rings to secure piston.
15. If applicable, install the cartridge-type holding valve

17. Prior to setscrew installation spot drill rod before
and fittings in the rod port block, using new o-rings
as applicable. (See Table 4-2, Holding Valve Torque installing the setscrew(s) which secure the piston
attaching nut to the diameter groove.
Specifications).
18. Remove the cylinder rod from the holding fixture.
19. Position the cylinder barrel in a suitable holding fix-

ture.
NOTICE
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
4-8 – JLG Lift – 3121133

20. With barrel clamped securely, and while adequately Be certain to fill pump and/or motor housing with clean
supporting the rod, insert the piston end into the hydraulic fluid prior to start-up. Fill housing by pouring fil-
barrel cylinder. Ensure that the piston loading o-ring tered oil into upper case drain port.
and seal ring are not damaged or dislodged.
Install a 0 to 500 psi (0 to 35 bar) pressure gauge in the
21. Continue pushing the rod into the barrel until the cyl- charge pressure gauge port to monitor charge pressure
inder head gland can be inserted into the barrel cyl- during start-up.
inder.
It is recommended that the external control input signal
22. If applicable, secure the cylinder head retainer using electrical connections be disconnected at the pump con-
a suitable chain wrench. trol until after initial start-up. This will allow the pump to
remain in its neutral position.
23. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior “Jog” or slowly rotate prime mover until charge pressure
to the reinstallation of any holding valve or valves. starts to rise. Start prime mover and run at the lowest pos-
sible RPM until charge pressure has been established.
24. If applicable, install the cartridge-type holding valve Excess air may be bled from high pressure lines through
and fittings in the port block using new o-rings as high pressure gauge ports.
applicable. Refer to Table 4-2, Holding Valve Torque
Specifications.
4.6 DRIVE PUMP START-UP PROCEDURE 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
NOTICE ACTUATED DURING INITIAL START-UP.
THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER-
FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING Once charge pressure has been established, increase
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR speed to normal operating RPM. Charge pressure should
HAVE BEEN REMOVED FROM THE SYSTEM.
be approximately 220 psi (15.5 bar) minimum. If charge
pressure is incorrect, shut down and determine cause for
THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER-
improper pressure.
FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR
HAVE BEEN REMOVED FROM THE SYSTEM.
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO
TOR’S ABILITY TO CONTROL THE MACHINE.
BE DISABLED (WHEELS RAISED OFF THE GROUND, DRIVE
FUNCTION DISCONNECTED, ETC.) WHILE PERFORMING THE
PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN Shut down prime mover and connect external control
AND OTHER PERSONNEL. TAKE NECESSARY SAFETY PRECAU- input signal. start prime mover, checking to be certain
TIONS BEFORE MOVING THE MACHINE. pump remains in neutral. with prime mover at normal
operating speed, slowly check for forward and reverse
Prior to installing pump and/or motor, inspect unit(s) for machine operation.
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses, valves, Charge pressure should remain at 220 psi to 240 psi (15.5
fittings, heat exchanger, etc.) are clean prior to filling with bar to 16.9 bar) minimum during forward or reverse opera-
hydraulic fluid. tion. Continue to cycle slowly between forward and
reverse for at least five minutes.
Fill reservoir with recommended hydraulic fluid, which
should be passed through a 10 micron (nominal, no Shut down prime mover, remove gauges, and plug ports.
bypass) filter prior to entering the reservoir. The use of Check reservoir level and add fluid if necessary.
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 – JLG Lift – 4-9

4.7 HYDRAULIC COMPONENT START-UP needs to be pressurized in order to start the flow of
oil, a vacuum reading should be taken at the inlet of
PROCEDURES AND the pump during operation in order to verify that the
RECOMMENDATIONS pump is not being asked to draw an inlet vacuum
higher than it is capable of.
From a hydrostatic component standpoint, the goal at
system start up is to put into functional operation, the Be certain to fill the pump and/or motor housing with
hydrostatic system in such a way as to preserve the clean hydraulic fluid prior to start up. Fill the housing by
designed life span of the system. The following start-up pouring filtered oil into the upper case drain port.
procedure should be adhered to whenever a new pump
or motor is initially installed into a machine, or a system is NOTE: It is highly recommended to use the highest possible
restarted after either a pump or motor has been removed case drain port, this ensures that the housing con-
and/or replaced. tains as much oil as possible and offers the greatest
amount of lubrication to the internal components.
THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO In initial start-up conditions, it may be convenient to
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK fill the housing, just prior to installing the case drain
FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING THE line. Component, (especially motor), location may be
PROCEDURE IN ORDER TO PREVENT INJURY. TAKE NECES- such that access to the case drain port after installa-
SARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/ tion is not realistic.
MACHINE.
Make certain that the oil being used to fill the compo-
Prior to installing the pump and/or motor, inspect the nent housing is as clean as possible, and store the
unit(s) for damage that may have been incurred during fill container in such a way as to prevent it from
shipping and handling. Make certain that all system com- becoming contaminated.
ponents (reservoir, hoses, valves, fittings, heat exchanger,
etc.) are clean prior to filling with fluid. Install a 60 bar (or 1000 psi) pressure gauge in the charge
pressure gauge port in order to monitor the charge pres-
Fill the reservoir with recommended hydraulic fluid. This sure during start-up.
fluid should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of It is recommended that the external control input signal,
contaminated fluid will cause damage to the components, (electrical connections for EDC), be disconnected at the
which may result in unexpected vehicle/machine move- pump control until after initial start-up. This will ensure that
ment. the pump remains in its neutral position.
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
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL
the entire hydraulic system will need to be flushed
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
and the fluid replaced. Failure to do so may cause
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
considerable damage to the entire system.
ACTUATED DURING INITIAL START-UP.
The inlet line leading from the reservoir to the pump must
be filled prior to start-up. Check the inlet line for property "Jog" or slowly rotate the engine until charge pressure
tightened fittings and make sure it is free of restrictions starts to rise. Start the engine and run at the lowest possi-
and air leaks. ble RPM until charge pressure has been established.
Excess air should be bled from the system lines as close
NOTE: In most cases, the reservoir is above the pump inlet to the motors as possible.
so that the pressure head created by the higher oil
level helps to keep the inlet pressures within an NOTE: With the engine on low idle, "crack", (loosen-don't
acceptable range and prevent high vacuum levels. remove), the system lines at the motor(s). Continue
However, due to hose routing or low reservoir loca- to run the engine at low idle and tighten the system
tions, there may be air trapped within this line. It is lines as soon as oil is observed to leak from them.
important to assure that the air is bled from this line. When oil is observed to "leak" at the motor the line is
This can be accomplished by loosening the hose at full, the air has been purged, and the system hoses
the fitting closest the pump. When oil begins to flow, should be retightened to their specified torque.
the line is full, the air has been purged, and the fitting
can be retightened to its specified torque. If the tank
4-10 – JLG Lift – 3121133

Once charge pressure has been established, increase Pump Disassembly

speed to normal operating RPM. Charge pressure should
be as indicated in the pump model code. If charge pres- 1. Clean outside of pump with a good grade solvent
sure is inadequate, shut down and determine the cause and dry thoroughly.
for improper pressure.
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,
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA- remove burrs from shaft end of keyway.
TOR' S ABILITY TO CONTROL THE MACHINE.
3. Using light clamping pressure on the ears of the
Shut down the engine and connect the external control front cover, secure unit in vise with shaft side down;
input signal. Also reconnect the machine function(s), if remove cap screws (14) and washers (9).
disconnected earlier. Start the engine, checking to be cer-
4. Separate rear cover (6) from the body (13). The
tain the pump remains in neutral. With the engine at nor-
static seal (8) may remain either with the body or the
mal operating RPM, slowly check for forward and reverse
cover. In either case, remove the static seal and dis-
machine operation.
card.
Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between for- 5. Lift out the rear bearing block (2), drive gear (12),
and driven gear (11).
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.
6. Separate body (13) from front cover (5). Dowel pins

(7) and the front static seal (8) may remain with
either the body (13) or the front cover (5). In either
case, remove the static seal and discard.
7. usually the front bearing block (2) will remain in the

body (13), so invert the body and lift out the bearing
block.
Before beginning disassembly, scribe "match marks" on
the body (13) and covers (5 and 6) to insure that the pump 8. Invert front cover (5) with shaft seal up. Remove the
will be reassembled in the same manner as it was shipped shaft seal (1) by prying it out with a large screw-
from the factory. If the body or rear cover is replaced dur- driver.
ing overhaul, scribe a match mark on the new part in the
same location as on the part it replaced.
3121133 – JLG Lift – 4-11

NOTE: During disassembly, take special note of the wear Pump Reassembly
patterns on the bearing blocks (2) and body (13).
Relate these patterns to the inlet and outlet sides of 1. Place the front cover (5) on a flat plate with the steal
the pump. The large port whether in the body (13) or shaft seal bore up. Install new shaft seal (1). Press
the rear cover (6) corresponds to the inlet side of the seal until it is 0.157 in (4.0mm) below front surface.
pump. The inlet side of the body can be identified by Pack the area between the double lip of the seal with
the gear contact pattern in the gear bore. The bear- Lubriplate or and equivalent grease.
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.
NOTE: A somewhat heavier wear pattern is normal on the

low pressure (inlet) side of the bearing blocks (2).
However, there should be no heavy scoring in this
area.
3. Remove anti extrusion 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.
4-12 – JLG Lift – 3121133

