Service & Maintenance Manual

Models
3394RT
4394RT
S/N 0200191606 to Present
including S/N’s:
0200186972,
0200187002,
0200187013

3121249

November 30, 2010

 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 AT IO 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
• No smoking is mandatory. never refuel during electrical
VIOLATION.
storms. ensure that fuel cap is closed and secure at all other
times.
The specific precautions to be observed during
• Remove all rings, watches and jewelry when performing any
maintenance are inserted at the appropriate point in
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
• Use caution when checking a hot, pressurized coolant system.
unstable position. When raising a portion of the
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.

3121249 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - October 6, 2008

Revised - November 3, 2008

Revised - November 30, 2010

b – JLG Lift – 3121249

 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, PLATFORM & SCISSOR ARMS
3.1 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Tires, Wheels & Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Integrated Torque/drive hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.4 Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3.5 Leveling Jacks (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3.6 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3.7 Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3.8 Side Compartment Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3.9 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3.10 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3.11 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3.12 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
3.13 Dual Fuel/LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
3.14 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3.15 GM Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3.16 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74
3.17 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
3.18 GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84
SECTION 4 - HYDRAULICS
4.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

3121249 – JLG Lift – i

 TABLE OF CONTENTS

4.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.5 Drive Pump Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4.6 Hydraulic Component Start-Up Procedures & Recommendations . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.7 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4.8 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4.9 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
4.10 Axial HI 45 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4.11 Charge Pump Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
4.12 Auxiliary Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
4.13 Cylinder Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
SECTION 5 - JLG CONTROL SYSTEM
5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.3 Flash Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
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 – 3121249

 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 - GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Integrated Torque/Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Drive Motor/Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-4. Drive Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
3-5. Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-6. Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-7. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-8. Leveling Jack Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-9. Leveling Jacks Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-10. Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-11. Deck Extension Cylinders Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-12. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-13. Joystick Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-14. Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-15. Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-16. Scissor Assembly Removal - Chassis Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-17. Ground Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-18. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-19. Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-20. Hydraulic Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
3-21. Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
3-22. Engine Tray Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-23. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
3-24. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-25. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-26. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-27. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
3-28. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-29. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-30. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-31. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-32. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
3-33. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
3-34. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
3-35. Generator (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
3-36. Exhaust System (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-37. Air Cleaner System (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
3-38. Relays (Deutz Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
3-39. Pump Assemblies (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-40. Pump Coupling (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3-41. Engine Removal (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-42. Radiator (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-43. Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

3121249 – JLG Lift – iii

 TABLE OF CONTENTS

3-44. Engine Tray Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

3-45. Generator (GM Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3-46. GM Exhaust System (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
3-47. Air Cleaner System (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-48. Radiator (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69
3-49. Fuel Components (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
3-50. Pump Assemblies (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71
3-51. Pump Coupling (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72
3-52. Engine Removal (GM Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
3-53. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74
3-54. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74
3-55. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
3-56. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-75
3-57. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-58. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-59. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-60. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-61. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-62. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79
3-63. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79
3-64. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-80
3-65. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81
3-66. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82
3-67. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-4. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-5. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-6. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-7. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-8. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-11. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-13. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-14. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-15. Hydraulic Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4-16. Main Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-17. Main Valve Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4-18. Flow Divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-19. Leveling Jacks Directional Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-20. Powerdeck Valve (Single) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-21. Powerdeck Valve (Double) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-22. Leveling Jack Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-23. Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
4-24. Axial HI 45 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4-25. Axial HI 45 Pump - Cross Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
4-26. Charge Pump Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
4-27. Auxiliary Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
4-28. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
4-29. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
4-30. Lift Cylinder Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
4-31. Oscillating Axle Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36
4-32. Leveling Jack Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
4-33. Leveling Jack Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38
4-34. Deck Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

iv – JLG Lift – 3121249

 TABLE OF CONTENTS

4-35. Oscillating Axle Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

5-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-2. Analyzer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5-3. Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-5. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-6. Analyzer Flow Chart - SW P1.X - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-7. Analyzer Flow Chart - SW P1.X - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-8. Analyzer Flow Chart - SW P1.X - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
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
6-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
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
6-18. Electrical Schematic - Deutz - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
6-19. Electrical Schematic - Deutz - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-20. Electrical Schematic - Deutz - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-21. Electrical Schematic - GM - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-22. Electrical Schematic - GM - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-23. Electrical Schematic - GM - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-24. Electrical Schematic - GM - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-25. Electrical Schematic - GM - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-26. Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-27. Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
6-28. Hydraulic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-29. Hydraulic Diagram (Powerdeck - Single) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6-30. Hydraulic Diagram (Powerdeck - Dual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
6-31. Hydraulic Diagram (Powerdeck - Mega). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
6-32. Hydraulic Diagram (Leveling Jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
6-33. Electrical Components Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6-34. Electrical Components Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

3121249 – 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 Deutz F3M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 GM 3.0L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Main Control Valve Relief Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 High Drive Cut-Out Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-8 Tilt Sensor Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-13 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-14 Mobil 424 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 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Torque/Drive Hub Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3 Gearbox Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-5 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-6 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
3-7 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3-8 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85
3-9 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88
3-10 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96
4-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-3 Main Valve Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4-4 Porting Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4-5 Leveling Jacks Directional Valve Torque Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-6 Powerdeck Valve Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-7 Leveling Jack Valves Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-8 Gear Pump Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
4-9 Axial HI 45 Pump Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
5-1 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-2 Fault Code Listing - Software P1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-3 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
5-4 Machine Tilt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-5 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

vi – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS 1.2 CAPACITIES

Table 1-1. Operating Specifications Table 1-2. Capacities

Description 3394RT 4394RT Description 3394RT 4394RT

Maximum Occupants 6 Fuel Tank 31.5 gal (119 L)
Maximum Workload Hydraulic Tank:
(Capacity): Total Capacity 32.3 gal (122.3 L)
Single Extension: 2250 lbs (1020 kg) 1500 lbs (680 kg) Full Level 27.3 gal (103.3 L)
Dual Extension: 2000 lbs (905 kg) 1250 lbs (565 kg) Low Level 23.6 gal (89.3 L)
Extension Only: 500 lbs (230 kg) 500 lbs (230 kg)
Maximum Travel Grade : 1.3 ENGINES
2 WD 35%
4WD 45% Table 1-3. Deutz F3M2011 Specifications
Maximum Travel Grade : 3° Fuel DIesel
Maximum Platform Height 33 ft 43 ft Oil Capacity 8.5 Quarts (8 L) w/Filter
Maximum Drive Speed 2 WD 3.0 mph (4.8 kph) 3.0 mph (4.8 kph) Low RPM 900
Maximum Drive Speed 4WD 3.5 mph (5.6 kph) 3.5 mph (5.6 kph)
High RPM 2800
LIft Up Speed
Alternator 95 Amp, Belt Drive
(Stowed to Full Height)
29 - 31 sec 40 - 45 sec Battery 112 Amphour, 950 Cold Crank-
Lift Down Speed
ing Amps, 12 VDC
(Full Height to Stowed)
Fuel Consumption:
Maximum Wind Speed 28 mph (12.5 m/s)
Low RPM 1.3 GPH (4.9 lph)
Maximum Horizontal Manual High RPM 1.6 GPH (6.0 lph)
Side Force:
Horsepower 48 @ 2800 RPM, full load
Single Extension 335 lb force (1490 N) 300 lb force (1335 N)
Dual Extension 300 lb force (1335 N) 300 lb force (1335 N)
Single Extension (CE/AUS) 90 lb force (400 N) 90 lb force (400 N) Table 1-4. GM 3.0L Specifications
Dual Extension (CE/AUS) 90 lb force (400 N) 90 lb force (400 N) (Tier 2 and 3 Engine)
Maximum Tire Load 4400 lbs (1996 kg) Fuel Gasoline or Gasoline/LP Gas
Ground Bearing Pressure 49 psi 56 psi No. of Cylinders 4
w/Standard tires (3.45 kg/cm2) (3.94 kg/cm2) HorsePower:
Leveling Jack Bearing
Gasoline 83 hp @ 3000 rpm
Pressure 69 psi (4.9 kg/cm2) LP 75 hp @ 3000 rpm

Wheelbase 9.67 ft (2.95 m)

Bore 4.0 in. (101.6 mm)
Stroke 3.6 in. (91.44 mm)
Ground Clearance 12 in (30 cm)
Displacement 181 cu.in. (3.0 L, 2966 cc)
Maximum Hydraulic System
3000 psi (207 bar) Oil Capacity w/filter
Pressure
Tier 2 4.5 qts. (4.25 L)
Electrical System Voltage 12 Volt
Tier 3 5.0 qts. (4.73L)
Inside Turning Radius 14.5 ft (4.39 m)
Minimum Oil Pressure:
Outside Turning Radius 20.1 ft (6.12 m) at idle 6 psi (0.4 Bar) @ 1000 rpm
Gross Vehicle Weight at operation 18 psi (1.2 Bar) @ 2000 rpm
(with One Extension) Compression Ratio
11,910 lbs 15,300 lbs
Note: Certain options or Tier 2 9.2:1
(5,402 kg) (6,940 kg)
country standards increase Tier 3 10.5:1
weight.
Firing Order 1-3-4-2
Maximum RPM 2800

3121249 – JLG Lift – 1-1

 SECTION 1 - SPECIFICATIONS

1.4 TIRES 1.6 PRESSURE SETTINGS

Table 1-5. Tire Specifications
Table 1-6. Main Control Valve Relief Settings
Ply Inflation Wheel Nut
Size Description 3394RT 4394RT
Rating Pressure Torque (Dry)
Main Relief 3000 psi (207 bar)
IN315/55D20 170 lb-ft
12 75 psi (5 bar) Steer Relief 2800 psi (193 bar)
Pneumatic (238 Nm)
IN315/55D20 Foam Fill to 170 lb-ft Lift Up Relief 2700 psi (186 bar)
12
Foam Filled 75 psi (5 bar) (238 Nm)
12 x 16.5
170 lb-ft 1.7 SERIAL NUMBER LOCATIONS
Pneumatic 10 90 psi (6 bar)
(238 Nm)
(Non-Marking) For machine identification, a serial number plate is affixed
12 x 16.5 to the machine. The plate is located at the rear of the
Foam Fill to 170 lb-ft machine on the center of the axle. In addition, should the
Foam Filled 10
90 psi (6 bar) (238 Nm) serial number plate be damaged or missing, the machine
(Non-Marking)
serial number is stamped onto the lip of the rear axle.
33/1550 x 16.5 170 lb-ft
14 90 psi (6 bar)
Pneumatic (238 Nm)
33/1550 x 16.5 Foam Fill to 170 lb-ft
14
Foam Filled 90 psi (6 bar) (238 Nm)
33/16LLx16.1 Foam Fill to 170 lb-ft
10
Foam Filled - Sand 50 psi (3.4 bar) (238 Nm)
31 x 15.50-15 170 lb-ft
10 60 psi (4 bar)
Grass Master (238 Nm)

1.5 MACHINE DIMENSIONS

Description 3394RT 4394RT

Machine Height
61.75 in (1.6 m) 70.4 in (1.8 m)
(rails down)
Machine Width 94 in (2.4 m)
Machine Length 156 in (4 m)

2 1
Rear of Machine

1. Serial Number Plate

2. Stamped Serial Number

Figure 1-1. Serial Number Location

1-2 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

1.8 SENSORS 1.9 CYLINDER SPECIFICATIONS

The machine is equipped with the following limit switches: Table 1-9. 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
4.5 in 83 in 3.5 in
heights listed in Table 1-7, High Drive Cut-Out Height. Lift Cylinder
(114 mm) (2.1 mm) (89 mm)
Table 1-7. High Drive Cut-Out Height
Leveling Jack 2.5 in 27 in 2 in
Model Height Cylinder (63.5 mm) (686 mm) (51 mm)
Lockout Cylinder 2.5 in 4.13 in 1.75 in
6-9 ft
3394RT (Oscillating Axle) (6.4 cm) (10.5 cm) (4.4 cm)
(1.8 - 2.7 m)
Power Deck 15 in 48 in 1 in
7-10 ft
4394RT Cylinders (38.1 mm) (1219.2 mm) (25.4 mm)
(2.1 - 3 m)
2.5 in 9.2 in 1.75 in
Tilt Alarm - An alarm sounds and a warning light is illumi- Steer Cylinder
(63.5 mm) (233.7 mm) (44.5 mm)
nated when the machine is operated on a slope that
exceeds the values in Table 1-8, Tilt Sensor Indicators.
The lift and drive functions will cut out at these set heights. 1.10 MAJOR COMPONENT WEIGHTS
NOTE: Alarm only sounds when above elevation. Table 1-10. Major Component Weights

If the machine is operated beyond the specified Component Weight

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

3121249 – JLG Lift – 1-3

 SECTION 1 - SPECIFICATIONS

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 1-13. Mobil DTE 13M Specs

Table 1-11. Critical Stability Weights ISO Viscosity Grade #32

Specific Gravity 0.877
Component Weight
Tires Pour Point, Max -40°F (-40°C)
IN315/55D20 Pneumatic 156 lbs (71 kg) Flash Point, Min. 330°F (166°C)
IN315/55D20 Foam Filled 156 lbs (71 kg)
12 x 16.5 Pneumatic 128 lbs (58 kg) Viscosity
12 x16.5 Foam Filled 328 lbs (149 kg) at 40°C 33cSt
33/1550-16.5 Pneumatic 135 lbs (61 kg)
at 100°C 6.6 cSt
33/1550-16.5 Foam Filled 395 lbs (179 kg)
33/16LL x 16.1 Foam Filled - Sand 426 lbs (193 kg) at 100°F 169 SUS
31 x 15.50-15 Grass Master 125 lbs (57 kg) at 210°F 48 SUS
Engine (Deutz) 441 lbs (200 kg) cp at -20°F 6,200
Engine (GM) 341 lbs (155 kg) Viscosity Index 140

1.12 LUBRICATION SPECIFICATIONS Table 1-14. Mobil 424 Specs

Table 1-12. Hydraulic Oil Type Synthetic Biodegradable

Hydraulic System Operating SAE Grade 10W-30

Sae Viscosity Grade
Temperature Range Gravity, API 29.0
0°F to +23°F
10W Density 7.35 lb/gal (
(-18°C to -5°C)
0°F to +210°F Pour Point, Max -46°F (-43°C)
10W-20,10W-30
(-18°C to +100°C) Flash Point, Min. 442°F (228°C)
+50°F to +210°F Viscosity
20W-20
(+10°C to +100°C)
at 40°C 55 cSt
at 100°C 9.3 cSt
Viscosity Index 152

1-4 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

1.13 OPERATOR MAINTENANCE

1. Fuel Tank
2. Drive Hubs
3. Hydraulic Oil Tank
4. Sliding Wear Pads
5. Oil Change w/Filter - Deutz
6. Oil Change w/Filter - GM
7. Fuel Filter - Deutz
8. Fuel Filter (Gasoline) - GM
9. Air Filter
10. Electronic Pressure Regulator

NOTE: Item #5 through #11 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
both ADD and FULL sight windows on tank. Do not • Fuel - Diesel or Gasoline
overfill tank. • Capacity - 31.5 gal (119 l)

Any time the pump coupling is removed, coat splines

of coupling with Texaco Code 1912 grease prior to
assembly.

3121249 – JLG Lift – 1-5

 SECTION 1 - SPECIFICATIONS

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

• Lube Point(s) - Fill Cap/Spin-on Element

• Lube Points - Fill Plugs (4) (JLG P/N 7016331)

• Lube - EPGL • Capacity - 6.3 qt. (5.9 L) engine only

• Interval - Every 2 years or 1200 hours • Lube - EO

3. Hydraulic Oil • Interval - Every Year or 600 hours of operation

• Comments - Check level daily/Change in accordance
with engine manual.
6. Oil Change w/Filter - GM

• Lube Point - Fill Cap/Fill Level

• Lube Point(s) - Fill Cap/Spin-on Element
• Lube - HO
(JLG P/N 7027965)
• Interval - Check oil every 10 hours of operation;
• Capacity - 4.5 qt. (4.25 L) w/filter
change oil every 2 years or 1200 hours of operation.
• Lube - EO
4. Sliding Wear Pads
• Interval - 3 Months or 150 hours of operation
• Lube Points - 8 Sliding Wear Pads
• Comments - Check level daily/Change in accordance
• Lube - MPG with engine manual.
• Interval - Every month or 50 hours.

1-6 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

7. Fuel Filter - Deutz 11. Fuel Filter (Propane) - GM

• Interval - 3 Months or 150 hours of operation

• Lube Point(s) - Replaceable Element • Comments - Replace filter. Refer to Propane Fuel Filter
Replacement
• Interval - Every Year or 600 hours of operation
8. Fuel Filter (Gasoline) - GM
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation
9. Air Filter
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator
10. Electronic Pressure Regulator (LP only)

• Interval - 3 Months or 150 hours of operation

• Comments - Drain oil build up. Refer to Draining Oil
Build Up From The Propane Regulator

3121249 – JLG Lift – 1-7

 SECTION 1 - SPECIFICATIONS

Draining Oil Build Up From The Propane

Regulator
During the course of normal operation oils may build
inside the primary and secondary chambers of the pro-
pane pressure regulator. These oils may be a result of
poor fuel quality, contamination of the fuel supply chain,
or regional variation in the make up of the fuel. If the build
up of the oil is significant this can effect the operation of
the fuel control system. Refer to Section 1.13, Operator
Maintenance for maintenance intervals. More frequent
draining may be required if the fuel supply has been con-
taminated.

FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM-

PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO 6. Remove the retainer clip for the LPG fuel temperature
FLOW FREELY FROM THE REGULATOR. sensor and remove the sensor from the regulator body.

1. Move the equipment to a well ventilated area. Ensure

there are no external ignition sources.
2. Start the engine and bring to operating temperature.
3. With the engine running, close the manual tank valve
and run the engine out of fuel.

NOTE: Have a small container ready to collect oil that will

drain freely from the regulator at this point.
7. Once all of the oil has been drained, reinstall the LPG
fuel temperature sensor and reconnect the electrical
connector.
8. Open the fuel tank manual valve.

4. Push in the Emergency Switch once the engine stops. 9. Start the engine and verify all connections are secure.

5. Disconnect the electrical connection to the LPG fuel 10. Dispose of any drained oil per local regulations in a
temperature sensor in the auxiliary fuel port of the EPR. safe and proper fashion.

1-8 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

Propane Fuel Filter Replacement INSTALLATION:

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

3121249 – JLG Lift – 1-9

 SECTION 1 - SPECIFICATIONS

1.14 TORQUE CHARTS

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red)

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7)

1-10 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 7))

3121249 – JLG Lift – 1-11

 SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM
Tensile Clamp Load Torque
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 7)

1-12 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 7)

3121249 – JLG Lift – 1-13

 SECTION 1 - SPECIFICATIONS

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7))

1-14 – JLG Lift – 3121249

 SECTION 1 - SPECIFICATIONS

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

3121249 – JLG Lift – 1-15

 SECTION 1 - SPECIFICATIONS

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

Torque
Torque
Torque (Lub OR Loctite®
Tensile (Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
Size PITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-16 – JLG Lift – 3121249

 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.

3121249 – JLG Lift – 2-1

 SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification

Pre-Start Prior to use each day; or

User or Operator User or Operator Operator and Safety Manual
Inspection At each Operator change.

Service and Maintenance

Pre-Delivery Prior to each sale, lease, or Qualified JLG
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
Frequent Qualified JLG
Out of service for a period of more than 3 Owner, Dealer, or User Manual and applicable JLG
Inspection Mechanic
months; or inspection form.
Purchased used.

Factory-Certified
Service and Maintenance
Annual Machine Annually, no later than 13 months from Service Technician
Owner, Dealer, or User Manual and applicable JLG
Inspection the date of the prior inspection. or a Qualified JLG
inspection form.
Mechanic

Preventative At intervals as specified in the Service Qualified JLG Service and Maintenance
Owner, Dealer, or User
Maintenance and 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 – 3121249

 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.

3121249 – 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°F (49°C). Sys-
1. The primary enemy of a hydraulic system is contam- tems using DTE 13 oil should not be operated at
ination. Contaminants enter the system by various temperatures above 200°F (94°C) under any condi-
means, e.g., using inadequate hydraulic oil, allowing tion.
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by Changing Hydraulic Oil
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suc- 1. Use of any of the recommended hydraulic oils elimi-
tion) lines. nates the need for changing the oil on a regular
basis. However, filter elements must be changed
2. The design and manufacturing tolerances of the after the first 50 hours of operation and every 300
component working parts are very close, therefore, hours thereafter. If it is necessary to change the oil,
even the smallest amount of dirt or foreign matter use only those oils meeting or exceeding the specifi-
entering a system can cause wear or damage to the cations appearing in this manual. If unable to obtain
components and generally results in faulty opera- the same type of oil supplied with the machine, con-
tion. Every precaution must be taken to keep sult local supplier for assistance in selecting the
hydraulic oil clean, including reserve oil in storage. proper equivalent. Avoid mixing petroleum and syn-
Hydraulic system filters should be checked, thetic base oils. JLG Industries recommends chang-
cleaned, and/or replaced as necessary, at the speci- ing the hydraulic oil annually.
fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of 2. Use every precaution to keep the hydraulic oil clean.
metal particles. If the oil must be poured from the original container
into another, be sure to clean all possible contami-
3. Cloudy oils indicate a high moisture content which nants from the service container. Always clean the
permits organic growth, resulting in oxidation or cor- mesh element of the filter and replace the cartridge
rosion. If this condition occurs, the system must be any time the system oil is changed.
drained, flushed, and refilled with clean oil.
3. While the unit is shut down, a good preventive main-
4. It is not advisable to mix oils of different brands or tenance measure is to make a thorough inspection
types, as they may not contain the same required of all hydraulic components, lines, fittings, etc., as
additives or be of comparable viscosities. Good well as a functional check of each system, before
grade mineral oils, with viscosities suited to the placing the machine back in service.
ambient temperatures in which the machine is oper-
ating, are recommended for use. Lubrication Specifications
Specified lubricants, as recommended by the component
NOTE: Metal particles may appear in the oil or filters of new
manufacturers, are always the best choice, however,
machines due to the wear-in of meshing compo-
multi-purpose greases usually have the qualities which
nents.
meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
Hydraulic Oil maintenance stock, consult your local supplier for evalua-
tion. Refer to Section 1 for an explanation of the lubricant
1. Refer to Section 1 for recommendations for viscosity key designations appearing in the Lubrication Chart.
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 – 3121249

 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.

3121249 – JLG Lift – 2-5

 SECTION 2 - GENERAL

2.6 PREVENTIVE MAINTENANCE AND

INSPECTION SCHEDULE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
The preventive maintenance and inspection checks are
“ANNUAL MACHINE INSPECTION REPORT” FORM.
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” 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 – 3121249

 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

3121249 – JLG Lift – 2-7

 SECTION 2 - GENERAL

4150548 D
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 15W-40

SAE 20W-50
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:

NO OPERATION ABOVE THIS
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
MOBIL DTE 13

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

DO NOT START UP HYDRAULIC SYSTEM
0°F (-18°C) 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 – 3121249

 SECTION 2 - GENERAL

4150548 D
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)
ENGINE
SPECIFICATIONS 70°F (21°C)

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)
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
DEPT. FOR APPLICATION)

120°F (49°C) NOTE:

NO OPERATION ABOVE THIS
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
MOBIL DTE 13

40°F (4°C)
30°F (-1°C)
20°F (-7°C)
10°F (-12°C)
DO NOT START UP HYDRAULIC SYSTEM
0°F (-18°C) WITHOUT HEATING AIDS WITH MOBILE 424
-10°F (-23°C) HYDRAULIC OIL BELOW THIS TEMPERATURE

-20°F (-29°C) DO NOT START UP HYDRAULIC SYSTEM

WITHOUT HEATING AIDS AND COLD WEATHER
-30°F (-34°C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-40°F (-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 2-2. Engine Operating Temperature Specifications - GM

3121249 – JLG Lift – 2-9

 SECTION 2 - GENERAL

NOTES:

2-10 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SECTION 3. CHASSIS, PLATFORM & SCISSOR ARMS

3.1 OPERATING CHARACTERISTICS Generator

When the generator switch is activated, the engine RPM
Leveling Jacks will increase to 2000 RPM for a 60 Hz generator or 1700
The machine may be equipped with auto leveling jacks. RPM for a 50 Hz generator.
These leveling jacks are operated through one switch
unlike the traditional four switch system. The leveling When a function is selected for operation, which requires
jacks are operated by a bang bang valve. a higher engine speed than the generator, the generator
will automatically shut off during the operation of the func-
NOTE: The engine speed will drop when the leveling jacks tion. Once the function has stopped, the generator will be
are in contact with the ground. active again.

1. Activate the leveling jack button located on the plat- Lift

form control box. There is a flow control valve which controls both the lift up
2. Extend the jacks by moving the joystick forward. and lift down speeds.
Anytime you abruptly change lift directions, there is a
NOTE: Once all four jacks make contact with the ground the three second delay between lift up and lift down.
system will go from set mode into level mode. At this
point the engine will return to idle. Drive
3. The tilt indicator will go out once the machine is If driving at high drive up a grade and you hit an 8° incline,
level. the drive function will cut back to mid drive speed. The
drive pump will shift back into high drive once the incline
NOTE: If the machine is not level it will not lift. If you hit the decreases to 5°. There will be a 2 second delay before the
end of stroke on any of the cylinders you cannot lift machine goes back into high drive.
the machine.
3.2 TIRES, WHEELS & DRIVE ASSEMBLY
NOTE: There is a limit switch on each cylinder that senses
when the cylinder is fully retracted when all four are Tire Inflation
fully retracted, the stowed light in the platform control
box will light. The air pressure for pneumatic tires must be equal to the
air pressure that is stenciled on the side of the JLG prod-
If you receive a 2/5 flash code through the system uct or rim decal for safe and proper operational character-
fault light at the platform control station the machine istics.
is unable to level. You must reposition and try again.
Tire Damage
The jacks are operational (extend or retract) if the machine
is in the stowed position. The proximity sensor and rotary For pneumatic tires, JLG Industries, Inc. recommends that
sensor together must sense that the machine is stowed. A when any cut, rip, or tear is discovered that exposes side-
failure of either sensor will prevent the jacks from being wall or tread area cords in the tire, measures must be
activated. taken to remove the JLG product from service immedi-
ately. Arrangements must be made for replacement of the
Power Deck tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. rec-
The power deck is operated through a non proportional
ommends that when any of the following are discovered,
valve. This will not effect any other function when acti-
measures must be taken to remove the JLG product from
vated.
service immediately and arrangements must be made for
replacement of the tire or tire assembly.
• a smooth, even cut through the cord plies which
BE SURE AND RETRACT ANY POWER DECK BEFORE LOWERING exceeds 3 inches (7.5 cm) in total length
MACHINE.
• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter

3121249 – JLG Lift – 3-1

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

• any damage to the bead area cords of the tire Tighten the lug nuts to the proper torque to prevent
wheels from coming loose. Use a torque wrench to tighten
If a tire is damaged but is within the above noted criteria, the fasteners. If you do not have a torque wrench, tighten
the tire must be inspected on a daily basis to ensure the the fasteners with a lug wrench, then immediately have a
damage has not propagated beyond the allowable crite- service garage or dealer tighten the lug nuts to the proper
ria. torque. Over-tightening will result in breaking the studs or
permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is as
Tire Replacement follows:

JLG recommends a replacement tire be the same size, ply 1. Start all nuts by hand to prevent cross threading. DO
and brand as originally installed on the machine. Please NOT use a lubricant on threads or nuts.
refer to the JLG Parts Manual for the part number of the 2. Tighten nuts in the following sequence:
approved tires for a particular machine model. If not using
a JLG approved replacement tire, we recommend that
replacement tires have the following characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to

the original

• Approved for the application by the tire manufacturer

(including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc., do

not replace a foam filled or ballast filled tire assembly with
a pneumatic tire. When selecting and installing a replace-
3. The tightening of the nuts should be done in stages.
ment tire, ensure that all tires are inflated to the pressure Following the recommended sequence, tighten nuts
recommended by JLG. Due to size variations between tire per wheel torque chart.
brands, both tires on the same axle should be the same.
Table 3-1. Wheel Torque Chart
Wheel Replacement TORQUE SEQUENCE

The rims installed on each product model have been 1st Stage 2nd Stage 3rd Stage
designed for stability requirements which consist of track 40 lb-ft 100 lb-ft 170 lb-ft
width, tire pressure, and load capacity. Size changes such (55 Nm) (130 Nm) (255 Nm)
as rim width, center piece location, larger or smaller diam-
4. Wheel nuts should be torqued after first 50 hours of
eter, etc., without written factory recommendations, may
operation and after each wheel removal. Check
result in an unsafe condition regarding stability. torque every 3 months or 150 hours of operation.

Wheel Installation
It is extremely important to apply and maintain proper
wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE

PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN
STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL
FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED
TO THE CONE ANGLE OF THE WHEEL.

3-2 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Drive Assembly

1. Tire & Rim

4 2. Lugnuts
5 3. Drive Motor/Hub Assembly
(Bosch Rexroth)
4. Bolt, 5/8"-11NC x 1 1/2"
1 5. Hardened Washer

NOTE: Rear Axle Shown

2
Figure 3-1. Drive Assembly (Bosch Rexroth )

REMOVAL: INSTALLATION:
1. Follow "Removal" procedures in reverse order.
SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO 2. Refer to Table 3-1, Wheel Torque Chart when
PREVENT MACHINE FROM MOVING DURING REPAIRS. torqueing Lugnuts (2).

1. Disconnect, cap and label all hydraulic lines NOTE: For detailed information on the Drive Motor/Hub
Assembly, refer to Section 3.3, Integrated Torque/
attached to Drive Motor/Hub Assembly (3). If appli-
cable, disconnect all electrical wiring. drive hub (Bosch Rexroth).

2. With axle raised and supported, remove the Tires (1)

from the drive motor/hub assembly by removing the
9 Lugnuts (2).
3. Remove the Drive Motor/Hub Assembly (3) by
removing the 6 Bolts (4) and Hardened Washers (5).

3121249 – JLG Lift – 3-3

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Tire & Rim

7 2. Lugnuts
8
3. Drive Hub (Fairfield)
4. Bolt, 5/8"-11NC x 1 3/4"
5. Hardened Washer, 5/8"
6. Drive Motor (Sauer)
1 6
7. Nut, 1/2"-13NC
8. Hardened Washer, 1/2"
3 NOTE: Rear Axle Shown
5
4

2
Figure 3-2. Drive Assembly - (Fairfield/Sauer)

REMOVAL: INSTALLATION:
1. Follow "Removal" procedures in reverse order.
SHUT MACHINE OFF, BRACE AXLES AND CHALK WHEELS TO 2. Refer to Table 3-1, Wheel Torque Chart when
PREVENT MACHINE FROM MOVING DURING REPAIRS. torqueing Lugnuts (2).

NOTE: For detailed information on the Drive Hub and Drive

1. Disconnect, cap and label all hydraulic lines
Motor, refer to Section 3.4, Drive Hub (Fairfield) and
attached to Drive Motor (6). If applicable, disconnect
Section 3.5, Drive Motor (Sauer).
all electrical wiring.
2. With axle raised and supported, remove the Tires (1)
from the Drive Hub (3) by removing the 9 Lugnuts
(2).
3. Remove the Drive Hub (3) and Drive Motor (6) from
the axle by removing the 6 Bolts (4) and Washers
(5).
4. The Drive Motor (6) can be removed from the Drive
Hub (3) by removing the 2 Nuts (7) and Washers (8).

3-4 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.3 INTEGRATED TORQUE/DRIVE HUB .

(BOSCH REXROTH)
The Integrated Torque/Drive Hub is an axial piston-
hydraulic motor with integrated, hydraulic released multi
plate parking brake and a 2-stage planetary gearbox and
a disconnect mechanism.

To ensure an optimum balancing of loads, each planetary

stage is comprised 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.

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 X3
WORKING PROPERLY.

