JLG 4394RT Service Manual
Service & Maintenance Manual
Models
3394RT
4394RT
S/N 0200191606 to Present
including S/N’s:
0200186972,
0200187002,
0200187013
3121249
May 16, 2014
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A. GENERAL
This section contains the general safety precautions
which must be observed during maintenance of the
aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to
themselves or others, or damage to the equipment.
A maintenance program must be followed to ensure
that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT
APPROVAL BY JLG INDUSTRIES INC., IS A SAFETY
VIOLATION.
The specific precautions to be observed during
maintenance are inserted at the appropriate point in
the manual. These precautions are, for the most
part, those that apply when servicing hydraulic and
larger machine component parts.
Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt
to move heavy parts without the aid of a mechanical
device. Do not allow heavy objects to rest in an
unstable position. When raising a portion of the
equipment, ensure that adequate support is provided.
reservoir. Pressure feed lines to system components
can then be disconnected with minimal fluid loss.
C. MAINTENANCE
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
• No smoking is mandatory. never refuel during electrical
storms. ensure that fuel cap is closed and secure at all other
times.
• Remove all rings, watches and jewelry when performing any
maintenance.
• Do not wear long hair unrestrained, or loose-fitting clothing
and neckties which are apt to become caught on or entangled
in equipment.
• Observe and obey all warnings and cautions on machine and in
service manual.
• Keep oil, grease, water, etc. wiped from standing surfaces and
hand holds.
• Use caution when checking a hot, pressurized coolant system.
• Never work under an elevated sizzor until platform has been
safely restrained from any movement by blocking or overhead
sling, or 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
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
B. HYDRAULIC SYSTEM SAFETY
• Battery should always be disconnected during replacement of
electrical components.
• Keep all support equipment and attachments stowed in their
proper place.
• Use only approved, nonflammable cleaning solvents.
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to
relieve any system pressure prior to disconnecting
or removing any portion of the system.
Relieve system pressure by cycling the applicable
control several times with the engine stopped and
ignition on, to direct any line pressure back into the
3121249 – JLG Lift – a
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
REVISION LOG
Original Issue - October 6, 2008
Revised - November 3, 2008
Revised - November 30, 2010
Revised - July 19, 2012
Revised - May 16, 2013
Revised - May 16, 2014
b – JLG Lift – 3121249
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
A Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
A Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-43. Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
. . . . . . . .3-63
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
Maximum Occupants 6
Maximum Workload
(Capacity):
Single Extension:
D ua l Ex t en s i on :
Extension Only:
Maximum Travel Grade :
2 WD
4 WD
Maximum Travel Grade : 3°
Maximum Platform Height 33 ft (10.06m) 43 ft (13.11m)
Maximum Drive Speed 2 WD
Maximum Drive Speed 4WD
LIft Up Speed
(Stowed to Full Height)
Lift Down Speed
(Full Height to Stowed)
Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Horizontal Manual
Side Force:
Single Extension
D ua l Ex t en s i on
Single Extension (CE/AUS)
D ua l Ex t en s i on ( CE / AU S )
Maximum Tire Load 4400 lbs (1996 kg)
Ground Bearing Pressure
w/Standard tires
Leveling Jack Bearing
Pressure
Wheelbase 9.67 ft (2.95 m)
Ground Clearance 12 in (30 cm)
Maximum Hydraulic System
Pressure
Electrical System Voltage 12 Volt
Inside Turning Radius 14.5 ft (4.39 m)
Outside Turning Radius 20.1 ft (6.12 m)
Gross Vehicle Weight
(with One Extension)
Note: Cer tain options or
country standards increase
weight.