2. Clamp front cover into vise so that the ring groove is 8. Place a small amount of grease in seal groove on
up. Apply a small amount of grease tot he seal the rear bearing block (2). Install a new load seal
groove and install a new seal ring (8) into the and anti extrusion seal in groove. Insert the bearing
groove. block into the body, making sure that the load seal
and anti extrusion seal are positioned properly.
3. Apply lubriplate or equivalent to outer surface of Ensure outside of the "W" seal is exposed to the dis-
drive shaft installation tool. Insert tool (bullet) into charge pressure.
shaft seal from seal ring groove side of front cover.
9. Apply a small amount of grease tot he seal groove in
4. Place a small amount of grease on the seal groove the rear cover (6) and install a new seal ring (8) into
on the front bearing block (2). Install a new load seal the groove. Set the rear cover (6) onto the body (13),
and anti extrusion seal in the groove. Insert the bear- matching the scribes marks on the body and rear
cover.
ing block into the body, making sure that the load
seal (3) and anti extrusion seal (4) are positioned 10. Insert he cap screw (14) and washers (9); torque to
properly. ensure the outside of the "W" seal is 42-46 ft lb. (57-62 Nm).
exposed to the discharge pressure.
11. On models equipped with keyed drive shaft, install
5. Apply a small amount of grease tot he dowel pins (7) drive key (10).
and install them into the body (13). 12. With an adjustable wrench, Check that the drive
shaft turns without evidence of a mechanical bind.
6. Set the body (13) onto the front cover (5), matching
the scribes marks on the body and front cover. The
dowel pins (7) should go into the mating holes on
the front cover (5).
7. Install drive gear (12), and driven gear (11).
3121133 – JLG Lift – 4-13

4.9 MAIN VALVE
7
1
6
3 MG
4 MS
10
Mp1
11
Valve Ft-lb Mn
1. Dump Valve 30 - 35 42 - 49
2. Lift Valve 25 - 30 35 - 42
3. Two Speed Valve 30 - 35 42 - 49
4. Brake Valve 30 - 35 42 - 49
5. Steer Valve 25 - 30 35 - 42
6. Lift Relief 30 - 35 42 - 49
7. Main Relief 25 - 30 35 - 42
8. Steer Relief 30 - 35 42 - 49
9. MG Port N/A N/A
10. MS Port N/A N/A
11. MP1 Port N/A N/A
Figure 4-15. Main Valve Torque Values
4-14 – JLG Lift – 3121133

Figure 4-16. Main Valve Hydraulic Schematic
Pressure Setting Procedures 5. Bottom out Steer function. Adjust Main Relief to
3000 psi (207 bar).
Cold temperatures have a significant impact on pressure
readings. JLG Industries Inc. recommends operating the 6. Bottom out Steer Right and Steer Left functions and
machine until the hydraulic system has warmed to normal adjust each Steer Crossover Relief to 2800 psi (193
operating temperatures prior to checking pressures. JLG bar).
Industries Inc. also recommends the use of a calibrated 7. Bottom out Lift Up functions and adjust Lift Pressure
gauge. Pressure readings are acceptable if they are within to 2700 psi (186 bar).
± 5% of specified pressures.
8. De-energize Lift function, shut down motor, and dis-
1. Install pressure gauge at the MP1 port. connect pressure gauge.
2. Adjust both Steer Section Crossover Relief’s all the

way in.
3. Adjust Main Relief Cartridge out several turns.
4. Activate engine and allow hydraulic system to come
up to operating temperature.
3121133 – JLG Lift – 4-15

4.10 DRIVE HEADER VALVE (2WD)
A1 B1 LRA RRB
LRB RRA LRA RRB
CV
LRB RRA 1
CV
B1 A1
Figure 4-17. Drive Header Valve (2wd)
item # Torque
45 - 50 ft-lbs
1 (FSDH-XAN)
(61 - 68 Nm)
25 - 30 ft-lbs
2 (CXAD-XCN)
(34 -41 Nm)
4.11 DRIVE HEADER VALVE (4WD)
LRA RRA LFB
RFB LFA LFB RFA RRB LRA RRA LRB
RRB LRB RFA

B1 A1 RFB
B1 A1 B2 A2
B2 A2 LFA
Figure 4-18. Drive Header Valve (4wd)
4-16 – JLG Lift – 3121133

4.12 HEADER VALVES (4WD)
MCD MX3 X3 CD
MX MX3 MCD
CD CD
MX X
X3 X3
X3 CD CD X3
X X
X X3 CD
X X
Figure 4-19. Header Valve (Fix)
OT X3
CD CD
X3 OT
OT OT
OP
OP OP
MX3
B B
X OP
TS TS
MCD MX TS B OP OT CD
Figure 4-20. Header Valve (Osc)
3121133 – JLG Lift – 4-17

4.13 DIRECTIONAL VALVE
PB4
PB3
PB2
PB1
PA4
PA3
PA2
PA1
PA1 PA2
PB3
PB1
PA3 LP
PB2 T
PA4 PB4
LP T
Figure 4-21. Directional Valve
Pressure Setting Procedure

item Torque Cold temperatures have a significant impact on pressure
40 ft-lbs readings. JLG Industries Inc. recommends operating the
PA1 machine until the hydraulic system has warmed to normal
(54 Nm)
operating temperatures prior to checking pressures. JLG
23 ft-lbs
PB1 Industries Inc. also recommends the use of a calibrated
(31 Nm)
gauge. Pressure readings are acceptable if they are within
± 5% of specified pressures.
1. Activate engine and allow hydraulic system to come

up to operating temperature.
2. Install pressure gauge at quick connect on main
valve (M1).
3. Energize and bottom ut the leveling jack function.
Adjust relief to 2800 psi (193 bar).
4. De-energize jack function and shut down engine.
Remove pressure gauge.
4-18 – JLG Lift – 3121133

4.14 POWER DECK SANDWICH VALVE
P1 ET
2
ET
1
EP
P LP
Figure 4-22. Power Deck Sandwich Valve (Dual Deck Extension Only)
item # Torque
30 - 35 ft-lbs
1
(41 - 47 Nm)
25 - 30 ft-lbs
2
(34 - 41 Nm)
4.15 POWER DECK MANIFOLD VALVE
EPB
M Power Deck (Optional)
SET AT 1500 PSI
M EPR
EP
EPR ET
EPR ET
EPB EPB
EP
EPB
EPR
Figure 4-23. Power Deck Manifold Valve
Port(s) Torque NOTE: Power Deck Manifold Valve is located on the under-
EP, ET 24 ft-lbs (32.5 Nm) side of the platform. Dual extension decks are
EPR, EPB 32 ft-lbs (43.4 Nm) equipped with two Manifold Valves. Single extension
decks have only one Manifold Valve.
3121133 – JLG Lift – 4-19

4.16 HYDRAULIC PUMP
Figure 4-24. Pump Pressure Locations
Table 4-3. Pump Pressure
Item # Name Pressure
1 Charge Pump Relief 320 psi (22 bar)
2 Cross Relief Pressure 3000 psi (207 bar)
3 G Port 4800 psi (331 bar)
4 PS Port 4800 psi (331 bar)
5 Coil N/A
6 Cross Relief Pressure N/A
4-20 – JLG Lift – 3121133

Auxiliary Pump Motor
1
4
5
2
3
Hydraulic Schematic
1. UNF -2A Terminal - Torque: 84 in-lbs (9.5 Nm)

2. 2x Torque: 96 - 120 in-lbs (11 - 14 Nm)
3. Check Valve Cap Torque: 144 - 180 in-lbs (16 - 20 Nm)
4. 4x Torque: 180 - 216 in-lbs (20 - 24 Nm)
5. 8x Torque: 114 - 150 in-lbs (13 - 17 Nm)
Figure 4-25. Auxiliary Pump Motor
• Displacement: 0.097 CU. IN/REV (1.59 CC/REV) • Delivers 1.2 min. GPM (4.5 min Liters/Min) at 1500 psi
(103.4 bar) and 165 Amps maximum at 12VDC
3121133 – JLG Lift – 4-21

4.17 CYLINDER ASSEMBLIES
4
6
11 1. Barrel
3 2. Rod
7 3. Cap
8 4. Ring, Washer
9
5. Socket Head Bolt
6. Wiper
1 7. Ring, Back-Up
8. O-Ring
9 9. Ring, Wear
10. Ring, Wear
8
11. Seal
7
3 12. T-Seal
11
6
4
2
5
10
12
Figure 4-26. Steer Cylinder - Prior to S/N 137518
4-22 – JLG Lift – 3121133

8
9
3
7
6
5
4 1. Barrel Weldment
2. Rod Weldment
3. Cylinder Head
4. Wear Ring
1 5. O-ring
6. Back-up Ring
7. O-ring
8. Wiper
4 9. Seal
5 10. Wear Ring

6 11. T-Seal
7
3
9
2 8
10
11
Figure 4-27. Steer Cylinder - S/N 137518 to Present
3121133 – JLG Lift – 4-23

10
9 10
6 11
6
OR
7 OR
5
4
26 1
25 10
3 OR 5
5
26
2 5 OR
27 23 22
23
21
30
19
20 14
17
24
12
18
15
16
28 13
29
26
26
1. Cable Adapter 11. Flat Washer 21. Nut

2. Bolt 12. Wiper 22. Seal
3. Bracket 13. Seal 23. Ring, Back-Up
4. Manual Descent Cable 14. Ring, Wear 24. Spacer
5. Plug, O-Ring 15. Seal 25. Plug, O-Ring
6. Jam Nut 16. Ring, Back-Up 26. Bushing
7. Cotter Pin 17. Setscrew 27. Piston
8. Cartridge, Lift Holding Solenoid 18. Head 28. Seal
9. Cartridge, Lift Holding Solenoid 19. Seal 29. Rod
10. Cartridge, Check 20. Ring, Wear 30. Barrel
Figure 4-28. Lift Cylinder
4-24 – JLG Lift – 3121133