Roll Test
The purpose of a roll test is to determine if the unit’s gears
are rotating freely and properly. Gears should be able to X
be rotated by applying a constant force to the roll checker.
T
If more drag is felt in the gears only at certain points, then
the gears are not rolling freely and should be examined for MA MB
proper installation or defects. Some gear packages roll
with more difficulty than others. Do not be concerned if
gears seem to roll hard as long as they roll with consis-
tency. 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 Figure 3-3. Integrated Torque/Drive Hub
the air checker starts to fall once the unit has been pres-
surized. Leaks will most likely occur at main seal or wher-
ever o-rings or gaskets are located. The exact location of Table 3-2. Torque/Drive Hub Specs
a leak can usually be detected by brushing a soap and
water solution around the main seal and where o-rings or Gearbox
gaskets meet the exterior of the unit, then checking for air Maximum Output Speed 30.25 rpm
bubbles. If a leak is detected in a seal, o-ring, or gasket,
Maximum Output Torque 4556.5 lb-ft (6177.7 Nm)
the part must be replaced.
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

3121249 – JLG Lift – 3-5

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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 3-4. Drive Motor/Hub Assembly

3-6 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-3. 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
- Inspect visually VEHICLE.
Weekly: - Check for unusual noise
- Check oil level ENGAGING PROCEDURE:
- Check the tightness of all screws
Monthly:
and bolts
Semi-annually: - Check oil quality PRIOR TO ENGAGING, THE MACHINE HAS TO BE ON LEVEL
GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT.
Annually: ENSURE AREA SURROUNDING THE DISCONNECT IS CLEANED
(or after 1500 motor operating - Change oil PRIOR TO OPERATION. MAKE SURE DIRT OR OTHER CONTAMI-
hours, whichever comes first) NANTS DO NOT ENTER THE GEAR DRIVE.

Disconnect Mechanism
CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING.
The disconnect mechanism on the torque/drive hub GEAR DRIVE MAY BE HOT AND CAUSE INJURY IF RECENTLY
allows the machine to be towed. When activated, the OPERATED.
mechanism disconnects the gear drive and motor.

DISENGAGING PROCEDURE:
THE COVER (28) IS UNDER SPRING FORCE.

For numbers in parenthesis, refer to Figure 3-4., Drive

PRIOR TO DISENGAGING, THE MACHINE MUST BE ON LEVEL Motor/Hub Assembly.
GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT.
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-
2. Remove the Cover.
NANTS DO NOT ENTER THE GEAR DRIVE.
3. Rotate the Cover 180° and assemble.
4. Tighten 2 Bolts (30) with a torque wrench to 6.3 lb-ft
(8.5 Nm).
CHECK GEAR DRIVE TEMPERATURE PRIOR TO HANDLING.
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 parenthesis, refer to Figure 3-4., Drive
Motor/Hub Assembly.
DO NOT OPERATE THE MOTOR TO OBTAIN ENGAGEMENT.
1. Remove the 2 Bolts (30) from the Cover (28).
6. Check again that all bolts are tight and that all com-
2. Remove the Cover.
ponents are returned to their original position.
3. Rotate Cover to show inside diameter. The gear drive should now be reengaged and the
machine can be disconnected from the towing vehicle.
4. Press Cover sufficiently against the Shift Rod (33) to
insert the 2 Bolts at least 2-3 threads into the Cover.
The Shift Rod is now subjected to the Spring (32)
force.

5. Install the 2 Bolts (30) and tighten until they are flush
with the Cover (28) with a torque wrench to 6.3 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.

3121249 – JLG Lift – 3-7

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Gearbox Disassembly 4. Remove Sun Gear Shaft (25).

For numbers in parenthesis, refer to Figure 3-4., Drive

Motor/Hub Assembly.

1. Remove Screw Plugs (18, 19) and drain oil into

appropriate container.

5. Remove complete 1st planet stage.

2. 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).

3-8 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7. Remove Snap Rings (13). 10. Drilling Hole Sketch

8. Pull out 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).

DO NOT DAMAGE THE BEARING CAGE OF THE BEARING (11).

DO NOT TURN THE SHAFT NUT; POSSIBILITY OF SPINDLE
THREAD DAMAGE.

DO NOT DAMAGE THE BEARING CAGE OF TAPERED ROLLER

BEARING. CAREFULLY REMOVE METAL CHIPS.

3121249 – JLG Lift – 3-9

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

12. Remove the Support Ring (6) from the Spindle (34). 15. Repair deformed threads on the Spindle (34) in the
Components stay in Supporting Ring (6). area of the ball detend with a thread file of 1.5mm
pitch.

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 out 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 the Sun 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.

3-10 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

c. Secure the gears with new Snap Rings (12). 5. Insert the bottom part of the double Tapered Roller
Bearing (11).

NOTE: Heat Supporting Ring (6) to approximately 189.5° F

(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).

3121249 – JLG Lift – 3-11

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

8. Heat upper ring with roller cage of double Tapered b. The Loctite® setting time equals 24 hours at
Roller Bearing (11) to approximately 189.5° F (70° C) ambient temperature of 68° F (20° C).
and mount onto Spindle (34). 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).

3-12 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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:

a. Determine clearance between contact face of
15. Install the ring gear hex head bolts. Tighten bolts to Sun Gear (3) and Sun Gear Shaft (25). (Recom-
proper torque of 15.5 lb-ft (21 Nm). mended clearance 1.0 -1.5mm)
19. Carefully insert a new greased O-ring (23) into the o-
ring groove of Ring Gear (22).

3121249 – JLG Lift – 3-13

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

20. Insert Shift Rod (33) into preassembled Cover (8). 23. Install Plugs (18) with new Seal Rings (19) into
Cover (8).

21. Install preassembled Cover (8) into Ring Gear (22).

22. Install Snap Ring (24).

NOTE: Prior to operating, fill the drive with new oil.

3-14 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-5. Drive Hub Assembly

3121249 – JLG Lift – 3-15

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Motor Disassembly 3. Disassemble guide ring:

a. Seal Ring (1)
1. Mark port plate to the supporting axle.
b. Pressure Springs (2) (quantity = 26)
c. Guide Ring (3)

1 3

2. Remove port plate.

4. Disassemble retaining ring.

3-16 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

5. Disassemble bearing with synchronizing plate. 8. Disassemble lamination kit.

6. Remove pressure ring with extractor. 9. Disassemble Seeger snap ring.

7. Remove pressure ring. 10. Disassemble cradle stop with 2 screws, M4 x 75mm.

3121249 – JLG Lift – 3-17

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

11. Disassemble rotary group completely with cradle. 14. Disassemble shaft seal ring.

15. Insert disc. Pull off bearing ring with device.

Remove disc.
12. Disassemble control piston with spring.

13. Pull out swivel balls. 16. Disassemble bearing ring from port plate.

3-18 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

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).

3121249 – JLG Lift – 3-19

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

3
1

23. Check that sliding surface is free of grooves (1);

cups are free of grooves 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).

3-20 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

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

29. Install shaft in supporting axle (1). Place in simula-

tion ring (2). Mount bearing with port plate, fix with 2
screws (3)

3121249 – JLG Lift – 3-21

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Motor Assembly 2. Install rotary group with cradle. Observe installation

position of swivel balls.
1. Press in swivel balls (with tool) (1). Insert shaft seal
ring (with tool) (2). Insert control piston with spring NOTE: Slightly grease swivel balls.
(3).

3. Mount sleeve and pressure ring in cradle stop. Insert

cradle stop.

NOTE: Stick with grease.

2
3

3-22 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Mount Seeger snap ring. Opening of snap ring must 6. Assemble piston with retaining plate. Oil piston and
be on the opposite side of the control piston. slipper pad.

7. Assembly aid: Hold the pistons by using an o-ring.

5. Fit pressure pins using an assembly aid. Pre-tension

the spring using a suitable device.

3121249 – JLG Lift – 3-23

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

8. Install laminations in correct order. 10. Grease seal rings, install in supporting axle.

9. Mount support ring (1) and quad ring (2) in pressure

ring. Be careful not to excessively extend the rings.

1 2
11. Mount retaining ring.
21

3-24 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

12. Mount seal rings (1). Insert and line-up guide ring. 14. Mount synchronizing disc (1) and bearing (2).

2
1

15. Mount bearing ring with device. Mount spool.

Mount fixation pin.

13. Align the two holes for fixation cylinder pin - port
plate (item 2).

Item 2

3121249 – JLG Lift – 3-25

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

16. Fix control plate with grease at port plate. 18. Mount and screw port plate on supporting axle.

17. Fill case with oil.

3-26 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.4 DRIVE HUB (FAIRFIELD) The following steps describe the proper procedure for
tightening and torquing bolts or socket head cap screws
in a bolt circle.
Roll and Leak Testing
1. Tighten (but do not torque) bolt ”A” until snug.
Always roll and leak test Drive-Hubs after assembly to 2. Go to the opposite side of the bolt circle and tighten
make sure that the unit’s gears and sealants are working bolt ”B” until equally snug.
properly. The following information briefly outlines what to
look for when performing these tests. 3. Continue around the bolt circle and tighten the
remaining bolts.
THE ROLL TEST 4. Now use a torque wrench to apply the specified
torque to bolt ”A”.
The purpose of a roll test is to determine if the unit’s gears
are rotating freely and properly. You should be able to 5. Continue around the bolt circle and apply an equal
rotate the gears in your unit by applying a constant force torque to the remaining bolts.
to the roll checker. If you feel more drag in the gears only
at certain points, then the gears are not rolling freely and Oil Information
you should examine them for improper installation or
defects. Some gear packages roll with more difficulty than 1. TYPE – EP90
others. Do not be concerned if the gears in your unit seem On normal applications, use EP90. On applications
to roll hard as long as they roll with consistency where the lubricant must meet special requirements,
the O.E.M. should be able to recommend a suitable
THE LEAK TEST substitute.
2. OIL TEMPERATURE
The purpose of a leak test is to make sure the unit is air Continuous – 160°F [70°C] Intermittent – 200°F
tight. You can tell if your unit has a leak if the pressure [95°C]
gauge reading on your air checker starts to fall once you
have pressurized the unit. Leaks will most likely occur at 3. OIL CHANGE
the main seal or wherever o-rings or gaskets are located. Initial – After 50 hours or 50,000 revolutions of oper-
Usually you can detect the exact location of a leak by ation. Subsequent – After 1000 hours or (1) year,
brushing a soap and water solution around the main seal whichever comes first.
and where o-rings or gaskets meet the exterior of the unit, NOTE: Higher temperatures make it necessary to change oil
then checking for air bubbles. If you detect a leak in a more frequently.
seal, o-ring, or gasket, replace the part immediately.
4. OIL FILL LEVEL AND VOLUME
Tightening and Torquing Bolts Unit mounted horizontal – half full
Approximate volume - 17 oz. (0.5 ltr)
“A” 5. REAR BRAKES
Rear brakes require 2.7 oz. (0.08 ltr) of DTE 13M
hydraulic fluid each to function properly.

“B”
If you use an air impact wrench to tighten bolts, take
extreme care to ensure that you do NOT tighten the bolts
beyond their indicated torque specification. Never use an
impact wrench to tighten shoulder bolts. Always tighten all
shoulder bolts by hand.

3121249 – JLG Lift – 3-27

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7B
7D 16
7C 29
7D
7 28
6F 30
6E 7A
10
6D
39 20
6C
6H 6G 2
6I 40
6 41
6G 6B
1I 37
1H 22
11 11
1F
6A
21

1E
1 24
5A

1G 21

4
15
24

5 3G 1J 19
3E
1D
34
33
1C
3
3A 27
1B
3B 1 36
14 3C 1A 35
3D
8 3C 25
38
13
3F
9
3B 12 26

32
23 31
23

17
18

Figure 3-6. Drive Hub

3-28 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTE: Refer to Figure 3-6., Drive Hub. Table 3-4. Drive Hub Part Description

Item # Description
Table 3-4. Drive Hub Part Description
11 Dowell Pin
Item # Description 12 Coupling
1 Spindle/Housing Assembly 13 Input Spacer
1A Spindle 14 Input Spacer
1B Seal 15 Brake Assembly
1C Bearing Cone 16 O-Ring
1D Bearing Cup 17 Threaded Rod
1E Bearing Cup 18 Nut 1/2"-13NC
1F Bearing Cone BRAKE ASSEMBLY
1G Housing/Ring Gear 19 Shaft
1H Thrust Washer 20 Housing
1I Retaining Ring 21 Friction Plate
1J Wheel Stud 22 Pressure Plate
2 Internal Gear 23 Gasket
3 Carrier Assembly 24 Outer Plate
3A Carrier 25 Gasket
3B Retaining Ring 26 Cylinder
3C Needle Bearing 27 Piston
3D Thrust Washer 28 Ball Bearing
3E Planet Shaft 29 Retaining Ring
3F Planet Gear 30 Shaft Seal
3G Rollpin 31 Capscrew
4 Ring Gear 32 Lockwasher
5 O-Ring 33 O-Ring
5A O-Ring 34 Back-up Ring
6 Cover Assembly 35 O-Ring
6A Thrust Spacer 36 Back-up Ring
6B Cover Plate 37 Dowel Pin
6C O-Ring 38 Plug
6D Disconnect Rod 39 Plug
6E Disengage Cap 40 Spring Kit (Natural)
6F Bolt 1/2"-20NC x 1/2" 41 Spring Kit (Blue)
6G Pipe Plug
6H Rivet
6I ID Plate
7 Input Shaft Assembly
7A Shaft
7B Retaining Ring
7C Spring
7D Thrust Spacer
8 Sun Gear
9 Thrust Washer
10 Bolt

3121249 – JLG Lift – 3-29

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

1. Hub-Spindle Sub-Assembly 2. Internal Gear 6 A. Cover 7 C. Spring

1 A. Spindle 3. Carier Sub-Assembly 6 B. Cover Cap 7 D. Spacer
1 B. Seal 3 A. Carrier Housing 6 C. Bolt 8. Input Gear
1 C. Bearing Cup 3 B. Thrust Washer 6 D. Disconnect Cap 9. Thrust Spacer
1 D. Bearing Cone 3 C. Needle Roller 6 E. Disconnect Rod 11. Thrust Spacer
1 E. Bearing Cup 3 D. Spacer 6 F. O Ring 12. Bolt
1 F. Bearing Cone 3 E. Planet Shaft 6 G. O Ring 13. Shoulder Bolt
1 G. Hub 3 F. Cluster Gear 6 H. Pipe Plug 14. Coupling
1 H. Spacer 3 G. Roll Pin 6 I. ID Plate 16. Flat Washer
1 I. Retaining Ring 4. Ring Gear 7. Input Shaft Sub Assembly
1 J. Pipe Plug 5. O Ring 7 A. Seal
1 K. Stud 6. Cover Sub-Assembly 7 B. Retaining Ring

Figure 3-7. Drive Hub (Cross-Section)

3-30 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Main Disassembly for Drive Hub

NOTE: Refer to Figure 3-7. for part location and listing. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU
REMOVE THE O-RING.
1. Turn hub (1G) over onto its side. Remove coupling
(14) from the wide end of spindle (1A). 16. Remove o-ring (5) from the counterbore in hub (1G).
Discard the o-ring.
2. Mark location of shoulder bolt holes on outside of
ring gear and hub for easy re-alignment when 17. At this point the main disassembly for drive hub is
rebuilding. Remove the four shoulder bolts (13) and complete.
twelve bolts (12) from cover (6).
3. Remove the sixteen flat washers (16) from cover (6).
Hub-Spindle Disassembly
4. Lift cover sub-assembly (6) off of ring gear (4), and NOTE: Start with large end of hub facing up, large end of
set cover on table, interior side facing up. spindle facing down.

CAUTION: BEWARE OF SHARP EDGES IN THE COUNTERBORE

WEAR SAFETY GLASSES DURING THIS STEP.
WHEN YOU REMOVE THE O-RING.
1. Remove retaining ring (1I) from around spindle (1A)
5. Remove o-ring (5) from the counterbore around the
in hub (1G).
edge of cover (6A). Discard the o-ring.
2. Remove spacer (1H) from around spindle (1A) in
NOTE: If o-ring is not in the cover counter- bore, it is in the
hub (1G).
ring gear counterbore. Remove it from the hub and
discard it. 3. Set hub (1G), small end/spindle facing down, up on
something that will support the hub’s flange while it
6. Remove thrust washer (11) from the counter- bore in lifts hub up so spindle is not resting on anything.
top of carrier (3A). Carefully press or hammer spindle (1A) down and
out of hub (1G).
7. Remove input gear (8) from the middle of carrier
sub-assembly (3). NOTE: If seal (1B) and bearing cone (1D) come out of hub
8. Lift ring gear (4) off of hub (1G). and rest on spindle, remove these parts from the
spindle and set them aside. Discard the seal.
9. Lift carrier sub-assembly (3) out of hub (1G).
4. If seal and bearing cone did not come out of the
10. Remove thrust spacer (9) from input shaft (7) in the
small end of hub (1G) when spindle is pressed out
middle of spindle (1A).
of hub, remove seal (1B) and bearing cone (1D)
11. Lift input shaft sub-assembly (7) out of middle of from the small end of hub. Discard the seal.
spindle (1A), and stand input shaft (7A) on its
splined end. 5. Bearing cone (1F) should be lying loose in wide end
of hub (1G). Remove bearing cone (1F) from inside
hub.

WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE NOTE: If you use a punch and hammer, make sure you do
THAT SPRING AND SPACERS COMPRESSED BY RETAINING not strike the counterbore with the punch when you
RING MAY POP SUDDENLY OFF SHAFT WHEN YOU REMOVE THE remove the bearing cup.
RETAINING RING.
6. Remove bearing cup (1C) from the counterbore in
12. Using retaining ring pliers, remove retaining ring the small end of hub (1G).
(7B) from the groove on input shaft (7A).
NOTE: If using a punch and hammer, make sure to not
13. Remove one spacer (7D), one spring (7C), and strike the counterbore with the punch when remov-
other spacer (7D) from input shaft (7A). ing the bearing cup.
14. Remove thrust washer (11) from around spindle
(1A). 7. Turn hub (1G) over and lift it out of the flange-sup-
port. Remove bearing cup (1E) from the counterbore
15. Lift internal gear (2) out of hub (1G). in the wide end of hub.

3121249 – JLG Lift – 3-31

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

8. Turn hub (1G) over onto its small end. Remove two 5. Remove one spacer (3D) from inside cluster gear
pipe plugs (1J) from the two pipe plug holes in the (3F).
side of hub.
6. Remove the remaining 16 needle rollers (3C) from
NOTE: If the unit does not have studs, skip this step: the other side of cluster gear (3F). Discard the nee-
dle rollers.
9. Press the nine studs (1N) out of the stud holes in
7. Repeat steps 1-6 to remove and disassemble the
hub (1G). two remaining cluster gears.
10. At this point the hub-spindle disassembly is com- 8. At this point the carrier disassembly is complete.
plete.
Assembly of the Carrier
Cover Disassembly
1. Apply grease to the inside of one cluster gear (3F)
1. Remove the two bolts (6C) holding disconnect cap and line one half of cluster gear with 16 needle roll-
(6D) to cover (6A). ers (3C).
2. Remove disconnect cap (6D) from top of cover cap
(6B) and cover (6A).
3. Remove the two bolts (6C) attaching cover cap (6B)
to cover (6A).
4. Remove cover cap (6B) from cover (6A).
5. Remove disconnect rod (6K) from cover cap (6B).
6. Pry o-ring (6F) out of the groove inside cover cap
(6B). Discard the o-ring.
7. Remove o-ring (6G) from the flange of cover cap
(6B). Discard the o-ring.
2. Place one spacer (3D) inside cluster gear (3F) so
8. Remove pipe plug (6H) from cover (6A).
that it rests on top of the needle rollers.
9. At this point the cover disassembly is complete.

Carrier Disassembly
NOTE: When removing the needle rollers from the cluster
gears, discard the old needle rollers and use new
ones during re-assembly.

1. Using a punch and hammer, drive roll pin (3G) into

planet shaft (3E).

NOTE: Be sure to drive the roll pin all the way into the planet
shaft. Failure to do so could result in damage to the
carrier when removing the planet shaft from the car- 3. Line the remaining half of cluster gear (3F) with 16
rier. needle rollers.

2. Using a punch and hammer, drive the planet shaft

(3E) out of the planet shaft hole in the carrier hous-
ing (3A).
3. When removing the planet shaft (3E) from the carrier
housing, one thrust washer (38), one cluster gear
(3F), and one more thrust washer will come off of the
planet shaft and come to rest inside the carrier.
Remove these parts from inside the carrier.
4. Remove 16 needle rollers (3C) from inside one end
of cluster gear (3F). Discard the needle rollers.

3-32 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Set carrier housing (3A) sideways on a table. Insert a 7. Following the cluster gear, place one more thrust
planet shaft (3E), roll pin hole last, into one of the washer (3B) onto planet shaft (3E) through the
planet shaft holes from roll-pin-holed side of carrier opposite planet shaft hole in carrier housing (3A).
housing.

8. Use an alignment punch or similar tool to align the

5. Place one thrust washer (3B) onto the end of planet roll pin holes in carrier housing (3A) and planet shaft
shaft (3E) inside carrier. Fit tang of thrust washer into (3E).
the slot on the inside edge of the planet shaft hole.

9. Drive roll pin (3G) down into the aligned roll pin
6. Following the thrust washer, place the cluster gear holes in carrier housing (3A) and planet shaft (3E).
(3F), large end toward roll pin hole in carrier hous-
ing, onto the planet shaft (3E).

10. Repeat steps 1 thru 9 to assemble and install the

two remaining cluster gears.
11. At this point the carrier sub-assembly is complete.

3121249 – JLG Lift – 3-33

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover
cap (6B) onto cover (6A), aligning the pipe plug hole
1. Using the disconnect rod, push o-ring (6F) into the in the cover cap over the pipe plug hole in the cover.
groove inside the cover cap (6B).

5. Place two of the cover cap bolts (6C) into any two
2. Place the o-ring (6G) onto the cover cap (6B) so that
it rests against the flange of the cover cap. bolt holes that are 180° apart on the cover cap (6B)
and tighten bolts.

3. Insert disconnect rod (6E) into cover cap (6B).

6. Using a torque wrench, apply 2.95 to 3.69 ft. lbs. (4
to 5 Nm) of torque to both bolts (6C).

3-34 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

7. With the large end down, place the disconnect cap 10. Apply a light coat of "Never-Seize" to pipe plug (6H)
(6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover
hole in the disconnect cap over the pipe plug hole in (6A).
the cover cap.

8. Place the two remaining bolts (6C) into the bolt

Hub-Spindle Sub-Assembly
holes in the disconnect cap (6D), and tighten the NOTE: Make sure the cup sits square with the counterbore
bolts. before pressing.

1. Set hub (1G) onto its large end. Press bearing cup
(1C) into the counterbore in the small end of the hub
(1G).

9. Using a torque wrench, apply 2.95 to 3.69 ft. lbs. (4

to 5 Nm) of torque to both bolts (6C).

2. Press the nine studs (1N) into the stud holes in hub
(1G).

3121249 – JLG Lift – 3-35

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3. Apply a light coat of "Never-Seize" to two pipe plugs 6. Press seal (1B) into the small end of hub (1G).
(1J) and tighten them into the two pipe plug holes in
the side of the hub (1G).

7. Oil spindle, then lower hub (1G), small end down,

onto spindle (1A).
NOTE: Make sure the cup sits square with the counterbore
before pressing.

4. Turn hub (1G) over onto its small end. Press bearing
cup (1E) down into the counterbore in the deep end
of the hub (1G).

8. Press bearing cone (1F) onto spindle (1A) in hub

(1G).

5. Set hub (1G) onto its large end. Place bearing cone
(1D) into bearing cup (1C).

3-36 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

9. Place spacer (1H) onto spindle (1A) in hub (1G). Main Assembly

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALL-

ING THE O-RING

1. Grease o-ring (5) and place it into the counterbore in

hub (1G).

NOTE: O-ring may be stretched or pinched together to

make it fit the counterbore exactly.

NOTE: Make sure the retaining ring is securely seated in the

groove.

10. Place retaining ring (1I) over the spacer onto spindle
(1A) in hub (1G).

2. Oil all exposed surfaces inside hub (1G).

11. At this point the hub-spindle sub-assembly is com-

plete.

3. Place internal gear (2) into hub (1G) so that its inter-
nal splines mesh with the external splines of spindle
(1A). Oil internal gear (2).

3121249 – JLG Lift – 3-37

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Place thrust washer (11) around spindle (1A) so it 7. Place other spacer (7D) onto the smooth end of
rests on the bottom of the internal gear (2). input shaft (7A).

5. Stand input shaft (7A) on its splined end. Place one

spacer (7D) onto the smooth end of input shaft (7A).
WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE
THAT SPRING AND SPACERS, COMPRESSED BY RETAINING
R I N G , M A Y P OP S U D DE N LY OF F S H A FT I F TH E RI N G I S
RELEASED BEFORE IT IS PROPERLY IN PLACE.

8. Using retaining ring pliers, insert retaining ring (7B)

into the groove on input shaft (7A) by compressing
the spring and spacers together.

6. Place one spring (7C) onto the smooth end of input

shaft (7A).

9. With large splined end down, place input shaft sub-

assembly (7) into spindle (1A).

3-38 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

10. Place thrust spacer (9) onto input shaft (7). the location of shoulder bolt holes on the outside of
ring gear and hub.

NOTE: You may lift the ring gear off the hub to align the
shoulder bolt holes. The ring gear and carrier are
installed together only to keep the punch marks on
the carrier in place.

11. Set carrier sub-assembly (3) on a flat work surface

so the large ends of cluster gears (3F) face up.
Locate the punch marks on the face of each cluster
gear (3F) and position them at 12 o’clock.

14. With the internal splines facing up (counterbore end

facing down), place input gear (8) into mesh with
carrier sub-assembly (3).

Figure 3-8. Cluster Gear Punch Marks

12. With "X" marked side facing up, place the ring gear
(4) around cluster gears (3F).

NOTE: This will hold the punch marks in position while 15. Oil all exposed surfaces inside the hub (1G). Place
installing the carrier into the hub. thrust washer (11) into the counterbore in top of the
carrier.

13. Place the carrier sub assembly (3) and ring gear (4)
together into mesh with internal gear (2), aligning
the "X" marked shoulder bolt hole in the ring gear (4) BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN YOU
over one of the shoulder bolt holes in the hub. Mark INSTALL THE O-RING.

3121249 – JLG Lift – 3-39

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

16. Set the cover (6A) on table, interior side up. Grease 19. Place shoulder bolts (13) into the four shoulder bolt
o-ring (5) and place it into the counterbore around holes in cover (6) and tighten by hand.
the edge of cover (6A).

NOTE: The o-ring may be stretched or pinched together to

make it fit the counterbore exactly.

20. Place the remaining 12 flatwashers (16) onto the

remaining bolt holes in cover (6).

17. Place cover sub-assembly (6) onto ring gear (4),

aligning the pipe plug holes according to the align-
ment prior to disassembly.

21. Place the 12 bolts into the remaining bolt holes in

cover (6) and tighten.

18. Place four flatwashers (16) on top of the bolt holes in

the cover sub-assembly.

3-40 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

22. Torque the shoulder bolts (13) 18 to 25 ft. lbs. (25 to 25. Leak test the unit at a pressure of 5 psi (0.34 bar) for
34 Nm). Torque bolts (12) 18 to 25 ft. lbs. (25 to 34 2 to 3 minutes.
Nm).

26. At this point the main assembly is complete.

23. Turn hub (1G) over onto its side. Insert coupling (14)
into the end of the spindle (1A).

24. Roll test the unit in both clockwise and counterclock-

wise directions. Perform the same number of turns
in each direction as the ratio of the unit. The ratio is
the last two digits of the model number on the unit’s
ID tag.

3121249 – JLG Lift – 3-41

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Tool List 3. T-140433 ASSEMBLY PRESSING TOOL for CUP

(1E)
The following specialized tools are used to assemble this
unit. The tool diagrams included in this manual are
intended for the customer who may wish to have a tool
made. All tools exist as one piece and must be made from
mild steel All dimensions are given in inches.

NOTE: In order to improve tool life, tools may be carburized

and hardened. If this is done, however, the tools
must be ground on all surfaces labeled with a "G" on
the tool diagram.

1. T-118126 SEAL PRESSING TOOL for SEAL (1B).

4. T-109691 ASSEMSLY PRESSING TOOL for CONE

(1F)

* These tools are for specific seals, cups or cones. There

is a specific tool for each cup and cone.

2. T-138903 ASSEMBLY PRESSING TOOL for CUP

Re-Aligning Torque Hub Input Coupling
(1C) The following procedure applies to torque hubs with inte-
gral brakes.

EQUIPMENT REQUIRED
1. Hydraulic power supply (hand pump) capable of
producing 200 psi (13.8 bar).

2. Hydraulic fittings to adapt hydraulic supply to brake

release port on hub.

PROCEDURE
1. Using appropriate fittings, connect a line from the
hydraulic power supply to the brake port.

2. Pressurize the brake release port 155 to 200 psi

(10.6 to 13.8 bar) to release the brake.

3. Verify that the brake is released by rotating the input

coupling or hub spindle.

4. Once the brake is released, the input coupling will

be free to re-align with the drive motor.

3-42 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

5. Install the drive motor on the hub, then release the Shaft Seal Replacement
hydraulic pressure at the brake release port. The
coupling will remain in position. REMOVAL
Disconnect the hydraulic power supply and reconnect the 1. Remove the snap ring (1) retaining the shaft seal
line going into the brake release port. and support washer.

3.5 DRIVE MOTOR (SAUER) 1

Description 2

The drive motors are low to medium power, two-position

axial piston motors incorporating an integral servo piston. 3
They are designed for operation in both open and closed
circuit applications. The standard control is a direct acting
single line hydraulic control. The integral servo piston con-
trols motor displacement.
The motors are spring biased to maximum displacement
and hydraulically shifted to minimum displacement. Mini-
mum and maximum displacement can be set with fixed
internal stops. The large diameter servo piston allows
smooth acceleration and deceleration with relatively large 1. Snap Ring
circuit orificing. 2. Support Washer
3. Shaft Seal
Bias spring Figure 3-10. Removing the Shaft Seal
Servo piston
Minimum
Angle Swashplate
Stop 2. Remove the support washer (2).
3. Carefully pry out the shaft seal (3).
Output
Cylinder Shaft To avoid damaging the shaft during removal, install
Block a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and
use the slide hammer to pull the seal.
Shaft 4. Discard the seal.
Seal
Piston
Endcap Slipper Bearing
Valve plate

Figure 3-9. Drive Motor Cross Section

3121249 – JLG Lift – 3-43

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

INSPECT THE COMPONENTS 2. Using a 1/4 in hex wrench, remove plug (3).

Inspect the new seal, the motor housing seal bore, and 3. Remove O-rings (4, 5, and 6).
the sealing area on the shaft for rust, wear, and contami- 4. Using pliers, remove centering springs (7, 8, and 9).
nation. Polish the shaft and clean the housing if neces-
sary. 5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
INSTALLATION
7. Remove orifice poppet (13).
1. Cover the shaft splines with an installation sleeve to
protect the shaft seal during installation. INSPECT THE COMPONENTS
Inspect new O-rings and the sealing area for rust, wear, or
2. Install a new shaft seal with the cupped side facing
contamination. Also check springs and poppet for wear.
the motor. Press seal into housing until it bottoms
out. Press evenly to avoid binding and damaging INSTALLATION
the seal.
1. Install orifice poppet (13).
3. Install seal support washer.
2. Install shift spool (12).
4. Install snap ring. 3. Install spring retaining washers onto springs (10 and
5. Remove the installation sleeve. 11).
4. Carefully install centering springs (7, 8, and 9).
Loop Flushing Valve
5. Install new O-rings (6, 4, and 5).
REMOVAL 6. Using a 1/4 in hex wrench, torque plug (3) to 20 ft.
lbs. (27 Nm).
1. Using a 11/16 in internal hex wrench, remove plug
(1) and (2). 7. Using a 11/16 in internal hex, torque plugs (2 and 1)
6 to 27 ft. lbs. (37 Nm).
9
11
2
11/16 in
27 ft.lbs.
(37 Nm)

10 12
8
4

1 13
11/16 in
27 ft.lbs.
(37 Nm) 7

5/8 in
5 3 20 ft.lbs.
(27 Nm)

1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer

Figure 3-11. Loop Flushing Spool

3-44 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Troubleshooting
Table 3-5. Excessive Noise and/or Vibration

Item Description Action

Check oil level in reservoir Insufficient hydraulic fluid could lead to cavitation that would Fill the reservoir to the proper level and ensure that oil supply
and oil supply to the motor. cause system noise. to the motor is adequate and the lines are unobstructed.
Air trapped within the system lines, or the motor itself, could Ensure that all of the system lines and components are
Check for air in the system.
result in cavitation that would cause system noise. purged of air.
Inspect the output shaft A loose or incorrect shaft coupling will produce vibrations Ensure that the correct coupling is used and that it fits prop-
couplings. that could result in system noise. erly onto the shaft.
Inspect the output shaft Misaligned shafts create excessive frictional vibration that
Ensure that the shafts are properly aligned.
alignment. could result in system noise.
Hydraulic oil viscosity Viscosity above acceptable limits will result in cavitation that Replace hydraulic oil with appropriate fluid for operating
above limits. would lead to system noise. conditions.