2250 lbs (1020 kg)
2000 lbs (905 kg)
500 lbs (230 kg)
3.0 mph (4.8 kph)
3.5 mph (5.6 kph)
29 - 31 sec 40 - 45 sec
335 lb force (1490 N)
300 lb force (1335 N)
90 lb force (400 N)
90 lb force (400 N)
49 psi
(3.45 kg/cm
69 psi (4.9 kg/cm
3000 psi (207 bar)
11,910 lbs
(5,402 kg)
1500 lbs (680 kg)
1250 lbs (565 kg)
500 lbs (230 kg)
35%
45%
3.0 mph (4.8 kph)
3.5 mph (5.6 kph)
300 lb force (1335 N)
300 lb force (1335 N)
90 lb force (400 N)
90 lb force (400 N)
2
)
(3.94 kg/cm2)
56 psi
2
)
15,300 lbs
(6,940 kg)
Description 3394RT 4394RT
Fuel Tan k 31.5 gal (1 19 L)
Hydraulic Tank:
Total Capacity
F ul l Le v el
L ow L e ve l
32.3 gal (122.3 L)
27.3 gal (103.3 L)
23.6 gal (89.3 L)
1.3 ENGINES
Table 1-3. Deutz - D 2.9 - L4 - Engine Specifications
(Tier 4 Final Engine)
Emissions EPA - Tier 4 Final
Fuel Type: Diesel
Oil Capacity 2.35 Gal. (8.9 L) w/Filter
Coolant Capacity 0.79 Gal. (3.0 L) - Engine Only
Engine RPM Control Deutz Electronic - EMR4
Low RPM Set 1200 RPM
High RPM Set 2600 RPM
Alternator 9 5 A m p, 1 2 V, B e lt D ri v e
Battery 112 Amp-Hour, 950 Cold Crank-
ing Amps, 12 VDC
Fuel Consumption: Low RPM
High RPM
Horsepower 49 Hp (36.4 Kw) @ 2600 RPM
Torque Rating 108 Ft. lb. (147 Nm) @ 1600 rpm
Cylinder Firing Order 1-3-4-2
Table 1-4. Deutz D2011 L03 T41-Flex Specifications
(Tier 4 Flex Engine)
Fuel Type: Diesel
Oil Capacity 8.5 Quarts (8 L) w/Filter
Low RPM 1200
High RPM 2800
Alternator 95 Amp, Belt Drive
Battery 112 Amp-Hour, 950 Cold Crank-
F ue l Co n su m p ti o n: L o w R P M
H ig h RP M
Horsepower 49 @ 2800 RPM, full load
1.3 GPH (4.9 lph)
1.6 GPH (6.0 lph)
ing Amps, 12 VDC
1.3 GPH (4.9 lph)
1.6 GPH (6.0 lph)
3121249 – JLG Lift – 1-1
SECTION 1 - SPECIFICATIONS
Table 1-5. Deutz F3M2011 Specifications
Fuel DIesel
Oil Capacity 8.5 Quarts (8 L) w/Filter
Low RPM 900
High RPM 2800
Alternator 95 Amp, Belt Drive
Battery 112 Amphour, 950 Cold Cranking
Amps, 12 VDC
Fuel Consumption:
L ow R P M
H ig h R PM
Horsepower 48 @ 2800 RPM, full load
Table 1-6. GM 3.0L Specifications
(Tier 2 and 3 Engine)
Fuel Gasoline or Gasoline/LP Gas
No. of Cylinders 4
HorsePower:
G as o l in e
L P
Bore 4.0 in. (101.6 mm)
Stroke 3.6 in. (91.44 mm)
Displacement 181 cu.in. (3.0 L, 2966 cc)
Oil Capacity w/filter
T ie r 2
T ie r 3
Minimum Oil Pressure:
a t i d l e
at operation
Compression Ratio
T ie r 2
T ie r 3
Firing Order 1-3-4-2
Maximum RPM 2800
6 psi (0.4 Bar) @ 1000 rpm
18 psi (1.2 Bar) @ 2000 rpm
1.3 GPH (4.9 lph)
1.6 GPH (6.0 lph)
83 hp @ 3000 rpm
75 hp @ 3000 rpm
4.5 qts. (4.25 L)
5.0 qts. (4.73L)
9.2:1
10.5:1
1.4 TIRES
Table 1-7. Tire Specifications
Size
IN315/55D20
Pneumatic
IN315/55D20
Foam Filled
12 x 16.5
Pneumatic
(Non-Marking)
12 x 16.5
Foam Filled
(Non-Marking)
33/1550 x 16.5
Pneumatic
33/1550 x 16.5
Foam Filled
33/16LLx16.1
Foam Filled - Sand
31 x 15.50-15
Grass Master
Ply
Rating
12 75 psi (5 bar)
12
10 90 psi (6 bar)
10
14 90 psi (6 bar)
14
10
10 60 psi (4 bar)
1.5 MACHINE DIMENSIONS
Description 3394RT 4394RT
Machine Height
(rails down)
Machine Width 94 in (2.4 m)
Machine Length 156 in (4 m)
61.75 in (1.6 m) 70.4 in (1.8 m)
Inflation
Pressure