Item Ft-Lbs Nm
1 25 35
2 10 - 12 14 - 17
3 35 49
4 5 7
5 30 42
Figure 4-29. Lift Cylinder Valve Cartridge Torque Values
3121133 – JLG Lift – 4-25

18
17
18 3
1. Ring, Wear
16 17
4 2. T-Seal
5 3. Ring, Wear
4. O-Ring
15
5. Ring, Back-Up
8 1 6. Seal, WIper
7. Polyseal
9
8. Bushing
2
9. Head
11 8 7 10. Rod
6 11. Barrel
12 12. Plug, O-Ring
13 13. Ring, Washer

14. Capscrew
15
15. Bleeder
16. Plug, O-Ring
10
14
17. Solenoid
18. Relief Valve
19. Bearing
19
Figure 4-30. Oscillating Axle Cylinder
4-26 – JLG Lift – 3121133

Item # Ft-Lbs Nm
1 18.5 - 22 25 - 30
2 3 - 4.5 4.2 - 6.3
3 20 - 25 28 - 35
Figure 4-31. Oscillating Axle Valve Cartridge Torque Values
3121133 – JLG Lift – 4-27

5
15
5
1. Head
2. Barrel
2
3. Rod
4. Jack Plate
5. Ring, Lock
6. Ring, Wear
7. Ring, Washer
3 8. Ring, Retaining
9. O-Ring
10. Screw
11. Capscrew
12. Seal
9 6 13. WIper
8 14. Ring, Back-Up
1 15. T-Seal
4 16. Jack Pad
12
14 10 8
13
10
7
11
10 16
Figure 4-32. Leveling Jack Cylinder
4-28 – JLG Lift – 3121133

3 5
4
6
9 1
10
11
12
7
13
1. Locknut 6. Spacer Tube 11. Seal

2. Piston 7. Head 12. Wiper Ring
3. Seal 8. Rod 13. Retaining Ring
4. O-Ring 9. O-Ring
5. Barrel 10. Back-up Ring
Figure 4-33. Deck Extension Cylinder
3121133 – JLG Lift – 4-29

Oscillating Axle Bleeding Procedure
OSCILLATING AXLE
BLEEDER
OSCILLATING AXLE CYLINDER
Figure 4-34. Oscillating Axle Bleeding
1. Attach 1/4" hose to bleeder valve to capture oil. 4. Run pump for 10 seconds, close bleeder valves.
2. Oscillate axle fully in one direction. 5. Oscillate axle fully in the opposite direction and
repeat steps 3 and 4.
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.
4-30 – JLG Lift – 3121133

SECTION 5. JLG CONTROL SYSTEM

5.1 HAND HELD ANALYZER
menu:
Analyzer Display HELP:PRESS ENTER
Escape Key Enter Key

To return home or access Stores and selects Top Level, Sub
previous menu Level, and item menus
Left & Right Arrow Keys

Up & Down Arrow Keys
Used to move between Top Level,
Value Selector
Sub Level, and item menus
Figure 5-1. Hand Held Analyzer
To Connect the Hand Held Analyzer: PCB in the ground control station or at the platform
control station as shown in. Connect the remaining
1. Connect the four pin end of the cable supplied with end of the cable to the analyzer.
the analyzer, to the four position connector on the
Ground Control Platform Controll

Analyzer Connection Analyzer Connection
Figure 5-2. Analyzer Connection
3121133 – JLG Lift – 5-1

NOTE: The cable has a four pin connector at each end of If you press ENTER, at the HELP:PRESS ENTER display,
the cable; the cable cannot be connected back- and a fault is present during power up, the analyzer dis-
wards. play will scroll the fault across the screen. If there was no
fault detected during power up, the display will read:
2. Power up the Control System by turning the lower In platform mode, HELP: EVERYTHING OK,
key to the platform position and pulling both emer- In ground mode, GROUND MODE OK
gency stop buttons on.
If ENTER is pressed again, the display moves to the fol-
lowing display:
Using the Analyzer:
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
help:
1: startup (2/1)
MENU:
HELP:PRESS ENTER
LOGGED HELP
1: STARTUP (2/1): (Or last recorded fault)
At this point, the analyzer will display the current fault, if
HELP: any are present. You may scroll through the fault logs to
view what the last fifteen faults were. Use the right and left
PRESS ENTER arrow keys to scroll through the fault logs. To return to the
At this point, using the RIGHT and LEFT arrow keys, you beginning, press ESC two times.
can move between the top level menu items. To select a When a top level menu is selected, a new set of menu
displayed menu item, press ENTER. To cancel a selected items may be offered; If for example you choose Personal-
menu item, press ESC; then you will be able to scroll ities:
using the right and left arrow keys to select a different
menu item. DRIVE
LIFT
The top level menus are as follows:
STEER
HELP GROUND
DIAGNOSTICS Pressing ENTER with any of the above displayed menus,
ACCESS LEVEL will display additional sub-menus within the selected
menu. In some cases the next level is the parameter or
PERSONALITIES information to be changed. Refer to the flow chart for what
MACHINE SETUP menus are available within the top level menus. You may
only view the personality settings for selected menus
ACTIVATE TESTS
while in access level 2. Remember, you may always can-
CALIBRATION cel a selected menu item by pressing the ESC key.
5-2 – JLG Lift– 3121133

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- MENU:
word to advance to a lower level. This ensures that a set- ACCESS LEVEL 1
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:
MENU:
ACCESS LEVEL 2
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings:
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of

the password, 3.
Then using the RIGHT arrow key, position the cursor to

the right one space to enter the second digit of the pass-
word.
Use the UP or DOWN arrow key to enter the second digit

of the password which is 3.
Repeat this process until you have entered all five digits of
the password which is 33271.
Once the correct password is displayed, press ENTER.

The access level should display the following, if the pass-
word was entered correctly:
3121133 – JLG Lift – 5-3

Adjusting Parameters Using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-
LAR MACHINE CAN RESULT IN IMPROPER OPERATION.
PERSONALITIES:
DRIVE ACCEL 3.0s
GROUND ALARM:
1=DESCENT
PERSONALITIES:
DRIVE ACCEL 3.0s
GROUND ALARM:
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if 1=DESCENT
the UP arrow is pressed when at the maximum value nor The effect of the machine digit value is displayed along
will the value decrease if the DOWN arrow is pressed and with its value. The above display would be selected if the
the value is at the minimum value for any particular per- machine was equipped with a ground alarm and you
sonality. If the value does not change when pressing the wanted it to sound when driving. There are certain set-
up and down arrows, check the access level to ensure tings allowed to install optional features or select the
you are at access level 1. machine model.
When selecting the machine model to match the size of
the machine, the personality settings will return to default
settings.
5-4 – JLG Lift– 3121133

NOTE: Refer to the appropriate Machine Personality Set-

tings Table, and the Machine Setup Table in the JLG NOTICE
Service Manual for the default settings. IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
Password 33271 will give you access to level 1, WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
which will permit you to change all machine person- CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
ality and/or machine setup settings. OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE
COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
PERFORMANCE OF YOUR MACHINE.
The flash code is indicated on the face of the platform

control box as shown:
SYSTEM
FAULT
1705189A
NOTE: Flash codes are also displayed on the handheld ana-

lyzer. For descriptions see Table 5-1, Fault Code
Listing.
3121133 – JLG Lift – 5-5

5.2 FLASH CODES AND DESCRIPTIONS

Table 5-1. Fault Code Listing - Software P1.X
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.
FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Reported when the trigger is not closed with function selected
and joystick out of center.
RUNNING AT CUTBACK – ABOVE ELEVATION Reported any time the machine is considered to be above ele-
vation.
ACCESSORY FAULT Reports when CAN faults are reported by an accessory mod-
ule.
FRONT LEFT LEVELING JACK AT END OF STROKE Reported when the front left leveling jack is reported to be at the
end of stroke pressure.
FRONT RIGHT LEVELING JACK AT END OF STROKE Reported when the front right leveling jack is reported to be at
the end of stroke pressure. 1
REAR LEFT LEVELING JACK AT END OF STROKE Reported when the rear left leveling jack is reported to be at the
end of stroke pressure.
REAR RIGHT LEVELING JACK AT END OF STROKE Reported when the rear right leveling jack is reported to be at
the end of stroke pressure.
LEVELING JACK SET PREVENTED - ECM LOST Reported when autoleveling is not available when communica-
tion with the ECM times-out.
GENERATOR PREVENTED - ECM LOST Reported when generator is not available when communica-
tion with the ECM times-out.
DRIVE PREVENTED - ECM LOST Reported when elevated drive is not available when communi-
cation with the ECM times-out.
ELEVATION SENSOR DISAGREEMENT Reported when elevation prox switch is closed when the 26 ft
(3394RT) or 30 ft (4394RT) voltage is reached on the elevation
angle sensor. (prevents further lift up from platform controls)
2/1 Flash code 2/1 indicates issues at power up.
KEYSWITCH FAULTY – PLATFORM & GROUND ACTIVE Reported when the ground module is reading both ground and 2
TOGETHER platform modes are selected by the keyswitch. The control
system defaults control to ground mode.
5-6 – JLG Lift– 3121133