Table 3-6. System Operating Hot

Item Description Action

Check oil level in reservoir Insufficient amount of hydraulic fluid will not meet the cool-
Fill the reservoir to the proper level.
and oil supply to the pump. ing demands of the system.
Ensure that heat exchanger is receiving adequate air flow
Inspect the heat exchanger, If the heat exchanger fails, or becomes obstructed, it may
and that the heat exchanger is in good operating condition.
(if so equipped). not meet the cooling demands of the system.
Repair or replace as necessary.
If a system relief valve becomes unseated for an extended Repair or replace any malfunctioning relief valves as appli-
Check the system relief
period of time or fails for any other reason, the system could cable and verify that the loads on the machine are not exces-
valves.
become overheated. sive.

Table 3-7. Won’t Shift or Slow to Start

Item Description Action

Obstructed or restricted flow through the servo control sig-
Check the signal line to the Ensure that the signal lines are not obstructed or restricted
nal lines could result in slow shift or no shift conditions
servo control port. and that signal pressure is adequate to shift the motor.
within the motor.
Check that the correct sup-
Supply and drain orifices determine the shift rate of the Ensure that the proper control orifices are installed in the
ply and drain orifices are
motor. The smaller the orifice, the longer the time it takes to motor and verify that they are not obstructed. Clean or
properly installed, and are
shift the motor. Obstruction will also increase shift times. replace as necessary.
not obstructed.

3121249 – JLG Lift – 3-45

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Disassembly
17
NOTE: Removal of the endcap voids warranty. 19

During assembly, coat all moving parts with a film of

clean hydraulic oil. This assures that these parts will
be lubricated during start-up.
15
Replace all O-Rings and gaskets.
14
It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.

21
6
9
5 11
2
7 18
13
3

16
10 12
8 16
4

1 20

14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
16. Control Line Plug 20. Drain Plug
17. Control Line Plug 21. Work Port Plug

Figure 3-13. Plugs, Fittings, and Speed

1. Plug 5. O-ring 9. Spring 12. Shift Spool Sensor
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet
3. Plug 7. Spring 11. Washer
4. O-ring 8. Spring 8. Remove all fittings from the unit. Discard any O-rings
on the fittings.
Figure 3-12. Loop Flushing Spool
9. Using an 11/16 in hex wrench, loosen the speed
sensor lock nut (14) if equipped. Then remove the
1. Using a 11/16 in wrench, remove plug (1) and (2).
speed sensor using a 1/2 inch hex wrench. Units
2. Using a 5/8 in hex wrench, remove plug (3). without speed sensor have an O-ring plug (15)
installed in that location; remove it with a 1/4 inch
3. Remove O-rings (4, 5, and 6).
internal hex wrench.
4. Using pliers, remove centering springs (7, 8, and 9).
10. Using a 1/4 in internal hex wrench, remove control
5. Remove spring retaining washers (10 and 11). line plugs (16, 17). Discard O-rings. Using a 3 mm
hex wrench, remove cavity plug (18, if equipped with
6. Remove shift spool (12).
two-line control) from X2 cavity.
7. Remove orifice poppet (13).
11. Using a 5/16 in internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

3-46 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

12. Using a 9/16 in internal hex wrench, remove work

port plugs (21, if equipped with axial ports). Discard
25
O-rings.

22
27
30

29
28
26
27
23

24

25. Valve Plate

26. End Cap
27. O-ring
22. Screw 28. Rear Shaft Bearing
23. End Cap 29. Minimum Angle Stop
24. O-ring 30. Servo Spring
Figure 3-14. End Cap Figure 3-15. Valve Plate & Rear Shaft Bearing

13. Using an 8 mm internal hex wrench, remove the

endcap screws (22).
14. Remove the endcap (23). Remove O-ring (24) from
TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE
the housing or endcap.
PLATE.
When the endcap screws are removed, pressure
from the servo spring will cause the endcap to bind 15. Remove the valve plate (25) and timing pin (26) from
on the shaft. Press down on the portion of the end- the endcap.
cap covering the servo piston and hold the endcap
level while removing. Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate
part number are stamped on its surface.

16. Remove and discard the O-rings (27).

17. Remove the rear shaft bearing (28) from the endcap
with a bearing puller.

The bearing may be difficult to remove with a puller.

Try this as an alternative: Pack the bearing cavity
with heavy grease. After the shaft is removed, insert
it into the bearing cavity and tap lightly with a soft
mallet on the splined end. The grease will force the
bearing out. Use caution not to drive the bearing
past the rear shaft journal as the bearing may
become trapped on the shaft and damaged.

3121249 – JLG Lift – 3-47

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

18. Remove minimum angle stop (29) and servo spring out the shaft seal (34). Discard the seal.
(30) from the housing.
To avoid damaging the shaft during seal removal,
install a large sheet metal screw into the chuck of a
slide hammer. Drive the screw into the seal surface
and use the slide hammer to pull the seal.

31
36
35
37

38
31. Cylinder Kit Assembly

Figure 3-16. Cylinder Kit

19. Turn the housing on its side and remove the cylinder
kit assembly (31). Set the assembly aside, being
careful not to scratch the running surface. 35. Inner Snap Ring
36. Snap Ring
NOTE: Grooves on the surface of the cylinder kit identify its 37. Bearing
displacement: 38. Shaft

Table 3-8. Displacement Identifiers Figure 3-18. Shaft & Front Bearing

# of Grooves Frame L Frame K

1 25 38 21. Remove the inner snap ring (35) and the shaft /
bearing assembly.
2 30 45
3 35 -- 22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).

32

33

34

32. Snap Ring

33. Support Washer
34. Shaft Seal

Figure 3-17. Shaft Seal

20. Turn the housing over and remove the snap ring
(32) retaining the shaft seal and support washer.
Remove the support washer (33) and carefully pry

3-48 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Lift here
44
39

45

47
40
48
43
42 49
41

46

53

52

39. Swashplate 50
40. Servo Piston 51
41. Piston Seal
42. O-ring
43. Journal Bearings

Figure 3-19. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring
45. Slipper Retainer 50. Block Spring Washer
46. Cylinder Block 51. Spiral Retaining Ring
23. Turn housing over and remove the swashplate (39) 47. Ball Guide 52. Block Spring
by lifting on the end opposite the servo lever. 48. Holddown Pins 53. Inner Block Spring Washer
24. Remove the servo piston (40). Remove the piston Figure 3-20. Cylinder Kit Disassembly
seal (41) and O-ring (42) from the servo piston. Dis-
card the seal and O-ring.
26. Remove pistons (44) and slipper retainer (45) from
25. Remove the journal bearings (43) from the housing.
the cylinder block (46).
If the bearings are to be reused, note the location
and orientation of each bearing for reassembly.
The pistons are not selectively fitted, however units
with high hourly usage may develop wear patterns.
Number the pistons and bores for reassembly if they
are to be reused.

27. Remove the ball guide (47), hold-down pins (48),

and retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems
with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK

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

3121249 – JLG Lift – 3-49

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

28. Turn the block over. Using a press, apply pressure SLIPPERS
on the block spring washer (50) to compress the
block spring. Compress the spring enough to safely Inspect the running surface of the slippers. Replace any
remove the spiral retaining ring (51). While maintain- piston assemblies with scored or excessively rounded
ing pressure, unwind the spiral retaining ring (51). slipper edges. Measure the slipper foot thickness.
Carefully release the pressure and remove the outer Replace any piston assemblies with excessively worn slip-
block spring washer (50), block spring (52), and
pers. Check the slipper axial end-play. Replace any piston
inner block spring washer (53) from the cylinder
block. assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end-

Inspection
play are given in the table below.
After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow to Table 3-9. Slipper Foot Thickness & End Play
air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area Measurement L Frame K Frame
and keep all parts free from contamination. Clean and dry 2.71 4.07
Slipper Foot Thickness
parts again after any rework or resurfacing. mm (0.11) (0.16)
(in.) 0.15
PISTON Piston/Slipper End Play
(0.006)
Inspect the pistons for damage and discoloration. Discol-
ored pistons may indicate excessive heat; do not reuse.
CYLINDER BLOCK

Measure the cylinder block height. Replace blocks worn

Maximum end play
beyond the minimum height specification. Inspect the run-
ning surface of the cylinder block. Replace or resurface
Minimum Slipper
slipper foot worn or scratched blocks. Blocks may be resurfaced to
thickness the specifications shown in the drawing, provided resur-
facing will not reduce the block height below the minimum
specification. Table 3-10, Cylinder Block Measurements.

Table 3-10. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
mm
(in.) 0.002 0.002 0.002 0.002 0.002
Cylinder Block Surface Flatness
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)

3-50 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

BALL GUIDE AND SLIPPER RETAINER Replace swashplate if the difference in thickness from one
side to the other exceeds specification.
Inspect the ball guide and slipper retainer for damage,
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not reuse.
0.0025 mm
[0.0001 in]
Slipper retainer
25.8 mm
LV [1.015 in]

KV 24.6 mm
[0.969 in]
Ball guide
Thickness equality
side to side:
0.05 mm [0.002 in]

VALVE PLATE
The condition of the valve plate is critical to the efficiency
of the motor. Inspect the valve plate surfaces carefully for
excessive wear, grooves, or scratches. Replace or resur-
face grooved or scratched valve plates. Measure the valve
plate thickness and replace if worn beyond the minimum Inspect the journal bearings for damage or excessive
specification. Valve plates may be resurfaced to the speci- wear. Replace journal bearings if scratched, warped, or
fications shown in the drawing, provided resurfacing will excessively worn. The polymer wear layer must be
not reduce the thickness below the minimum specifica- smooth and intact.
tion. SHAFT BEARINGS
3.83 mm [0.151 in] min.
Inspect bearings for excessive wear or contamination.
0.025 mm Rotate the bearings while feeling for uneven movement.
[0.001 in] Bearings should spin smoothly and freely. Replace bear-
ings that appear worn or do not rotate smoothly.

0.0076 mm
[0.00030 in]
convex max

SWASHPLATE AND JOURNAL BEARINGS SHAFT

Inspect the running face, servo ball-joint, and swashplate Inspect the motor shaft. Look for damage or excessive
journal surfaces for damage or excessive wear. Some wear on the output and block splines. Inspect the bearing
material transfer may appear on these surfaces and is surfaces and sealing surface. Replace shafts with dam-
acceptable providing the surface condition meets specifi- aged or excessively worn splines, bearing surfaces, or
cations shown. Measure the swashplate thickness from sealing surfaces.
the journals to the running face. Replace swashplate if
damaged or worn beyond minimum specification.

3121249 – JLG Lift – 3-51

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

SERVO PISTON AND MINIMUM ANGLE STOP Assembly

Inspect the minimum angle stop, servo piston head, and
servo piston ball-socket for damage or excessive wear. 1. Install new O-ring (1) and piston seal (2) to the servo
Replace if necessary. piston (3). Install the piston seal over the O-ring.

Installing the piston seal stretches it, making it diffi-

cult to install the servo piston in its bore. Allow 30
minutes for the seal to relax after installation. To
speed up seal relaxation, compress the seal by
installing the piston head into the servo cavity in the
end-cap and let it stand for at least five minutes.

2
3

LOOP FLUSHING SPOOL

Inspect the loop flushing spool. Check for cracks or dam- 1
age. Replace if necessary.

1. O-ring
2. Piston Seal
3. Servo Piston
Figure 3-21. Servo Piston

2. After piston seal has relaxed, lubricate and install

servo piston into the housing bore. Align the piston
with the ball socket facing the inside of the housing.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK

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

3-52 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3. Install the inner block spring washer (4), block 6. Install the journal bearings (13) into the housing
spring (5), and outer washer (6) into the cylinder seats. Use assembly grease to keep the bearings
block. Using a press, compress the block spring seated during assembly. Ensure the locating nubs
enough to expose the retaining ring groove. Wind drop into the cavities in the seats. If you're reusing
the spiral retaining ring (7) into the groove in the cyl- the bearings, install them in the original location and
inder block. orientation. Lubricate the journal bearings.

11 14
13
12

10

9
8
13

5
13. Journal Bearings
6 14. Swash Plate

7 Figure 3-23. Swash Plate and Journal Bearing

7. Install the swashplate (14) into the housing. Tilt the

swashplate and guide the servo lever ball into its
4. Block Spring Washer 9. Holddown Pins
socket in the servo piston rod. Ensure the swash-
5. Block Spring 10. Ball Guide
plate seats into the journal bearings and moves
6. Outer Washer 11. Piston
freely. Lubricate the running surface of the swash-
7. Spiral Retaining Ring 12. Slipper Retainer
plate.
8. Retaining Ring

Figure 3-22. Cylinder Kit Assembly

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylin-
der block.

5. Install the pistons (11) to the slipper retainer (12).

Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer
seats on the ball guide. If you're reusing the pistons,
install them to the original block bores. Lubricate the
pistons, slippers, retainer, and ball guide before
assembly. Set the cylinder kit aside on a clean sur-
face until needed.

3121249 – JLG Lift – 3-53

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated.
bearing onto shaft with lettering facing out. Lubricate Install the cylinder kit (19) onto the shaft. Install with
bearing rollers. Install snap-ring (17) onto shaft. the slippers facing the swashplate. Rock the shaft to
align the block splines and slide the cylinder kit into
place. Orient the motor with the shaft pointing down-
ward and verify the cylinder kit, swashplate, journal
bearings, and servo piston are all secure and prop-
erly installed.

19

15
16

19. Cylinder Kit

17 Figure 3-25. Cylinder Kit Installation

18
11. Lubricate and install the servo spring (20), and mini-
15. Front Shaft Bearing mum angle stop (21) into the housing bore.
16. Shaft
17. Snap Ring
18. Snap Ring

Figure 3-24. Shaft and Front Bearing

21

9. While holding the swashplate in place, turn the 20

housing on its side. Install the install shaft/bearing
assembly into housing from the flange end. Install
the snap-ring (18).

20. Servo Spring

21. Minimum Angle Stop

Figure 3-26. Servo Spring and Minimum

Angle Stop

3-54 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

12. Press the rear shaft bearing (22) into the endcap. 15. Install the endcap (25) onto the housing with the
Install the bearing with letters facing out. Press until endcap screws (26). Check to ensure the endcap
bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) will properly seat onto the housing without interfer-
above endcap surface. ence. Improper assembly of the internal compo-
nents may prevent the endcap from seating
22
23
3 mm properly. Ensure the O-rings seat properly when
[0.12 in]
2 mm installing the endcap.
[0.08 in]

26
8 mm
23 35-45 ft.lbs.
(47-61 Nm)
22

24

25

23

22. Rear Shaft Bearing 25. End Cap

23. Timing Pin 26. Screw
24. Valve Plate
Figure 3-28. End Cap
Figure 3-27. Valve Plate and Rear Bearing

16. Using an 8 mm internal hex wrench, tighten the end-

13. Install timing pin (23) into its bore in the endcap. cap screws. Tighten the screws in opposite corners
Install the pin with its groove facing toward or away slowly and evenly to compress the servo spring and
from the shaft. Press the pin until the end protrudes properly seat the endcap. Torque endcap screws
0.12 ±0.01 in (3 ±0.25 mm) above endcap surface. 35-45 lb-ft (47-61 Nm).

14. Install the valve plate (24) onto the endcap. Install 17. Before installing the shaft seal, ensure the shaft
the valve plate with the yellow surface toward the turns smoothly with less than 120 in.lbs. (13.5 Nm)
cylinder block. Align the slot in the valve plate with of force. If the shaft does not turn smoothly within
the timing pin. Apply a liberal coat of assembly the specified maximum force, disassemble and
grease to the endcap side of the valve plate to keep check the unit.
it in place during installation.

3121249 – JLG Lift – 3-55

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing.
a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and
motor. Press seal into housing until it bottoms out. installation torques.
Press evenly to avoid binding and damaging the
1/4 in
seal. Install seal support washer (28) and snap ring 5/16 in
63 ft.lbs. 33 ft.lbs.
(29). (85 Nm) (45 Nm)

29

28

27

9/16 in
125 ft.lbs.
(170 Nm)

3 mm
1.5 to 2.5 ft.lbs.
(2.03 to 3.39 Nm)
27. Shaft Seal
28. Seal Support Washer
29. Snap Ring
1/4 in
Figure 3-29. Shaft Seal 33 ft.lbs.
(45 Nm)

5/16in
63 ft.lbs.
(85 Nm)

Figure 3-30. Plugs and Fittings Installation

3-56 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

20. Install orifice poppet (30). Initial Start-up Procedures

37 Follow this procedure when starting-up a new motor or
36 when installing a motor that has been removed.
39 33
41
34
11/16 in
Prior to installing the motor, inspect for damage incurred
30
27 ft.lbs.
during shipping. Make certain all system components
40
(37 Nm) (reservoir, hoses, valves, fittings, heat exchanger, etc.) are
5/8 in
20 ft.lbs.
clean prior to filling with fluid.
(27 Nm)
1. Fill the reservoir with recommended hydraulic fluid.
32
31 Always filter fluid through a 10 micron filter when
35 pouring into the reservoir. Never reuse hydraulic
38 fluid.
42 2. Fill the inlet line leading from the pump to the reser-
11/16 in
voir. Check the inlet line for properly tightened fit-
27 ft.lbs.
(37 Nm) tings and ensure it is free of restrictions and air
leaks.
3. Fill the pump and motor housing with clean hydrau-
lic fluid. Pour filtered oil directly into the upper most
case drain port.
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug
4. To ensure the pump and motor stay filled with oil,
31. Shift Spool 35. Spring 38. O-ring 41. Plug
install case drain lines into the upper most case
32. Spring 36. Spring 39. O-ring 42. Plug drain ports.
33. Spring
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the
Figure 3-31. Loop Flushing Spool charge pressure gauge port of the pump to monitor
system pressure during start up.
6. While watching the pressure gauge, run the engine
21. Install shift spool (31).
at the lowest possible speed until system pressure
22. Install spring retaining washers onto springs (32 and builds to normal levels [minimum 160 psi (11 bar)].
33). Once system pressure is established, increase to full
operating speed. If system pressure is not main-
23. Carefully install centering springs (34, 35, and 36). tained, shut down the prime mover, determine
24. Install new O-rings (37, 38, and 39). cause, and take corrective action.

25. Using a 5/8 in wrench torque plug (40) to 20 lb-ft (27 7. Operate the hydraulic system for at least fifteen min-
Nm). utes under light load conditions.
8. Check and adjust control settings as necessary after
26. Using a 11/16 in wrench, torque plugs (41 and 42) to
installation.
27 lb-ft (37 Nm).
9. Shut down the prime mover and remove the pres-
sure gauge. Replace plug at the charge pressure
gauge port.
10. Check the fluid level in the reservoir; add clean fil-
tered fluid if necessary. The motor is now ready for
operation.

3121249 – JLG Lift – 3-57

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.6 FRONT AXLE

Steering Assembly

16
14
17
15 1
13 12
11
2 10
20
5 9
19
8
18 4
6 3
7
15 3
14
1. Steer Cylinder 6. Bearing 11. Washer 16. Thrust Washer
2. Screw, 3/4"D x 1 3/4" 7. Tie Rod 12. Cylinder Block 17. Bearing
3. Nut 8. End Bearing Rod 13. Spindle 18. Thrust Washer
4. Thrust Washer 9. Nut 14. Bolt, 3/8"-16 x 3/4" 19. O-ring
5. Thrust Washer 10. Bolt, 1/2"-13 x 3 1/2" 15. Kingpin 20. Bearing

Figure 3-32. Steering Assembly

STEER CYLINDER REMOVAL: 2. Support spindle. Disconnect tie rod (7) from spindle
by removing bolt (2), nut (3) and thrust washer (5).
1. Disable machine operation and block all wheels.
Disconnect, cap and label all hydraulic lines and 3. Remove spindle from axle by removing 8 bolts (14),
electrical wiring on steer cylinder (1). 2 kingpins (15), 5 thrust washers (16, 18) and o-ring
(19).
2. Support steer cylinder. Remove the screws (2), nuts
(3) and thrust washers (4) connecting cylinder to tie ASSEMBLY:
rod (7). Remove end bearing rod (8) and nut (9) 1. When assembling steer cylinder and spindle, follow
from cylinder. Removal Steps in reverse.
3. Remove 4 bolts (10) and washers (11) connecting NOTE: Apply Loctite® #242 to bolts (10, 14) and nut (3).
cylinder to axle. Carefully remove cylinder. Apply bearing grease lube to the grooves on the
bearings (17, 20) before installing.
Spindle Removal:
Ensure thrust washer (5) is between tie rod (7) and
1. Remove wheel and drive assembly prior to spindle top side of spindle (13).
(13) removal (refer to Figure 3-1., Drive Assembly Refer to Figure 4-28., Steer Cylinder for steer cylin-
(Bosch Rexroth )). der breakdown.

3-58 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Axle Assembly

7
5
5
7 4
6 3
2

1. Front Axle 4. Axle Pivot Pin 7. Bearing

2. Bolt, 5/8"-11NC x 1 1/2" 5. Thrust Washer
3. Pin Keeper 6. Thrust-Axle Washer

Figure 3-33. Axle Assembly

REMOVAL: ASSEMBLY:
1. When installing the axle assembly, follow Removal
Steps in reverse.
SUPPORT THE FRAME AND AXLE BEFORE ATTEMPTING ANY
NOTE: Apply Loctite® #271 to bolt (2).
REMOVAL AND/OR ASSEMBLY PROCEDURES.

1. Disable machine operation. Remove wheel and

drive assemblies (refer to Figure 3-1., Drive Assem-
bly (Bosch Rexroth )).

2. Remove the bolt (2) and pin keeper (3).

3. Push the axle pivot pin (4) out and remove the thrust
washers (5, 6) and bearings (7).

4. Axle can now be moved away from the frame.

3121249 – JLG Lift – 3-59

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Axle Lockout Cylinder

1
3
2
1. Axle Lockout Cylinder
2. Bolt, 1/2"-11NC x 2 3/4"
3. Washer

Figure 3-34. Axle Lockout Cylinder

REMOVAL: INSTALLATION:
1. Disable machine operation. 1. Attach cylinder to frame using four bolts (2) and
washers (3).
2. Disconnect, cap and label hydraulic lines on the axle
lockout cylinder (1). NOTE: Apply Loctite® #242 and Loctite® Primer #7471 to
bolts (2).
3. Remove the four bolts (2) and washers (3) connect-
ing the cylinder to the frame.
2. Uncap and reconnect hydraulic lines to cylinder.
4. Carefully remove cylinder from the frame.
NOTE: Refer to Section 4.13, Cylinder Assemblies for axle
lockout cylnder breakdown and bleeding procedure.

3. Operate axle lockout cylinder function to ensure

proper functioning.

3-60 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.7 LEVELING JACKS (IF EQUIPPED)

Cylinder Removal

1
1. Cover
2. Bolt, 1/4"-20NC x 7/8"
3. Flatwasher
3 3 2 4. Tinnerman Nut
2
5. Jack Cover Bracket
4
4 8 6. Bolt, 1/2"-13NC x 3"

7 7. Nut

5 8. Leveling Jack Cylinder

Figure 3-35. Leveling Jack Cylinder Removal

REMOVAL: INSTALLATION:
1. Disable machine operation. 1. Follow Removal Steps in reverse.
2. Remove the four bolts (2), flatwashers (3) and tinner- NOTE: Refer to Figure 4-32., Leveling Jack Cylinder for cyl-
man nuts (4) from cover (1). Carefully lift cover up inder breakdown.
and off of machine.
2. Operate leveling jacks to ensure proper operation.
3. Disconnect, cap and label all hydraulic lines and
wires connected to the leveling jack cylinder (8).
4. Support cylinder. Remove the four bolts (6) and nuts
(7) attaching cylinder to cylinder mount. Remove
jack cover bracket (5).
5. Carefully remove cylinder from mount.

3121249 – JLG Lift – 3-61

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Assembly Removal
NOTE: Applies to both front and rear of machine.

2 5 7
7
4 6

9 8

4
3
1

1. Leveling Jacks Assembly 4. Washer 7. Washer

2. Bolt, 1/2"-13NC x 1 3/8" 5. Bolt, 3/4" - 10NC x 3 1/4" 8. Plate
3. Nut 6. Nut 9. Support

Figure 3-36. Leveling Jacks Assembly

REMOVAL: 5. Carefully lower assembly from the supports (9).

6. Supports can be removed from chassis by removing
the four bolts (5), nuts (6) and washers (7).
SUPPORT THE LEVELING JACKS ASSEMBLY BEFORE ATTEMPT- INSTALLATION:
ING ANY REMOVAL AND/OR ASSEMBLY PROCEDURES.
1. Follow Removal Steps in reverse.
1. Disable machine operation and block all wheels. NOTE: Torque bolts (5) to 280 lb-ft (379.6 Nm).

2. Remove covers from leveling jack cylinders (refer to 2. Uncap and reconnect hydraulic lines and electrical
Figure 3-35., Leveling Jack Cylinder Removal). wires to cylinders and switches.
3. Disconnect, cap and label hydraulic lines connected 3. Operate leveling jacks to ensure proper operation.
to leveling jack cylinders. Disconnect and label all
electrical wiring attached to cylinder and switches.

4. Remove the four bolts (2), nuts (3) and washers (4).

3-62 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.8 PLATFORM

1. Platform
2. Scissor Arms
3. Slide Block
4. Bolt, (metric) 10 x 200
1 5. Locknut, (metric) M10 x 1.5
6. Pin

3 7. Spacer Tube
8. Bolt, 3/8"-16NC x 1 3/8"
4 3 7 9. Locknut
8 10. Pin Keeper
9 11. Pin
10
11
3
6 5

Figure 3-37. Platform Removal

4. Detach the center attach link from the platform by

removing the bolt (8), locknut (9) pin keeper (10)
NEVER WORK UNDER ELEVATED PLATFORM WITHOUT FIRST and pin (11).
PROPERLY SUPPORTING THE PLATFORM AND BRACING/
5. With scissor arm assembly (2) braced, remove the
BLOCKING SCISSOR ARM ASSEMBLY.
slide block (3) at each corner of the platform by
removing the bolt (4), locknut (5), pin (6) and spacer
REMOVAL: tube (7).

1. Disable machine operation. 6. Lift platform away from the machine.

INSTALLATION:
2. Place lifting straps at each end of the platform (1).
Using an overhead crane lift platform. 1. Follow Removal Steps in reverse.

NOTE: For machines equipped with Load Sensing System,

NOTE: Use lifting straps and overhead crane capable of lif-
refer to JLG Supplement P/N 3124288.
ing at least 6000 lbs (2722 kg).

3. Disconnect, cap and label hydraulic lines on deck

extension cylinders. Disconnect and label all electri- TIGHTEN BOLTS (4) AND LOCKNUTS (5) TO JUST MAKE CON-
cal wires going to platform. TACT WITH THE SLIDE BLOCKS (3). DO NOT OVERTIGHTEN.

3121249 – JLG Lift – 3-63

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Deck Extension Cylinders (if equipped)

1. Platfrom & Deck Extension

2. Deck Extension Cylinders
3. Shoulder Screw
4. Flatwasher
5. Locknut, 5/8"-11NC
6. Hanger Bracket
7. Clamp
1 8. Bolt, 3/8"-16NC x 4 1/2"
9. Locknut, 3/8"-16NC
8, 9, 10
10. Flatwasher
6 8, 9, 10 11
11. Cylinder Attach Bracket
3, 12, 13
12. Shoulder Screw
13. Flatwasher
3, 4, 5
2

7
2

Figure 3-38. Deck Extension Cylinders Removal

REMOVAL: INSTALLATION:
NOTE: Each deck extension has two deck extension cylin- 1. Follow Removal Steps in reverse.
ders. 2. Reconnect hydraulic lines to cylinder.

1. Disable machine operation. 3. Operate deck extension function to ensure proper

operation.
2. Disconnect, cap and label hydraulic lines attached
to extension cylinders (2). Disconnect and label any NOTE: Refer to Figure 4-34., Deck Extension Cylinder for
electrical wires attached to cylinders. cylinder breakdown.

3. Support extension cylinders before disconnecting

from bottom side of platform (1).
4. Remove the shoulder screws (3, 12), locknuts (5, 9),
bolts (8) and flatwashers (4, 10, 13).
5. Carefully remove the extension cylinder.

3-64 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Platform Control Station

5
14 1. Mounting Bracket

1 2. Bolt, 1/4"-20NC x 1/2"

7, 9 3. Starwasher

23 6 4. Console Box
7 5. Console Lid
8
6. Self Tapping Screw, #8-18 x 3/4"
7. Washer
8. Insulation Tape
9. Plastite Screw, #10-32NC x 1/2"
10. Self Tapping Screw, #8-18 x 3/4"
11. Terminal Nut
12. D-Ring Bracket

4 13. Harness
14. Joystick Controller
13

12
10
11
Figure 3-39. Platform Control Station

DISASSEMBLY: ASSEMBLY
1. Disconnect the cable from the harness on the under- 1. Follow Disassembly Procedures in reverse.
side of the platform control station.
2. Ensure electrical wires are properly and securely
2. Remove the control station from the mounting attached to switches, buttons and bulbs.
bracket (1) by removing the four bolts (2) and star-
3. Apply a new layer of insulation tape (8) between lid
washers (3).
and box if needed.
3. Remove the seven screws (6) and washers (7) to
remove the console lid (5) from the console box (4). NOTE: Ensure wires are not pinched when placing lid onto
box.
4. Once lid is removed, switches, buttons and bulbs
can be removed for replacement. 4. Reattach cable to harness on underside of platform
control station.
5. Remove the the four screws (7) and washers (9) to
remove the joystick controller (14). 5. Operate functions with platfrom control console to
ensure proper operation.
6. The harness (13) can be removed from the box by
removing the terminal nut (11), two screws (10) and
d-ring bracket.

3121249 – JLG Lift – 3-65

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Joystick Controller

Figure 3-40. Joystick Controller

Table 3-11. Joystick Specifications Table 3-12. Joystick Plug Loading Chart

Input Voltage 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 (-)

3-66 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.9 SCISSOR ARMS

Lift Cylinder Removal

1 2
5 4

Bottom Connection
Point

Top Connection Point

8 1 7
6

1. Lift Cylinder 4. Nut 7. Bolt, 1/2"-13NC x 1 5/8"

2. Pin 5. Collar 8. Nut
3. Bolt, 3/8"-16NC x 3" 6. Pin

Figure 3-41. Lift Cylinder Removal

REMOVAL: 4. Attach lifting straps to overhead crane and lift cylin-

der and support cylinder before attempting to
remove from arm assembly.
NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT 5. Remove the upper pin (2) by removing the bolt (3),
FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEM- nut (4) and collar (5). Push pin out.
BLY.
6. Remove the lower pin (6) by removing the bolt (7)
1. Remove platform (refer to Figure 3-37.). and nut (8). Push pin out.
2. Elevate the scissor arm assembly enough to gain 7. Carefully lift cylinder up and out of arm assembly.
access to the upper and lower connection pins (2,
6). Block/brace scissor arms and disable machine. INSTALLATION:
3. Disconnect, cap and label all hydraulic lines con- 1. Follow Removal Steps in reverse.
nected to lift cylinder (1). Disconnect and label all 2. After assembly, operate lift cylinder to ensure proper
electrical wires connected to lift cylinder. operation.
NOTE: Refer to Figure 4-29., Lift Cylinder for cylinder break-
down.

