Jlg Service And Maintenance Manual (3394rt & 4394rt)

Full download: http://manualplace.com/download/jlg-service-and-maintenance-manual-3394rt-4394rt/

Service & Maintenance Manual

Models
3394RT
4394RT

Prior to S/N 0200191606

excluding S/N’s:
0200186972,
0200187002,
0200187013

3121133

October 6, 2008

This is the cut pages sample. Download all 228 page(s) at: ManualPlace.com
 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

Relieve system pressure by cycling the applicable

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

3121133 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - April 12, 2002

Revised - May 10, 2002

Revised - August 30, 2002

Revised - October 14, 2002

Revised - March 6, 2003

Revised - October 24, 2003

Revised - April 28, 2004

Revised - August 18, 2004

Revised - August 12, 2005

Revised - October 4, 2005

Revised - March 1, 2006

Revised - May 11, 2006

Revised - October 31, 2006

Revised - April 3, 2007

Revised - October 12, 2007

Revised - January 23, 2008

Revised - March 17, 2008

Revised - October 6, 2008

b – JLG Lift – 3121133

 TABLE OF CONTENTS

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

3121133 – JLG Lift – i

 TABLE OF CONTENTS

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

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

ii – JLG Lift – 3121133

 TABLE OF CONTENTS

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-3. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-2. Engine Operating Temperature Specifications - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2-3. Engine Operating Temperature Specifications - GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
3-1. Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Level Sensor and Analyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-3. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-5. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-6. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-7. Integrated Torque/Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-8. Drive Motor/Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-9. Drive Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-10. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-11. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3-12. Generator (Ford Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-13. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
3-14. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
3-15. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-16. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
3-17. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
3-18. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-19. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-20. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-21. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
3-22. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
3-23. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
3-24. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
3-25. Generator (Deutz Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-26. Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59
3-27. Generator (GM Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-28. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3-29. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-30. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-31. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-32. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
3-33. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-34. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-35. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
3-36. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
3-37. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
3-38. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
3-39. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-40. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
3-41. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70
3-42. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

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 TABLE OF CONTENTS

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

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

iv – JLG Lift – 3121133

 TABLE OF CONTENTS

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

6-19. Electrical Schematic - Dual Fuel - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-20. Electrical Schematic - Dual Fuel - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-21. Electrical Schematic Diesel (Prior to S/N 138634) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-22. Electrical Schematic Diesel (Prior to S/N 138634) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-23. Electrical Schematic Diesel (Prior to S/N 138634) - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-24. Electrical Schematic - Dual Fuel GM - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-25. Electrical Schematic - Dual Fuel GM - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-26. Electrical Schematic Dual Fuel - GM - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-27. Electrical Schematic Dual Fuel - GM - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-28. Electrical Schematic Dual Fuel - GM - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
6-29. Electrical Schematic Diesel (S/N 138634 to Present) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . .6-28
6-30. Electrical Schematic Diesel (S/N 138634 to Present) - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . .6-29
6-31. Electrical Schematic Diesel (S/N 138634 to Present) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . .6-30
6-32. Hydraulic Schematic 4WD - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
6-33. Hydraulic Schematic 4WD - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
6-34. Hydraulic Schematic 4WD - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
6-35. Hydraulic Schematic 4WD - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
6-36. Hydraulic Schematic 2WD - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
6-37. Hydraulic Schematic 2WD - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37
6-38. Hydraulic Schematic 2WD - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38
6-39. Hydraulic Schematic 2WD - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39
6-40. Hydraulic Diagram - (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40
6-41. Hydraulic Diagram - (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41
6-42. Hydraulic Diagram - (Leveling Jacks) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-42
6-43. Hydraulic Diagram - Deck Extension (Single) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43
6-44. Hydraulic Diagram - Deck Extension (Dual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44
6-45. Hydraulic Diagram - Deck Extension (Dual Megadeck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45
6-46. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46
6-47. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-47