Fault Flash
Code
2/2 Flash code 2/2 indicates difficultly with the platform controls.
TRIGGER SWITCH WIRING SHORTED HIGH IN PLAT- Reports when the CAN message coming from the platform
FORM CABLE board and the DI on ground board conflict.
TRIGGER SWITCH WIRING SHORTED LOW IN PLAT- Reports when the CAN message coming from the platform
FORM CABLE board and the DI on ground board conflict.
FUNCTION LOCKED OUT – DRIVE SELECT PERMA- Reported when drive select is closed during power up.
NENTLY CLOSED
FUNCTION LOCKED OUT – LIFT SELECT PERMA- Reported when lift select is closed during power up.
NENTLY CLOSED
FUNCTION LOCKED OUT – FRONT DECK SELECT PER- Reported when front deck select is closed during power up.
MANENTLY CLOSED
FUNCTION LOCKED OUT – REAR DECK SELECT PER- Reported when rear deck select is closed during power up.
MANENTLY CLOSED
FUNCTION LOCKED OUT – START PERMANENTLY Reported when the start switch is closed during power up.
CLOSED
FUNCTION LOCKED OUT – STEER LEFT PERMA- Reported when the left steer switch is closed during power up.
NENTLY CLOSED
FUNCTION LOCKED OUT – STEER RIGHT PERMA- Reported when the right steer switch is closed during power
NENTLY CLOSED up. 3
FUNCTION LOCKED OUT – AUX POWER SWITCH PER- Reported when the auxiliary switch is closed during power up.
MANENTLY CLOSED
FUNCTION LOCKED OUT – GENERATOR SWITCH PER- Reported when the generator switch is closed during power up.
MANENTLY CLOSED
FUNCTION LOCKED OUT – AUTOLEVEL SWITCH PER- Reported when the leveling jack select switch is closed during
MANENTLY CLOSED power up.
TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Reported when trigger is closed for ten seconds and no func-
tion selected.
FUNCTION LOCKED OUT – JOYSTICK NOT CENTERED Reported when joystick is not centered while selecting a func-
tion.
FUNCTION LOCKED OUT – TRIGGER SWITCH PERMA- Reported when the trigger switch is closed during power up.
NENTLY CLOSED
JOYSTICK FAULTY – STEER SWITCHES ACTIVE Reported when both the left and right steer switches are closed
TOGETHER at the same time.
FUNCTION LOCKED OUT – HORN SWITCH PERMA- Reported when the horn switch is closed during power up.
NENTLY CLOSED
JOYSTICK CALIBRATION FAULTY Reported when joystick calibration is improper. (Platform P1.6
or later only)
3121133 – JLG Lift – 5-7

Fault Flash
Code
2/3 Flash code 2/3 indicates difficultly with ground controls.
FUNCTION LOCKED OUT – GROUND LIFT UP PERMA- Reported when the ground lift up switch is closed during power
NENTLY CLOSED up.
FUNCTION LOCKED OUT – GROUND LIFT DOWN PER- Reported when the ground lift down switch is closed during
MANENTLY CLOSED power up.
FUNCTION LOCKED OUT – GROUND FRONT DECK EXT Reported when the ground front deck extend switch is closed
PERMANENTLY CLOSED during power up.
FUNCTION LOCKED OUT – GROUND FRONT DECK RET Reported when the ground front deck retract switch is closed
PREMANENTLY CLOSED during power up.
FUNCTION LOCKED OUT – GROUND REAR DECK EXT Reported when the ground rear deck extend switch is closed
FUNCTION LOCKED OUT – GROUND REAR DECK RET Reported when the ground rear deck retract switch is closed
GROUND LIFT UP/DOWN ACTIVE TOGETHER Reported when the ground lift up and lift down switches are
closed at the same time. 4
GROUND FRONT DECK EXTEND/RETRACT ACTIVE Reported when the ground front deck extend and retract
TOGETHER switches are closed at the same time.
GROUND REAR DECK EXTEND/RETRACT ACTIVE Reported when the ground rear deck extend and retract
TOGETHER switches are closed at the same time.
NO SIGNAL FROM TILT SENSOR X AXIS – CHECK WIR- Reported when sensor X-axis value is not valid.
ING
NO SIGNAL FROM TILT SENSOR Y AXIS – CHECK WIR- Reported when sensor Y-axis value is not valid.
ING
LEVEL SENSOR FAILURE Reported when the tilt sensor frequency is outside the range of
acceptable value.
FUNCTION LOCKED OUT – GROUND AUX SWITCH PER- Reported when the ground auxiliary power switch is closed
MANENTLY CLOSED during power up.
FUNCTION LOCKED OUT – GROUND START SWITCH Reported when the ground start switch is closed during power
PERMANENTLY CLOSED up.
5-8 – JLG Lift– 3121133

Fault Flash
Code
2/5 Flash code 2/5 indicates issues that may cutout functions.
ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR Reported when the elevation rotary sensor voltage is outside
VOLTAGE OUT OF RANGE the range of acceptable values.
ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when the rotary calibration value does not exist.
ELEVATION PROX SWITCH PERMANENTLY CLOSED Reported when the elevation rotary sensor is reporting above
elevation and the elevation proximity switch is still closed.
ELEVATION PROX SWITCH PERMANENTLY OPEN Reported when the elevation rotary sensor is reporting stowed
and the elevation proximity switch is open.
FRONT LEFT LEVELING JACK PRESSURE TRANS- Reported when the front left leveling jack pressure reading is
DUCER FAILURE well below 0PSI.
FRONT RIGHT LEVELING JACK PRESSURE TRANS- Reported when the front right leveling jack pressure reading is
REAR LEFT LEVELING JACK PRESSURE TRANS- Reported when the rear left leveling jack pressure reading is
REAR RIGHT LEVELING JACK PRESSURE TRANS- Reported when the rear right leveling jack pressure reading is
PLATFORM OVERLOAD Reported when the overload is setup and the LSS is reading the
platform is overloaded.
FRONT LEFT LEVELING JACK STOW SWITCH PERMA- Reported when the FRONT LEFT Leveling Jack Stow Switch is 5
NENTLY CLOSED closed and the FRONT LEFT pressure transducer reads "Set"
pressure.
FRONT RIGHT LEVELING JACK STOW SWITCH PER- Reported when the FRONT RIGHT Leveling Jack Stow Switch
MANENTLY CLOSED is closed and FRONT RIGHT pressure transducer reads "Set"
pressure.
REAR LEFT LEVELING JACK STOW SWITCH PERMA- Reported when the REAR LEFT Leveling Jack Stow Switch is
NENTLY CLOSED closed and the REAR LEFT pressure transducer reads "Set"
pressure.
REAR RIGHT LEVELING JACK STOW SWITCH PERMA- Reported when the REAR RIGHT Leveling Jack Stow Switch is
NENTLY CLOSED closed and the REAR RIGHT pressure transducer reads "Set"
pressure.
ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when elevation height calibration has not been per-
formed or is not logical (increasing voltages from stowed).
Vehicle assumed to be at full height.
ELEV ANGLE SENSOR FAULTY - NOT MOUNTED OR Reported when elevation angle sensor is outside the 0.30V to
VOLTAGE OUT OF RANGE 4.85V range. Vehicle assumed to be at full height.
ELEV ANGLE SENSOR NOT DETECTING CHANGE Reported when elevation angle sensor voltage does not
change for 5 sec during lift up >20%. Vehicle assumed to be at
full height. Fault cleared only in valid stowed position.
3121133 – JLG Lift – 5-9

Fault Flash
Code
2/6 Flash code 2/6 indicates leveling jack or power deck issues.
FRONT LEFT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the
front left leveling jack is open circuit.
FRONT LEFT LEVELING JACK SHORT TO GROUND Reported by the I/O module and during system test when the
front left leveling jack is short to ground.
FRONT LEFT LEVELING JACK SHORT TO BATTERY Reported by the I/O module and during system test when the
front left leveling jack is short to battery.
FRONT RIGHT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the
front right leveling jack is open circuit.
FRONT RIGHT LEVELING JACK SHORT TO GROUND Reported by the I/O module and during system test when the
front right leveling jack is short to ground.
FRONT RIGHT LEVELING JACK SHORT TO BATTERY Reported by the I/O module and during system test when the
front right leveling jack is short to battery.
REAR LEFT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the 6
rear left leveling jack is open circuit.
REAR LEFT LEVELING JACK SHORT TO GROUND Reported by the I/O module and during system test when the
rear left leveling jack is short to ground.
REAR LEFT LEVELING JACK SHORT TO BATTERY Reported by the I/O module and during system test when the
rear left leveling jack is short to battery.
REAR RIGHT LEVELING JACK OPEN CIRCUIT Reported by the I/O module and during system test when the
rear right leveling jack is open circuit.
REAR RIGHT LEVELING JACK SHORT TO GROUND Reported by the I/O module and during system test when the
rear right leveling jack is short to ground.
REAR RIGHT LEVELING JACK SHORT TO BATTERY Reported by the I/O module and during system test when the
rear right leveling jack is short to battery.
LEVELING JACK EXTEND VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
leveling jack extend valve is open circuit.
5-10 – JLG Lift– 3121133

Fault Flash
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.
LEVELING JACK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
leveling jack extend valve is short to battery.
LEVELING JACK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
leveling jack retract valve is open circuit.
LEVELING JACK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
leveling jack retract valve is short to ground.
LEVELING JACK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
leveling jack retract valve is short to battery.
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.
FRONT DECK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
front deck extend valve is short to ground.
FRONT DECK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
front deck extend valve is short to battery.
FRONT DECK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
6
front deck retract valve is open circuit.
FRONT DECK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
front deck retract valve is short to ground.
FRONT DECK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
front deck retract valve is short to battery.
REAR DECK EXTEND VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
rear deck extend valve is open circuit.
REAR DECK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
rear deck extend valve is short to ground.
REAR DECK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
rear deck extend valve is short to battery.
REAR DECK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
rear deck retract valve is open circuit.
REAR DECK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
rear deck retract valve is short to ground.
REAR DECK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
rear deck retract valve is short to battery.
3121133 – JLG Lift – 5-11