3121249 – JLG Lift – 3-67

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Scissor Arms Removal Scissor Arm Assembly Removal

3
1

6
1

3
2
2

5 3
5 4
4

1. Scissor Arm 4. Bolt, 3/8"-16NC x 1 1/4"

2. Slider 5. Nut
1. Scissor Arm 4. Nut 3. Pin
2. Pin 5. Collar
Figure 3-43. Scissor Assembly Removal - Chassis
3. Bolt, 3/8"-16NC x 3" 6. Bearing Connection

Figure 3-42. Scissor Arms Removal

NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT

FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEM-
NEVER WORK UNDER ELEVATED SCISSOR ARMS WITHOUT BLY.
FIRST PROPERLY BRACING/BLOCKING SCISSOR ARM ASSEM-
BLY. REMOVAL:
NOTE: Applies to all four corners.
NOTE: Scissor arms can be removed individually or as an
entire assembly. 1. Remove platform (refer to Figure 3-37., Platform
Removal).
ARM REMOVAL:
2. Disconnect, cap and label all hydraulic hoses and
1. Remove platform (refer to Figure 3-37.) and lift cylin-
wiring attached to scissor arms and lift cylinder.
der (refer to Figure 3-41.).
2. Disconnect, cap and label all hydraulic hoses and 3. Support the scissor arm assembly with appropriate
wiring attached to scissor arms. lifting straps and overhead crane.

3. Support the scissor arm(s) being removed. 4. Disconnect the scissor arm assembly from the four
sliders (2) by removing the bolts (4) and nuts (5)
4. Remove the pin (2) from the scissor arm (1) by
removing the two bolts (3), nuts (4) and collar (5). 5. Push pins (3) out.
5. Push pin and bearing (6) out from scissor arms. 6. Carefully lift arm assembly up and away from chas-
6. Repeat at each connecting pin. sis.
INSTALLATION: INSTALLATION:
1. Follow Removal Steps in reverse. 1. Follow Removal Steps in reverse.

3-68 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.10 SIDE COMPARTMENT COVERS Inside:

REMOVAL:
Front:

1 2, 3, 4 9 5, 6, 7

2, 3, 4 9
6. Open the hood (8).
7. Remove the two bolts (2), washers, (3) and nuts (4)
attaching the cover to the bracket (9).
8 Rear:
2, 3, 4

1. Compartment Cover 6. Washer

2. Bolt, 3/8"-16NC x 1 1/8" 7. Nut
3. Washer 8. Hood
4. Nut 9. Bracket
5. Screw, 3/8" x 1"

NOTE: Procedures apply to both left and right side compart-

ment hoods.
1. Elevate the platform to a height where, when
removed and lifted, the compartment covers (1)
clear the underside of the platform. Engage the arm
1
safety prop and/or block the scissor arms to prevent
lowering.
2. Disable machine operation. 2, 3, 4
3. Attach lifting straps to each end of the hood and 8. Remove the two bolts (2), washers, (3) and nuts (4)
support with an overhead lifting device. from the rear of the cover.
4. Remove the four bolts (2), washers, (3) and nuts (4) 9. Carefully lift the cover up and away from the
from the front and top of the cover. machine.
NOTE: On engine side only, remove the exhaust tail pipe 10. Remove the bolts on the two hinges (not shown)
from the cover by removing the bolts, washers, and and detach the gas springs to remove the hood from
nuts. the cover (not shown).
5. Disconnect the the ladder from the bracket (9) by INSTALLATION:
removing the two screws (5) washers (6) and nuts
(7). 1. Follow Removal Steps in reverse.

3121249 – JLG Lift – 3-69

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.11 GROUND CONTROL STATION Ground Control Station

Control Station Removal

2 2 1

1. Ground Control Box 2. Lid

4
Figure 3-45. Ground Control Station

3 DISASSEMBLY:
1. Disconnect the harnesses from the ground control
box (1).
2. Open the lid (2) to gain access to components
inside the ground control box.
1. Ground Control Box 3. Bolt, 1/4"-20NC x 3/4" 3. Disconnect any wires and/or plugs from damaged
2. Control Box Mount 4. Lockwasher components.
4. Remove and replace components if necessary.
Figure 3-44. Ground Control Station Removal
ASSEMBLY:
REMOVAL: 1. Reattach any wires and/or plugs.

1. Disconnect and label the harnesses from the ground 2. Close lid (2) and secure.
control box (1).
3. Reattach harnesses to the ground control box (1).
2. Remove the ground control box from the control box
NOTE: If tilt sensor is removed and replaced, it must be cali-
mount (2) by removing the four bolts (3) and lock-
brated (refer to Section 5.2, Calibrations).
washers (4).
INSTALLATION:
1. Follow Removal Steps in reverse.

NOTE: Apply Loctite® #242 to the four bolts (3).

3-70 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.12 FUEL TANK

1. Fuel Tank
2. Fuel Lines

3, 4, 5 3. Bolt, 3/8"-16NC x 1 1/8"

4. Washer
5. Nut
6. Bolt, 3/8"-16NC x 1"
7. Washer
8. Nut

2 6, 7, 8
Figure 3-46. Fuel Tank Removal

REMOVAL: INSTALLATION:
1. Disable machine operation. 1. Follow Removal Steps in reverse.
2. Drain fuel from the fuel tank (1). Store fuel in appro- NOTE: Apply pipe sealant (Loctite® #80724) to fuel line (2)
priate receptacle. fittings on the fuel tank (1).
Torque fuel line fittings to 12 lb-ft (16.3 Nm).
3. Disconnect and cap the two fuel lines (2) attached to
the fuel tank.
2. Refill fuel tank with proper fuel.
4. Remove the bolts (3), washers (4) and nuts (5) from
the bracket on the backside of the fuel tank.
5. Remove the bolts (6), washers (7) and nuts (8) from ENSURE PROPER FUEL LINES ARE ATTACHED TO PROPER FIT-
the bracket on the frontside of the fuel tank. TING ON FUEL TANK. FUEL TANK IS LABELED WITH RETURN
LINE AND SUPPLY LINE.
6. Remove the fuel tank from the hydraulic compart-
ment. 3. Ensure there is no fuel leakage.

3121249 – JLG Lift – 3-71

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.13 HYDRAULIC TANK

1. Hydraulic Tank
2. Drain Plug
3. Ground Control Box Mount
4. Bolt, 3/8"-16NC x 1"
5. Washer
6. Nut
7. Bolt, 3/8"-16NC x 1 1/8"
8. Washer
9. Nut

7, 8, 9 3 1 4, 5, 6

Figure 3-47. Hydraulic Tank Removal

REMOVAL: NOTE: Hydraulic tank has two lifting lugs on the top corners
for lifting.
NOTE: It is recommended to remove the side compartment Empty tank weighs approximately 105 lbs (47.6 kg).
cover before attempting to remove the hydraulic tank
(refer to Section 3.10, Side Compartment Covers). INSTALLATION:

1. Disable machine operation. 1. Follow Removal Steps in reverse.

2. Ensure drain plug (2) is closed. Refill hydraulic tank
2. Drain hydraulic fluid from hydraulic tank (1) by open- (1) with 34 gal (128.7 ltr) hydraulic fluid.
ing the drain plug (2). Store hydraulic fluid in appro-
priate receptacle.

3. Disconnect, cap and label all hoses connected to

tank.

4. Remove the ground control box (not shown) (refer to

Figure 3-44., Ground Control Station Removal) and
ground control box mount (3) from the tank by
removing the four bolts (4) washers (5) and nuts (6).

5. Remove the two bolts (7), washers (8) and nuts (9)
attaching the hydraulic tank to the machine. Remove
tank from machine.

3-72 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.14 BATTERY

1. Battery
2. Battery Terminal (+)
3. Battery Terminal (-)
4. Bracket, Bolt, Nut & Washers
5. Fuse Mounting Block

Figure 3-48. Battery Removal

REMOVAL: INSTALLATION:
1. Disconnect the red battery cable from the positive 1. Place battery in the seat. Positive battery terminal (2)
battery terminal (2). should be closest to outside of machine.
2. Disconnect the black battery cable from the negative 2. Secure battery in place with bracket, bolt, nut and
battery terminal. washers (4).
3. Remove the bolt, nut, and washers (4) to remove the 3. Reconnect red battery cable to positive battery ter-
bracket securing the battery in place. Remove bat- minal (2). Secure terminal cover in place over termi-
tery. nal.
4. The fuse mounting block (5) can be removed by first 4. Reconnect black battery cable to negative battery
disconnecting the cables. Remove the bolts, wash- terminal (3).
ers and nuts securing the fuse block to the machine.
5. Secure fuse mounting block (5) to machine using
two bolts, nuts and washers. Reconnect cables.

3121249 – JLG Lift – 3-73

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.15 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.
1. Start engine from platform control station. 2. LPG is extremely flammable. No smoking.
2. 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.

3-74 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.16 DEUTZ ENGINE Deutz EMR 2

The EMR2 consists of the sensors, the control unit and the
Engine Tray actuator. Engine-side controls as well as the JLG Control
System are connected by means of separate cable har-
nesses to the EMR control unit.
The sensors attached to the engine provide the electron-
ics in the control unit with all the relevant physical parame-
ters In accordance with the information of the current
condition of the engine and the preconditions (throttle
position etc.), the EMR2 controls an actuator that operates
the control rod of the injection pump and thus doses the
fuel quantity in accordance with the performance require-
ments.
The exact position of the regulating rod is reported back
and, if necessary, is corrected, by means of the control
rod travel sensor, situated together with the rotation mag-
nets in a housing of the actuator.
The EMR2 is equipped with safety devices and measures
in the hardware and software in order to ensure emer-
gency running (Limp home) functions.
In order to switch the engine off, the EMR2 is switched in a
de-energized fashion over the ignition switch. A strong
spring in the actuator presses the control rod in the de-
energized condition into the zero position. As a redun-
dancy measure, an additional solenoid serves for switch-
ing off and this, independently of the actuator, also moves
1,2,3 the control rod in the de-energized condition into the zero
position.

1. Bolt, 5/8"-11NC x 2" 3. Washer After the programming, that is carried out over the
ISO9141 interface, the EMR2 possesses a motor-specific
2. Nut data set and this is then fixedly assigned to the engine.
NOTE: When servicing the engine and components, Included in this are the various application cases as well
remove the bolt (1), nut (2) and washer (3) to as the customer’s wishes regarding a particular scope of
swing the engine tray out for better access (as function.
shown below).
Each EMR2 module is matched by serial number to the
engine. Modules cannot be swapped between engines.

Figure 3-49. Engine Tray Swing

3121249 – JLG Lift – 3-75

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

CONTROL ROD POSITION

SENSOR/ACTUATOR

POWER SUPPLY

COOLANT TEMPERATURE CAMSHAFT SPEED

SENSOR SENSOR

JLG SYSTEM HANDLES ENGINE START/

STOP; EMR2 TAKES CONTROL OF THE
ENGINE AT 700RPM

GLOW PLUG

JLG SYSTEM USES JLG ANALYZER TO

REPORT FAULTS

DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS-

TEM USES THIS TO CONTROL THE ENGINE &
OIL PRESSURE
FAULT REPORTING.
SENSOR

Figure 3-50. EMR 2 Engine Side Equipment

3-76 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-51. Deutz EMR 2 Troubleshooting Flow Chart

3121249 – JLG Lift – 3-77

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-52. Deutz EMR 2 Vehicle Side Connection Diagram

3-78 – JLG Lift – 3121249

3121249
– JLG Lift –
Figure 3-53. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3-79
3-80
– JLG Lift –
SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-54. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

3121249
 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-55. EMR 2 Engine Plug Pin Identification

3121249 – JLG Lift – 3-81

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-56. EMR 2 Vehicle Plug Pin Identification

3-82 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-57. EMR2 Fault Codes - Sheet 1 of 5

3121249 – JLG Lift – 3-83

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-58. EMR2 Fault Codes - Sheet 2 of 5

3-84 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-59. EMR2 Fault Codes - Sheet 3 of 5

3121249 – JLG Lift – 3-85

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-60. EMR2 Fault Codes - Sheet 4 of 5

3-86 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Figure 3-61. EMR2 Fault Codes - Sheet 5 of 5

3121249 – JLG Lift – 3-87

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Generator (if equipped)

5, 6 1 2
3, 4

-OR-

1. Generator (120V or 220V) 4. Washer 7. Voltage Regulator

2. Deutz Engine 5. Bolt, 7/16"-14NC x 2 1/4"
3. Bolt, 5/16"-18NC x 1" 6. Washer

Figure 3-62. Generator (Deutz Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse. Ensure belt is tight
SERVICING. before securing generator with the bolts.

REMOVAL: NOTE: Apply Loctite® #242 to the bolts (3, 5).

1. Disable machine operation. Disconnect and label Table 3-13. Generator Specifications
electrical wires attached to generator (1).
Description 110 Bluemax 220 Powermax
2. Remove the generator from the engine (2) by remov-
ing the three bolts (3, 5) and washers (4, 5). Voltage 120V 220V
3. Replace belt if damaged. Continuous 3.5 KW 2.0 KW
Peak 4.5 KW 3.0 KW
Amps Peak 37 Amps 13 Amps

3-88 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Exhaust System

8, 9 7 6
3, 4, 5

1 2

10, 11

1. Muffler 5. Nut 9. Washer

2. Exhaust Tail Pipe 6. Clamp 10. Bolt, 3/8"NC-16 x 1"
3. Bolt, 3/8"NC-16 x 1" 7. Exhaust Pipe 11. Washer
4. Washer 8. Nut

Figure 3-63. Exhaust System (Deutz Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING. NOTE: Apply Loctite® #242 to bolt (10).

REMOVAL:
1. Disable machine operation.

2. Remove the tail pipe (2) by removing the bolts (3),

washers (4) and nuts (5).

3. Loosen the clamp (6).

4. Remove the bolts (10) and washers (11) connecting

the muffler (1) to the mounting bracket. Remove
muffler.

5. Remove exhaust pipe (7) by removing the nuts (8)

and washers (9).

3121249 – JLG Lift – 3-89

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Air Cleaner System

1 1. Air Cleaner
2. Air Intake Hose
3. Clamp
4. Mounting Bracket
5. Engine

Figure 3-64. Air Cleaner System (Deutz Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING.

REMOVAL:
1. Disable machine operation.

2. Loosen the two clamps (3) attaching the air intake

hose (2) to the engine (5) and air cleaner (1).

3. Unscrew the bolt on the clamp (3) and remove the

air cleaner.

4. Remove the air intake hose.

NOTE: The filter element can be removed from the air

cleaner by releasing the latches on the end of the air
cleaner. Replace filter element as needed.

3-90 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Relays

1
3, 4, 5
6
1. Weather Proof Relay
2. Solenoid Relay
2 3. Bolt, NO10-24 x 0.75"
4. Locknut
7, 8, 9 5. Washer
6. Relay Mounting Bracket
10
7. Glow Plug Harness
8. Bolt, NO8-32 x 0.625"
9. Locknut
10. Muffler Mounting Bracket

Figure 3-65. Relays (Deutz Engine)

REMOVAL: INSTALLATION:
1. Disable machine operation. 1. Follow Removal Steps in reverse.
2. Disconnect and label the wires and harnesses
attached to the weather proof relay (1), solenoid
relay (2) and glow plug harness (7).
3. Remove the relays from the mounting bracket (6) by
removing the bolts (3), locknuts (4) and washers (5).
4. The relay mounting bracket can be removed from
the muffler mounting bracket (10) by removing the
two bolts, nuts and washers (not shown).

3121249 – JLG Lift – 3-91

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Pumps

7
6

4
1

3
2

1. Gear Pump 4. O-ring 7. Washer,

2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Pump Coupling
3. Washer 6. Bolt, 1/2"-13NC x 1 1/2"

Figure 3-66. Pump Assemblies (Deutz Engine)

4. Remove the two bolts (6) and washers (7) attaching

the axial pump to the flange of the motor. Carefully
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE remove the axial pump.
SERVICING.
INSTALLATION:
REMOVAL: 1. Follow Removal Steps in reverse.

1. Disable machine operation. Disconnect, cap and NOTE: Apply Loctite® #242 to bolts (2, 5).
label all hydraulic hoses connected to pumps (1, 5). Apply grease to internal splines of pump coupling (7)
Disconnect and label all wiring connected to pumps. and external splines of axial pump (4) shaft prior to
installing pump.
2. Remove the two bolts (2) and washers (3) attaching
the gear pump (1) to the axial pump (5). Carefully Install a new o-ring (4) during installation.
remove the gear pump.
NOTE: Refer to Section 4.9, Gear Pump and Section 4.10,
3. Remove and discard the o-ring (4). Axial HI 45 Pump for more information on pumps.

3-92 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Pump Coupling

1. Muffler Mounting Bracket

2. Bolt, M10 x 85mm
3. Washer
4. Pump Coupling
5. Bolt, Coupling
5
3
2

Figure 3-67. Pump Coupling (Deutz Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING. NOTE: Apply Loctite® #242 to bolts (2).
Torque coupling bolts to 50 lb-ft (68 Nm).
REMOVAL:
1. Disable machine operation.

2. Remove exhaust system and pumps (refer to Figure

3-63. and Figure 3-66.).

3. Remove the four bolts (2) and washers to remove

the muffler mounting bracket (1) from the pump cou-
pling (4).

4. Remove the eight coupling bolts (5) to remove the

pump coupling from the engine

3121249 – JLG Lift – 3-93

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Engine Removal

1. Deutz Engine
2. Rear Engine Mount
3. Bolt, M14 x 30mm
4. Front Engine Mount
5. Bolt, M14 x 55mm
6. Spacer Tube

4
5, 6
1
2
3
Figure 3-68. Engine Removal (Deutz Engine)

6. Remove the bolts (5) and spacer tubes (6) securing

the engine to the front engine mount (4).
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE
7. Slowly lift the engine up and out of the engine com-
SERVICING.
partment.

REMOVAL:
1. Disable machine operation. BE CAREFUL NOT TO DAMAGE THE RADIATOR FAN ON THE
RADIATOR HOUSING WHEN LIFTING THE ENGINE.
2. Remove exhaust system, air cleaner system and
hydraulic pumps (refer to Figure 3-63., Figure 3-64. INSTALLATION:
and Figure 3-66.).
1. Follow Removal Steps in reverse.
3. Disconnect, cap and label all hoses connected to
NOTE: Apply Loctite® #242 to bolts (3, 5).
engine (1). Disconnect and label all electrical wiring
connected to engine.

4. Support engine with lifting device capable of lifting

500 lbs (227 kg) (refer to engine manual for proper
lifting information).

5. Remove the bolts (3) securing the motor to the rear

engine mount (2).

3-94 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Radiator

3, 4, 5 1. Radiator
2. Radiator Hose
3. Bolt, 3/8"-16NC x 1"
2
4. Washer
5. Nut
2 6. Bolt, 5/16"-18NC x 7/8"
7. Washer

6, 7

Figure 3-69. Radiator (Deutz Engine)

INSTALLATION:
1. Follow Removal Steps in reverse.
ALLOW RADIATOR TO COOL DOWN BEFORE SERVICING.

REMOVAL:
1. Disable machine operation.
2. Disconnect, cap and label the radiator hoses (2) on
the radiator (1).
3. Remove the engine (refer to Figure 3-68., Engine
Removal (Deutz Engine)).
4. Remove the bolts (3, 6), washers (4, 7) and nuts (5)
to remove the radiator from the engine compart-
ment.

3121249 – JLG Lift – 3-95

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.17 GM ENGINE • Check the Positive and Negative battery cables for any
corrosion build up, rubbing or chafing, Check connec-
tion on the chassis to ensure they are tight.
Maintenance of the Drive Belt
• Check the entire engine wire harness for rubbing chaf-
The serpentine drive belt utilizes a spring loaded tensioner ing, cuts or damaged connections. Repair if necessary.
which keeps the belt properly adjusted. The drive belt is
an integral part of the cooling and charging systems and • Check all wire harness connectors to ensure they are
should be inspected frequently. fully seated and locked.

When inspecting the belts, check for: • Check ignition coil and spark plug cables for harden-
ing, cracking, chafing, separation, split boot covers
• Cracks or breaks and proper fit.
• Chunking of the belt • Replace spark plugs at the proper intervals as pre-
• Splits scribed in the engine manufacturer’s manual.

• Material hanging from the belt • Check to make sure all electrical components are fitted
securely.
• Glazing and hardening
• Check the ground and platform control stations to
• Damaged or improperly aligned pulleys ensure all warning indicator lights are functioning.
• Improperly performing tensioner
Checking/Filling Engine Oil Level
Check the belt tensioner by pressing down on the midway
point of the longest stretch between pulleys. The belt
should not depress beyond 1/2 inch (13mm). If the
depression is more than allowable, adjust the tension. AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED
FULL MARK) CAN CAUSE AN OIL LEAK, A FLUCTUATION OR
DROP IN THE OIL PRESSURE, AND ROCKER ARM "CLATTER" IN
THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE THE ENGINE.
USE OF "BELT DRESSING" OR "ANTI SLIPPING AGENTS" ON
THE DRIVE BELT.

BELT ADJUSTMENT: CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL
LEVEL. OIL LEVEL MUST BE MAINTAINED BETWEEN THE "ADD"
1. Remove existing belt and discard. MARK AND "FULL" MARK ON THE DIPSTICK.
2. Install new belt (21mm x 1187mm). To ensure that you are not getting a false reading, make
3. Unload spring in belt tensioner. sure the following steps are taken before checking the oil
level.
4. Return alternator adjustment to original position and
tighten bolt. 1. Stop the engine if in use.

5. Release belt tensioner. 2. Allow sufficient time (approximately 5 minutes) for

the oil to drain back into the oil pan.
6. Check position of belt tensioner stop.
3. Remove the dipstick. Wipe with a clean cloth or
7. Readjust alternator position as necessary to allow paper towel and reinstall. Push the dipstick all the
correct position of belt tensioner stop. 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
ensure the connections are tight.
• Check the battery for any cracks or damage to the
case.

3-96 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

5. Oil level must be between the "FULL" and "ADD" Engine Tray
marks.

Figure 3-43. Engine Oil Dip Stick

6. If the oil level is below the "ADD" mark, proceed to

Step 7 and 8 and reinstall the dipstick into the dip-
stick tube.
7. Remove the oil filter cap from the valve rocker arm
cover.
8. Add the required amount of oil to bring the level up
to but not over "FULL" mark on the dipstick.
9. Reinstall the oil fill cap to the valve rocker cover and
wipe away any excess oil.

Changing The Engine Oil

1,2,3
WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER.
CHANGE OIL WHEN THE ENGINE IS WARM FROM OPERATION 1. Bolt, 5/8"-11NC x 2" 3. Washer
AS THE OIL WILL FLOW FREELY AND CARRY AWAY MORE
IMPURITIES. 2. Nut
To change the oil use the following steps: NOTE: When servicing the engine and components,
remove the bolt (1), nut (2) and washer (3) to
1. Start the engine and run until it reaches normal swing the engine tray out for better access (as
operating temperature. shown below).
2. Stop the engine.
3. Remove the drain plug and allow the oil to drain.
4. Remove and discard the oil filter and its sealing ring.
5. Coat the sealing ring on the filter with clean engine
oil and wipe the sealing surface on the filter
mounting surface to remove any dust, dirt and
debris. Tighten the filter securely (follow the filter
manufacturer’s instructions). Do not over tighten.
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.
Figure 3-70. Engine Tray Swing
9. Stop the engine and check the oil level to ensure the
oil level is at "FULL".
10. Dispose of the oil and filter in a safe manner.

3121249 – JLG Lift – 3-97

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Generator

1 2
3, 4 5, 6

1. Generator 4. Washer 7. Voltage Regulator

2. GM Engine 5. Bolt,7/16"-14NC x 1 1/4"
3. Bolt, 5/16"-18NC x 1 1/4" 6. Washer

Figure 3-71. Generator (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse. Ensure belt is tight
SERVICING. before securing generator with the bolts.

REMOVAL: NOTE: Apply Loctite® #242 to the bolts (3, 5).

1. Disable machine operation. Disconnect and label Table 3-14. Generator Specifications
electrical wires attached to generator (1).
Voltage 120V
2. Remove the generator from the engine (2) by remov-
Continuous 3.5 KW
ing the three bolts (3, 5) and washers (4, 5).
Peak 4.5 KW
3. Replace belt if worn or damaged.
Amps Peak 37 Amps

3-98 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Exhaust System

7
6
8

5
2, 3, 4 1

1. Tail Pipe 4. Nut 7. Exhaust Pipe

2. Bolt, 3/8"-16NC x 1" 5. Exhaust Pipe 8. Mounting Bracket
3. Washer 6. Muffler

Figure 3-72. GM Exhaust System (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING.

REMOVAL:
1. Disable machine operation.

2. Remove the exhaust pipe (5) from the muffler (6)

and tail pipe (1) by removing the bolts.

3. Remove the tail pipe by removing the bolts (2),

washers (3) and nuts (4).

4. Remove exhaust pipe (7) from the muffler and

engine by removing the bolts.

5. Remove the bolts connecting the muffler to the

mounting bracket (8). Remove muffler.

3121249 – JLG Lift – 3-99

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Air Cleaner System

1. Air Cleaner
4
2. Mounting Bracket
3. Rubber Elbow
4. Air Intake Tube
5. Sleeve
6. Air Intake Tube
1

3
Figure 3-73. Air Cleaner System (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING.

REMOVAL:
1. Disable machine operation.
2. Pull the rubber elbow (3) off of the air cleaner (1) and
air intake tube (4).
3. Pull the air intake tube out of the sleeve (5). Pull the
sleeve and air intake tube (6) out of the engine.
4. Loosen the bolt on the mounting bracket (2) to
remove the air cleaner (1).

NOTE: The filter element can be removed from the air

cleaner by releasing the latches on the end of the air
cleaner. Replace filter element as needed.

3-100 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Radiator

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

8
Figure 3-74. Radiator (GM Engine)

INSTALLATION:

ALLOW RADIATOR TO COOL DOWN BEFORE SERVICING. 1. Follow Removal Steps in reverse.
2. Ensure drain valve on radiator (1) is closed. Refill
REMOVAL: radiator with 2.63 gal (10 ltr) of anti-freeze fluid.
1. Drain the anti-freeze fluid from the radiator (1) by
opening the valve on the bottom corner of the radia-
tor. Store fluid in a suitable container.
2. Loosen the clamps on the radiator hoses (2, 3, 5)
and remove the hoses.
3. Disconnect and cap the hoses connected to the
coolant overflow container (4).
4. Remove the bolts (5) washers (6) and nuts (7) to
remove the coolant overflow container from the
mounting bracket.
5. Remove the four bolts (9), washers (10) and nuts
(11) to remove the radiator.

NOTE: The engine must be removed before the radiator can

be removed.

3121249 – JLG Lift – 3-101

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Fuel Components

10 9 8
5
6

1. Fuel Pump
2. Fuel Tank
3. Fuel Line - Supply from Tank
4. Fuel Line - to Fuel Filter
5. Fuel Filter
6. Fuel Line - to Fuel Pump
7. Fuel Line
8. Fuel Regulator
9. Fuel Line - Return to Tank
10. Fuel Line - to Engine

2 3
1 4
Figure 3-75. Fuel Components (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING. 2. Uncap and connect the fuel line (3) to the supply
valve of the fuel tank (2) and the fuel pump (1).
REMOVAL:
3. Uncap and connect the fuel line (4) to the fuel pump
1. Disable machine operation. and fuel filter (5).
2. Disconnect, label and cap all fuel lines (3, 4, 6, 7, 9, 4. Uncap and connect the fuel line (7) to the fuel filter
10). and fuel regulator (8).
NOTE: Fuel will still be in the fuel lines. Drain the lines and 5. Uncap and connect the fuel line (9) to the fuel regu-
store fuel in a suitable container. lator and the return valve on the fuel tank.
6. Uncap and connect the fuel line (10) to the fuel regu-
3. Remove the bolts, nuts and washers attaching the
lator and the fuel rail on the engine.
fuel pump (1), fuel filter (5) and fuel regulator (8) to
the machine.

3-102 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Pumps

7
6

3
2
4 5 8

1. Gear Pump 4. O-ring 7. Washer

2. Bolt, 3/8"-16NC x 1" 5. Axial HI 45 Pump 8. Coupling Flange
3. Washer 6. Bolt, 1/2"-13NC x 1 1/2"

Figure 3-76. Pump Assemblies (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING. NOTE: Apply Loctite® #242 to bolts (2, 5).
Apply grease to internal splines of pump coupling
REMOVAL: and external splines of axial pump (4) shaft prior to
1. Disable machine operation. Disconnect, cap and installing pump.
label all hydraulic hoses connected to pumps (1, 4).
Disconnect and label all wiring connected to pumps. Install a new o-ring (4) during installation.

2. Remove the two bolts (2) and washers (3) attaching NOTE: Refer to Section 4.9, Gear Pump and Section 4.10,
the gear pump (1) to the axial pump (4). Carefully Axial HI 45 Pump for more information on pumps.
remove the gear pump.
3. Remove and discard the o-ring (4).
4. Remove the two bolts (5) and washers (6) attaching
the axial pump to the flange (7) of the coupling.
Carefully remove the axial pump.

3121249 – JLG Lift – 3-103

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Pump Coupling

1
3
2

1. Muffler Mounting Bracket 2. Coupling Cover 3. Coupling 4. Engine

Figure 3-77. Pump Coupling (GM Engine)

INSTALLATION:

ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE 1. Follow Removal Steps in reverse.
SERVICING.

REMOVAL:
1. Disable machine operation.
2. Remove exhaust system and pumps (refer to Figure
3-72. and Figure 3-76.).
3. Remove the bolts and washers to remove the muffler
mounting bracket (1) from the coupling cover (2).
4. Remove the bolts on the coupling cover to remove
the cover from the engine.
5. Remove the bolts on the coupling (3) to remove the
coupling from the engine.

3-104 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Engine Removal

1. Bolt, 1/2"-13NC x 1 1/2"

2. Washer
3. Nut
4. Engine
5. Engine Tray

1, 2, 3
4 5
1, 2, 3
Figure 3-78. Engine Removal (GM Engine)

6. Slowly lift the engine up and out of the engine com-

partment.
ALLOW ENGINE AND COMPONENTS TO COOL DOWN BEFORE
SERVICING.
BE CAREFUL NOT TO DAMAGE THE RADIATOR FAN ON THE
REMOVAL: RADIATOR HOUSING WHEN LIFTING THE ENGINE.
1. Disable machine operation. INSTALLATION:
2. Remove exhaust system, air cleaner system and 1. Follow Removal Steps in reverse.
hydraulic pumps (refer to Figure 3-72., Figure 3-73.
and Figure 3-76.).

3. Disconnect, cap and label all hoses connected to

engine (4). Disconnect and label all electrical wiring
connected to engine.

4. Support engine with lifting device capable of lifting

500 lbs (227 kg) (refer to engine manual for proper
lifting information).

5. Remove the bolts (1), washers (2) and nuts (3) at the
four corners of the engine.

3121249 – JLG Lift – 3-105

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.18 GM ENGINE DUAL FUEL SYSTEM lock off supply voltage is controlled by the engine control
module (ECM).
The Dual Fuel system allows the operator to operate the
vehicle on either gasoline or LPG by positioning a selector
switch on the platform control station. When the operator
places the selector switch in the gasoline mode, the gaso-
line fuel pump is energized. While in the gasoline mode,
the LPG fuel lock-off is isolated and will not energize. In
addition, the gasoline injector circuit is enabled and injec-
tor pulses are provided to each injector and the ECM cali-
bration for gasoline is also enabled. When the operator
selects the LPG mode, the Low Pressure LPG lock-off is Figure 3-79. Electric Fuel Lock Off
energized and fuel from the LPG tank flows to the Elec-
tronic Pressure Regulator (EPR). The EPR receives an
electronic signal to position the secondary lever for the Electronic Pressure Regulator Assembly
start or run positions and when the engine begins to The EPR assembly is a combination Low Pressure Regu-
crank, the mixer air valve will rise and fuel will begin flow- lator and a Voice Coil Assembly. The Voice Coil is an elec-
ing to engine. During this mode, the gasoline fuel pump is tronic actuator which is controlled by an internal
isolated and will not be activated. The primary compo- microprocessor. The microprocessor provides output
nents of the gasoline dual fuel system are the gasoline data to the ECM and receives input data over a CAN BUS
tank, electric fuel pump and filter, fuel supply line, injector connection. The internal microprocessor receives electri-
rail and injectors and the fuel pressure regulator. The pri- cal signals from the Fuel Pressure Sensor (FPS) and the
mary components of the LPG dual fuel system are the Fuel Temperature Pressure FTP and communicates the
LPG fuel tank, in-fuel filter, LPG Low Pressure lock-off, data to the ECM. The ECM uses the FPS and FTP data to
EPR and the fuel mixer module. The LPG fuel system calculate the location of the secondary lever in the LPR
operates at pressures which range from 14.0 inches and sends that data back to the EPR via the CAN BUS.
(355.60 mm) of water column up to 312 psi (21.5 bar). The internal microprocessor in the EPR will then output a
signal, which causes the voice coil to move and position
Components which are shared by both systems include the secondary lever to the correct location.
the Electronic Throttle Control and the ECM. The ECM
contains a dual calibration; one controls the gasoline fuel
system during gasoline operation and one controls the
LPG fuel system during LPG operation.