Foam Fill to
75 psi (5 bar)
Foam Fill to
90 psi (6 bar)
Foam Fill to
90 psi (6 bar)
Foam Fill to
50 psi (3.4 bar)
1.6 PRESSURE SETTINGS
Table 1-8. Main Control Valve Relief Settings
Wheel Nut
Torq ue ( Dry)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
Description 3394RT 4394RT
Main Relief 3000 psi (207 bar)
Steer Relief 2800 psi (193 bar)
Lift Up Relief 2700 psi (186 bar)
1-2 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
1
2
Rear of Machine
1. Serial Number Plate
2. Stamped Serial Number
Figure 1-1. Serial Number Location
1.7 SERIAL NUMBER LOCATIONS
For machine identification, a serial number plate is affixed
to the machine. The plate is located at the rear of the
machine on the center of the axle. In addition, should the
serial number plate be damaged or missing, the machine
serial number is stamped onto the lip of the rear axle.
1.8 SENSORS
The machine is equipped with the following limit switches:
Elevation Switch/Rotary Position Sensor - High drive
speed is cut out when platform is raised above the preset
heights listed in Table 1-9, High Drive Cut-Out Height.
Table 1-9. High Drive Cut-Out Height
Model Height
3394RT
4394RT
Tilt Alarm - An alarm sounds and a warning light is illuminated when the machine is operated on a slope that
exceeds the values in Table 1-10, Tilt Sensor Indicators.
The lift and drive functions will cut out at these set heights.
NOTE: Alarm only sounds when above elevation.
If the machine is operated beyond the specified
slope, with the platform completely lowered, only the
warning light is illuminated.
Table 1-10. Tilt Sensor Indicators
6-9 ft
(1.8 - 2.7 m)
7-10 ft
(2.1 - 3 m)
Model Front To Back Side To Side
3394RT
(ANSI, ANSI Expor t, Aus)
4394RT
(ANSI, ANSI Expor t, Aus)
3394RT/4394RT
(CSA)
3394RT/4394RT
(CE)
5° to 26 ft (8 m)
5° to full height
5° to full height
3° to full height 3° to full height
5° to full height 3° to full height
4° to 30 ft (9 m)
3° to 33 ft (10 m)
5° to 26 ft (8 m)
4° to 30 ft (9 m)
3° to 43 ft (13 m)
3121249 – JLG Lift – 1-3
SECTION 1 - SPECIFICATIONS
1.9 CYLINDER SPECIFICATIONS
Table 1-11. Cylinder Specifications
Description Bore Stroke Rod Dia
Lift Cylinder
Leveling Jack
Cylinder
Lockout Cylinder
(Oscillating Axle)
Power Deck
Cylinders
Steer Cylinder
4.5 in
(114 mm)
2.5 in
(63.5 mm)
2.5 in
(6.4 cm)
15 in
(38.1 mm)
2.5 in
(63.5 mm)
83 in
(2.1 mm)
27 in
(686 mm)
4.13 in
(10.5 cm)
48 in
(1219.2 mm)
9.2 in
(233.7 mm)
(25.4 mm)
(44.5 mm)
1.10 MAJOR COMPONENT WEIGHTS
Table 1-12. Major Component Weights
Component Weight
Fixed Platform 1070 lbs (485 kg)
Platform Extension 440 lbs (200 kg)
Arm Assembly- (Includes Lift Cylinder):
3394RT
4394RT
Chassis with Pneumatic Tires:
3394RT
4394RT
Chassis with Foam Filled Tires:
3394RT
4394RT
3600 lbs (1633 kg)
4550 lbs (2064 kg)
6790 lbs (3080 kg)
9080 lbs (4119 kg)
7788 lbs (3533 kg)
9086 lbs (4121 kg)
3.5 in
(89 mm)
2 in
(51 mm)
1.75 in
(4.4 cm)
1 in
1.75 in
1.11 CRITICAL STABILITY WEIGHTS
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE:
FILLED TIRES, ENGINE) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.