Fault Flash
Code
4/3 Flash code 4/3 indicates engine issues.
FUEL SENSOR SHORT TO BATTERY Reported when the fuel sensor is reading a value that is much
too high.
FUEL SENSOR SHORT TO GROUND Reported when the fuel sensor is reading ground.
FUEL SENSOR DISCONNECTED Reported when the fuel sensor is reading a value that is too
high.
OIL PRESSURE SHORT TO BATTERY Reported when the oil pressure sensor is reading a value that is
too high.
OIL PRESSURE SHORT TO GROUND Reported when the oil pressure sensor is reading a value that is
too low.
COOLANT TEMPERATURE SHORT TO GROUND Reported when the coolant temperature sensor is reading a
value that is too low.
FORD FAULT CODE Reported by the Ford engine. 7
ENGINE TEMPERATURE HIGH This fault is not reported at this time.
AIR FILTER BYPASSED This fault is not reported at this time.
NO ALTERNATOR OUTPUT Reported when the engine is running for at least a few seconds
and the alternator input is on the ground board is high.
OIL PRESSURE LOW Reported when the oil pressure is below eight PSI and the
engine is running for at least a few seconds.
485 COMMUNICATIONS LOST Reported when a Ford engine is selected and communications
with the Ford engine controller are lost.
ENGINE SHUTDOWN COMMANDED – CHECK ENGINE Reported when the engine is commanded to shutdown by the
SENSORS control system.
WRONG ENGINE SELECTED Reported when CAN ECM is detected and not configured.
DEUTZ ECM FAULT CODE Reported when the Deutz Engine Controller is giving a fault.
4/4 Flash code 4/4 indicates a battery supply issue.
BATTERY LOW Reported when the voltage on the system is below 11 volts.
BATTERY TOO HIGH – SYSTEM SHUTDOWN Reported when the voltage on the system is above 16 volts.
8
BATTERY TOO LOW – SYSTEM SHUTDOWN Reported when the voltage on the system is below 9 volts.
LSS BATTERY VOLTAGE HIGH Reported when the voltage on the LSS is above 34 volts.
LSS BATTERY VOLTAGE LOW Reported when the voltage on the LSS is below 9 volts.
5/5 Flash code 5/5 indicates a speed sensor issue.
SPEED SENSOR READING INVALID SPEED Reported when the speed sensor is reading a value over 4000
RPM. 9
SPEED INPUT LOST Reported when the speed sensor is reading zero RPM and the
oil pressure is over eight PSI.
6/6 Flash code 6/6 indicates CANbus issues. 10
CAN BUS FAILURE Reported when there is a problem with the CANbus.
LSS NOT SENDING CAN MESSAGES Reported when the LSS is configured and not seen on the CAN-
bus.
ENGINE CONTROLLER CAN COMMUNICATION LOST Reported when the engine is configured to be CAN controlled
and the system is not communicating with it.
TWO PLATFORM MODULES DETECTED Reported when there are two platform modules connected to
the control system.
5-12 – JLG Lift– 3121133

Fault Flash
Code
8/* Flash codes 8/* indicate load cells issues.
8/1 LSS CELL #1 ERROR Reported when there is a problem with cell #1 on the LSS.
8/2 LSS CELL #2 ERROR Reported when there is a problem with cell #2 on the LSS. 11
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 in
the LSS.
9/3 LSS HAS NOT BEEN CALIBRATED Reported when the LSS is configured but not calibrated.
9/9 LSS NEEDS TO BE RE-CALIBRATED Reported when the LSS is configured and reporting a value that
is less than half of the offset value; this will be reported as a 12
negative value.
LSS INTERNAL ERROR – PIN EXCITATION Reported when a pin in the LSS is reporting a voltage below
4.25 volts.
LSS INTERNAL ERROR – DRIVER FAULT Reported when the LSS detects this internal error.
LSS INTERNAL ERROR – DRDY MISSING FROM A/D Reported when the LSS detects this internal error.
EEPROM FAILURE – CHECK ALL SETTINGS Reported when the memory in the ground or platform module
has become corrupt.
4150588 D
3121133 – JLG Lift – 5-13

5-14
ACCESS LEVEL:
CODE 33271
MENU: ACCESS LEVEL:

ACCESS LEVEL 1 CODE 00000
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PERSONALITIES DRIVE LIFT STEER POWER DECK GROUND MODE LOAD JOYSTICK
DRIVE: LIFT: STEER: DECK EXTEND: GROUND MODE: LOAD: JOYSTICK:

ACCEL X.X S ACCEL X.X S ENGINE XXXX RPM ENGINE XXXX RPM LIFT UP X% OVERLD XXXX KG FWD MAX X.XX V
DRIVE: LIFT: DECK RETRACT: GROUND MODE: LOAD: JOYSTICK:

DECEL X.X S DECEL X.X S ENGINE XXXX RPM LIFT DN X% ACC’Y XX KG FWD MIN X.XX V
DRIVE: LIFT: LOAD: JOYSTICK:

MIN FORWARD X% MIN UP X% OVR DBNCE X.XS REV MIN X.XX V
DRIVE: LIFT: LOAD: JOYSTICK:

MAX FORWARD X% MAX UP X% OVR HOLD X.XS REV MAX X.XX V
DRIVE: LIFT:
CONT’D ON SHEET 2 MIN REVERSE X% MIN DOWN X%
– JLG Lift–
DRIVE: LIFT:
MAX REVERSE X% MAX DOWN X%
DRIVE: LIFT:
ELEV FWD MAX XX% ENGINE XXXXRPM
DRIVE: LIFT:
ELEV REV MAX XX% MID ENG XXXXRPM
DRIVE:
ENGINE XXXXRPM
DRIVE:
MID ENG XXXXRPM
Figure 5-3. Analyzer Flow Chart - SW P1.X - Sheet 1 of 3
3121133
3121133
FROM SHEET 1
MENU: MODEL NUMBER: ENGINE: MARKET: TILT CUTOUT: GLOW PLUG: LEVELING JACKS: POWER DECK:
MACHINE SETUP 0=33RT 2WD 0=FORD EFI D/F 0=ANSI USA 0=NO 0=NO GLOW PLUGS 0=NO 0=NONE
MODEL NUMBER: ENGINE: MARKET: TILT CUTOUT: GLOW PLUG: LEVELING JACKS: POWER DECK:
1=33RT 4WD 1=DEUTZ F3 1=ANSI EXPORT 1=YES 1=5 SEC GLOW 1=YES 1=FRONT
MODEL NUMBER: ENGINE: MARKET: GLOW PLUG: POWER DECK:

2=43RT 2WD 2=FORD D/F(T2) 2=CSA 2=10 SEC GLOW 2=DUAL
MODEL NUMBER: ENGINE: MARKET: GLOW PLUG:

3=43RT 4WD 3=DEUTZ F3(T2) 3=CE 3=20 SEC GLOW
ENGINE: MARKET: GLOW PLUG:

4=DEUTZ ECM 4=AUSTRALIA 4=30 SEC GLOW
ENGINE: GLOW PLUG:

5=DUAL FUEL ECM 5=40 SEC GLOW
GLOW PLUG:
6=50 SEC GLOW
GLOW PLUG:
– JLG Lift –
7=60 SEC GLOW
ENGINE SHUTDOWN: GROUND ALARM: LOAD: FUNCTION CUTOUT GENERATOR:

0=NO 0=NO 0=NONE 0=NOT INSTALLED 0=NOT INSTALLED
ENGINE SHUTDOWN: GROUND ALARM: LOAD: FUNCTION CUTOUT GENERATOR:

1=SHUTDOWN 1=DESCENT 1=CUTOUT PLT 1=DRV & LIFT UP 1=60 HZ
GROUND ALARM: LOAD: FUNCTION CUTOUT GENERATOR:

2=MOTION 2=CUTOUT ALL 2=ALL FUNCTIONS 2=50 HZ
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

CALIBRATIONS TILT SENSOR SET STOW ELEV SET XXFT ELEV SET XXFT ELEV LOAD JOYSTICK
LEVEL VEHICLE: SET STOW ELEV: SET XXFT ELEV: SET XXFT ELEV: LOAD: JOYSTICK:
YES: ENTER NO: ESC YES: ENTER NO: ESC YES: ENTER NO: ESC YES: ENTER NO: ESC YES: ENTER NO:ESC YES: ENTER NO:ESC
TO SHEET 3
5-15
5-16
FROM SHEET 2
MENU: ACTIVATE TEST:

SYSTEM TEST YES: ENTER NO: ESC
MENU: HELP:
HELP:PRESS ENTER GROUND MODE OK
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS PLATFORM GROUND SYSTEM VALVES ELEV SENSOR LOAD ENGINE DATALOG VERSIONS
PLATFORM: GROUND: SYSTEM: VALVES: ELEV SENSOR: LOAD: ENGINE: DATALOG: VERSIONS:
DRIVE SEL XXXX LIFT UP XXXX GM BATTERY XX.XV FORWARD X% READING X.XXV PLTLOAD XXXX KG START XXXX ENGINE XH XM GROUND PX.XX
LIFT SEL XXXX LIFT DN XXXX PM BATTERY XX.XV REVERSE X% STOWED CAL X.XXV PLTGROS XXXX KG BATTERY XX.XV DRIVE XH XM GND HW REV X
HORN XXXX F DECK EXT XXXX AUX POWER XXXX STEER LEFT XXX XXFT CAL X.XXV OVERLOADED? XXX COOLANT XXC LIFT XH XM PLATFORM PX.X
START XXXX F DECK RET XXXX HORN XXXX STEER RIGHT XXX XXFT CAL X.XXV CELL 1 XXXX KG OIL PRS X PSI RENTAL XH XM I/O MOD PX.X
DRIVE SPD XXXX R DECK EXT XXXX TILT XX.X XX.X DUMP XXX ELEV PROX XXX CELL 2 XXXX KG FUEL SELECT GAS ERASE RENTAL? LSS MOD PX.X
PLATFORM: GROUND: SYSTEM: VALVES: ELEV SENSOR: LOAD: ENGINE: VERSIONS:

HI ENGINE XXXX R DECK RET XXXX FNT LFT XXX PSI BRAKE XXX (STATUS) CELL 3 XXXX KG FUEL LEVEL OK ANALYZER V6.3
PLATFORM: GROUND: SYSTEM: VALVES: LOAD: ENGINE:

AUTO LEV XXXX AUX POWER XXXX FNT RHT XXX PSI 2 SPD XXX CELL 4 XXXX KG GLOW PLUG XXX
PLATFORM: SYSTEM: VALVES: ENGINE:

GENERATOR XXXX REAR LT XXX PSI LIFT UP XXX LP ASSIST XXX
– JLG Lift–
STR LEFT XXXX REAR RT XXX PSI LIFT DN XXX ACTUAL XXXX RPM

STR RIGHT XXXX FNT LFT SW XXXX PROP LIFT X% TARGET XXXX RPM
DIAGNOSTICS: SYSTEM: VALVES:

TRIGGER XXXX FNT RHT SW XXXX LOSC AXLE XXX NOTE: SOME SCREENS MAY NOT
BE AVAILABLE DEPENDING
PLATFORM: SYSTEM: VALVES: VALVES:
JOYSTICK XXXX R LFT SW XXXX ROSC AXLE XXX Rr DECK RET XXX
UPON MACHINE CONFIGURATION
AND SOFTWARE VERSION.
PLATFORM: SYSTEM: VALVES: VALVES:
F DECK SEL XXXX R RHT SW XXXX FL L/J VLVE XXX Rr DECK EXT XXX
PLATFORM: SYSTEM: VALVES: VALVES: = Top Level Menu

F DECK SEL XXXX ELEV STAT XXX FR L/J VLVE XXX Ft DECK RET XXX
SYSTEM: VALVES: VALVES: = Sub Level Menu

FTN C/O XXX RL L/J VLVE XXX Ft DECK EXT XXX
SYSTEM: VALVES: VALVES: =Item To Be Viewed

CANBUS TERM XXX RR L/J VLVE XXX OPTION VLVE XXX
or Changed
SYSTEM: VALVES: VALVES:
JOYSTICK X.XX V L/J EXT XXX L/J RET XXX
3121133
Table 5-2. Machine Model Adjustment
Model Default Values

Adjustment Adjustment Range
3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD
DRIVE
Accel 0.1 - 5.0 (sec) 3 3 3 3
Decel 0.1 - 3.0 (sec) 1.2 1.2 1.2 1.2
Min Forward 0 - 35% 24 24 24 24
Max Forward 0 -100% 56 56 56 56
Min Reverse 0 - 35% 24 24 24 24
Max Reverse 0 -100% 55 55 55 55
Elev Fwd Max 20 - 50% 41 41 41 41
Elev Rev Max 21 - 50% 41 41 41 41
Engine 800 - 2900RPM 2800 2800 2800 2800
Mid Engine 800 - 2700RPM 2000 2000 2000 2000
LIFT
Accel 0.1 - 5.0 (sec) 2 2 2 2
Decel 0.8 - 1.5 (sec) 1 1 1 1
Min Up 0 - 35% 12 12 12 12
Max Up 0 - 65% 55 55 45 45
Min Down 0 - 35% 12 12 12 12
Max Down 0 - 65% 55 55 40 40
Engine 800 - 2900RPM 2800 2800 2800 2800
Mid Engine 800 - 2700RPM 2000 2000 2000 2000
STEER
Engine 800 - 2900RPM 2800 2800 2800 2800
POWER DECK
Deck Extend 800 - 2900RPM 1200 1200 1200 1200
Deck Retract 800 - 2900RPM 1200 1200 1200 1200
GROUND
Lift Up 0 - 65% 55 55 45 45
Lift Down 0 - 65% 55 55 40 40
LOAD
Overload 1000 - 2700 lbs 2475 2475 1650 1650
(454 - 1225 kg) (1123 kg) (1123 kg) (748 kg) (748 kg)
Acc’y 0 - 500 lbs 0 0 0 0
(0 - 227 kg)
Overload Dbnce 0 - 10 (sec) 3 3 3 3
Overload Hold 1 - 10 (sec) 5 5 5 5
JOYSTICK
Forward Max 0.00 - 5.00V 0.75 0.75 0.75 0.75
Forward Min 0.00 - 5.00V 2.24 2.24 2.24 2.24
Reverse Min 0.00 - 5.00V 2.82 2.82 2.82 2.82
Reverse Max 0.00 - 5.00V 4.32 4.32 4.32 4.32
4150389 D
NOTE: These settings may be changed in order to achieve optimal performance.
3121133 – JLG Lift – 5-17

NOTE: When configuring an RT, the Machine Configuration must be completed before any Personality settings can be
changed. Changing the Personality settings first and then changing the Model of the Machine Configuration will cause
the Personality settings to return to default values.
Table 5-3. Machine Configuration Programming Information
Configuration Digit Setting Description Default Number

0 33RT 2WD
1 1 33RT 4WD
1
(MODEL) 2 43RT 2WD
3 43RT 4WD
0 FORD EFI D/F
1 DEUTZ F3
2 2 FORD D/F (T2)
4
(ENGINE) 3 DEUTZ F3 (T2)
4 DEUTZ ECM
5 DUAL FUEL ECM - GM/PSI Engine
0 ANSI USA
1 ANSI EXPORT
3
2 CSA 0
(MARKET)
3 CE
4 AUSTRALIA
0 NO - Tilt Cutout is not active
4
1 Yes - Tilt Cutout is active 1
(TILT CUTOUT)
(Screen only visible to CE Market)
0 NO GLOW PLUGS
1 5 SEC GLOW
2 10 SEC GLOW
5 3 20 SEC GLOW
5
(GLOW PLUGS) 4 30 SEC GLOW
5 40 SEC GLOW
6 50 SEC GLOW
7 60 SEC GLOW
0 No - Leveling Jacks not installed on vehicle.
6
0
(LEVELING JACKS)
1 YES – Leveling Jacks are installed on vehicle.
0 NONE – Power Deck Extensions not installed on vehicle.
7
1 FRONT – Power Deck Extension is installed on the Front of the vehicle. 0
(POWER DECK)
2 DUAL – Power Deck Extensions are installed on the Front and Rear of the vehicle.
0 NOT INSTALLED – Generator is not installed on the vehicle.
8
1 60HZ – Generator is installed and engine speed set for 2000RPM when enabled. 0
(GENERATOR)
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 & LIFT UP – Vehicle is equipped with a Function Cutout device. Drive and Lift Up will
9
be prevented when active. 0
(FUNCTION CUTOUT)
2 ALL FUNCTIONS – Vehicle is equipped with a Function Cutout device. All Functions will
be prevented when active.
5-18 – JLG Lift– 3121133

Table 5-3. Machine Configuration Programming Information
Configuration Digit Setting Description Default Number

0 NOT INSTALLED – Load Sensing System (LSS) is not fitted to the vehicle.
1 CUTOUT PLT – Load Sensing System (LSS) is fitted, and Platform Controls are pre-
vented in the event of an Overload. Ground Controls remain functional. This is the default
10 setting for CE machines. 0
(LOAD)
2 CUTOUT ALL – Load Sensing System (LSS) is fitted. Platform and Ground Controls are
prevented in the event of an Overload.
NOTE: Certain market selections will alter default setting.

0 NOT INSTALLED – Vehicle alarm will function for Overload (if LOAD enabled).
1 DESCENT – Vehicle alarm will function for Overload (if LOAD enabled) and during Lift
11 Down motion.
2
(GROUND ALARM)
2 MOTION – Vehicle alarm will function for Overload (if LOAD enabled), during Drive
motion, and during Lift motion.
NOTE: Certain market selections will alter default setting.