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 TABLE OF CONTENTS

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Deutz F3M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 GM 3.0L Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 High Drive Cut-Out Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-9 Tilt Sensor Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-10 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-12 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-14 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
3-1 Tilt Sensor Harness Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-2 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-3 Torque/Drive Hub Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-4 Gearbox Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-5 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
3-6 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3-7 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-8 Generator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
3-9 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73
3-10 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-11 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-76
3-12 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-13 Joystick Plug Loading Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-77
3-14 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-78
3-15 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86
4-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-3 Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
5-1 Fault Code Listing - Software P1.X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-2 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-3 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5-4 Machine Tilt Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

vi – JLG Lift – 3121133

 SECTION 1 - SPECIFICATIONS

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

3121133 – JLG Sizzor – 1-1

 SECTION 1 - SPECIFICATIONS

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

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

1.4 TIRES 1.7 SERIAL NUMBER LOCATIONS

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

12 x 16.5 Foam Fill to 170 ft lbs

10
Foam Filled 90 psi (6 bar) (238 Nm)

12 x 16.5
170 ft lbs
Pneumatic 10 90 psi (6 bar)
(238 Nm)
(Non-Marking)

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

33/1550 x 16.5 170 ft lbs

14 90 psi (6 bar)
Pneumatic (238 Nm)

33/1550 x 16.5 Foam Fill to 170 ft lbs

14
Foam Filled 90 psi (6 bar) (238 Nm)

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

10
Foam Filled - Sand 50 psi (3.4 bar) (238 Nm)

31 x 15.50-15 170 ft lbs

10 60 psi (4 bar) SERIAL NUMBER
Grass Master (238 Nm) PLATE SERIAL NUMBER
STAMPED

Figure 1-1. Serial Number Location

1-2 – JLG Sizzor – 3121133

 SECTION 1 - SPECIFICATIONS

1.8 SENSORS 1.9 CYLINDER SPECIFICATIONS

The machine is equipped with the following limit switches: Table 1-10. Cylinder Specifications

Elevation Switch/Rotary Position Sensor - High drive Description Bore Stroke Rod Dia
speed is cut out when platform is raised above the preset
heights listed in Table 1-8, High Drive Cut-Out Height. 4.5 in 83 in 3.5 in
Lift Cylinder
Table 1-8. High Drive Cut-Out Height (11.4 cm) (211 cm) (8.9 cm)

3 in 21.5 in 2 in
Model Feet Meters Leveling Jack Cylinder
(7.6 cm) (54.6 cm) (5 cm)
3394RT 6-9 1.8 - 2.7 Lockout Cylinder 2.5 in 6.0 in 1.75 in
(Oscillating Axle) (6.4 cm) (15.2 cm) (4.4 cm)
4394RT 7-10 2.1 - 3
Power Deck Extension 1.5 in 48 in 1 in
Tilt Alarm - An alarm sounds and a warning light is illumi- Cylinders (3.8 cm) (122 cm) (2.5 cm)
nated when the machine is operated on a slope that
exceeds the values in Table 1-9, Tilt Sensor Indicators. 2.5 in 4.6 in 1.75 in
Steer Cylinder
The lift and drive functions will cut out at these set heights. (6.4 cm) (11.2 cm) (4.4 cm)
NOTE: Alarm only sounds when above elevation.

If the machine is operated beyond the specified

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

3121133 – JLG Sizzor – 1-3

 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 1-14. Mobil DTE 13M Specs

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

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

1-4 – JLG Sizzor – 3121133

 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 - Ford
6. Oil Change w/Filter - Deutz
7. Oil Change w/Filter - GM
8. Fuel Filter - Ford
9. Fuel Filter - Deutz
10. Fuel Filter (Gasoline) - GM
11. Air Filter
12. Electronic Pressure Regulator (LP Only)
13. Fuel Filter (Propane) - GM

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

side of the machine and not shown.

Figure 1-2. Operator Maintenance and Lubrication Diagram

1. Fuel Tank

TO AVOID PERSONAL INJURY, USE SAFETY PROP FOR ALL

MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED.