Fuel Filter
Propane fuel like all other motor fuels is subject to con-
tamination from outside sources. Refueling of the equip-
ment’s tank and removal of the tank from the equipment
can inadvertently introduce dirt and other foreign matter
into the fuel system. It is therefore necessary to filter the
fuel prior to entering the fuel system components down-
stream of the tank. An inline fuel filter has been installed in
the fuel system to remove the dirt and foreign matter from
the fuel. The inline filter is replaceable as a unit only. Main-
tenance of the filter is critical to proper operation of the
fuel system and should be replaced as specified in Sec- 1. Pressure Regulator Section 4. Primary Test Port
tion 1. In severe operating conditions, more frequent 2. Fuel Inlet 5. Secondary Test Port
replacement of the filter may be necessary. 3. Coolant Passage 6. Voice Coil Section
Figure 3-80. EPR Assembly
Electric Lock Off
The Electric Lock Off device is an integrated assembly.
When energized, the solenoid opens the valve and allows
the Propane fuel to flow through the device. The valve
opens during cranking and run cycles of the engine. The

3-106 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Low Pressure Regulator (LPR) Air Fuel Mixer

The LPR is a combination vaporizer, pressure regulating The air valve mixer is an air-fuel metering device and is
device. The LPR is a negative pressure, two stage regula- completely self-contained. The mixer is an air valve
tor that is normally closed when the engine is not running. design, utilizing a relatively constant pressure drop to
When the engine is cranking or running, a partial vacuum draw fuel into the mixer from cranking to full load. The
is created in the fuel line which connects the regulator to mixer is mounted in the air stream ahead of the throttle
the mixer. This partial vacuum opens the regulator permit- control device.
ting fuel to flow to the mixer.
When the engine begins to crank, (it draws in air with the
Propane fuel enters the primary port of the LPR and air valve covering the inlet) negative pressure begins to
passes through the primary jet and into the primary/ build. This negative pressure signal is communicated to
exchanger chamber. As the propane passes through the the top of the air valve chamber through 4 vacuum ports in
heat exchanger, the fuel expands and creates pressure the air valve assembly. A pressure/force imbalance begins
inside the chamber. The pressure rises as the fuel to build across the air valve diaphragm between the air
expands. When the pressure rises above 1.5 psi (0.103 valve vacuum chamber and the atmospheric pressure
bar), sufficient pressure is exerted on the primary dia- below the diaphragm. The air valve vacuum spring is cali-
phragm to cause the diaphragm plate to pivot and press brated to generate from 4.0 inches (101.6 mm) of water
against the primary valve pin, thus closing off the flow of column at start to as high as 14.0 inches (355.60 mm) of
fuel. This action causes the flow of fuel into the regulator water column at full throttle. The vacuum being created is
to be regulated. referred to as Air Valve Vacuum (AVV). As the air valve
vacuum reaches 4.0 inches (101.6 mm) of water column,
When the engine is cranking, sufficient vacuum will be
the air valve begins to lift against the air valve spring. The
introduced into the secondary chamber from the mixer
amount of AVV generated is a direct result of the throttle
drawing the secondary diaphragm down onto the spring
position. At low engine speed, the air valve vacuum is low
loaded lever and opening the secondary valve allowing
and the air valve position is low, thus creating a small ven-
vaporized fuel to pass to the mixer. This mechanical
turi for the fuel to flow. As the engine speed increases, the
action, in conjunction with the EPR reactions, causes the
AVV increases and the air valve is lifted higher, thus creat-
downward action on the secondary lever, causing it to
ing a much larger venturi. This AVV is communicated from
open wider allowing more fuel to flow to the mixer.
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
THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMIS- further down, forcing the secondary valve lever to open
SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE wider.
COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT
WITH AN OEM REPLACEMENT PART ONLY.

Figure 3-81. Low Pressure Regulators Figure 3-82. Air Fuel Mixer

3121249 – JLG Lift – 3-107

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Electronic Throttle Control (ETC) Engine Control Module (ECM)

Engine speed and load control is maintained by an ETC To obtain maximum effect from the catalyst and accurate
device. Speed and load control are determined by the
control of the air fuel ratio, the emission certified engine is
ECM. Defaults programmed into the ECM software and
throttle position sensors allow the ECM to maintain safe equipped with an onboard computer or ECM. The ECM is
operating control over the engine. The Electronic Throttle a 32 bit controller which receives input data from sensors
Control device, or "throttle body assembly", is connected fitted to the engine and fuel system and then outputs vari-
to the intake manifold of the engine. The ETC device uti- ous signals to control engine operation.
lizes an electric motor connected to the throttle shaft.
When the engine is running, electrical signals are sent One specific function of the controller is to maintain
from the equipment controls to the engine ECM when the "closed loop fuel control". Closed loop fuel control is
operator depresses an equipment function switch. The
accomplished when the exhaust gas oxygen sensor
ECM then sends an electrical signal to the motor on the
electronic throttle control to increase or decrease the (HEGO) mounted in the exhaust system sends a voltage
angle of the throttle blade, thus increasing or decreasing signal to the controller. The controller then calculates any
the air/fuel flow to the engine. correction that may need to be made to the air fuel ratio.
The electronic throttle control device also incorporates The controller then outputs signals to the EPR to correct
two internal Throttle Position Sensors (TPS) which provide the amount of fuel being supplied to the mixer. At the
output signals to the ECM as to the location of the throttle same time, the ECM may correct the throttle blade posi-
shaft and blade. The TPS information is used by the ECM tion to correct the speed and load of the engine.
to correct speed and load control as well as emission con-
trol. The controller also performs diagnostic functions on the
fuel system and notifies the operator of malfunctions by
turning on a Malfunction Indicator Light (MIL) mounted in
the Ground Control Station and the Platform Control Sta-
tion. Malfunctions in the system are identified by a Diag-
nostic Code number. In addition to notifying the operator
of the malfunction in the system, the controller also stores
the information about the malfunction in its memory.

Figure 3-83. ETC throttle control device

Figure 3-84. LPG Engine Control Unit (ECM)

Figure 3-85. ECM Assembly

3-108 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Heated Exhaust Gas Oxygen Sensor (HEGO) Gasoline Fuel Pump

There are two Heated Exhaust Gas Oxygen Sensors The Gasoline is stored as a liquid in the fuel tank and is
(HEGO). The first HEGO is mounted in the exhaust system drawn into the fuel system by an electric fuel pump. The
downstream of the engine. It is used to measure the fuel pump will receive a signal from the ECM to prime the
amount of oxygen present in the exhaust stream and com- fuel system for approximately 2 seconds prior to start.
municate that to the ECM via an electrical signal. The Priming of the fuel system provides for a quicker start
amount of oxygen present in the exhaust stream indicates when the engine begins to crank.
whether the fuel/air ratio is too rich or too lean. If the
HEGO sensor signal indicates that the exhaust stream is Gasoline Pressure And Temperature Sensor
too rich, the ECM will decrease or lean the fuel mixture Manifold
during engine operation. If the mixture is too lean, the
ECM will richen the mixture. The ECM continuously moni- This engine is equipped with a fuel injector rail that does
tors the HEGO sensor output. If a rich or lean condition is not have a pressure regulator or a return circuit to the fuel
present for an extended period of time and the ECM can- tank. Fuel pressure for this engine is regulated by the
not correct the condition, the ECM will set a diagnostic engine’s ECM. The ECM receives fuel pressure and tem-
code and turn on the MIL light in the control box. perature feedback from the gasoline fuel sensor manifold
and uses this information to control the ground side of the
The second HEGO is mounted in the exhaust system after fuel pump. Fuel pressure is regulated by the ECM pulse
the muffler. It measures the amount of oxygen in the width modulating (PWM) the fuel pump. The fuel pressure
exhaust system after the catalyst treatment has been com- and temperature sensor manifold has a return, or "bleed",
pleted in the muffler. If the ECM detects that the catalytic circuit that connects back to the fuel tank. This circuit is
action in the muffler is not sufficient and fuel correction used to bleed off any vapor that develops in the line and
cannot correct the malfunction, the MIL light is illuminated return a small amount of fuel to the tank. The fuel comes
in the control box and a DTC code will be stored in the from the fuel tank and passes through the fuel pump. Fuel
computer. exits the fuel pump, passes through the filter and then
enters the fuel pressure and temperature manifold assem-
bly. Fuel flows through the feed circuit and is delivered to
the fuel injector rail. Fuel that enters the bleed circuits
THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION through the bypass valve in the manifold is returned to the
CONTROL DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE fuel tank.
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 3-86. 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 Figure 3-87. Gasoline Fuel Pressure and Temperature
pump, fuel pressure and temperature sensor manifold, Manifold Assembly
fuel filter and fuel rail.

3121249 – JLG Lift – 3-109

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Fuel Filter 3.19 GM ENGINE FUEL SYSTEM REPAIR

After the fuel is drawn into the fuel pump, the fuel flows
through the gasoline fuel filter. The fuel filter will trap small
Propane Fuel System Pressure Relief
particles as the fuel passes through the filter to remove
debris and prevents the fuel pressure and temperature
manifold and fuel injectors from becoming damaged. THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
Maintenance of the fuel filter is required as indicated in 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
Section 1. SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
SURE (WHERE APPLICABLE) BEFORE SERVICING THE
Fuel Injector Rail PROPANE FUEL SYSTEM COMPONENTS.
Fuel flows from the fuel pressure and temperature mani-
fold assembly to the fuel rails where the fuel is delivered to To relieve propane fuel system pressure:
the fuel injectors. The fuel rail also contains a Schrader 1. Close the manual shut-off valve on the propane fuel
valve which is utilized to test the regulated pressure of the tank.
fuel system.
2. Start and run the vehicle until the engine stalls.
Fuel Injector 3. Turn the ignition switch OFF.
The fuel supply is maintained on the top of the injector
from the injector rail. The injector is fed a "pulse" signal
through the wire harness which causes the injector to RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
open. During regular operating conditions, the ECM con- SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
trols the opening and duration of opening of the injector. BEFORE DISCONNECTING ANY FUEL LINE.
During lower RPM operation, the injector signals, or
"pulses", are less frequent than when the engine is operat- Propane Fuel System Leak Test
ing at higher RPMs. The engine has been calibrated to
deliver the precise amount of fuel for optimum perfor-
mance and emission control.
NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR
PROPANE FUEL SYSTEM LEAKS.

Always inspect the propane fuel system for leaks after per-
forming service. Check for leaks at the fittings of the ser-
viced or replaced component. Use a commercially
available liquid leak detector or an electronic leak detec-
tor. When using both methods, use the electronic leak
detector first to avoid contamination by the liquid leak
detector.

3-110 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Propane Fuel Filter Replacement 3. Install the housing seal.

4. Drop the magnet into the bottom of the filter hous-

ing.
1 7 5. Install the filter into the housing.
8
6. Install the retaining bolt into the filter housing.
2
9
3 7. Install the filter up to the bottom of the electric lock
10 off.

4 8. Tighten the filter retaining bolt to 106 in.lbs. (12 Nm).

5 9. Open manual shut-off valve. Start the vehicle and

11 leak check the propane fuel system at each serviced
fitting. Refer to Propane Fuel System Leak Test.
6

12 Electronic Pressure Regulator (EPR)

Assembly Replacement
1. Electric Lock Off Solenoid 7. Electrical Connector
2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring
4. Filter Magnet 10. Filter
5. Filter Housing 11. Fuel Inlet
6. Seal 12. Retaining Bolt
Figure 3-88. Filter Lock Assembly

REMOVAL:

1. Relieve the propane fuel system pressure. Refer to

Propane Fuel System Pressure Relief.

2. Disconnect the negative battery cable.

3. Slowly loosen the filter housing retaining bolt and

remove it.

4. Pull the filter housing from the Electric lock off 1. Pressure Regulator Section 4. Primary Test Port
assembly. 2. Fuel Inlet 5. Secondary Test Port
3. Coolant Passage 6. Voice Coil Section
5. Locate Filter magnet and remove it.
Figure 3-89. EPR Assembly
6. Remove the filter from the housing.
The EPR assembly is made up of two separate compo-
7. Remove and discard the housing seal. nents. The Voice Coil Section is not serviceable and can
8. Remove and discard the retaining bolt seal. only be replaced as an assembly. The pressure regulator
section is serviceable and will be detailed in this section.
9. Remove and discard the mounting plate to lock off
O-ring seal. REMOVAL:

INSTALLATION: 1. Relieve the propane fuel system pressure. Refer to

Propane Fuel System Pressure Relief.

2. Disconnect the negative battery cable.

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-
ING BEFORE INSTALLING NEW SEAL. 3. Slowly remove the fuel inlet fitting at the Electric
Lock Off.
1. Install the mounting plate to lock off O-ring seal.
NOTE: Residual vapor pressure will be present in the fuel
2. Install the retaining bolt seal. system.

3121249 – JLG Lift – 3-111

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

4. Disconnect the electrical connector from the Electric 7. Connect the fuel supply line and tighten until fully
Lock off. seated.
5. Remove the Electric Lock Off from the regulator. 8. Connect the EPR electrical connector.
6. Remove the lock pin from the vapor fitting on the 9. Open the manual valve.
regulator housing. Remove the fitting and hose and
10. Start the vehicle and leak check the propane fuel
retain the pin.
system at each serviced fitting. Refer to Propane
7. Remove the lock pin from the pressure sensor on Fuel System Leak Test.
the regulator housing. Remove the sensor and retain
the pin.
8. Using clamp pliers, pinch off the hoses on the cool-
ant lines to the regulator.
9. Remove the lock pin from both water fittings on the
regulator housing. Remove the fittings and hoses
and retain the pin.
10. Disconnect the EPR electrical connector.
11. Remove the three nuts from the EPR isolators and
the EPR mounting bracket.
Figure 3-90. Pressure Regulator Section
12. Remove the EPR from the bracket.
13. Remove the three mounting isolators. PRESSURE REGULATOR SECTION REMOVAL:

INSTALLATION: 1. Remove the EPR. Refer to EPR Removal Procedure.

2. Remove the six regulator to voice coil screws using
the special tool and separate the regulator from the
DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQ- actuator.
UID PIPE THREAD SEALANT WHEN INSTALLING FITTINGS.

CHECK ALL THE O-RINGS ON THE VAPOR AND WATER FIT- DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING
TINGS FOR ANY DAMAGE. REPLACE IF NECESSARY. PLATE AND DIAPHRAGM. THIS WILL VOID THE WARRANTY OF
THE ACTUATOR SECTION.
LUBE ALL THE O-RINGS WITH AN O-RING LUBE BEFORE
INSTALLING. PRESSURE REGULATOR SECTION INSTALLATION:

1. Install the three rubber isolators to the bottom of the 1. Install the regulator to the actuator section using the
EPR. six retaining screws and tighten to 70 in.lbs. (8 Nm).

2. Install the EPR assembly to the bracket and tighten 2. Install the EPR. Refer to EPR Installation.
the retaining nuts.

NOTE: Do not overtighten the isolators and cause a separa-

tion of the isolators.

3. Install the fuel temperature sensor into the regulator

opening and lock in place with the locking pin. Con-
nect the electrical connector.
4. Insert the fuel vapor line and fitting into the regulator
port and lock in place with the locking pin.
5. Install both the water hoses and fittings into the reg-
ulator and lock in place with the locking pin. Remove
the clamp pliers from the hoses.
6. Install the electric lock off into the regulator inlet and
tighten into proper location. Connect the electrical
connector.

3-112 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Temperature Manifold Absolute Pressure Electronic Throttle Control Replacement

(TMAP) Sensor See Figure 3-91.

REMOVAL:
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Release the hose clamp on the vapor fuel line and
remove the vapor hose.
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.
Figure 3-91. (TMAP) Sensor & Electronic Throttle 8. Remove electronic throttle control device.
Control (ETC)
9. Remove the O-rings gasket and discard.
REMOVAL: INSTALLATION:
1. Disconnect the TMAP electrical connector.
2. Remove the two retaining bolts.
LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO
3. Remove the TMAP. ADAPTER O-RINGS.

INSTALLATION: 1. Install the O-ring on throttle body. Press it down to

the bottom of the surface.
NOTE: Apply a small amount of O-ring lubricant before
installation.

1. Install in the TMAP.

2. Tighten retaining bolts to 62 lb-in (7 Nm).
3. Start the vehicle and check for proper operation.

3121249 – JLG Lift – 3-113

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

2. Install the two quad seals. Install one seal at a time 4. Place gasket on intake manifold and attach mixer/
to ensure the seal does not roll. The seal must sit flat throttle assembly to manifold.
on the throttle body.

Figure 3-92. Mixer Assembly

Mixer Replacement
3. Attach mixer and throttle body together. The two See Figure 3-92.
parts do not bolt together; they will be secured when
you mount it on the intake. Notice the orientation of REMOVAL:
the air inlet and throttle body cover.
1. Remove the throttle control device. Refer to Elec-
tronic Throttle Body Replacement.
2. Remove the four (4) bolts to the throttle control
device to mixer adapter bolts.
3. Remove and discard the gasket between the mixer
and adapter.
INSTALLATION:

COVER THROTTLE BODY ADAPTER OPENING TO PREVENT

DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY.

1. Install the gasket onto the mixer.

2. Install the mixer to the throttle control device to
mixer adapter. Secure with 4 retaining screws.
Tighten 80 lb-in (9 Nm).
3. Install throttle body. Refer to Electronic Throttle Con-
trol Device Replacement.
4. Start the engine and leak check all fittings and con-
nections.

3-114 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Coolant Hose Replacement INSTALLATION:

REMOVAL:
THE CONTROLLER IS CALIBRATED FOR EACH ENGINE. VERIFY
1. Drain the coolant into an appropriate container. YOU HAVE THE CORRECT CONTROLLER
2. Using hose clamp pliers, disconnect both hose 1. Plug connector into controller.
clamps on each hose.
2. Push lock into place.
3. Remove the hose from each of the fittings.
3. Mount controller into mounting bracket.
INSTALLATION: 4. Reconnect battery cable.

NOTE: Use hose material and lengths specified by JLG. 5. Start engine.
6. Check for any DTC codes and clear.
1. Install the hose clamps to each hose and set the
7. Verify engine is in closed loop and no warning lights
clamp back on each hose to make installation eas-
are illuminated.
ier.

2. Fit the hose to the fittings. Heated Exhaust Gas Oxygen Sensor
Replacement
3. Secure by positioning each of the clamps.
REMOVAL:
Vapor Hose Replacement 1. Disconnect Negative battery cable.

REMOVAL: 2. Disconnect the O2 sensor electrical connector.

3. Using an O2 Sensor socket, remove the O2 Sensor
1. Using hose clamp pliers, disconnect both hose and discard.
clamps.
INSTALLATION:
2. Remove the vapor hose from each fitting.

INSTALLATION:
BEFORE INSTALLING THE O2 SENSOR, LUBRICATE THREADS
WITH ANTI-SEIZE COMPOUND GM P/N 5613695 OR EQUIVALENT.
AVOID GETTING COMPOUND ON THE SENSOR TIP.
THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED. DO
1. Install O2 sensor. Tighten to 30 lb-ft (41 Nm).
NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPEC-
IFIED PARTS. 2. Start engine.
3. Check for any DTC codes and clear.
1. Install hose clamps and set back on each hose.
4. Verify engine is in closed loop and no warning lights
2. Reinstall the vapor hose to each fitting. are illuminated.

3. Reset clamps.

4. Start engine and check for leaks.

Engine Control Module Replacement

REMOVAL:

1. Disconnect Negative battery cable.

2. Remove controller from mounting bracket.

3. Push connector lock back to unlock connector.

4. Unplug controller and remove.

3121249 – JLG Lift – 3-115

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

3.20 GM ENGINE LPG FUEL SYSTEM Diagnostic Aids

DIAGNOSIS This procedure is intended to diagnose a vehicle operat-
ing on LPG. If the vehicle will not continue to run on LPG,
Fuel System Description refer to Hard Start for preliminary checks. Before proceed-
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 3-93. EPR Assembly
Pressure Gauges:
• IMPCO ITK-2 Test kit
To maintain fuel and emission control on the LPG fuel sys-
tem, the Engine Control Unit (ECM) relies on numerous • Water Column Gauge / Manometer (GM 7333-6 or
engine sensor and output data from the Electronic Pres- equivalent)
sure Regulator (EPR). The ECM will then determine the • 0-10 PSI Gauge
target fuel calibration and command the EPR to reposition
the voice coil to the proper position which, subsequently Test Description:
repositions the secondary lever in the pressure regulator The numbers below refer to step numbers in Table 3-15,
to maintain proper control. The EPR and ECM will con- LPF Fuel System Diagnosis.
tinue to communicate back and forth during normal oper-
ation. 5. This step determines if the LPR requires replacement.
6. This step determines if the problems are in the mechan-
In the event that the EPR fails to communicate or the Com-
ical side of the Pressure Regulator or the Electronic Voice
munications Area Network (CAN) cable fails to transmit
Coil.
data, the regulator will operate in an open loop configura-
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
14. This step determines if the Lock Off requires replace-
motion. This downward motion will cause the secondary
ment.
lever to open, thus allowing more fuel to enter the mixer.
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.

3-116 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-15. 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
Go to the
Perform the On Board Diagnostic (OBD) System Check.
2 -- applicable DTC Go to Step 3
Are any DTCs present in the ECM?
Table
Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual
3 valve is open and the tank quick connect is fully engaged. -- Go to Step 4 --
Does the vehicle have fuel?
1. Connect a water column gauge or a manometer to the secondary test port
of the low pressure regulator (LPR).
4 -- Go to Step 5 Go to Step 8
2. Start the engine and allow it to reach operating temperature.
Does the engine start and run?
With the engine idling, observe the pressure reading for the LPR secondary
-1.0" to
5 pressure. Go to Step 25 Go to Step 6
-2.0" w.c
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range?
1. Disconnect the EPR electrical connectors.
NOTE: This action will cause a DTC to be set by the ECM.
-1.0" to Go to Fuel Control
6 2. With the engine idling, observe the pressure reading on the secondary test Go to Step 7
-2.0" w.c System Diagnosis
port.
Is the fuel pressure WITHIN the specified range?
1. Inspect the air intake stream between the mixer assembly and the throttle
body for leaks.
2. Inspect the fuel hose connection between the LPR and mixer assembly for
7 -- Go to Step 26 Go to Step 22
damage or leakage.
3. Inspect any vacuum hoses for leaks.
Was a problem found and corrected?
1. Connect a water column gauge or a manometer to the secondary test port
of the low pressure regulator (LPR).
8 2. Crank the engine and observe the pressure reading for the LPR secondary -- Go to Step 12 Go to Step 9
pressure.
Does the fuel pressure indicate a vacuum is present?
1. Remove Air induction hose to the mixer.
2. Observe the air valve for movement while the engine is cranking.
9 -- Go to Step 11 Go to Step 10
Note: Movement of the air valve will be minimal at cranking speeds.
Does the air valve move when the engine is cranked?
1. Inspect the air intake stream to the mixer assembly and the throttle body for
vacuum leaks.
10 2. Inspect the vacuum hoses from the mixer for proper connection and condi- -- Go to Step 26 Go to Step 24
tion.
Was a problem found and repaired?
Inspect the fuel hose connection between the LPR and the mixer assembly for
11 damage or leakage. -- Go to Step 26 Go to Step 12
Was a problem found and repaired?
1. Connect a 0-10 psi gauge to the primary test port of the low pressure regu-
lator (LPR).
12 2. Crank the engine and observe the pressure reading for the LPR primary 1- 3 PSI Go to Step 22 Go to Step 13
pressure.
Is the fuel pressure ABOVE the specified value?

3121249 – JLG Lift – 3-117

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-15. LPF Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

1. Turn OFF the ignition.
2. Disconnect the LPL connector.
13 3. Install a test light between the pins of the LPL connector. -- Go to Step 14 Go to Step 16
4. Crank the engine. The test light should illuminate.
Does the test light illuminate?
Using a DVOM, check the resistance of the low pressure lock-off (LPL).
14 12W - 16W Go to Step 15 Go to Step 23
Is the resistance within the specified range?
1. Turn the ignition OFF.
2. Close the manual shut-off valve on the LPG tank.
CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present.
15 -- Go to Step 23 Go to Step 17
Perform 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?
1. Turn OFF the ignition.
2. Connect the test light to chassis ground and probe pin A of the LPL connec-
16 tor. -- Go to Step 20 Go to Step 21
3. Crank the engine. The test light should illuminate.
Does the test light illuminate?
1. Remove the LPG fuel filter / LPL.
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG fuel filter onto a clean sur-
face.
17 -- Go to Step 19 Go to Step 18
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?
The fuel supply system or hoses are plugged or restricted, locate and repair
18 the problem. -- Go to Step 26 --
Is the action complete?
Replace the fuel filter. Refer to Fuel Filter Replacement.
19 -- Go to Step 26 --
Is the action complete?
Repair the open in the lock-off ground circuit.
20 -- Go to Step 26 --
Is the action complete?
Repair the open in the lock-off power circuit.
21 -- Go to Step 26 --
Is the action complete?
Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator
22 Replacement. -- Go to Step 26 --
Is the action complete?
Replace the lock-off. Refer to Lock-off Replacement.
23 -- Go to Step 26 --
Is the action complete?
Replace the mixer assembly. Refer to Fuel Mixer Replacement.
24 -- Go to Step 26 --
Is the action complete?

3-118 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-15. LPF Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

The fuel supply system is operating normally, if a failure of the control sole-
noids is suspected. Refer to Fuel Control System Diagnosis.

25 1. Install the test plug in the LPR secondary chamber. -- System OK --

2. If you were sent to this routine by another diagnostic chart, return to the
previous diagnostic procedure.
Is the action complete?
1. Disconnect all test equipment.
2. Install the primary and secondary test port plugs.
26 3. Start the engine. -- System OK --
4. Using SNOOP or equivalent, leak check the test port plugs.
Is the action complete?

3121249 – JLG Lift – 3-119

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. 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 valu-
able 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 • Check all ECM system fuses and circuit breakers.
• Check the ECM ground for being clean, tight and in its proper location.
• Check the vacuum hoses for splits, kinks and proper connections.
• Check thoroughly for any type of leak or restriction.
• Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
• Check for proper installation of the mixer module assembly.
• Check for air leaks at the mixer assembly.
• Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
• Check the wiring for the following items:
- Proper connections, pinches or cuts
• The following symptom tables contain groups of possible causes for each symptom. The order of these pro-
cedures 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 • Refer to Important Preliminary Checks.
• Do 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 • Faulty electrical connections or wiring can cause most intermittent problems.
Wiring • Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient
• Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact ten-
sion. If necessary, replace all the connector terminals in the problem circuit in order to ensure the proper con-
tact tension.
• Checking 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
problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.

3-120 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s):
Lamp (MIL) • A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference.
Normally, the problem will occur when the faulty component is operating.
• The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
• The ignition secondary voltage shorted to a ground.
• The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
• The Control Module grounds.
Loss of DTC Memory To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.

The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If
the TMAP DTC does not store and remain, the ECM is faulty.
No Start
DEFINITION: The engine cranks OK, but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
• Check for proper communication with both the ECM.
• Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
• Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics.
Verify voltage and/or continuity for each circuit.
Sensor Checks • Check the TMAP sensor.
• Check the Magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
• Check for air intake system leakage between the mixer and the throttle body.
• Verify proper operation of the low pressure lock-off solenoids.
• Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
• Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline oper-
ating conditions.
• Check for the proper ignition voltage output with J 26792 or the equivalent.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check for bare or shorted ignition wires.
• Check for loose ignition coil connections at the coil.
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake
manifold leakage than the gasoline fuel supply system.
• Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes

3121249 – JLG Lift – 3-121

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Exhaust System Checks • Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure
• Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis.
Hard Start
DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks • Refer to Important Preliminary Checks.
• Make sure the vehicle's operator is using the correct starting procedure.
Sensor Checks • Check 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 sen-
sor circuit. Refer to DTC 111.
• Check the Crankshaft Position (CKP) sensor.
• Check 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.
• Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
• Check mixer module assembly for proper installation and leakage.
• Verify proper operation of the low pressure lock-off solenoids.
• Verify proper operation of the EPR.
• Check for air intake system leakage between the mixer and the throttle body.
• Check the fuel system pressures. Refer to the Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline oper-
ating conditions.
• Check for the proper ignition voltage output with J 26792 or the equivalent.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check for bare or shorted ignition wires.
• Check for moisture in the distributor cap, if applicable.
• Check for loose ignition coil connections.
Important:
1. 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
manifold leakage than the gasoline fuel supply system.
• Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
• Check the intake and exhaust manifolds for casting flash.

3-122 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Exhaust System Checks • Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure
• Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust
System in the GM Base Engine Service Manual.
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases 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.
Preliminary Checks • Refer to Important Preliminary Checks.
Ignition System Checks • Start the engine.
• Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring
as you apply water.
• Check for proper ignition output voltage with spark tester J 26792.
• Check for a cylinder misfire.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Remove the spark plugs in these cylinders and check for the following conditions:
- Insulation cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Visually/Physically inspect the secondary ignition for the following:
- Ignition wires for arcing, cross-firing and proper routing
- Ignition coils for cracks or carbon tracking
Engine Mechanical Checks • Perform a cylinder compression check.
• Check the engine for the following:
- Improper valve timing
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes
- Broken or weak valve springs
• Check the intake and exhaust manifold passages for casting flash.
Fuel System Checks • Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
• Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
• EMI on the reference circuit can cause a missing condition.
• Monitoring the engine RPM with a scan tool can detect an EMI.
• A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
• If 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 condi-
tion may cause the engine to stall if it's severe enough.
Preliminary Checks Refer to Important Preliminary Checks.
Fuel System Checks • Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
• Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below
specification, there is possibly a faulty low pressure regulator or a restriction in the fuel system.
• Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
• Check LPL electrical connection.
• Check the mixer air valve for sticking or binding.
• Check the mixer module assembly for proper installation and leakage.
• Check the EPR electrical connections.

3121249 – JLG Lift – 3-123

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline oper-
ating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only igni-
tion system failure and test the system accordingly.
• Check for the proper ignition voltage output with J 26792 or the equivalent.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check for faulty spark plug wires.
• Check for fouled spark plugs.
Additional Check • Check for manifold vacuum or air induction system leaks.
• Check the generator output voltage.
Backfire
DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check • Refer to Important Preliminary Checks.
Ignition System Checks Important: LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gaso-
line operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
• Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent.
• Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter
reads over 30,000 ohms, replace the wires.
• Check the connection at each ignition coil.
• Check for deteriorated spark plug wire insulation.
• Check the spark plugs. The correct spark plugs for LPG are (R42LTS).
• Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Engine Mechanical Check Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake
manifold leakage than a gasoline fuel supply system.
• Check the engine for the following:
- Improper valve timing
- Engine compression
- Manifold vacuum leaks
- Intake manifold gaskets
- Sticking or leaking valves
- Exhaust system leakage
• Check the intake and exhaust system for casting flash or other restrictions.
Fuel System Checks • Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
Lack of Power, Sluggishness, or Sponginess
DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal.
Preliminary Checks • Refer to Important Preliminary Checks.
• Refer to the LPG Fuel system OBD System Check.
• Compare 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.
• Remove the air filter and check for dirt or restriction.
• Check the vehicle transmission Refer to the OEM transmission diagnostics.

3-124 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Fuel System Checks • Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diag-
nosis.
• Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
• Check for proper installation of the mixer module assembly.
• Check all air inlet ducts for condition and proper installation.
• Check for fuel leaks between the LPR and the mixer.
• Verify that the LPG tank manual shut-off valve is fully open.
• Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks • Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper
operation of the MAP sensor.
• Check for proper operation of the TPS sensor.
Exhaust System Checks • Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure
- Check for possible plugged catalytic converter
Engine Mechanical Check • Check the engine for the following:
- Engine compression
- Valve timing
- Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual
Additional Check • Check the ECM grounds for being clean, tight, and in their proper locations.
• Check the generator output voltage.
• If all procedures have been completed and no malfunction has been found, review and inspect the following
items:
- Visually and physically, inspect all electrical connections within the suspected circuit and/or systems
- Check the scan tool data
Poor Fuel Economy
DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on
this vehicle at one time, as previously shown by refueling records.
Preliminary Checks • Refer to Important Preliminary Checks.
• Check the air cleaner element (filter) for dirt or being plugged.
• Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
• Check the operator’s 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?
• Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
• Suggest that a different operator use the equipment and record the results.
Fuel System Checks • Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
• Check the fuel system for leakage.
Sensor Checks • Check the Temperature Manifold Absolute Pressure (TMAP) sensor.