0 NO - The engine will not be automatically shutdown.
12
1 SHUTDOWN - The engine will automatically shutdown in the event of high engine coolant 1
(ENGINE SHUTDOWN)
temperature, low oil pressure, or a temperature sensor or oil pressure sensor fault.
4150390 J
Table 5-4. Machine Tilt Configuration
Model Market LImits

Lift Up and Drive prevented when Elevated and Tilted beyond the following limits:
ANSI USA Front to Back: ±5° to Full Height
Side to Side: ±5° to 26 Feet; ±4° to 30 Feet; ±3° to Full Height
ANSI EXPORT Same as ANSI USA
33RT 2WD,
CSA Front to Back: ±3° to Full Height
33RT 4WD
Side to Side: ±3° to Full Height
Tilt Lamp energized when Tilted beyond the following limits:
CE Front to Back: ±5° to Full Height
AUSTRALIA Same as ANSI USA
ANSI USA Front to 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
33RT 2WD
CSA Front to Back: ±3° to Full Height
33RT 4WD
Tilt Lamp energized when Tilted beyond the following limits:
CE Front to Back: ±5° to Full Height
AUSTRALIA Same as ANSI USA
4150390 J
NOTE: Vehicle Tilt Configuration based on Model and Market Settings
3121133 – JLG Lift – 5-19

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.
3394RT 2WD
LEVELING JACKS
MODEL NUMBER
POWER DECK
TILT CUTOUT
GLOW PLUG
MARKET
ENGINE
ANSI USA 0 4 0 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
ANSI EXPORT 0 4 1 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CSA 0 4 2 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CE 0 4 3 0 1 0 1 2 3 4 5 6 7 0 1 0 1 2
AUSTRALIA 0 4 4 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
3394RT 2WD
ENGINE SHUTDOWN
FUNCTION CUTOUT
GROUND ALARM
GENERATOR
LOAD
ANSI USA 0 1 2 0 1 2 0 X X 0 1 2 0 1
ANSI EXPORT 0 1 2 0 1 2 0 1 2 0 1 2 0 1
CSA 0 1 2 0 1 2 0 X X 0 1 2 0 1
CE 0 1 2 0 1 2 0 1 2 0 1 2 0 1
AUSTRALIA 0 1 2 0 1 2 0 X 2 X X 2 0 1
4150390 J
5-20 – JLG Lift– 3121133

NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
3394RT 4WD
LEVELING JACKS
MODEL NUMBER
POWER DECK
TILT CUTOUT
GLOW PLUG
MARKET
ENGINE
ANSI USA 1 4 0 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
ANSI EXPORT 1 4 1 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CSA 1 4 2 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CE 1 4 3 0 1 0 1 2 3 4 5 6 7 0 1 0 1 2
AUSTRALIA 1 4 4 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
3394RT 4WD
ENGINE SHUTDOWN
FUNCTION CUTOUT
GROUND ALARM
GENERATOR
LOAD
ANSI USA 0 1 2 0 1 2 0 X X 0 1 2 0 1
ANSI EXPORT 0 1 2 0 1 2 0 1 2 0 1 2 0 1
CSA 0 1 2 0 1 2 0 X X 0 1 2 0 1
CE 0 1 2 0 1 2 0 1 2 0 1 2 0 1
AUSTRALIA 0 1 2 0 1 2 0 X 2 X X 2 0 1
4150390 J
3121133 – JLG Lift – 5-21

4394RT 2WD
LEVELING JACKS
MODEL NUMBER
POWER DECK
TILT CUTOUT
GLOW PLUG
MARKET
ENGINE
ANSI USA 2 4 0 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
ANSI EXPORT 2 4 1 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CSA 2 4 2 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CE 2 4 3 0 1 0 1 2 3 4 5 6 7 0 1 0 1 2
AUSTRALIA 2 4 4 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
4394RT 2WD
ENGINE SHUTDOWN
FUNCTION CUTOUT
GROUND ALARM
GENERATOR
LOAD
ANSI USA 0 1 2 0 1 2 0 X X 0 1 2 0 1
ANSI EXPORT 0 1 2 0 1 2 0 1 2 0 1 2 0 1
CSA 0 1 2 0 1 2 0 X X 0 1 2 0 1
CE 0 1 2 0 1 2 0 1 2 0 1 2 0 1
AUSTRALIA 0 1 2 0 1 2 0 X 2 X X 2 0 1
4150390 J
5-22 – JLG Lift– 3121133

4394RT 4WD
LEVELING JACKS
MODEL NUMBER
POWER DECK
TILT CUTOUT
GLOW PLUG
MARKET
ENGINE
ANSI USA 3 4 0 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
ANSI EXPORT 3 4 1 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CSA 3 4 2 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
CE 3 4 3 0 1 0 1 2 3 4 5 6 7 0 1 0 1 2
AUSTRALIA 3 4 4 X 1 0 1 2 3 4 5 6 7 0 1 0 1 2
4394RT 4WD
ENGINE SHUTDOWN
FUNCTION CUTOUT
GROUND ALARM
GENERATOR
LOAD
ANSI USA 0 1 2 0 1 2 0 X X 0 1 2 0 1
ANSI EXPORT 0 1 2 0 1 2 0 1 2 0 1 2 0 1
CSA 0 1 2 0 1 2 0 X X 0 1 2 0 1
CE 0 1 2 0 1 2 0 1 2 0 1 2 0 1
AUSTRALIA 0 1 2 0 1 2 0 X 2 X X 2 0 1
4150390 J
3121133 – JLG Lift – 5-23

NOTES:
5-24 – JLG Lift– 3121133

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

A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter
with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows dia-
grams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary.
Please consult the meter operator’s manual for more information.
Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors. Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed con-
nector by backprobing both sides of a connector terminal and measuring resistance. Do this after giving each wire a gentle
pull to ensure the wires are still attached to the contact and contacts are seated in the connector.
Min/Max
Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while
alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the
solenoid and meter, is held down.
Polarity
Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and that the leads are connected to the device under test cor-
rectly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other
port goes to the positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
µ = micro = (Displayed Number) / 1,000,000
Example: 1.2 kΩ = 1200 Ω
Example: 50 mA = 0.05 A
3121133 – JLG Sizzor – 6-1

Voltage Measurement Resistance Measurement
Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement
• If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together.
(See multimeter’s operation manual) Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads tance)
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
6-2 – JLG Sizzor – 3121133

Continuity Measurement Current Measurement
Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC)
• Some meters require a separate button press to • Set up the meter for the expected current range
enable audible continuity testing • Be sure to connect the meter leads to the correct
• Circuit power must be turned OFF before testing con- jacks for the current range you have selected
tinuity • If meter is not auto ranging, set it to the correct range
• Disconnect component from circuit before testing (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
3121133 – JLG Sizzor – 6-3

Continuity Measurement Over Long Distances

When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.
Requirements:
• Harness with at least three separate wires including the wire under test.
• These wires must be able to be isolated from other wires, etc.
• Jumper or method to connect contacts on one side of harness.
• Meter that can measure resistance or continuity.
Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate mea-
surement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach
of the jumper.
1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not com-
pletely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
3. On one side, jumper from contact of wire #1 and wire #2.
4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this
test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measure-
ment. If still no continuity, repair wires or consult schematic for other wires to use for test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.
6-4 – JLG Sizzor – 3121133

6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS

Silicone Dielectric Compound must be used on the AMP connections for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and
female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by
using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside
the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus
preventing the housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
Figure 6-5. AMP Connector
3121133 – JLG Sizzor – 6-5

Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Pro-
ceed as follows:
Figure 6-6. Connector Assembly (1 of 4)
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector
Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Fig-
ure 6-7. Connector Assembly (2 of 4)).
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the lock-
ing latches by squeezing them inward (See Figure 6-8. Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)).
6-6 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-7

Disassembly
5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
6. Pry open the wedge lock to the open position.
7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
Figure 6-10. Connector Disassembly
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
6-8 – JLG Sizzor – 3121133

Service - Voltage Reading
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The
resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies
the effectiveness of the connector seals and could result in system failure.
Figure 6-11. Connector Installation
3121133 – JLG Sizzor – 6-9

6.4 WORKING WITH DEUTSCH CONNECTORS

DT/DTP Series Assembly
Figure 6-12. DT/DTP Contact Installation
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in
place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedge-
lock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
DT/DTP Series Disassembly
Figure 6-13. DT/DTP Contact Removal
5. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
6. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it
away from the contact with a screwdriver.
7. Hold the rear seal in place, as removing the contact may displace the seal.
HD30/HDP20 Series Assembly
Figure 6-14. HD/HDP Contact Installation
8. Grasp contact about 25mm behind the contact crimp barrel.
9. Hold connector with rear grommet facing you.
6-10 – JLG Sizzor – 3121133

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

11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
12. Slide tool along into the insert cavity until it engages contact and resistance is felt.
13. Pull contact-wire assembly out of connector.
Figure 6-17. HD/HDP Unlocking Contacts

NOTE: Do Not twist or insert tool at an angle.
3121133 – JLG Sizzor – 6-11

6.5 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. De-energize the circuit.
2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an
open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will
be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two
terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.
Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually oper-
ated switches except that the moving object operates the switch. These switches can be tested the same way as a stan-
dard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive
proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do
not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform
position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find
the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch
as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the
switch and object sensed.
6-12 – JLG Sizzor – 3121133

Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener-
gized to actuate.
1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.
2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do
this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for exam-
ple. The state indicated in the control system should change.
Switch Wiring - Low Side, High Side

When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can mea-
sure the voltage at both power terminals with respect to battery ground. The difference between those two measure-
ments is the voltage applied to the load.
3121133 – JLG Sizzor – 6-13

6.6 SCHEMATICS
Figure 6-18. Electrical Schematic - Dual Fuel - Sheet 1 of 3
6-14 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-15

1870143 H
6-16 – JLG Sizzor – 3121133

NOTES:
3121133 – JLG Sizzor – 6-17

Figure 6-21. Electrical Schematic Diesel (Prior to S/N 138634) - Sheet 1 of 3
6-18 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-19