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

NOTE: Recommended lubricating intervals are based on

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

Operate hydraulic functions through one complete

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

Any time the pump coupling is removed, coat splines

of coupling with Texaco Code 1912 grease prior to
assembly.

3121133 – JLG Sizzor – 1-5

 SECTION 1 - SPECIFICATIONS

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

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

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

6. Oil Change w/Filter - Deutz

• Lube Point - Fill Cap/Fill Level

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

1-6 – JLG Sizzor – 3121133

 SECTION 1 - SPECIFICATIONS

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

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

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

8. Fuel Filter - Ford 11. Air Filter

• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator

12. Electronic Pressure Regulator (LP only)

• Lube Point(s) - Replaceable Element

• Interval - Every Year or 600 hours of operation

• Interval - 3 Months or 150 hours of operation

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

3121133 – JLG Sizzor – 1-7

 SECTION 1 - SPECIFICATIONS

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

• Interval - 3 Months or 150 hours of operation

• Comments - Replace filter. Refer to Propane Fuel Filter
Replacement

Draining Oil Build Up From The Propane

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

NOTICE
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM-
PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO
FLOW FREELY FROM THE REGULATOR.
NOTE: Have a small container ready to collect oil that will
1. Move the equipment to a well ventilated area. drain freely from the regulator at this point.
Ensure there are no external ignition sources.
7. Once all of the oil has been drained, reinstall the
2. Start the engine and bring to operating temperature. LPG fuel temperature sensor and reconnect the
3. With the engine running, close the manual tank electrical connector.
valve and run the engine out of fuel. 8. Open the fuel tank manual valve.
4. Push in the Emergency Switch once the engine 9. Start the engine and verify all connections are
stops. secure.
10. Dispose of any drained oil per local regulations in a
safe and proper fashion.

1-8 – JLG Sizzor – 3121133

 SECTION 1 - SPECIFICATIONS

Propane Fuel Filter Replacement INSTALLATION:

NOTICE
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-
ING BEFORE INSTALLING NEW SEAL.

1. Install the mounting plate to lock off O-ring seal.

2. Install the retaining bolt seal.
3. Install the housing seal.
4. Drop the magnet into the bottom of the filter hous-
ing.
5. Install the filter into the housing.
6. Install the retaining bolt into the filter housing.
7. Install the filter up to the bottom of the electric lock
off.
1. Electric Lock Off Solenoid 7. Electrical Connector
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).
2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring 9. Open manual shut-off valve. Start the vehicle and
4. Filter Magnet 10. Filter leak check the propane fuel system at each serviced
5. Filter Housing 11. Fuel Inlet fitting. Refer to Propane Fuel System Leak Test.
6. Seal 12. Retaining Bolt
Figure 1-3. Filter Lock Assembly Propane Fuel System Pressure Relief

REMOVAL:
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
1. Relieve the propane fuel system pressure. Refer to
312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
Propane Fuel System Pressure Relief.
SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
2. Disconnect the negative battery cable. SURE (WHERE APPLICABLE) BEFORE SERVICING THE
PROPANE FUEL SYSTEM COMPONENTS.
3. Slowly loosen the Filter housing retaining bolt and
remove it. To relieve propane fuel system pressure:
4. Pull the filter housing from the Electric lock off 1. Close the manual shut-off valve on the propane fuel
assembly. tank.
5. Locate Filter magnet and remove it. 2. Start and run the vehicle until the engine stalls.
6. Remove the filter from the housing. 3. Turn the ignition switch OFF.
7. Remove and discard the housing seal.
8. Remove and discard the retaining bolt seal.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
9. Remove and discard mounting plate to lock off O- SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
ring seal. BEFORE DISCONNECTING ANY FUEL LINE.

3121133 – JLG Sizzor – 1-9

Jlg Service And Maintenance Manual (3394rt & 4394rt)
Full download: http://manualplace.com/download/jlg-service-and-maintenance-manual-3394rt-4394rt/
SECTION 1 - SPECIFICATIONS

1.14 TORQUE CHARTS

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3)

1-10 – JLG Sizzor – 3121133

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