3121249 – JLG Lift – 3-125

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Ignition System Checks • Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
• Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks • Check the engine thermostat for always being open or for the wrong heat range.
Additional Check • Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
• Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: The engine runs unevenly 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 • Check 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 delivered to the engine causing a severe driveability problem.
• Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
• Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks • Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint.
Monitoring the oxygen sensors will help identify the problem.
• Check for a sticking mixer air valve.
• Verify proper operation of the EPR.
• Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
• Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
• Check mixer module assembly for proper installation and connection.
Ignition System Checks • Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
• Check the spark plug wires by connecting an 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
manifold leakage than the gasoline fuel supply system.
• Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control
command.
• Check the ECM grounds for being clean, tight, and in their proper locations.
• Check 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.

3-126 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-16. Symptom Diagnosis

Checks Action
Engine Mechanical Check • Check the engine for the following:
- Broken motor mounts
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
Surges/Chuggles
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the
accelerator pedal.
Preliminary Checks Refer to Important Preliminary Checks.
Sensor Checks • Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks • Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint.
Monitoring the oxygen sensors will help identify the problem.
• Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
• Verify proper fuel control solenoid operation.
• Verify that the LPG manual shut-off valve is fully open.
• Check the in-line fuel filter for restrictions.
Ignition System Checks • Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
• Verify that the spark plugs are correct for use with LPG (R42LTS).
• Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor
Additional Check • Check the ECM grounds for being clean, tight, and in their proper locations.
• Check the generator output voltage.
• Check the vacuum hoses for kinks or leaks.
• Check Transmission.

3121249 – JLG Lift – 3-127

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-17. 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
264 Injector Driver 2 Open 652 5
265 Injector Driver 2 Shorted 652 6
267 Injector Driver 3 Open 653 5
268 Injector Driver 3 Shorted 653 6
270 Injector Driver 4 Open 654 5
271 Injector Driver 4 Shorted 654 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1

3-128 – JLG Lift – 3121249

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

Table 3-17. 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

3121249 – JLG Lift – 3-129

 SECTION 3 - CHASSIS, PLATFORM & SCISSOR ARMS

NOTES:

3-130 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

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 CYLINDER CHECKING PROCEDURE
valve.
NOTE: Cylinder check must be performed anytime a system
4.2 VALVES - THEORY OF OPERATION component is replaced or when improper system
operation is suspected.

Solenoid Control Valves (Bang-Bang) Cylinders Without Counterbalance Valves

Control valves used are four-way three-position solenoid
1. Using all applicable safety precautions, activate
valves of the sliding spool design. When a circuit is acti-
engine and fully extend cylinder to be checked. Shut
vated and the control valve solenoid energizes, the spool
down engine.
is shifted and the corresponding work port opens to per-
mit oil flow to the component in the selected circuit, with 2. Carefully disconnect hydraulic hoses from retract
the opposite work port opening to reservoir. Once the cir- port of cylinder. There will be some initial weeping of
cuit is deactivated (control returned to neutral), the valve hydraulic fluid which can be caught in a suitable
spool returns to neutral (center) and oil flow is then container. After the initial discharge, there should be
directed through the valve body and returns to reservoir. A no further drainage from the retract port.
typical control valve consists of the valve body, sliding
spool, and two solenoid assemblies. The spool is 3. Activate engine and extend cylinder.
machine fitted in the bore of the valve body. Lands on the 4. If cylinder retract port leakage is less than 6-8 drops
spool divide the bore into various chambers, which, when per minute, carefully reconnect hose to port and
the spool is shifted, align with corresponding ports in the retract cylinder. If leakage continues at a rate of 6-8
valve body open to common flow. At the same time other drops per minute or more, cylinder repair must be
ports would be blocked to flow. The spool is spring- made.
loaded to center position, therefore when the control is
released, the spool automatically returns to neutral, pro- 5. With cylinder fully retracted, shut down engine and
hibiting any flow through the circuit. carefully disconnect hydraulic hose from cylinder
extend port.
Relief Valves 6. Activate engine and retract cylinder. Check extend
port for leakage.
Main relief valves are installed at various points within the
hydraulic system to protect associated systems and com- 7. If extend port leakage is less than 6-8 drops per
ponents against excessive pressure. Excessive pressure minute, carefully reconnect hose to extend port,
can be developed when a cylinder reaches its limit of than activate cylinder through one complete cycle
travel and the flow of pressurized fluid continues from the and check for leaks. If leakage continues at a rate of
system control. The relief valve provides an alternate path 6-8 drops per minute or more, cylinder repairs must
for the continuing flow from the pump, thus preventing be made.

3121249 – JLG Lift – 4-1

 SECTION 4 - HYDRAULICS

Cylinders With Single Counterbalance Valve Oscillating Axle Cylinder Test (Lockout)

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
ONLY. ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.
1. Using all applicable safety precautions, activate
hydraulic system. NOTE: Ensure platform is fully lowered prior to beginning
lockout cylinder test.
2. Shut down hydraulic system and allow machine to
sit for 10-15 minutes. If machine is equipped with
bang-bang or proportional control valves, turn igni- 1. Place a 6 inch (15.2 cm) high block with ascension
tion switch to on, move control switch or lever for ramp in front of left front wheel.
applicable cylinder in each direction, then turn igni- 2. From platform control station, select LOW drive
tion switch to off. If machine is equipped with speed.
hydraulic control valves, move control lever for
applicable cylinder in each direction. This is done to 3. Place DRIVE control switch to FORWARD position
relieve pressure in the hydraulic lines. and carefully drive the machine up ascension ramp
Carefully remove hydraulic hoses from appropriate until left front wheel is on top of block.
cylinder port block.
4. Raise machine platform approximately 9 ft (2.7 m)
3. There will be initial weeping of hydraulic fluid, which on the 3394RT or 10 ft (3.1 m) on the 4394RT.
can be caught in a suitable container. After the initial
5. Place DRIVE control switch to REVERSE position
discharge, there should be no further leakage from
and carefully drive the machine off the block and
the ports. If leakage continues at a rate of 6-8 drops
ramp.
per minute or more, the counterbalance valve is
defective and must be replaced. 6. Have an assistant check to see that the left front
wheel remains locked in position off the ground.
4. To check piston seals, carefully remove the counter-
balance valve from the retract port. After initial dis- 7. Lower the machine platform; the lockout cylinder
charge, there should be no further leakage from the should then release and allow wheel to rest on the
ports. If leakage occurs at a rate of 6-8 drops per ground. It may be necessary to activate DRIVE to
minute or more, the piston seals are defective and release cylinders.
must be replaced.
8. Place the 6 inch (15.2 cm) high block with ascension
5. If no repairs are necessary or when repairs have ramp in front of right front wheel.
been made, replace counterbalance valve and care-
fully connect hydraulic hoses to cylinder port block. 9. From platform control station, select LOW drive
speed.
6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic sys- 10. Place DRIVE control switch to FORWARD position
tem and run cylinder through one complete cycle to and carefully drive the machine up ascension ramp
check for leaks. until right front wheel is on top of block.
11. Raise machine platform approximately 9 ft (2.7 m)
on the 3394RT or 10 ft (3.1 m) on the 4394RT.
12. Place DRIVE control switch to REVERSE position
and carefully drive the machine off the block and
ramp.
13. Have an assistant check to see that the right front
wheel remains locked in position off the ground.
14. Lower the machine platform; the lockout cylinder
should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to
release cylinders.
15. If the lockout cylinders do not function properly,
have qualified personnel correct the malfunction
prior to any further operation.

4-2 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

4.4 CYLINDER REPAIR 4. Place the cylinder barrel into a suitable holding fix-
ture.
NOTE: The following are general procedures that apply to
all cylinders on this machine. Procedures that apply
to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON

A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source

to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. Figure 4-2. Cylinder Barrel Support
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.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Dis-
card o-rings.

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
punch or wooden dowel and hammer to drive the
rod guide about one inch down into the cylinder
bore. Using a screw driver, carefully push one end of
the round retaining ring back towards the inside of
the cylinder and then slip the screwdriver tip under
Figure 4-1. Lift Cylinder Holding Valve and Fitting that end. Pull the ring out of the groove toward the
Removal wall mouth. Once one end of the retaining ring is
free from the groove, the remainder can be easily
pried free using ones fingers or pliers.

3121249 – JLG Lift – 4-3

 SECTION 4 - HYDRAULICS

tighten the cap screw(s) until the bushing is loose

on the piston.

13. Remove the bushing from the piston.

7. Attach a suitable pulling device to the cylinder rod

port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-

Figure 4-5. Tapered Bushing Removal
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES. 14. Screw the piston counter-clockwise, by hand, and
remove the piston from cylinder rod.
8. With the barrel securely clamped, apply pressure to
the rod pulling device and carefully withdraw the 15. Remove and discard the piston o-rings, seal rings,
complete rod assembly from the cylinder barrel. and backup rings.

16. Remove piston spacer, if applicable, from the rod.

17. Remove the rod from the holding fixture. Remove

the cylinder head gland and retainer plate, if applica-
ble. Discard the o-rings, back-up rings, rod seals,
and wiper seals.

Cleaning and Inspection

1. 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.
Figure 4-4. Cylinder Rod Support
3. Inspect threaded portion of rod for excessive dam-
9. Using suitable protection, clamp the cylinder rod in age. Dress threads as necessary.
a vise or similar holding fixture as close to the piston 4. Inspect inner surface of cylinder barrel tube for scor-
as possible. ing or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
NOTE: Step 11 applies only to the steer cylinder.
5. Inspect threaded portion of barrel for damage. Dress
10. Loosen and remove the nut which attaches the pis- threads as necessary.
ton to the rod, and remove the piston.
6. Inspect piston surface for damage and scoring and
11. Loosen and remove the cap screw(s), if applicable, for distortion. Dress piston surface or replace piston
which attach the tapered bushing to the piston. as necessary.

12. Insert the cap screw(s) in the threaded holes in the 7. Inspect threaded portion of piston for damage.
outer piece of the tapered bushing. Progressively Dress threads as necessary.

4-4 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

8. Inspect seal and o-ring grooves in piston for burrs Assembly

and sharp edges. Dress applicable surfaces as nec-
essary.
NOTE: Prior to cylinder assembly, ensure that the proper
9. Inspect cylinder head inside diameter for scoring or cylinder seal kit is used. See your JLG Parts Manual.
other damage and for ovality and tapering. Replace
as necessary. Apply a light film of hydraulic oil to all components prior to
10. Inspect threaded portion of head for damage. Dress assembly.
threads as necessary.
1. A special tool is used to install a new rod seal into
11. Inspect seal and o-ring grooves in head for burrs the applicable cylinder head gland groove.
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.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod/barrel
must be replaced. Figure 4-7. Rod Seal Installation
c. Lubricate inside of steel bushing with WD40
prior to bearing installation.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing. WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA-
NOTE: Install pin into the Gar-Max bearing dry. Lubrication TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
is not required with nickel plated pins and bearings. INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
STEEL
COMPOSITE
BUSHING
BUSHING WHEN INSTALLING THE WIPER SEAL ON THE LOWER (TOWER)
LIFT CYLINDER, APPLY LOCTITE® #609 ON THE WIPER SEAL IN
THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE
SEAL.

2. Use a soft mallet to tap a new wiper seal into the

ARBOR applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland-
Figure 4-6. Bushing Installation groove.

14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
Figure 4-8. Poly-Pak Piston Seal Installation
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3121249 – JLG Lift – 4-5

 SECTION 4 - HYDRAULICS

Figure 4-9. Wiper Seal Installation

3. Place a new “o”ring and back-up seal in the applica-

ble outside diameter groove of the cylinder head.

Figure 4-11. Piston Seal Kit Installation

8. Using suitable protection, clamp the cylinder rod in

Figure 4-10. Installation of Head Seal Kit a vise or similar holding fixture as close to piston as
possible.

4. Install washer ring onto rod. Carefully install the 9. Carefully thread the piston on the cylinder rod hand
head gland on the rod, ensuring that the wiper and tight, ensuring that the o-ring and back-up rings are
rod seals are not damaged or dislodged. Push the not damaged or dislodged.
head along the rod to the rod end, as applicable. 10. Thread piston onto rod until it abuts the spacer end
5. Carefully slide the piston spacer on the rod. and install the tapered bushing.

6. If applicable, correctly place new o-ring in the inner NOTE: When installing the tapered bushing, piston and mat-
piston diameter groove. (The backup ring side fac- ing end of rod must be free of oil.
ing the O-ring is grooved.)
7. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
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 must be positioned so as not to be
in alignment with each other.

4-6 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

11. Assemble the tapered bushing loosely into the pis- 16. Place new guide locks and seals in the applicable
ton and insert JLG capscrews (not vendor cap- outside diameter grooves of the cylinder piston.
screws) through the drilled holes in the bushing and (See Figure 4-11.)
into the tapped holes in the piston.
17. Position the cylinder barrel in a suitable holding fix-
ture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.

18. With barrel clamped securely, and while adequately

supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
19. Continue pushing the rod into the barrel until the cyl-
inder head gland can be inserted into the barrel cyl-
inder.
Figure 4-12. Tapered Bushing Installation 20. Secure the cylinder head gland using the washer
ring and socket head bolts.
12. Tighten the capscrews evenly and progressively in
rotation to the specified torque value.

13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;

a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between
the capscrews.
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.
Figure 4-14. Rod Assembly Installation

21. 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.
22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 4-2, Holding Valve Torque
Specifications).

Figure 4-13. Seating the Tapered Bearing

14. Re-torque the capscrews evenly and progressively

in rotation to the specified torque value.

15. Remove the cylinder rod from the holding fixture.

3121249 – JLG Lift – 4-7

 SECTION 4 - HYDRAULICS

Table 4-1. Cylinder Piston Nut Torque Specifications

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
Setscrew torque
Description Nut Torque Value OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
Value
AND CYLINDER BARREL SURFACES.
400 lb-ft 100 in.lbs.
Lift Cylinder 27. With barrel clamped securely, and while adequately
(542 Nm) (12 Nm)
supporting the rod, insert the piston end into the
Lockout Cylinder N/A N/A barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
Steer Cylinder N/A N/A
28. Continue pushing the rod into the barrel until the cyl-
inder head gland can be inserted into the barrel cyl-
inder.
Table 4-2. Holding Valve Torque Specifications
29. If applicable, secure the cylinder head retainer using
Description Torque Value a suitable chain wrench.

30 - 35 lb-ft 30. After the cylinder has been reassembled, the rod
Sun - 7/8 hex M20 x 1.5 thds should be pushed all the way in (fully retracted) prior
(41 - 48 Nm)
to the reinstallation of any holding valve or valves.
45 - 50 lb-ft
Sun - 1-1/8 hex 1 - 14 UNS thds 31. If applicable, install the cartridge-type holding valve
(61 - 68 Nm)
and fittings in the port block using new o-rings as
150 - 153 lb-ft applicable. Refer to Table 4-2, Holding Valve Torque
Sun - 1-1/4 hex M36 x 2 thds Specifications.
(204 - 207 Nm)

Racine - 1-1/8 hex 1-1/16 - 12 thds

50 - 55 lb-ft 4.5 DRIVE PUMP START-UP PROCEDURE
(68 - 75 Nm)

75 - 80 lb-ft
Racine - 1-3/8 hex 1-3/16 - 12 thds
(102 - 109 Nm) THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER-
100 - 110 lb-ft FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING
Racine - 1-7/8 hex 1-5/8 - 12 thds AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR
(136 - 149 Nm)
HAVE BEEN REMOVED FROM THE SYSTEM.

23. Push the piston onto the rod until it abuts the spacer THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER-
end and install the attaching nut. FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING
AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR
HAVE BEEN REMOVED FROM THE SYSTEM.
WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE® #242 TO
PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT. THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO
REFER TO TABLE 4-1, CYLINDER PISTON NUT TORQUE SPECIFI- BE DISABLED (WHEELS RAISED OFF THE GROUND, DRIVE
CATIONS. FUNCTION DISCONNECTED, ETC.) WHILE PERFORMING THE
PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN
NOTE: The Steer Cylinder uses snap rings to secure piston. AND OTHER PERSONNEL. TAKE NECESSARY SAFETY PRECAU-
TIONS BEFORE MOVING THE MACHINE.
24. Prior to setscrew installation spot drill rod before
installing the setscrew(s) which secure the piston Prior to installing pump and/or motor, inspect unit(s) for
attaching nut to the diameter groove. damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses, valves,
25. Remove the cylinder rod from the holding fixture. fittings, heat exchanger, etc.) are clean prior to filling with
hydraulic fluid.
26. Position the cylinder barrel in a suitable holding fix-
ture. Fill reservoir with recommended hydraulic fluid, which
should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
contaminated fluid will cause damage to components,
which may result in unexpected machine movement.

4-8 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

The inlet line leading from the reservoir to the pump 4.6 HYDRAULIC COMPONENT START-UP
should be filled prior to start-up. Check inlet line for prop-
erly tightened fittings and make sure it is free of restric-
PROCEDURES & RECOMMENDATIONS
tions and air leaks. From a hydrostatic component standpoint, the goal at
system start up is to put into functional operation, the
Be certain to fill pump and/or motor housing with clean hydrostatic system in such a way as to preserve the
hydraulic fluid prior to start-up. Fill housing by pouring fil- designed life span of the system. The following start-up
tered oil into 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
Install a 0 to 500 psi (0 to 35 bar) pressure gauge in the restarted after either a pump or motor has been removed
charge pressure gauge port to monitor charge pressure and/or replaced.
during start-up.

It is recommended that the external control input signal

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO
electrical connections be disconnected at the pump con-
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK
trol until after initial start-up. This will allow the pump to
FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING THE
remain in its neutral position. PROCEDURE IN ORDER TO PREVENT INJURY. TAKE NECES-
SARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/
“Jog” or slowly rotate prime mover until charge pressure
MACHINE.
starts to rise. Start prime mover and run at the lowest pos-
sible RPM until charge pressure has been established. Prior to installing the pump and/or motor, inspect the
Excess air may be bled from high pressure lines through unit(s) for damage that may have been incurred during
high pressure gauge ports. shipping and handling. Ensure all system components
(reservoir, hoses, valves, fittings, heat exchanger, etc.) are
clean prior to filling with fluid.

DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL Fill the reservoir with recommended hydraulic fluid. This
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU- fluid should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
contaminated fluid will cause damage to the components,
ACTUATED DURING INITIAL START-UP.
which may result in unexpected vehicle/machine move-
ment.
Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should NOTE: If a pump or motor is being replaced due to internal
damage, the remaining units (pump or motors) need
be approximately 220 psi (15.5 bar) minimum. If charge
to be inspected for damage and contamination, and
pressure is incorrect, shut down and determine cause for
the entire hydraulic system will need to be flushed
improper pressure. and the fluid replaced. Failure to do so may cause
considerable damage to the entire system.

The inlet line leading from the reservoir to the pump must
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-
be filled prior to start-up. Check the inlet line for property
TOR’S ABILITY TO CONTROL THE MACHINE. tightened fittings and make sure it is free of restrictions
and air leaks.
Shut down prime mover and connect external control
NOTE: In most cases, the reservoir is above the pump inlet
input signal. Start prime mover, checking to ensure pump
so that the pressure head created by the higher oil
remains in neutral. With prime mover at normal operating
level helps to keep the inlet pressures within an
speed, slowly check for forward and reverse machine acceptable range and prevent high vacuum levels.
operation. However, due to hose routing or low reservoir loca-
tions, there may be air trapped within this line. It is
Charge pressure should remain at 220 psi to 240 psi (15.5 important to ensure that the air is bled from this line.
bar to 16.9 bar) minimum during forward or reverse opera- This can be accomplished by loosening the hose at
tion. Continue to cycle slowly between forward and the fitting closest to the pump. When oil begins to
reverse for at least five minutes. flow, the line is full, the air has been purged, and the
fitting can be retightened to its specified torque. If the
Shut down prime mover, remove gauges, and plug ports. tank needs to be pressurized in order to start the
Check reservoir level and add fluid if necessary. flow of oil, a vacuum reading should be taken at the

3121249 – JLG Lift – 4-9

 SECTION 4 - HYDRAULICS

inlet of the pump during operation in order to verify sure is inadequate, shut down and determine the cause
that the pump is not being asked to draw an inlet for improper pressure.
vacuum higher than it is capable of.

Be certain to fill the pump and/or motor housing with INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-
clean hydraulic fluid prior to start up. Fill the housing by TOR' S ABILITY TO CONTROL THE MACHINE.
pouring filtered oil into the upper case drain port.
Shut down the engine and connect the external control
NOTE: It is highly recommended to use the highest possible
input signal. Also reconnect the machine function(s), if
case drain port, this ensures that the housing con-
disconnected earlier. Start the engine, checking to be cer-
tains as much oil as possible and offers the greatest
tain the pump remains in neutral. With the engine at nor-
amount of lubrication to the internal components.
mal operating RPM, slowly check for forward and reverse
machine operation.
In initial start-up conditions, it may be convenient to
fill the housing, just prior to installing the case drain Charge pressure may slightly decrease during forward or
line. Component, (especially motor), location may be reverse operation. Continue to cycle slowly between for-
such that access to the case drain port after installa- ward and reverse for at least five minutes.
tion is not realistic.
Shut down engine, remove gauges, and plug ports.
Make certain that the oil being used to fill the compo- Check reservoir level and add filtered fluid if needed.
nent housing is as clean as possible. Store the fill The machine is now ready for operation.
container in such a way as to prevent it from becom-
ing contaminated. 4.7 HYDRAULIC GEAR PUMP
Install a 60 bar (or 1000 psi) pressure gauge in the charge Overhaul pump only in a clean, dust free location, using
pressure gauge port in order to monitor the charge pres- clean tools and equipment. dirt and grit will damage the
sure during start-up. highly machined surfaces and will result in leakage or pre-
mature failure of the pump.
It is recommended that the external control input signal,
(electrical connections for EDC), be disconnected at the
pump control until after initial start-up. This will ensure that
the pump remains in its neutral position.

DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL

POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
ACTUATED DURING INITIAL START-UP.

"Jog" or slowly rotate the engine until charge pressure

starts to rise. Start the engine and run at the lowest possi-
ble RPM until charge pressure has been established.
Excess air should be bled from the system lines as close Before beginning disassembly, scribe "match marks" on
to the motors as possible. the body (13) and covers (5 and 6) to ensure that the
pump will be reassembled in the same manner as it was
NOTE: With the engine on low idle, "crack", (loosen-don't shipped from the factory. If the body or rear cover is
remove), the system lines at the motor(s). Continue replaced during overhaul, scribe a match mark on the new
to run the engine at low idle and tighten the system part in the same location as on the part it replaced.
lines as soon as oil is observed to leak from them.
When oil is observed to "leak" at the motor, the line Pump Disassembly
is full, the air has been purged, and the system
hoses should be retightened to their specified 1. Clean outside of pump with a good grade solvent
torque. and dry thoroughly.
2. On models with a splined drive shaft, proceed to
Once charge pressure has been established, increase step 3. On models with a keyed drive shaft, remove
speed to normal operating RPM. Charge pressure should drive key (10) from drive shaft. Using a file or stone,
be as indicated in the pump model code. If charge pres- remove burrs from shaft end of keyway.

4-10 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

3. Using light clamping pressure on the ears of the NOTE: A somewhat heavier wear pattern is normal on the
front cover, secure unit in vise with shaft side down. low pressure (inlet) side of the bearing blocks (2).
Remove the cap screws (14) and washers (9). However, there should be no heavy scoring in this
area.
4. Separate rear cover (6) from the body (13). The
static seal (8) may remain either with the body or the
cover. In either case, remove the static seal and dis-
card.

5. Lift out the rear bearing block (2), drive gear (12),
and driven gear (11).

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. Separate body (13) from front cover (5). Dowel pins
6. Inspect body for wear and scoring. If gear contact
(7) and the front static seal (8) may remain with
wear on low pressure side (inlet) exceeds 0.005 in.
either the body (13) or the front cover (5). In either
(0.127mm) depth, replace body. If the body is
case, remove the static seal and discard.
usable, lightly wipe and remove burrs with suitable
7. The front bearing block (2) will typically remain in the de-burring tool.
body (13). Invert the body and lift out the bearing
block. Pump Reassembly
8. Invert front cover (5) with shaft seal up. Remove the 1. Place the front cover (5) on a flat plate with the steel
shaft seal (1) by prying it out with a large screw- shaft seal bore up. Install new shaft seal (1). Press
driver. seal until it is 0.157 in (4.0mm) below front surface.
Pack the area between the double lip of the seal with
NOTE: During disassembly, take special note of the wear Lubriplate or an equivalent grease.
patterns on the bearing blocks (2) and body (13).
Relate these patterns to the inlet and outlet sides of
the pump. The large port ,whether in the body (13) or
the rear cover (6), corresponds to the inlet side of the
pump. The inlet side of the body can be identified by
the gear contact pattern in the gear bore. The bear-
ing block will have somewhat heavier wear patterns
on the inlet side.

Parts Inspection
1. Wash all parts and dry thoroughly.

2. Inspect front and rear bearing block. Replace if scor-

ing or uneven wear is observed.

3121249 – JLG Lift – 4-11

 SECTION 4 - HYDRAULICS

2. Clamp front cover into vise so that the ring groove is 8. Place a small amount of grease in the seal groove
up. Apply a small amount of grease to the seal on the rear bearing block (2). Install a new load seal
groove and install a new seal ring (8) into the and anti extrusion seal in the groove. Insert the bear-
groove. ing 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 the outside of the "W" seal is exposed to the
drive shaft installation tool. Insert tool (bullet) into discharge pressure.
shaft seal from seal ring groove side of front cover.
9. Apply a small amount of grease to the 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 lb-ft. (57-62 Nm).
exposed to the discharge pressure.
11. On models equipped with keyed drive shaft, install
5. Apply a small amount of grease to the dowel pins (7) drive key (10).
and install the pins 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 scribe 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).

4-12 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

4.8 VALVES

1 3
2

1. Main Valve 2. Flow Divider Valve 3. Outrigger Directional Valve

Figure 4-15. Hydraulic Compartment

REMOVAL: INSTALLATION:
1. Disconnect, cap and lable all hydraulic hoses and 1. Re-attach valve blocks to tray with bolts.
any electrical harness connected to valves.
2. Re-connect all hydraulic lines and electrical harness.
2. Remove the valve blocks from the hydraulic tray by
removing the attaching bolts.

3121249 – JLG Lift – 4-13

 SECTION 4 - HYDRAULICS

Main Valve

SV5, CL1 SV7, CL2

OSC AXLE 1 DUMP VALVE

SV6, CL2 CV1

OSC AXLE 2 PLG6

SV1, CL2
LIFT UP
SV2, CL1, CL1
STEER

SV4, CL1
BRAKES
LS1
SV3, CL1
2-SPD
T1

P3

PLG6
PLG4

L2
T3 CV3 T4 LO
F
PLG6 P2 R
RV2 P1
L1
MP1 RV1
S1
S2
B2
G
T2
MP2 RV3
ORF1
2S2
B1
PLG6 ORF2

2S1

Figure 4-16. Main Valve Block

4-14 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Table 4-3. Main Valve Torque Specs Table 4-4. Porting Specs

Component Torque Port Size

L2, P1 & T1 SAE 10
SV1 (Lift Up) 25 lb-ft (34.2 Nm)
L1 SAE 08
SV2 (Steer) 20 lb-ft (27.3 Nm) G, P2, P3, T4 & T2 SAE 06

SV3 (2-Spd) 20 lb-ft (27.3 Nm) All Others SAE 04

SV4 (Brakes) 20 lb-ft (27.3 Nm)

SV5 (Osc Axle 1) 20 lb-ft (27.3 Nm)

SV6 (Osc Axle 2) 25 lb-ft (34.2 Nm)

SV7 (Dump Valve) 25 lb-ft (34.2 Nm)

CL1 & CL2 (Coil) 5 lb-ft (6.8 Nm)

RV1, RV2 & CV3 25 lb-ft (34.2 Nm)

RV3, LS1, CV1 & CV2 20 lb-ft (27.3 Nm)

Figure 4-17. Main Valve Schematic

3121249 – JLG Lift – 4-15

 SECTION 4 - HYDRAULICS

Flow Divider Valve

9 13 7 9 3

CV4 CV3
CV5
CV6

6 CV2 10 8

OR2 11 5, OR1

FD2
2 FD1
12

OR3 CV7 4 CV8 FD3

Figure 4-18. Flow Divider Valve

4-16 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Leveling Jacks Directional Valve

PB4
PB3
PB2
PB1
PA4
PA3
PA2
PA1
LP
PA2 PB1
PA1
PB3
T
PA3
PB2
PA4 PB4 LP T

Figure 4-19. Leveling Jacks Directional Valve

Table 4-5. Leveling Jacks Directional Valve Torque

Specs

Item Torque
40 lb-ft
PA4
(54 Nm)
23 lb-ft
PB4
(31 Nm)
40 lb-ft
T
(54 Nm)

3121249 – JLG Lift – 4-17

 SECTION 4 - HYDRAULICS

Powerdeck Valves

SV1, CL1, CL1

P
1
T
2

RV1

Figure 4-20. Powerdeck Valve (Single)

SV1, CL1, SV2, CL1,

CL1 CL1

3 1
P
4 2
T

RV1 RV2

Figure 4-21. Powerdeck Valve (Double)

Table 4-6. Powerdeck Valve Torque Specs NOTE: All ports are SAE 04.

Item Torque
SV1, SV2 25 lb-ft (34.2 Nm)
CL1 5 lb-ft (6.8 Nm)
RV1, RV2 20 lb-ft (27.3 Nm)

4-18 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Leveling Jack Valves

4
1
2

B
A

NOTE: Applies to all four Leveling Jacks.