J2 & J5 RECEPTACLE
J1 RECEPTACLE
PFDTH (J2-1)
PFDTH (J1-1) PFDTH1 (J2-2) FL LJ
PFDTH1 (J1-2) IGN (J5-9) VALVE FR LJ
SFDTH (J1-3) GND (J2-3) BLACK Y18 VALVE RL LJ
BLACK GND (J1-4) DO00 (J2-11) ORN/WHT 55-20 Y19 VALVE RR LJ
YEL/RED 2-7-3 IGN (J1-5) DO01 (J2-12) ORN/WHT 55-21 Y20 VALVE LJ EXTEND 1
RED __ CANH (J1-6) DO02 (J5-1) ORN/WHT 55-22 Y21 VALVE LJ EXTEND 2
BLACK _ CANL (J1-7) DO03 (J5-2) ORN/WHT 55-23 Y22 VALVE LJ RETRACT
SHIELD CAN SHIELD (J1-8) DO04 (J5-3) ORN/WHT 55-24 Y28 VALVE
DO05 (J5-4) ORN/WHT 55-25 Y23
DO06 (J5-5)
DI00/SFDTH (J2-4)
IGN (J4-1) DI05 (J2-9)
GND (J4-2) ANLG4 (J2-10) FD EXT.
CAN H (J4-3) DI01 (J2-5) VALVE FD RET.
CAN L (J4-4) DI02 (J2-6) Y24 VALVE RD EXT.
CAN SHIELD (J4-5) DI03 (J2-7) GREEN17-2 Y25 VALVE RD RET.
SPARE (J4-6) DO07 (J5-6) GREEN 18-2 Y26 VALVE
DO08 (J5-7) GREEN 19-2 Y27
DO09 (J5-8) GREEN 20-2
J4 DI04 (J2-8)
RECEPTACLE RX (J5-10)
TX (J5-11
GND (J5-12) BLACK
J3 RECEPTACLE
GND (J3-12)
ANLG3 (J3-11)
APWR3 (J3-10)
GND (J3-9)
ANLG2 (J3-8)
APWR2 (J3-7)
GND (J3-6)
ANLG1 (J3-5)
APWR1 (J3-4)
GND (J3-3)
ANLO0 (J3-2)
APWR0 (J3-1)
YEL/RED 2-20
S25
FNT LFT STOWED
BLACK SWITCH WHITE
S26
FNT RHT STOWED
BLACK SWITCH WHITE
S27
REAR LFT STOWED
BLACK SWITCH WHITE
S28
REAR RHT STOWED
BLACK SWITCH WHITE
RED
BLACK
BLACK
BLACK
BLACK
WHITE
WHITE
WHITE
WHITE
RED
RED
RED
B C A B C A B C A B C A
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 1870153 G
SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK
WIRE AT J3.
6-20 – JLG Sizzor – 3121133

NOTES:
3121133 – JLG Sizzor – 6-21

Figure 6-24. Electrical Schematic - Dual Fuel GM - Sheet 1 of 5
6-22 – JLG Sizzor – 3121133

Figure 6-25. Electrical Schematic - Dual Fuel GM - Sheet 2 of 5
3121133 – JLG Sizzor – 6-23

Figure 6-26. Electrical Schematic Dual Fuel - GM - Sheet 3 of 5
6-24 – JLG Sizzor – 3121133

NOTES:
3121133 – JLG Sizzor – 6-25

6-26 – JLG Sizzor – 3121133

1870204 E
3121133 – JLG Sizzor – 6-27

Figure 6-29. Electrical Schematic Diesel (S/N 138634 to Present) - Sheet 1 of 3
6-28 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-29

1870190 D
6-30 – JLG Sizzor – 3121133

NOTES:
3121133 – JLG Sizzor – 6-31

Figure 6-32. Hydraulic Schematic 4WD - Sheet 1 of 4
6-32 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-33

6-34 – JLG Sizzor – 3121133

2792543 D
3121133 – JLG Sizzor – 6-35

6-36 – JLG Sizzor – 3121133

3121133 – JLG Sizzor – 6-37

6-38 – JLG Sizzor – 3121133

2792544D
3121133 – JLG Sizzor – 6-39

Figure 6-40. Hydraulic Diagram - (2WD)
6-40 – JLG Sizzor – 3121133

Figure 6-41. Hydraulic Diagram - (4WD)
3121133 – JLG Sizzor – 6-41

8
8
Figure 6-42. Hydraulic Diagram - (Leveling Jacks)
6-42 – JLG Sizzor – 3121133

Power Deck Manifold Valve
Right
Front Extension Cylinders
Left
Note: “*” on a line indicates a

Power Deck Sandwich Valve non-straight hose end
Mounted on top of Main Manifold
Hydraulic Oil
Tank
Aux. Pump
Figure 6-43. Hydraulic Diagram - Deck Extension (Single)
3121133 – JLG Sizzor – 6-43

6-44
Power Deck Manifold
Valve
Power Manifold Valve
Right Right
Front Extension Cylinders Rear Extension Cylinders
Left Left
– JLG Sizzor –
Power Deck Sandwich Valve
Mounted on top of Main Manifold Note: “*” on a line indicates a
non-straight hose end
Figure 6-44. Hydraulic Diagram - Deck Extension (Dual)

Hydraulic Oil
Aux. Pump Tank
3121133
Power Deck Manifold
Power Deck Manifold Valve
Valve
3121133
Right Right
Front Extension Cylinders Rear Extension Cylinders
Left Left
– JLG Sizzor –
Note: “*” on a line indicates a
Power Deck Sandwich Valve
non-straight hose end
Mounted on top of Main Manifold
Figure 6-45. Hydraulic Diagram - Deck Extension (Dual Megadeck)

Hydraulic Oil
Aux. Pump Tank
6-45
FUSE (FOR
FUTURE STARTER
OPTIONS)
THROTTLE
OIL ACTUATOR
BATTERY PRESSURE
SWITCH
GLOW
PLUG OIL
TEMP
SWITCH
ALTERNATOR
(DIESEL
MACHINES)
AC POWER
AT PLATFORM
AUXILIARY
AUXILIARY PUMP POWER
RELAY
GENERATOR
CONTROL BOX
GENERATOR
GENERATOR RELAY
LEVELING
JACK
PORT
BLOCKS
LEVELING J2 J5
JACK
PORT
BLOCKS OPTIONS J4
MODULE
LEVELING J1 J3
JACK
VALVE
Figure 6-46. Electrical Components Installation - Sheet 1
6-46 – JLG Sizzor – 3121133

PLATFORM
CONTROL
BOX
ENGINE START LP LOCK & ASSIST
SPEED RELAY (GAS MACHINES)
SENSOR
GLOW
PLUG
RELAY IGNITION
RELAY
ALTERNATOR
(GAS
MACHINES) THROTTLE
CONTROLLER
(GAS MACHINES)
LIFT CYLINDER J2 J5
PORT BLOCK
J4
PROP
HYDRAULIC VALVE
J1 J3
PUMPS
PLATFORM
MODULE
LIFT
DOWN VALVE
FUEL BEACON HORN

LEVEL LIGHT ROTARY
SENSOR SENSOR
PORT
BLOCKS
(OSCILLATING
AXLE ALARM
CYLINDERS)
ELEVATION
SWITCH
MAIN
VALVE
FUEL
PUMP
(GAS
MACHINES)
GROUND
CONTROL
BOX
Figure 6-47. Electrical Components Installation - Sheet 2
3121133 – JLG Sizzor – 6-47

NOTES:
6-48 – JLG Sizzor – 3121133

3121133
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N. T. Italy The Netherlands
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 +31 (0)23 565 5665
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +31 (0)23 557 2493
(852) 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Sverige AB

UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 176 27 Jarfalla
+48 (0)914 320 245 Scotland 08755 Castellbisbal, Barcelona Sweden
+48 (0)914 358 200 Spain +46 (0)850 659 500
+44 (0)141 781 6700
+34 93 772 4700 +46 (0)850 659 534
+44 (0)141 773 1907
+34 93 771 1762
www.jlg.com

Manual de Servicio 3394RT

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Service & Maintenance Manual

Prior to S/N 0200191606

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

Relieve system pressure by cycling the applicable

3121133 – JLG Lift – a

Original Issue - April 12, 2002

Revised - May 10, 2002

Revised - August 30, 2002

Revised - October 14, 2002

Revised - March 6, 2003

Revised - October 24, 2003

Revised - April 28, 2004

Revised - August 18, 2004

Revised - August 12, 2005

Revised - October 4, 2005

Revised - March 1, 2006

Revised - May 11, 2006

Revised - October 31, 2006

Revised - April 3, 2007

Revised - October 12, 2007

Revised - January 23, 2008

Revised - March 17, 2008

Revised - October 6, 2008

b – JLG Lift – 3121133

3121133 – JLG Lift – i

4.7 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .4-10

ii – JLG Lift – 3121133

3121133 – JLG Lift – iii

3-43. Joystick Controller - (JLG P/N 1600308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76

iv – JLG Lift – 3121133

6-18. Electrical Schematic - Dual Fuel - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

3121133 – JLG Lift – v

vi – JLG Lift – 3121133

3121133 – JLG Sizzor – 1-1

Table 1-5. GM 3.0L Specifications 1.5 MACHINE DIMENSIONS

1.4 TIRES 1.7 SERIAL NUMBER LOCATIONS

12 x 16.5 Foam Fill to 170 ft lbs

33/1550 x 16.5 170 ft lbs

33/1550 x 16.5 Foam Fill to 170 ft lbs

33/16LLx16.1 Foam Fill to 170 ft lbs

31 x 15.50-15 170 ft lbs

Figure 1-1. Serial Number Location

1-2 – JLG Sizzor – 3121133

1.8 SENSORS 1.9 CYLINDER SPECIFICATIONS

If the machine is operated beyond the specified

3121133 – JLG Sizzor – 1-3

Table 1-12. Critical Stability Weights ISO Viscosity Grade #32

1-4 – JLG Sizzor – 3121133

1.13 OPERATOR MAINTENANCE

NOTE: Item #5 through #13 are on the opposite

Figure 1-2. Operator Maintenance and Lubrication Diagram

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL

NOTE: Be sure to lubricate like items on each side.

NOTE: Recommended lubricating intervals are based on

Operate hydraulic functions through one complete

Any time the pump coupling is removed, coat splines

3121133 – JLG Sizzor – 1-5

2. Drive Hub 5. Oil Change w/Filter - Ford