Table 1-13. Critical Stability Weights
Component Weight
Tires
IN315/55D20 Pneumatic
IN315/55D20 Foam Filled
12 x 16.5 Pneumatic
12 x16.5 Foam Filled
33/1550-16.5 Pneumatic
33/1550-16.5 Foam Filled
33/16LL x 16.1 Foam Filled - Sand
31 x 15.50-15 Grass Master
Engine (Deutz) 441 lbs (200 kg)
Engine (GM) 341 lbs (155 kg)
156 lbs (71 kg)
156 lbs (71 kg)
128 lbs (58 kg)
328 lbs (149 kg)
135 lbs (61 kg)
395 lbs (179 kg)
426 lbs (193 kg)
125 lbs (57 kg)
1-4 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
1.12 LUBRICATION SPECIFICATIONS
Table 1-14. Hydraulic Oil
Hydraulic System Operating
Temperature Range
0°F to +23°F
(-18°C to -5°C)
0°F to +210°F
(-18°C to +100°C)
+50°F to +210°F
(+10°C to +100°C)
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152.
Table 1-15. Mobil DTE 13M Specs
ISO Viscosity Grade #32
Specific Gravity 0.877
Pour Point, Max -40°F (-40°C)
Flash Point, Min. 330°F (166°C)
Viscosity
at 40°C 33cSt
at 100°C 6.6 cSt
at 100°F 169 SUS
at 210°F 48 SUS
cp at -20°F 6,200
Viscosity Index 140
Sae Viscosity Grade
10W
10W-20,10W-30
20W-20
Table 1-16. Mobil 424 Specs
Ty pe Synthetic Biodegradable
SAE Grade 10W-30
Gravity, API 29.0
Density 7.35 lb/gal (
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
at 40°C 55 cSt
at 100°C 9.3 cSt
Viscosity Index 152
3121249 – JLG Lift – 1-5
SECTION 1 - SPECIFICATIONS
Figure 1-2. Operator Maintenance and Lubrication Diagram
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
(LP Only)
11. Fuel Filter (Propane) - GM
NOTE: Item #5 through #11 are on the
opposite side of the machine and
not shown. See following pages.
1.13 OPERATOR MAINTENANCE
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, lubrication frequencies must be increased accordingly.
Operate hydraulic functions through one complete
cycle before checking hydraulic oil level in tank. Oil
should be visible in ADD sight window on hydraulic
tank. If oil is not visible, add oil until oil is visible in
both ADD and FULL sight windows on tank. Do not
overfill tank.
Any time the pump coupling is removed, coat splines
of coupling with Texaco Code 1912 grease prior to
assembly.
Fuel Tank
• Fuel - Diesel or Gasoline
• Capacity - 31.5 gal (119 l)
1-6 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
Drive Hub
• Lube Points - Fill Plugs (4)
• Lube - EPGL - Mobilube HD 80W-90 or equivalent
• Interval - Every 2 years or 1200 hours
• Total Capacity - 23.75 oz. each hub
Hydraulic Oil
Engine Oil Change w/Filter - Deutz
• Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7016331)
• Capacity - 6.3 qt. (5.9 L) engine only
•Lube - EO
• Interval - Every Year or 600 hours of operation
• Comments - Check level daily/Change in accordance
with engine manual.