Figure 4-22. Leveling Jack Valves

Table 4-7. Leveling Jack Valves Torque Specs

Item Torque
3 to 4.5 lb-ft
1
(4.1 to 6.1 Nm)
18.5 to 22 lb-ft
2
(25.1 to 29.8 Nm)
40 lb-ft
3
(54.2 Nm)
32 lb-ft
4
(43.4 Nm)

3121249 – JLG Lift – 4-19

 SECTION 4 - HYDRAULICS

Pressure Setting Procedures decrease. (The relief valve is on the same face
as the solenoid valves).
Cold temperatures have a significant impact on pressure
readings. JLG Industries Inc. recommends operating the 5. Single Power Deck Relief Valve
machine until the hydraulic system has warmed to normal a. Refer to Figure 4-20., Powerdeck Valve (Single).
operating temperatures prior to checking pressures. JLG
Industries Inc. also recommends the use of a calibrated b. A pressure gauge must be hosed in the power
gauge. Pressure readings are acceptable if they are within deck retract circuit. Tee the gauge in port 2 of
± 5% of specified pressures. the power deck valve.
c. Retract the power deck. Gauge should read
1. Main Relief 1500 psi (103 bar).

a. Refer to Figure 4-16., Main Valve Block. d. Adjust the relief valve (RV1) clockwise to
increase, counter-clockwise to decrease.
b. Locate the lift up solenoid valve. Remove the coil
nut and remove the coil from the cartridge. Do NOTE: This type of relief valve is a bi-directional type. Port 2
not remove the wire out of the coil plug. is the primary setting. Port 1 is the secondary set-
c. Install a pressure gauge, 3000 psi (207 bar) or ting. Port 1 is a function of Port 2. When setting the
higher, at port MP1. Start the engine and activate primary setting, the secondary setting can be as
lift up. much as 300 psi (21 bar) lower. In order to check
Port 1, tee in a gauge at Port 1.
d. Gauge should read 3000 psi (207 bar).
e. Adjust the main relief (RV2) clockwise to 6. Dual Power Deck Relief Valve
increase, counter-clockwise to decrease. Front Power Deck:
f. Reintall the coil to the cartridge and torque to 5
a. Refer to Figure 4-21., Powerdeck Valve (Dou-
lb-ft (6.8 Nm).
ble).
2. Lift Up Relief Valve b. A pressure gauge must be hosed in the power
a. Refer to Figure 4-16., Main Valve Block. deck retract circuit. Tee in a gauge at Port 4 of
the dual deck valve.
b. Install a pressure gauge, 3000 psi (207 bar) or
higher, at port MP1. Start the engine and activate c. Retract the power deck. Gauge should read
lift up. 1500 psi (103 bar).

c. Gauge should read 2700 psi (186 bar). d. Adjust the relief valves (RV1, RV2) clockwise to
increase, counter-clockwise to decrease.
d. Adjust the lift up relief (RV1) clockwise to
increase, counter-clockwise to decrease. NOTE: This type of relief valve is a bi-directional type. Port 4
is the primary setting. Port 3 is the secondary set-
3. Steer Relief Valve ting. Port 3 is a function of Port 4. When setting the
primary setting, the secondary setting can be as
a. Refer to Figure 4-16., Main Valve Block.
much as 300 psi (21 bar) lower. In order to check
b. Install a pressure gauge, 3000 psi (207 bar) or Port 3, tee in a gauge at Port 3.
higher, at port MS. Start the engine and activate
steer right or left. Rear Power Deck:
c. Gauge should read 2500 psi (172 bar). a. Refer to Figure 4-21., Powerdeck Valve (Dou-
d. Adjust the steer relief (RV3) clockwise to ble).
increase, counter-clockwise to decrease. This b. A pressure gauge must be hosed in the power
relief valve takes care of both right and left. deck retract circuit. Tee in a gauge at Port 2 of
the dual deck valve.
4. Leveling Jack Retract Relief Valve
c. Retract the power deck. Gauge should read
a. Refer to Figure 4-16., Main Valve Block. 1500 psi (103 bar).
b. Install a pressure gauge, 3000 psi (207 bar) or d. Adjust the relief valves (RV1, RV2) clockwise to
higher, at port MP1. Start the engine and activate increase, counter-clockwise to decrease.
jack retract.
NOTE: This type of relief valve is a bi-directional type. Port 2
c. When all jacks are retracted the gauge should is the primary setting. Port 1 is the secondary set-
read 2500 psi(172 bar). ting. Port 1 is a function of Port 2. When setting the
d. Adjust the relief valve located on the leveling primary setting, the secondary setting can be as
jack directional valve (refer to Figure 4-19.) much as 300 psi (21 bar) lower. In order to check
clockwise to increase, counter-clockwise to Port 1, tee in a gauge at Port 1.

4-20 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

4.9 GEAR PUMP Table 4-8. Gear Pump Specs

Rotation (Viewing Drive End) Clockwise

0.878 in/rev
Displacement
(14.4 cc/rev)
Max Rated Speed 3500 rpm
3625 psi
Rated Pressure
(250 bar)
Minimum Speed at Rated Pressure 1000 rev/min

Gear Pump Priming

The gear pump is mounted with the suction hose up. Air
trapped in this area can cause an air lock on start up. dur-
1 ing this period, the pump is running dry, which can cause
gear wear, which affects the volumetric efficiency of the
pump.

To prime the pump:

1. Fill the hydraulic tank to the full mark.
2. Using a 2" wrench, loosen the suction hose fitting at
the gear pump. The hose fitting does not need to be
removed, just loosened enough to let the air escape.
3. When oil leaks at the hose end, re-torque the hose
end to 115 lb-ft ( Nm). The pump is primed and the
machine is ready to start.

1. Outlet Port, 7/8-14UNF-2B

SAE #10
2. Inlet Port, 1-1/16-12UN-2B
SAE #16

Figure 4-23. Gear Pump

3121249 – JLG Lift – 4-21

 SECTION 4 - HYDRAULICS

4.10 AXIAL HI 45 PUMP

2
4 5
3 11 12

10

1. Case Drain Port L2 (SAE#12) 5. Charge Pressure Filtration Port 9. Port A (SAE#16)
(to inlet on filter)
2. Deutsch DT04-2P Connector 10. Charge Pump Suction Port
6. MB Gage Port (SAE#6) (SAE#16)
3. M5 Servo Gage Port (SAE#4)
7. M3 Charge Gage Port (SAE#6) 11. Port B (SAE#16)
4. Charge Pressure Filtration Port
(from outlet on filter) 8. M14 Gage Port (SAE#4) 12. Case Drain Port L1 (SAE#12)

Figure 4-24. Axial HI 45 Pump

Table 4-9. Axial HI 45 Pump Specs

Rotataion Clockwise
Max Pressure 6525 psi (450 bar)
Displacement 2.75 in³ (45 cm³)
755 mA Threshold
Control Current
1640 mA Max Displacement
12 CC Charge Pump Pressure 348 psi (24 bar)
Max Operating Speed 3500 rpm

4-22 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

1 14

2
13

12
3 11

9 10

1. Electric Displacement Control 6. Shaft 11. Charge Pump

2. Swashplate Feedback Pin 7. Front Bearing 12. Rear Bearing
3. Piston 8. Swashplate Bearing 13. Valve Plate
4. Slipper 9. Swashplate 14. Servo Piston
5. Shaft Seal 10. Cylinder Block

Figure 4-25. Axial HI 45 Pump - Cross Section View

3121249 – JLG Lift – 4-23

 SECTION 4 - HYDRAULICS

General Repair Instructions Start-Up Procedure

REMOVAL: Follow this procedure when starting-up a new pump
installation or when restarting an installation in which the
pump has bee n removed and re-installed on the
machine. Ensure pump has been thoroughly tested on a
PRIOR TO PERFORMING REPAIRS, REMOVE THE UNIT FROM test stand before installing on a machine.
THE MACHINE. CHOCK WHEELS ON THE MACHINE TO INHIBIT
MOVEMENT. BE AWARE THAT HYDRAULIC FLUID MAY BE These pumps should never be dry started. The time it
UNDER HIGH PRESSURE AND/OR HOT. INSPECT THE OUTSIDE takes for the charge pump to create a vacuum to draw in
OF THE PUMP AND FITTINGS FOR DAMAGE. CAP HOSES AFTER the fluid, send it out through the charge pump filter and
REMOVAL TO PREVENT CONTAMINATION. then back in to the pump may take 30-40 seconds. During
this time the surface between the cylinder barel and valve
KEEP IT CLEAN plate are running dry. This can afec the volumetric effi-
Clean the outside of the pump thoroughly before disas- ciency of the pump and cause premature failure of the
sembly. Take care not to contaminate system ports. Clean pump. Pre-filling the case also reduces the time it takes fro
parts using a clean solvent wash and air dry. the pump to create a vacuum to draw fluid into the pump.

AS WITH ANY PRECISION EQUIPMENT, YOU MUST KEEP ALL TO PROTECT AGAINST UNINTENDED MOVEMENT, SECURE THE
PARTS FREE OF FOREIGN MATERIAL AND CHEMICALS. PRO- MACHINE OR DISABLE/DISCONNECT THE MECHANISM WHILE
TECT ALL EXPOSED SEALING SURFACES AND CAVITIES FROM SERVICING.
DAMAGE AND FOREIGN MATERIAL. IF LEFT UNATTENDED,
COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC. NOTE: Prior to installing the pump, inspect for damage that
may have occurred during shipping.
REPLACE ALL O-RINGS & GASKETS
Replace all o-rings and seals during service. Lightly lubri- 1. Ensure that the machine hydraulic oil and system
cate o-rings with clean petroleum jelly prior to assembly. components (reservoir, hoses, valves, fittings, and
heat exchanger) are clean and free of any foreign
SECURE THE UNIT material.
Place the unit in a stable position with the shaft pointing
2. Install new system filter element(s) if necessary.
downward. It will be necessary to secure the pump while
Check that inlet line fittings are properly tightened
removing and torquing fasteners and components.
and there are no air leaks.
3. Install the pump. Install a 1000 psi (50 bar) gauge in
the charge pressure gauge port M3.
PERFORMING MINOR REPAIRS ACCORDING TO THIS SECTION
WILL NOT AFFECT THE PUMP’S WARRANTY. MAJOR REPAIRS 4. Fill the housing by adding filtered oil in the upper
REQUIRING THE REMOVAL OF THE UNIT’S CENTER SECTION, case drain port. If the control is installed on top,
SERVO SLEEVES, OR FRONT FLANGE VOIDS WARRANTY. open the construction plug in the top of the control
to assist in air bleed.
5. Fill the reservoir with hydraulic fluid of the recom-
mended type and viscosity. Use a 10-micron filler fil-
ter. Fill inlet line from reservoir to pump. Ensure
construction plug in control is closed after filling.
6. Disconnect the pump from all control input signals.
7. Close construction plug removed in step 4.

AFTER START-UP, THE FLUID LEVEL IN THE RESERVOIR MAY

DROP DUE TO SYSTEM COMPONENTS FILLING. DAMAGE TO
HYDRAULIC COMPONENTS MAY OCCUR IF THE FLUID SUPPLY
RUNS OUT. ENSURE RESERVOIR REMAINS FULL OF FLUID DUR-
ING START-UP.
AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAM-

4-24 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

AGE HYDRAULIC COMPONENTS. CHECK CAREFULLY FOR NOTE: Be careful, do not damage solenoids and electrical
INLET LINE LEAKS. connections when using straps or chains to support
DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE the pump.
OF AIR AND FLUID HAS BEEN THOROUGHLY FILTERED.
INSPECTION:
8. Disable the engine to prevent it from starting. Crank
the starter for several seconds. Do not exceed the 4. Ensure the work surface and surrounding area are
engine manufacturer’s recommendation. Wait 30 clean and free of contaminants such as dirt and
seconds and then crank the engine a second time grime.
as stated above. This operation helps remove air 5. Inspect the system for contamination.
from the system lines. Refill the reservoir to recom-
mended full oil level. 6. Look at the hydraulic fluid for signs of system con-
tamination, oil discoloration, foam in the oil, sludge,
9. When the gauge begins to register charge pressure, or metal particles.
enable and start engine. Let the engine run for a
minimum of 30 seconds at low idle to allow the air to REASSEMBLY:
work itself out of the system. Check for leaks at all
line connections and listen for cavitation. Check for 7. Before replacing the pump, replace all filters and
proper fluid level in reservoir. drain the hydraulic system. Flush the system lines
and fill the reservoir with the correct, filtered hydrau-
10. When adequate charge pressure is established (as lic fluid.
shown in model code), increase engine speed to
normal operating rpm to further purge residual air 8. Fill the pump with clean, filtered hydraulic fluid.
from the system. 9. Attach the pump to the prime mover. Torque mount-
11. Shut off engine. Connect pump control signal. Start ing screws according to the manufacturers recom-
engine, checking to be certain pump remains in mendation.
neutral. Run engine at normal operating speed and 10. Replace all hydraulic lines. Ensure the charge inlet
carefully check for forward and reverse control oper- line is filled with fluid.
ation.
12. Continue to cycle between forward and reverse for
at least five minutes to bleed all air and flush system
contaminants out of loop.

NOTE: Normal charge pressure fluctuation may occur dur-

ing forward and reverse operation.

13. Check that the reservoir is full. Remove charge pres-

sure gauge. The pump is now ready for operation.

Removing the pump

CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND

VOID THE MANUFACTURER’S WARRANTY.
TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN
REMOVING AND INSTALLING SYSTEM LINES.

DISASSEMBLY:
1. With the prime mover off, thoroughly clean all dirt
and grime from the outside of the pump.
2. Tag, disconnect, and cap each hydraulic line con-
nected to the pump. As hydraulic lines are discon-
nected, plug each open port, to ensure that dirt and
contamination do not get into the pump.
3. Remove the pump and its auxiliary pump (if applica-
ble) as a single unit.

3121249 – JLG Lift – 4-25

 SECTION 4 - HYDRAULICS

Electric Control Module

D050 (3X)
4 mm
4 ft.lbs. (5 Nm) D1

D025A D250
5 mm
10 ft.lbs.

D025A D050 (3X)

Torque sequence D084 4 mm

2 1 4 ft.lbs.
(5 Nm)
D150

6 5

F100 (2X)
4 3 3 mm
1.8 ft.lbs.
(2.5 Nm)
D300 (2X)

REMOVAL: 8. Install the control module and six cap screws

(D250).
1. Using a 5 mm internal hex wrench, remove the six
cap screws (D250). 9. Using a 5 mm internal hex wrench, torque the cap
screws (D250) to 10 lb-ft (13.5 Nm).
2. Remove the control module and gasket (D150). Dis-
card the gasket.
Control Solenoids
3. If necessary, remove orifices (F100) using a 3 mm
internal hex wrench. Tag and number them for rein- REMOVAL:
stallation.
1. Disconnect electrical connection and remove the
INSPECTION: three cap screws (D050) using a 4 mm internal hex
wrench.
4. Inspect the machined surfaces on the control and
top of the pump. If you find any nicks or scratches, 2. Remove the solenoid (D025) and O-ring (D025A).
replace the component. Discard the O-ring.
REASSEMBLY: 3. If necessary, remove the coil using a 12 point 26 mm
socket.
NOTE: Ensure you install dowel pins (D300) in housing
before installing control.
INSPECTION:
5. Install a new gasket (D150). 4. Inspect the machined surface on the control. If you
6. If you removed screen (D084), install a new one. find any nicks or scratches, replace the component.
Install with the mesh facing outward (see drawing).
REASSEMBLY:
7. If previously removed, install orifices (F100) using a
3 mm internal hex wrench. Torque to 1.8 lb-ft (2.5 5. Lubricate new O-ring (D025A) using petroleum jelly
Nm). and install.

4-26 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

6. Install solenoid with three cap screws (D050) using a ing ring diameter is less than 1.53 in (38.84 mm)
4 mm internal hex wrench. Torque screws to 5 Nm (4 when installed on the shaft.
lb-ft).
7. Install the shaft/bearing assembly into the pump.
7. Install coil using a 12 point 26 mm socket. Torque
8. Lubricate and install a new O-ring (J260) onto seal
coil nut to 3.7 lb-ft (5 Nm).
carrier (J275). Press a new seal (J250) into the seal
8. Reconnect electrical connections and test the pump carrier. Press the seal until it is flush within 0.005 in
for proper operation. (+0.12mm ) or 0.0028 in (-0.72 mm) of the inside lip
of the carrier: see illustration.
Shaft Seal, Roller Bearing & Shaft
Replacement Positioning seal in seal carrier
Press flush to this surface
NOTE: The shaft assembly is serviceable without disassem-
bling the pump. Orient the pump on the work surface 0.005 in (+0.12 mm) / 0.028 in (-0.72 mm)
so the shaft is pointing to the side.

REMOVAL: Seal

1. Unwind the spiral ring (J300) from the housing to

release the shaft/seal/bearing subassembly. 9. Cover the shaft with a protective sleeve while install-
2. Pry on the lip of the seal carrier (J275) to dislodge it ing the seal carrier. Hand press the seal carrier into
from the pump. Remove the seal carrier. Remove the housing. Ensure the seal carrier clears the spiral
and discard O-ring (J260). Press the seal (J250) out ring groove in the housing. Remove the protective
of the carrier and discard. sleeve.

3. Pull the shaft (J100) with bearing (J150) out of the 10. Wind the spiral ring into the housing. Ensure the
pump. If necessary, tap lightly on the shaft to dis- inside diameter of the spiral ring is greater than
lodge it from the cylinder block. 2.677 in (68 mm) after installation.

4. Remove the retaining ring (J200) using retaining ring Charge Pump
pliers. Press the bearing off the shaft.
If the pump has an auxiliary pump attached, remove the
Shaft assembly
auxiliary pump and connecting shaft before removing the
auxiliary pad.

REMOVAL:

Protective 1. Position pump so end cover or auxiliary pad is on

J100 sleeve top.
J150 2. If necessary, remove auxiliary pump (not shown), or
J200
J250 shipping cover (K300) and pad seal (K250) as
J260 shown on following page.
J150
J275
J300 3. Remove end cover/auxiliary pad screws (K400)
using a 10 mm internal hex wrench.

NOTE: Alignment pins (G450) are in end cover. They may

dislodge during disassembly.

INSPECTION: 4. Remove and discard gasket (K150).

5. Inspect the shaft journals for wear, scratching, and 5. Remove thrust washer (K500). Note thrust washer
pits. Check the splines for fretting; replace if dam- orientation.
aged. Rotate the bearing, if it does not rotate
smoothly, replace it. 6. Use a small hook to remove pressure balance plate
(S200) and seal (S300). Note plate orientation. Dis-
REASSEMBLY: card seal.
6. Press the bearing (J150) onto the shaft (J100) and 7. Remove coupling (K200). Use a small hook if neces-
replace the retaining ring (J200). Ensure the retain- sary.

3121249 – JLG Lift – 4-27

 SECTION 4 - HYDRAULICS

8. Remove the charge pump outer ring (S150), and

gearset (S100). Charge pump removal/installation

9. Remove valve plate (S250) with seal (S300). Discard

seal K400
8 mm

INSPECTION:
10. Inspect the components for wear, scratches or pit-
K100
ting. Carefully inspect the valve and pressure-bal-
G450
ance plates. Scratches on these components will
cause a loss of charge pressure. If any component G450
shows signs of wear, scratching or pitting, replace it.
K150

REASSEMBY:
K500
11. Install new seals (S300) in the valve (S250) and
pressure-balance (S200) plates. S300

12. Install valve plate (S250) in the same orientation as S200

removed.

13. Lubricate and install charge pump (S100) and outer K200

ring (S150).

14. Install charge pump coupling (K200). S100

15. Install pressure balance plate (S200) in the same ori-

entation as removed. S250

16. Install the thrust washer (K500). Coated side goes S300
toward charge pump coupling (K200).

17. Install a new cover gasket. (K150). If removed, install

guide pins (K450).

18. Install the auxiliary pad or charge pump cover and

cap screws. Using a 10mm internal hex wrench,
torque the cap screws (K400) to 68 lb-ft (92 Nm).
Torque in sequence below.

19. Reinstall auxiliary pump or pad seal (K250) and

shipping cover (K300).
Auxilliary pads

K350 .
(see table)
K300 Cover Screw K350
Torque sequence
Cover Pad Wrench Size; Torque
K250
K400 A 17 mm; 35 lb-ft (48 Nm)
1 4 8 mm
B, C 19 mm; 58 lb-ft (77 Nm)

SAE B SAE A

3 2

4-28 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Charge Check/HPRV Charge Pressure Relief Valve

Replace the charge pressure relief valve (V10) as a com-
REMOVAL:
plete unit. Do not attempt to repair the internal compo-
1. Using a 22 mm hex wrench, remove the HPRVs nents of the valve. Torque to 38 lb-ft (52 Nm).
(L100/L200). Remove and discard the O-rings
(L060) and backup rings (L068). REMOVAL:

INSPECTION: 1. Using a 22 mm wrench, remove the charge pressure

relief valve (V10). Discard seal (V024).
2. Inspect the sealing surfaces in the pump for nicks or
scratches. Check the valves for damage. Replace INSPECTION:
any damaged components.
2. Inspect the sealing surfaces of the pump for nicks or
REASSEMBY: scratches.

3. Lubricate and install new backup rings (L068) and REASSEMBY:

O-rings (L060).
3. Lubricate and install new seal (V024).
4. Install HPRVs. Torque to the value in the illustration
below. 4. Install the charge pressure relief valve. Torque to 38
lb-ft (52 Nm).
5. Operate the machine through full range of controls
to ensure proper operation. Check for leaks. 5. Operate machine through full range of controls to
ensure proper operation.
High Pressure Relief Valves (HPRVs)
Charge Pressure Relief Valve

L060

L068
V024

L100 / L200 V10

22 mm 22 mm
81 ft.lbs. 38 ft.lbs.
(110 Nm) (52 Nm)

3121249 – JLG Lift – 4-29

 SECTION 4 - HYDRAULICS

Pressure Limiter Valve Replacement 4.11 CHARGE PUMP FILTER

NOTE: Replace the pressure limiter valve as a complete
unit. Do not attempt to repair individual components. 2 1

REMOVAL:
1. Using a 14 mm wrench, remove the pressure limiter
valves (L300/L400). Discard O-rings.

INSPECTION:
2. Inspect the sealing surfaces of the pump for nicks or
scratches.

REASSEMBY:
3. Install new O-ring. Lubricate 0-ring with petroleum
jelly.
4. Replace pressure limiter valves. Torque to 22 lb-ft
(30 Nm).
5. Operate pump at full range of controls to ensure
proper machine operation.

Pressure Limiter

L300
14 mm
22 ft.lbs. (30 Nm)

L400
1. Charge Pump Filter
14 mm
22 ft.lbs. (30 Nm) 2. Bolt, 3/8"-16NC x 5/8"
L022
Figure 4-26. Charge Pump Filter

REMOVAL:
1. Disconnect and cap the hydraulic lines on the filter
(1).
2. Remove the four bolts (2) to remove the filter from
the bracket.

INSTALLATION:
1. Attach filter (1) to bracket using the four bolts (2).
2. Uncap and reconnect the hydraulic lines to the filter.

4-30 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

4.12 AUXILIARY PUMP MOTOR

1
4
5

2
3

Hydraulic Schematic

Item # Torque
1. UNF-2A Terminal 84 in-lbs (9.5 Nm)
2. 2x 96 - 120 in-lbs (11 - 14 Nm)
3. Check Valve Cap 144 - 180 in-lbs (16 - 20 Nm)
4. 4x 180 - 216 in-lbs (20 - 24 Nm)
5. 8x 114 - 150 in-lbs (13 - 17 Nm)

Figure 4-27. Auxiliary Pump Motor

• Displacement: 0.097 CU. IN/REV (1.59 CC/REV) • Delivers 1.2 min. GPM (4.5 min Liters/Min) at 1500 psi
(103.4 bar) and 165 Amps maximum at 12VDC

3121249 – JLG Lift – 4-31

 SECTION 4 - HYDRAULICS

4.13 CYLINDER ASSEMBLIES

8
9

3
7
6
5
4

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

10

11

Figure 4-28. Steer Cylinder

NOTE: Apply ant-seize lube to threads of Cylinder Head (3)

and torque to 200 lb-ft (271.2 Nm).

4-32 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

10
9 10
6 11
6
7 OR OR
5
4
26 1
25 3 10
OR 5
5
26
2 5 OR
8

27 23 22
21 23
30
19

20 14
17
24
12

18
15
16
28 13

29
26

26

1. Cable Adapter 11. Flat Washer 21. Nut [torque to 475 lb-ft (644 Nm)]
2. Bolt 12. Wiper 22. Seal
3. Bracket 13. Seal 23. Ring, Back-Up
4. Manual Descent Cable 14. Ring, Wear 24. 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 4-29. Lift Cylinder

3121249 – JLG Lift – 4-33

 SECTION 4 - HYDRAULICS

Hydraulic Schematic
3

Lift Cylinder
Port Block
9 10

12 11 1

Hydraulic Schematic 4 Hydraulic Schematic

6

5
7

Item Torque
1 100 lb-ft (135.6 Nm)
2 100lb-ft (135.6 Nm)
3 25 lb-ft (33.9 Nm)
4 10 - 12 lb-ft (13.6 - 16.3 Nm)
5 35 lb-ft (47.5 Nm)
6 5 lb-ft (6.8 Nm)
7 30 lb-ft (40.7 Nm)
8 25 lb-ft (33.9 Nm)
9 40 lb-ft (54.2 Nm)
10 40 lb-ft (54.2 Nm)
11 40 lb-ft (54.2 Nm)
12 60 lb-ft (81.3 Nm)

Figure 4-30. Lift Cylinder Valve Cartridge Torque Values

4-34 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

1 1. Barrel
2. Rod
3. Wiper
4. Wear Ring
4 5. Rod Seal
6. Plug
7. Piston Pilot
5
8. Check Valve
9. Bleeder Valve

4 NOTE: Torque item #8 to 25-27 lb-ft

(34-37 Nm)

THE CYLINDER ROD CAN SLIDE OUT OF THE CYL-

INDER IF THE BLEEDER VALVE IS LOOSENED.
2

Figure 4-31. Oscillating Axle Cylinder

3121249 – JLG Lift – 4-35

 SECTION 4 - HYDRAULICS

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

NOTE: Apply a light coat of grease to the Cylinder Rod (3) before installing the Jack Pad (16).
Apply Loctite® #242 to Capscrews (11) and torque to 30 lb-ft ( 40.7 Nm).

4-36 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Hydraulic
1 Schematic

Item Description Torque

1 Solenoid Directional Valve 40 lb-ft (54.2 Nm)
2 Straight Fitting 32 lb-ft (43.4 Nm)
3 Straight Fitting 40 lb-ft (54.2 Nm)

Figure 4-33. Leveling Jack Torques

3121249 – JLG Lift – 4-37

 SECTION 4 - HYDRAULICS

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 4-34. Deck Extension Cylinder

4-38 – JLG Lift – 3121249

 SECTION 4 - HYDRAULICS

Oscillating Axle Cylinder Bleeding Procedure

1. Oscillating Axle Cylinder 2. Bleeder Valve

Figure 4-35. Oscillating Axle Cylinder Bleeding

1. Start the engine. NOTE: A fast stream of oil will exhaust the air out of the
hoses and cylinder better than a slow stream of oil.
2. Raise the arms high enough so that the left axle cyl-
inder bleeder valve can be accessed.
8. Every 3-4 seconds, close the bleeder valve so that a
3. Let engine run at idle. slower stream of oil is being purged. When only oil
and no air is being purged, close the bleeder valve.
4. Position a suitable container [approx 0.5 gal (1.9 ltr)]
over the bleeder valve. 9. A new system can take 10-15 seconds per cylinder
to bleed.
5. Using a 3/8" wrench, slowly open bleeder valve.

6. Keep the container close enough to the bleeder

valve to catch the aerated oil.
ANYTIME EITHER OF THE HOSES PLUMBING TO THE CYLIN-
7. Open the bleeder valve enough to get a fast stream DERS ARE BROKEN INTO, AIR HAS BEEN INTRODUCED INTO
of oil. THE SYSTEM. THE CYLINDERS MUST BE BLED.

3121249 – JLG Lift – 4-39

 SECTION 4 - HYDRAULICS

NOTES:

4-40 – JLG Lift – 3121249

 SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

5.1 HAND HELD ANALYZER

men u:
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

3121249 – JLG Lift – 5-1

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: The cable has a four pin connector at each end; the play will scroll the fault across the screen. If there was no
cable cannot be connected backwards. fault detected during power up, the display will read:
In platform mode, HELP: EVERYTHING OK,
2. Power up the Control System by turning the lower In ground mode, GROUND MODE OK
key to the platform position and pulling out both
emergency stop buttons. 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:
hel p:
1: st ar t up ( 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
PRESS ENTER view what the last fifteen faults were. Use the right and left
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
displayed menu item, press ENTER. To cancel a selected When a top level menu is selected, a new set of menu
menu item, press ESC; then you will be able to scroll items may be offered; If for example you choose Personal-
using the right and left arrow keys to select a different ities:
menu item.
DRIVE
The top level menus are as follows: LIFT
HELP STEER
DIAGNOSTICS
GROUND
ACCESS LEVEL
Pressing ENTER with any of the above displayed menus
PERSONALITIES will display additional sub-menus within the selected
MACHINE SETUP menu. In some cases the next level is the parameter or
ACTIVATE TESTS information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may
CALIBRATION only view the personality settings for selected menus
If you press ENTER, at the HELP:PRESS ENTER display, while in access level 2. Remember, you may always can-
and a fault is present during power up, the analyzer dis- cel a selected menu item by pressing the ESC key.

5-2 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Changing the Access Level of the Hand Held Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass-
Analyzer: word was entered correctly:

When the analyzer is first connected, you will be in access

level 2 which enables you to only view most configuration
settings which cannot be changed until you enter a pass-
word to advance to a lower level. This ensures that a set-
ting cannot be accidentally altered. To change the access
level, the correct password must be entered. To enter the
MENU:
password, scroll to the ACCESS LEVEL menu. For exam-
ACCESS LEVEL 1
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.

3121249 – JLG Lift – 5-3

 SECTION 5 - JLG CONTROL SYSTEM

Adjusting Parameters Using the Hand Held Machine Setup

Analyzer When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-
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 the 1=DESCENT
UP arrow is pressed when at the maximum value nor will The effect of the machine digit value is displayed along
the value decrease if the DOWN arrow is pressed and the with its value. The above display would be selected if the
value is at the minimum value for any particular personal- machine was equipped with a ground alarm and you
ity. If the value does not change when pressing the up and wanted it to sound when driving. There are certain set-
down arrows, check the access level to ensure you are at tings allowed to install optional features or select the
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– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: Refer to Table 5-3, Machine Configuration Program-

ming Information and Table 5-5, Machine Model
Adjustment for 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-
alities 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.

3121249 – JLG Lift – 5-5

 SECTION 5 - JLG CONTROL SYSTEM

5.2 CALIBRATIONS

1 3
2

1. Scissor Arm Assembly 3. Rotary Angle Sensor

2. Proximity Sensor
(on frame inbord slide channel)

Figure 5-3. Limit Switch Location

Elevation Sensor Calibration 3. SET 30FT ELEV (3394RT) or SET 36FT ELEV
(4394RT);
Using the Analyzer, in Access Level 1, go to MENU: CALI-
BRATION: a. Raise platform to a height of 30 feet on the
3394RT or 36 feet for the 4394RT (measured
1. SET STOW ELEV; deck to ground).

a. Completely lower platform to stowed position. b. Enter YES on the Analyzer.

b. Enter YES on the Analyzer. c. COMPLETE will display on the analyzer when
calibrated.
c. COMPLETE will show on the analyzer when cali-
brated. NOTE: Elevation Proximity Switch must be mounted and
functioning properly to calibrate the Elevation Sen-
2. SET 26FT ELEV (3394RT) or SET 30FT ELEV
sor.
(4394RT);

a. Raise platform to a height of 26 feet for the

3394RT or 30 feet for the 4394RT (measured
deck to ground). FOR MACHINE TO OPERATE TO CAPACITY, BE SURE TO CALI-
BRATE ELEVATION SENSOR AT ALL THREE POSITIONS.
b. Enter YES on the Analyzer.
c. COMPLETE will show on the analyzer when cali-
brated.

5-6 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Joystick Calibration b. Tilt sensor mounting on machine or wedged

crooked in control box:
Using the Analyzer, in Access Level 1, go to MENU: CALI- If the machine mounting/grade appears accept-
BRATION: JOYSTICK and press ENTER. able, open the Ground Control box carefully.
Observe whether the tilt sensor is properly
1. Following the analyzer screen prompts: seated.
a. Move the Joystick FORWARD and press ENTER.
b. Allow Joystick to be in CENTER position and 2 1
press ENTER.
c. Move the Joytstick REVERSE and press ENTER.
2. CAL COMPLETE or CAL FAILED will display on the
analyzer.
3. Possible reasons if calibration failure:
a. The forward position must be a lower voltage
than reverse position.
b. The difference between center and forward &
center and reverse must be atleast 1V.

Tilt Sensor Calibration:

1. Drive the machine onto a measured level surface 1. Ground Control Box 2. Tilt Sensor
(±0.5° for both x and y axis).
2. Using the Analyzer, go to MENU: CALIBRATION; c. Tilt sensor has developed an offset shift:
TILT SENSOR. Press Enter. LEVEL VEHICLE will dis- Remove the tilt sensor from the Ground Control
play. Press Enter again to calibrate. box, but keep both the tilt sensor and Ground
3. Both axis’ raw angles need to be within 5.0°, other- Control box electrically connected. Level one
wise the machine is too unlevel and the software will axis of the tilt sensor and observe the raw read-
prohibit calibration. Should this occur, attempt to ing (should be within ±2.0°). Do the same for the
dissect the three areas of error to find the primary other axis. If either axis is greater than ±2.0°,
contributor: replace the tilt sensor.
Some possible reasons that the tilt sensor will not cali-
a. Machine mounting and/or grade:
brate are:
With a digital level, measure the top of the
Ground Control box for levelness. If unable to a. The surface the machine is sitting on is off level
get a good reading, check the box’s mounting by a few degrees (flat doesn’t imply level; park-
surface for levelness. ing lots are often not level).
b. The tilt sensor has failed one or both of the
2 channels (X axis and Y axis).
c. Tilt sensor has moisture intrusion that has
shifted its output.
d. Water and/or corrosion in the box has corrupted
electrical connections or caused a tilt sensor or
1 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
level.
For the following troubleshooting steps, a bubble level
(smaller is better) will be needed and the machine must
be on a level surface:

1. Ground Control Box 2. Digital Level 1. On the Analyzer, go to Diagnostics/System and read
the tilt angle. If either angle reports +20.0°, there is

3121249 – JLG Lift – 5-7

 SECTION 5 - JLG CONTROL SYSTEM

an electrical/electronic failure (tilt sensor, control 4. The Tilt Sensor (1) can be removed from the Sensor
board, electrical connections). Mount (2) by removing the three Screws (7).

a. Open the Ground Control Box. NOTE: Follow the above procedures in reverse order when
installing the tilt sensor assembly. After installing, be
b. Disconnect the sensor and clean any corrosion
sure to calibrate the tilt sensor (refer to Section 5.2,
off of the tilt sensor and control board connec-
Calibrations).
tions.
c. Reassemble and test. If fault persists, replace tilt
sensor. 1
6
2. If the Analyzer displays angles other than +20.0°, 7
attempt to calibrate. If machine will not calibrate,
note the reason displayed on Analyzer: 2
a. SENSOR FAILURE – tilt sensor internal fre- 5
quency is out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an
4
offset or it is too unlevel as mounted on the 3
machine.

Tilt Sensor

2 1

1. Tilt Sensor (JLG P/N 4000021)

2. Sensor Mount
3. Screw, 6-32 x 1

1. Ground Control Box 4. Lockwasher

2. Tilt Sensor Assembly (JLG P/N 1810140) 5. Standoff Insulator

6. Washer, 0.313 x 0.250 Nylon
Figure 5-4. Tilt Sensor Location
7. Screw, M3.5 x 0.6 x 10

Figure 5-5. Tilt Sensor Removal

NOTE: Refer to Figure 5-5., Tilt Sensor Removal for num-
bers in parenthesis.

1. Disconnect the batteries. Table 5-1. Tilt Sensor Harness

2. Open the Ground Control Box to gain access to the Wire Color Function Connector Pin
Tilt Sensor Assembly.
Red VCC 1
3. Remove the four Screws (3), Lockwashers (4), Green PWMX 2
Standoff Insulators (5), and Washers (6) to remove
White PWMY 3
the Tilt Sensor (1) and Sensor Mount (2) from the
Ground Control Box. Black Ground 4

5-8 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

5.3 FLASH CODES AND DESCRIPTIONS

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
No flash code is indicated for the following help messages.
They are intended to hint at a possible problem if the vehicle is
not behaving as expected.
Reported when the trigger is not closed with function selected and
FUNCTION SELECTED BUT TRIGGER SWITCH OPEN
joystick out of center.
Reported any time the machine is considered to be above eleva-
RUNNING AT CUTBACK – ABOVE ELEVATION
tion.
ACCESSORY FAULT Reports when CAN faults are reported by an accessory module.
Reported when the front left leveling jack is reported to be at the
FRONT LEFT LEVELING JACK AT END OF STROKE
end of stroke pressure.
Reported when the front right leveling jack is reported to be at the
FRONT RIGHT LEVELING JACK AT END OF STROKE
end of stroke pressure.
None Reported when the rear left leveling jack is reported to be at the 1
REAR LEFT LEVELING JACK AT END OF STROKE
end of stroke pressure.
Reported when the rear right leveling jack is reported to be at the
REAR RIGHT LEVELING JACK AT END OF STROKE
end of stroke pressure.
Reported when autoleveling is not available when communication
LEVELING JACK SET PREVENTED - ECM LOST
with the ECM times-out.
Reported when generator is not available when communication
GENERATOR PREVENTED - ECM LOST
with the ECM times-out.
Reported when elevated drive is not available when communica-
DRIVE PREVENTED - ECM LOST
tion with the ECM times-out.
Reported when elevation prox switch is closed when the 26 ft
ELEVATION SENSOR DISAGREEMENT (3394RT) or 30 ft (4394RT) voltage is reached on the elevation
angle sensor. (prevents further lift up from platform controls)
Flash code 2/1 indicates issues at power up.
Reported when the ground module is reading both ground and 2
2/1 KEYSWITCH FAULTY – PLATFORM & GROUND ACTIVE
platform modes are selected by the keyswitch. The control sys-
TOGETHER
tem defaults control to ground mode.

3121249 – JLG Lift – 5-9

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
Flash code 2/2 indicates difficultly with the platform controls.
TRIGGER SWITCH WIRING SHORTED HIGH IN PLAT- Reports when the CAN message coming from the platform board
FORM CABLE and the DI on ground board conflict.
TRIGGER SWITCH WIRING SHORTED LOW IN PLAT- Reports when the CAN message coming from the platform board
FORM CABLE 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-
2/2 Reported when the right steer switch is closed during power up. 3
NENTLY CLOSED
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.
Reported when trigger is closed for ten seconds and no function
TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
selected.
FUNCTION LOCKED OUT – JOYSTICK NOT CENTERED Reported when joystick is not centered while selecting a function.
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 at
TOGETHER the same time.
FUNCTION LOCKED OUT – HORN SWITCH PERMA-
Reported when the horn switch is closed during power up.
NENTLY CLOSED
Reported when joystick calibration is improper. (Platform P1.6 or
JOYSTICK CALIBRATION FAULTY
later only)

5-10 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
Flash code 2/3 indicates difficultly with ground controls.
FUNCTION LOCKED OUT – GROUND LIFT UP PERMA- Reported when the ground lift up switch is closed during power
NENTLY CLOSED up.
FUNCTION LOCKED OUT – GROUND LIFT DOWN PER- Reported when the ground lift down switch is closed during power
MANENTLY CLOSED up.
FUNCTION LOCKED OUT – GROUND FRONT DECK EXT Reported when the ground front deck extend switch is closed dur-
PERMANENTLY CLOSED ing power up.
FUNCTION LOCKED OUT – GROUND FRONT DECK RET Reported when the ground front deck retract switch is closed dur-
PREMANENTLY CLOSED ing power up.
FUNCTION LOCKED OUT – GROUND REAR DECK EXT Reported when the ground rear deck extend switch is closed dur-
PERMANENTLY CLOSED ing power up.
FUNCTION LOCKED OUT – GROUND REAR DECK RET Reported when the ground rear deck retract switch is closed dur-
PERMANENTLY CLOSED ing power up.
Reported when the ground lift up and lift down switches are
GROUND LIFT UP/DOWN ACTIVE TOGETHER
2/3 closed at the same time. 4
GROUND FRONT DECK EXTEND/RETRACT ACTIVE Reported when the ground front deck extend and retract switches
TOGETHER are closed at the same time.
GROUND REAR DECK EXTEND/RETRACT ACTIVE Reported when the ground rear deck extend and retract switches
TOGETHER 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
Reported when the tilt sensor frequency is outside the range of
LEVEL SENSOR FAILURE
acceptable value.
FUNCTION LOCKED OUT – GROUND AUX SWITCH PER- Reported when the ground auxiliary power switch is closed during
MANENTLY CLOSED power up.
FUNCTION LOCKED OUT – GROUND START SWITCH
Reported when the ground start switch is closed during power up.
PERMANENTLY CLOSED

3121249 – JLG Lift – 5-11

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

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

5-12 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
Flash code 2/6 indicates leveling jack or power deck issues.
Reported by the I/O module and during system test when the front
FRONT LEFT LEVELING JACK OPEN CIRCUIT
left leveling jack is open circuit.
Reported by the I/O module and during system test when the front
FRONT LEFT LEVELING JACK SHORT TO GROUND
left leveling jack is short to ground.
Reported by the I/O module and during system test when the front
FRONT LEFT LEVELING JACK SHORT TO BATTERY
left leveling jack is short to battery.
Reported by the I/O module and during system test when the front
FRONT RIGHT LEVELING JACK OPEN CIRCUIT
right leveling jack is open circuit.
Reported by the I/O module and during system test when the front
FRONT RIGHT LEVELING JACK SHORT TO GROUND
right leveling jack is short to ground.
Reported by the I/O module and during system test when the front
FRONT RIGHT LEVELING JACK SHORT TO BATTERY
right leveling jack is short to battery.
Reported by the I/O module and during system test when the rear
REAR LEFT LEVELING JACK OPEN CIRCUIT
left leveling jack is open circuit.
Reported by the I/O module and during system test when the rear
REAR LEFT LEVELING JACK SHORT TO GROUND
left leveling jack is short to ground.
Reported by the I/O module and during system test when the rear
REAR LEFT LEVELING JACK SHORT TO BATTERY
left leveling jack is short to battery.
Reported by the I/O module and during system test when the rear
REAR RIGHT LEVELING JACK OPEN CIRCUIT
right leveling jack is open circuit.
Reported by the I/O module and during system test when the rear
REAR RIGHT LEVELING JACK SHORT TO GROUND
2/6 right leveling jack is short to ground. 6
Reported by the I/O module and during system test when the rear
REAR RIGHT LEVELING JACK SHORT TO BATTERY
right leveling jack is short to battery.
Reported by the I/O module and during system test when the level-
LEVELING JACK EXTEND VALVE OPEN CIRCUIT
ing jack extend valve is open circuit.
Reported by the I/O module and during system test when the level-
LEVELING JACK EXTEND VALVE SHORT TO GROUND
ing jack extend valve is short to ground.
Reported by the I/O module and during system test when the level-
LEVELING JACK EXTEND VALVE SHORT TO BATTERY
ing jack extend valve is short to battery.
Reported by the I/O module and during system test when the level-
LEVELING JACK RETRACT VALVE OPEN CIRCUIT
ing jack retract valve is open circuit.
Reported by the I/O module and during system test when the level-
LEVELING JACK RETRACT VALVE SHORT TO GROUND
ing jack retract valve is short to ground.
Reported by the I/O module and during system test when the level-
LEVELING JACK RETRACT VALVE SHORT TO BATTERY
ing jack retract valve is short to battery.
Reported by the I/O module and during system test when the front
FRONT DECK EXTEND VALVE OPEN CIRCUIT
deck extend valve is open circuit.
Reported by the I/O module and during system test when the front
FRONT DECK EXTEND VALVE SHORT TO GROUND
deck extend valve is short to ground.
Reported by the I/O module and during system test when the front
FRONT DECK EXTEND VALVE SHORT TO BATTERY
deck extend valve is short to battery.
Reported by the I/O module and during system test when the front
FRONT DECK RETRACT VALVE OPEN CIRCUIT
deck retract valve is open circuit.

3121249 – JLG Lift – 5-13

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
Reported by the I/O module and during system test when the front
FRONT DECK RETRACT VALVE SHORT TO GROUND
deck retract valve is short to ground.
Reported by the I/O module and during system test when the front
FRONT DECK RETRACT VALVE SHORT TO BATTERY
deck retract valve is short to battery.
Reported by the I/O module and during system test when the rear
REAR DECK EXTEND VALVE OPEN CIRCUIT
deck extend valve is open circuit.
Reported by the I/O module and during system test when the rear
REAR DECK EXTEND VALVE SHORT TO GROUND
deck extend valve is short to ground.
2/6 6
Reported by the I/O module and during system test when the rear
REAR DECK EXTEND VALVE SHORT TO BATTERY
deck extend valve is short to battery.
Reported by the I/O module and during system test when the rear
REAR DECK RETRACT VALVE OPEN CIRCUIT
deck retract valve is open circuit.
Reported by the I/O module and during system test when the rear
REAR DECK RETRACT VALVE SHORT TO GROUND
deck retract valve is short to ground.
Reported by the I/O module and during system test when the rear
REAR DECK RETRACT VALVE SHORT TO BATTERY
deck retract valve is short to battery.
Flash code 4/3 indicates engine issues.
Reported when the fuel sensor is reading a value that is much too
FUEL SENSOR SHORT TO BATTERY
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.
Reported when the oil pressure sensor is reading a value that is
OIL PRESSURE SHORT TO BATTERY
too high.
Reported when the oil pressure sensor is reading a value that is
OIL PRESSURE SHORT TO GROUND
too low.
Reported when the coolant temperature sensor is reading a value
COOLANT TEMPERATURE SHORT TO GROUND
that is too low.
4/3 7
ENGINE TEMPERATURE HIGH This fault is not reported at this time.
AIR FILTER BYPASSED This fault is not reported at this time.
Reported when the engine is running for at least a few seconds
NO ALTERNATOR OUTPUT
and the alternator input is on the ground board is high.
Reported when the oil pressure is below eight PSI and the engine
OIL PRESSURE LOW
is running for at least a few seconds.
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.
Reported when the Deutz Engine Controller is giving a fault. See
DEUTZ ECM FAULT CODE
engine manual for more information.
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.
4/4 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.

5-14 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-2. Fault Code Listing - Software P1.X

Fault Flash
Communicated (Displayed on Analyzer) Fault Description Priority
Code
Flash code 5/5 indicates a speed sensor issue.
Reported when the speed sensor is reading a value over 4000
SPEED SENSOR READING INVALID SPEED
5/5 RPM. 9
Reported when the speed sensor is reading zero RPM and the oil
SPEED INPUT LOST
pressure is over eight PSI.
Flash code 6/6 indicates CANbus issues. 10
CAN BUS FAILURE Reported when there is a problem with the CANbus.
Reported when the LSS is configured and not seen on the CAN-
LSS NOT SENDING CAN MESSAGES
bus.
6/6
Reported when the engine is configured to be CAN controlled and
ENGINE CONTROLLER CAN COMMUNICATION LOST
the system is not communicating with it.
Reported when there are two platform modules connected to the
TWO PLATFORM MODULES DETECTED
control system.
8/* Flash codes 8/* indicate load cells issues.
8/1 LSS CELL #1 ERROR Reported when there is a problem with cell #1 on the LSS.
8/2 LSS CELL #2 ERROR Reported when there is a problem with cell #2 on the LSS. 11
8/3 LSS CELL #3 ERROR Reported when there is a problem with cell #3 on the LSS.
8/4 LSS CELL #4 ERROR Reported when there is a problem with cell #4 on the LSS.
9/* Flash codes 9/* indicate LSS or memory issues.
Reported when the LSS’s microprocessor watchdog has been
9/1 LSS WATCHDOG RESET
triggered.
Reported when there is a problem with the stored memory in the
9/2 LSS EEPROM ERROR
LSS.
9/3 LSS HAS NOT BEEN CALIBRATED Reported when the LSS is configured but not calibrated.
Reported when the LSS is configured and reporting a value that is
LSS NEEDS TO BE RE-CALIBRATED less than half of the offset value; this will be reported as a negative 12
value.
Reported when a pin in the LSS is reporting a voltage below 4.25
LSS INTERNAL ERROR – PIN EXCITATION
9/9 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.
Reported when the memory in the ground or platform module has
EEPROM FAILURE – CHECK ALL SETTINGS
become corrupt.
4150588 D

3121249 – JLG Lift – 5-15

5-16
ACCESSLEVEL:
CODE33271

MENU: ACCESSLEVEL:
ACCESSLEVEL1 CODE00000

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PERSONALITIES DRIVE LIFT STEER POWERDECK GROUNDMODE LOAD JOYSTICK

DRIVE: LIFT: STEER: DECKEXTEND: GROUNDMODE: LOAD: JOYSTICK:

ACCELX.XS ACCELX.XS ENGINEXXXXRPM ENGINEXXXXRPM LIFTUP X% OVERLDXXXXKG FWDMAXX.XXV

DRIVE: LIFT: DECKRETRACT: GROUNDMODE: LOAD: JOYSTICK:

DECELX.XS DECELX.XS ENGINEXXXXRPM LIFTDNX% ACC’YXXKG FWDMINX.XXV
SECTION 5 - JLG CONTROL SYSTEM

DRIVE: LIFT: LOAD: JOYSTICK:

MINFORWARDX% MINUP X% OVRDBNCEX.XS REVMINX.XXV

DRIVE: LIFT: LOAD: JOYSTICK:

MAXFORWARDX% MAXUP X% OVRHOLDX.XS REVMAXX.XXV

DRIVE: LIFT:
CONT’DONSHEET2 MINREVERSEX% MINDOWNX%

– JLG Lift–
DRIVE: LIFT:
MAXREVERSEX% MAXDOWNX%

DRIVE: LIFT:
ELEVFWDMAXXX% ENGINEXXXXRPM

DRIVE: LIFT:
ELEVREVMAXXX% MIDENGXXXXRPM

DRIVE:
ENGINEXXXXRPM

DRIVE:
MIDENGXXXXRPM

Figure 5-6. Analyzer Flow Chart - SW P1.X - Sheet 1 of 3

3121249
3121249
FROMSHEET1

MENU: MODELNUMBER: ENGINE: MARKET: TILTCUTOUT: GLOWPLUG: LEVELINGJACKS: POWERDECK:

MACHINESETUP 0= 33RT2WD 0= FORDEFI D/F 0= ANSI USA 0= NO 0= NOGLOWPLUGS 0= NO 0= NONE

MODELNUMBER: ENGINE: MARKET: TILTCUTOUT: GLOWPLUG: LEVELINGJACKS: POWERDECK:

1= 33RT4WD 1= DEUTZF3 1= ANSI EXPORT 1= YES 1= 5SECGLOW 1= YES 1= FRONT

MODELNUMBER: ENGINE: MARKET: GLOWPLUG: POWERDECK:

2= 43RT2WD 2= FORDD/F(T2) 2= CSA 2= 10SECGLOW 2= DUAL

MODELNUMBER: ENGINE: MARKET: GLOWPLUG:

3= 43RT4WD 3= DEUTZF3(T2) 3= CE 3= 20SECGLOW

ENGINE: MARKET: GLOWPLUG:

4= DEUTZECM 4= AUSTRALIA 4= 30SECGLOW

ENGINE: GLOWPLUG:
5= DUALFUELECM 5= 40SECGLOW

GLOWPLUG:
6= 50SECGLOW

GLOWPLUG:

– JLG Lift –
7= 60SECGLOW

ENGINESHUTDOWN: GROUNDALARM: LOAD: FUNCTIONCUTOUT GENERATOR:

0= NO 0= NO 0= NONE 0= NOTINSTALLED 0= NOTINSTALLED

ENGINESHUTDOWN: GROUNDALARM: LOAD: FUNCTIONCUTOUT GENERATOR:

1= SHUTDOWN 1= DESCENT 1= CUTOUTPLT 1= DRV&LIFTUP 1= 60 HZ

GROUNDALARM: LOAD: FUNCTIONCUTOUT GENERATOR:

2= MOTION 2= CUTOUTALL 2= ALLFUNCTIONS 2= 50 HZ

MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

CALIBRATIONS TILTSENSOR SETSTOWELEV SETXXFTELEV SETXXFTELEV LOAD JOYSTICK

LEVELVEHICLE: SETSTOWELEV: SETXXFTELEV: SETXXFTELEV: 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
TOSHEET3

Figure 5-7. Analyzer Flow Chart - SW P1.X - Sheet 2 of 3

5-17
SECTION 5 - JLG CONTROL SYSTEM
5-18
FROMSHEET2

MENU: ACTIVATETEST:
SYSTEMTEST YES: ENTER NO: ESC

MENU: HELP:
HELP:PRESSENTER GROUNDMODEOK

MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS PLATFORM GROUND SYSTEM VALVES ELEVSENSOR LOAD ENGINE DATALOG VERSIONS

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: DATALOG: VERSIONS:

DRIVESELXXXX LIFTUP XXXX GMBATTERYXX.XV FORW ARDX% READINGX.XXV PLTLOADXXXXKG STARTXXXX ENGINEXHXM GROUNDPX.XX

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: DATALOG: VERSIONS:

LIFTSELXXXX LIFTDNXXXX PMBATTERYXX.XV REVERSEX% STOWEDCALX.XXV PLTGROSXXXXKG BATTERYXX.XV DRIVEXHXM GNDHWREVX

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: DATALOG: VERSIONS:

HORNXXXX FDECKEXTXXXX AUXPOWERXXXX STEERLEFTXXX XXFTCALX.XXV OVERLOADED?XXX COOLANTXXC LIFTXHXM PLATFORMPX.X

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: DATALOG: VERSIONS:

STARTXXXX FDECKRETXXXX HORNXXXX STEERRIGHTXXX XXFTCALX.XXV CELL1XXXXKG OILPRSXPSI RENTALXHXM I/OMODPX.X
SECTION 5 - JLG CONTROL SYSTEM

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: DATALOG: VERSIONS:

DRIVESPDXXXX RDECKEXTXXXX TILTXX.XXX.X DUMP XXX ELEVPROXXXX CELL2XXXXKG FUELSELECTGAS ERASERENTAL? LSSMODPX.X

PLATFORM: GROUND: SYSTEM: VALVES: ELEVSENSOR: LOAD: ENGINE: VERSIONS:

HI ENGINEXXXX RDECKRETXXXX FNTLFTXXXPSI BRAKEXXX (STATUS) CELL3XXXXKG FUELLEVELOK ANALYZERV6.3

PLATFORM: GROUND: SYSTEM: VALVES: LOAD: ENGINE:

AUTOLEVXXXX AUXPOWERXXXX FNTRHTXXXPSI 2SPDXXX CELL4XXXXKG GLOWPLUGXXX

PLATFORM: SYSTEM: VALVES: ENGINE:

GENERATORXXXX REARLTXXXPSI LIFTUP XXX LPASSISTXXX

– JLG Lift–
PLATFORM: SYSTEM: VALVES: ENGINE:
STRLEFTXXXX REARRTXXXPSI LIFTDNXXX ACTUALXXXXRPM

PLATFORM: SYSTEM: VALVES: ENGINE:

STRRIGHTXXXX FNTLFTSWXXXX PROP LIFTX% TARGETXXXXRPM

DIAGNOSTICS: SYSTEM: VALVES:

TRIGGERXXXX FNTRHTSWXXXX LOSCAXLEXXX NOTE: SOME SCREENS MAY NOT
BE AVAILABLE DEPENDING
PLATFORM: SYSTEM: VALVES: VALVES:
JOYSTICKXXXX RLFTSWXXXX ROSCAXLEXXX Rr DECKRETXXX
UPON MACHINE CONFIGURATION
AND SOFTWARE VERSION.
PLATFORM: SYSTEM: VALVES: VALVES:
FDECKSELXXXX RRHTSWXXXX FLL/J VLVEXXX Rr DECKEXTXXX

PLATFORM: SYSTEM: VALVES: VALVES: = Top Level Menu

FDECKSELXXXX ELEVSTATXXX FRL/J VLVEXXX Ft DECKRETXXX

SYSTEM: VALVES: VALVES: = Sub Level Menu

FTNC/OXXX RLL/J VLVEXXX Ft DECKEXTXXX

SYSTEM: VALVES: VALVES: =Item To Be Viewed

CANBUSTERMXXX RRL/J VLVEXXX OPTIONVLVEXXX
or Changed
SYSTEM: VALVES: VALVES:
JOYSTICKX.XXV L/J EXTXXX L/J RETXXX

Figure 5-8. Analyzer Flow Chart - SW P1.X - Sheet 3 of 3

3121249
 SECTION 5 - JLG CONTROL SYSTEM

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

Table 5-3. Machine Configuration Programming Information

Configuration Digit Setting Description Default Number

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.

3121249 – JLG Lift – 5-19

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-3. Machine Configuration Programming Information

Configuration Digit Setting Description Default Number

0 NOT INSTALLED – Load Sensing System (LSS) is not fitted to the vehicle.

1 CUTOUT PLT – Load Sensing System (LSS) is fitted, and Platform Controls are pre-
vented in the event of an Overload. Ground Controls remain functional. This is the default
10 setting for CE machines. 0
(LOAD)
2 CUTOUT ALL – Load Sensing System (LSS) is fitted. Platform and Ground Controls are
prevented in the event of an Overload.

NOTE: Certain market selections will alter default setting.

0 NOT INSTALLED – Vehicle alarm will function for Overload (if LOAD enabled).

1 DESCENT – Vehicle alarm will function for Overload (if LOAD enabled) and during Lift
11 Down motion.
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
Lift Up and Drive prevented when Elevated and Tilted beyond the following limits:
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
Side to Side: ±3° to Full Height
AUSTRALIA Same as ANSI USA

Lift Up and Drive prevented when Elevated and Tilted beyond the following limits:
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
Lift Up and Drive prevented when Elevated and Tilted beyond the following limits:
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
Side to Side: ±3° to Full Height
AUSTRALIA Same as ANSI USA
4150390 J

NOTE: Vehicle Tilt Configuration based on Model and Market Settings

5-20 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.

3394RT 2WD

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

3121249 – JLG Lift – 5-21

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: .Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.

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

5-22 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.

4394RT 2WD

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

3121249 – JLG Lift – 5-23

 SECTION 5 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.

4394RT 4WD

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

5-24 – JLG Lift– 3121249

 SECTION 5 - JLG CONTROL SYSTEM

Table 5-5. Machine Model Adjustment

Model Default Values

Adjustment Adjustment Range
3394RT 2WD 3394RT 4WD 4394RT 2WD 4394RT 4WD
DRIVE
Accel 0.1 - 5.0 (sec) 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
1000 - 2700 lbs 2475 2475 1650 1650
Overload
(454 - 1225 kg) (1123 kg) (1123 kg) (748 kg) (748 kg)
0 - 500 lbs
Acc’y 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.

3121249 – JLG Lift – 5-25

 SECTION 5 - JLG CONTROL SYSTEM

NOTES:

5-26 – JLG Lift– 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

SECTION 6. GENERAL ELECTRICAL INFORMATION & SCHEMATICS

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

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 k = 1200 

Example: 50 mA = 0.05 A

3121249 – JLG Lift – 6-1

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Voltage Measurement Resistance Measurement

Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement

• If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together.
(See multimeter’s operation manual) Resistance should read a short circuit (very low resis-
• 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 Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Current Measurement

Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC)

• Some meters require a separate button press to • Set up the meter for the expected current range
enable audible continuity testing • 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

3121249 – JLG Lift – 6-3

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Continuity Measurement Over Long Distances

When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.

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 Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS

Silicone Dielectric Compound must be used on the AMP connections for the following reasons:

• To prevent oxidation at the mechanical joint between male and female pins.
• 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

3121249 – JLG Lift – 6-5

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

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

Figure 6-6. Connector Assembly (1 of 4)

1. 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)).

Figure 6-7. Connector Assembly (2 of 4)

6-6 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-8. Connector Assembly (3 of 4)

Figure 6-9. Connector Assembly (4 of 4)

3121249 – JLG Lift – 6-7

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Disassembly
5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
6. Pry open the wedge lock to the open position.
7. 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 Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. 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

3121249 – JLG Lift – 6-9

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.4 WORKING WITH DEUTSCH CONNECTORS

DT/DTP Series Assembly

Figure 6-12. DT/DTP Contact Installation

1. Grasp crimped contact about 25mm behind the contact barrel.

2. Hold connector with rear grommet facing you.

3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in
place.

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 Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly
locked in place.

Figure 6-15. HD/HDP Locking Contacts Into Position

NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing

HD30/HDP20 Series Disassembly

Figure 6-16. 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.

3121249 – JLG Lift – 6-11

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.5 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. 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 Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener-
gized to actuate.
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.

3121249 – JLG Lift – 6-13

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

6.6 SCHEMATICS

Figure 6-18. Electrical Schematic - Deutz - Sheet 1 of 3

6-14 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-19. Electrical Schematic - Deutz - Sheet 2 of 3

3121249 – JLG Lift – 6-15

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

1001103487 B

Figure 6-20. Electrical Schematic - Deutz - Sheet 3 of 3

6-16 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

3121249 – JLG Lift – 6-17

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-21. Electrical Schematic - GM - Sheet 1 of 5

6-18 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-22. Electrical Schematic - GM - Sheet 2 of 5

3121249 – JLG Lift – 6-19

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-23. Electrical Schematic - GM - Sheet 3 of 5

6-20 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

3121249 – JLG Lift – 6-21

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-24. Electrical Schematic - GM - Sheet 4 of 5

6-22 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

1001103488 B

Figure 6-25. Electrical Schematic - GM - Sheet 5 of 5

3121249 – JLG Lift – 6-23

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Figure 6-26. Hydraulic Schematic - Sheet 1 of 2

6-24 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

1001106835_D
Figure 6-27. Hydraulic Schematic - Sheet 2 of 2

3121249 – JLG Lift – 6-25

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

1001106834_F

Figure 6-28. Hydraulic Diagram

6-26 – JLG Lift – 3121249

3121249
Right

Front Rear
Front Extension Cylinders

Left

Powerdeck
Valve Single

– JLG Lift –
Main
Valve
Hydraulic
Powerdeck Tank

Figure 6-29. Hydraulic Diagram (Powerdeck - Single)

Selection Valve
Aux
Pump
Suction

In Out
1001103708 A
Aux Pump

6-27
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
6-28
Right

Front Rear
Front Extension Cylinders Rear Extension Cylinders

Powerdeck
Valve Dual Left

– JLG Lift –
Main
Valve
Hydraulic
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

Powerdeck Tank

Figure 6-30. Hydraulic Diagram (Powerdeck - Dual)

Selection Valve
Aux Pump
Suction

In Out

1001103709 A Aux Pump

3121249
3121249
Right

Front Rear
Front Extension Cylinders Rear Extension Cylinders

Powerdeck
Valve Dual Left

– JLG Lift –
Main
Valve
Hydraulic
Tank
Powerdeck
Selection Valve

Figure 6-31. Hydraulic Diagram (Powerdeck - Mega)

Aux Pump
Suction

In Out

Aux Pump
1001103711 A

6-29
SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

1001103552_B

Figure 6-32. Hydraulic Diagram (Leveling Jacks)

6-30 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

3121249 – JLG Lift – 6-31

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

STARTER
THROTTLE ENGINE
ACTUATOR CONTROL
(DEUTZ)

FUSE BATTERY OIL

BLOCK PRESSURE
+ SWITCH

OIL
TEMP GLOW
SWITCH PLUG
IGNITION
RELAY
HEADLIGHTS
ALTERNATOR
(DIESEL ENGINE
LIGHTS MACHINES) HARNESS
CIRCUIT RELAY (DEUTZ)
BREAKER

PLATFORM
WORKLIGHTS TAILLIGHTS
AC POWER
POWER AT PLATFORM
DECK
VALVES

GENERATOR

GENERATOR
VOLTAGE
AUXILIARY PUMP REGULATOR

AUX
POWER
RELAY
GENERATOR
CONTROL BOX

GENERATOR
RELAY

LEVELING
JACK
PORT
BLOCKS (W/ POWER DECK)
(W/O JACK OPTION)

(W/O POWER DECK)

(W/ POWER DECK)

LEVELING J2 J5
JACK
PORT OPTIONS J4
BLOCKS MODULE
J1 J3
LEVELING
JACK
VALVE

Figure 6-33. Electrical Components Installation - Sheet 1 of 2

6-32 – JLG Lift – 3121249

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM
CONTROL
ENGINE BOX
SPEED
GLOW SENSOR LP LOCK & ASSIST
PLUG (GAS MACHINES)
RELAY START
RELAY

OR

GLOW
PLUGS

IGNITION
RELAY

ALTERNATOR
(GAS
MACHINES)
LIFT CYLINDER
PORT BLOCK
J2 J5
PROP J4
VALVE
HYDRAULIC J1 J3
PUMPS

LIFT ELEVATION PLATFORM

IGNITION DOWN SWITCH MODULE
POWER ENGINE VALVE
RELAY CONTROL FUEL
(GM MACHINES) (GM) LEVEL BEACON
SENSOR LIGHT
FUEL ROTARY
REGULATOR SENSOR
(GM HARNESS)
PORT HORN
BLOCKS
(OSCILLATING
AXLE ALARM
CYLINDERS) BOSCH FUEL
REGULATOR
(GM)

TO OPTION
VALVE
FUEL
PUMP
(GAS
MACHINES)
GROUND VALVE
SPLICE SPLICE

GROUND
MAIN VALVE SPLICE

DEUTZ GROUND
IGNITION SPLICE DIANOSTICS
(DIESEL) PLUG CONTROL
IGNITION SPLICE (GAS) BOX
GROUND SPLICE (DIESEL)

Figure 6-34. Electrical Components Installation - Sheet 2 of 2

3121249 – JLG Lift – 6-33

 SECTION 6 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

6-34 – JLG Lift – 3121249

 3121249

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. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte Ltd.
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 639379 - Singapore
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591-9030
(852) 2639 5797 +65-6591-9031

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