Engine Oil Change w/Filter - Deutz D2.9 L4 T4F
• Lube Point - Fill Cap/Fill Level
•Lube - HO
• Interval - Check oil every 10 hours of operation;
change oil every 2 years or 1200 hours of operation.
1. Sliding Wear Pads
• Lube Points - 8 Sliding Wear Pads
•Lube - MPG
• Interval - Every month or 50 hours.
• Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7016641)
• Capacity - 2.35 Gal. (8.9 L) engine only
•Lube - EO
• Interval - Every Year or 600 hours of operation
• Comments - Check level daily/Change in accordance
with engine manual.
3121249 – JLG Lift – 1-7
SECTION 1 - SPECIFICATIONS
Oil Change w/Filter - GM
• Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7027965)
• Capacity - 4.5 qt. (4.25 L) w/filter
•Lube - EO
• Interval - 3 Months or 150 hours of operation
• Comments - Check level daily/Change in accordance
with engine manual.
Engine Fuel Filter - Deutz
Engine Fuel Filter - Deutz D 2.9 L4 - T4F
• Lube Point(s) - Replaceable Element - on engine and
Pre-Filter w/pressure sensor next to fuel tank
• Interval - Every Year or 600 hours of operation
Engine Fuel Filter (Gasoline) - GM
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation
Air Filter
• Lube Point(s) - Replaceable Element
• Interval - Every Year or 600 hours of operation
• Lube Point(s) - Replaceable Element
• Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator
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
1-8 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
Fuel Filter (Propane) - GM
• Interval - 3 Months or 150 hours of operation
• Comments - Replace filter. Refer to Propane Fuel Filter
Replacement
Draining Oil Build Up From The Propane Regulator
During the course of normal operation oils may build
inside the primary and secondary chambers of the propane 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 contaminated.
4. Push in the Emergency Switch once the engine stops.
5. Disconnect the electrical connection to the LPG fuel
temperature sensor in the auxiliary fuel port of the EPR.
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO
FLOW FREELY FROM THE REGULATOR.
1. Move the equipment to a well ventilated area. Ensure
there are no external ignition sources.
2. Start the engine and bring to operating temperature.
3. With the engine running, close the manual tank valve
and run the engine out of fuel.
6. Remove the retainer clip for the LPG fuel temperature
sensor and remove the sensor from the regulator body.
NOTE: Have a small container ready to collect oil that will
drain freely from the regulator at this point.
3121249 – JLG Lift – 1-9
SECTION 1 - SPECIFICATIONS
1
2
3
4
5
6
7
8
9
10
11
12
1. Electric Lock Off Solenoid
2. Mounting Plate
3. Housing Seal
4. Filter Magnet
5. Filter Housing
6. Seal
7. Electrical Connector
8. Fuel Outlet
9. O-ring
10. Filter
11. Fu el In le t
12. Retaining Bolt
Figure 1-3. Filter Lock Assembly
7. Once all of the oil has been drained, reinstall the LPG
fuel temperature sensor and reconnect the electrical
connector.
8. Open the fuel tank manual valve.
9. Start the engine and verify all connections are secure.
10. Dispose of any drained oil per local regulations in a
safe and proper fashion.
Propane Fuel Filter Replacement
INSTALLATION:
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING 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 housing.
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.
8. Tighten the filter retaining bolt to 106 in.lbs. (12 Nm).
9. Open manual shut-off valve. Start the vehicle and leak
check the propane fuel system at each serviced fitting.
Refer to Propane Fuel System Leak Test.
Propane Fuel System Pressure Relief
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE
PROPANE FUEL SYSTEM COMPONENTS.
To relieve propane fuel system pressure:
1. Close the manual shut-off valve on the propane fuel
tank.
REMOVAL:
1. Relieve the propane fuel system pressure. Refer to Pro-
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
pane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing retaining bolt and
remove it.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
BEFORE DISCONNECTING ANY FUEL LINE.
4. Pull the filter housing from the Electric lock off assembly.
5. Locate Filter magnet and remove it.
6. Remove the filter from the housing.
7. Remove and discard the housing seal.
8. Remove and discard the retaining bolt seal.
9. Remove and discard mounting plate to lock off O-ring
seal.
1-10 – JLG Lift – 3121249
1.14 TORQUE CHARTS
SECTION 1 - SPECIFICATIONS
Figure 1-4. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
3121249 – JLG Lift – 1-11
SECTION 1 - SPECIFICATIONS
Figure 1-5. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
1-12 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
Figure 1-6. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
3121249 – JLG Lift – 1-13
SECTION 1 - SPECIFICATIONS
Figure 1-7. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
1-14 – JLG Lift – 3121249
SECTION 1 - SPECIFICATIONS
Figure 1-8. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
3121249 – JLG Lift – 1-15
SECTION 1 - SPECIFICATIONS
NOTES:
1-16 – JLG Lift – 3121249
SECTION 2. GENERAL
SECTION 2 - GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The
following table outlines the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
environment, severity and frequency of usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to performing the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent Inspection
The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different 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 service for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection
JLG recommends that an annual machine inspection be
performed by a Factory-Certified Service Technician on an
annual basis, no later than thirteen (13) months from the
date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG
Service Training School for the subject JLG product
model. Reference the machine Service and Maintenance
Manual and appropriate JLG inspection form for performance of this inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.
Preventative Maintenance
In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.
3121249 – JLG Lift – 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Type Frequency
Pre-Start
Inspection
Pre-Delivery
Inspection
Frequent
Inspection
Annual Machine
Inspection
Preventative
Maintenance
Prior to use each day; or
At each Operator change.
Prior to each sale, lease, or
rental delivery.
In service for 3 months or 150 hours,
whichever comes first; or
Out of service for a period of more than 3
months; or
Purchased used.
Annually, no later than 13 months from
the date of the prior inspection.
At intervals as specified in the Ser vice
and Maintenance Manual.
2.2 SERVICE AND GUIDELINES
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this book.
Safety and Workmanship
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
Cleanliness
1. The most important single item in preserving the
long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User
Owner, Dealer, or User
Owner, Dealer, or User
Owner, Dealer, or User
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their containers until they are ready to be used.
Service
Qualification
Qualified JLG
Mechanic
Qualified JLG
Mechanic
Factory-Certified
Service Technician
or a Qualified JLG
Mechanic
Qualified JLG
Mechanic
Reference
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual and applicable JLG
inspection form.
Service and Maintenance
Manual
Components Removal and Installation
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90°.
3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.
2-2 – JLG Lift – 3121249
SECTION 2 - GENERAL
Component Disassembly and Reassembly
When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.
Pressure-Fit Parts
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.
Bearings
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the
inner race.
Gaskets
2. Unless specific torque requirements are given within
the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See
Torque Chart Section 1.)
Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.
Hydraulic System
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain
and flush the entire system.
2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
Lubrication
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.
Battery
Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.
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
Hydraulic System
1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suction) lines.
2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
components and generally results in faulty operation. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.
4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is operating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
This will allow start up at temperatures down to -20°F
(-29°C). However, use of this oil will give poor performance at temperatures above 120°F (49°C). Systems using DTE 13 oil should not be operated at
temperatures above 200°F (94°C) under any condition.
Changing Hydraulic Oil
1. Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular
basis. However, filter elements must be changed
after the first 50 hours of operation and every 300
hours thereafter. If it is necessary to change the oil,
use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain
the same type of oil supplied with the machine, consult local supplier for assistance in selecting the
proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.
2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contaminants from the service container. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.
Lubrication Specifications
Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.
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 necessary to start the system in a sub-zero environment, 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
Loading...