JLG GM Engine Parts Illustrated Parts Manual 3121245 – PDF DOWNLOAD

Illustrated Parts Manual

GM Engine Parts Supplement P/N 3121245 December 30, 2013

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REVISION LOG NOTES:

GROUND MODULE MODULE IDENTIFICATION NOTE: MODULE IS LOCATED NEAR THE GROUND CONTROLS OR IN GROUND CONTROL BOX .

MODULE ON MACHINES “WITH UGM” (UNIVERSAL GROUND MODULE)

MODULE ON MACHINES “WITHOUT UGM” (UNIVERSAL GROUND MODULE)

March 15, 2008 - Original Issue Of Manual May 1, 2011 - Revised Manual July 25, 2011 - Revised Manual October 21, 2011 - Revised Manual February 15, 2012 - Revised Manual August 2, 2012 - Revised Manual January 23, 2013 - Revised Manual June 30, 2013 - Revised Manual December 30, 2013 - Revised Manual

3121245

GM Engine Parts Supplement

A

REVISION LOG

B

GM Engine Parts Supplement

3121245

TABLE OF CONTENTS FIGURE NO.

TITLE

PAGE NO.

SECTION 1 - USAGE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 SECTION 2 - .97L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10

SHORT BLOCK COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CYLINDER HEAD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 LONG BLOCK & DRESS COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 ALTERNATOR, WATER PUMP & PULLEYS COMPONENTS . . . . . . . . . . . . . . . . . . . 2-14 STARTER COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 FLYWHEEL HOUSING/PUMP COUPLING COMPONENTS . . . . . . . . . . . . . . . . . . . . . 2-18 THERMOSTAT & INTAKE MANIFOLD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 2-20 FUEL SUPPLY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 EXHAUST COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

SECTION 3 - 3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17

SHORT BLOCK COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 CYLINDER HEAD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 LONG BLOCK & DRESS KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 ALTERNATOR & PULLEY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 STARTER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 FLYWHEEL HOUSING/PUMP COUPLING COMPONENTS . . . . . . . . . . . . . . . . . . . . . 3-24 AIR INTAKE COMPONENTS (SCISSORS LIFTS ONLY). . . . . . . . . . . . . . . . . . . . . . . . 3-26 FUEL SUPPLY COMPONENTS - TIER 1 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 FUEL SUPPLY COMPONENTS - TIER 2 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 FUEL SUPPLY COMPONENTS - TIER 3 & 4 INTERIM ENGINES . . . . . . . . . . . . . . . . 3-36 MIXER ASSEMBLY (TIER 1 & 2 ENGINES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 INTAKE/EXHAUST MANIFOLD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 MUFFLER COMPONENTS - BOOM LIFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 MUFFLER COMPONENTS - SCISSOR LIFTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 COOLANT SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 ENGINE MOUNTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

SECTION 4 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 SECTION 5 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

3121245

GM Engine Parts Supplement

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TABLE OF CONTENTS FIGURE NO.

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TITLE

GM Engine Parts Supplement

PAGE NO.

3121245

SECTION 1 USAGE CHART

USAGE CHART Part Number

Description MODEL & ENGINE USAGE: Note: UGM refers to Universal Ground Module located near machine Ground Controls. See Revision Log for identification.

JLG Boom Lift Models:

1001117892

2000354 1001091583 See Note 1001114595 1001141139

2000354 1001091583 1001101819 1001114595 1001141139

2000354 1001091768 1001101823 1001114600

2000354 1001091583 See Note 1001114595

3121245

Qty Ref Ref

Ref

340AJ (See Section 2 for Breakdown) Tier 3 .97L Complete Engine

Ref Ref

400S/460SJ (See Section 3 for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109274 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109274 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109274 to Present without UGM & with Arctic Package) (Note: Not available for purchase) Tier 3 & 4 interim 3.0L Complete Engine (Machines Prior to SN 0300161285 with UGM) Tier 3 & 4 interim 3.0L Complete Engine (Machines SN 0300161285 to Present with UGM)

Ref Ref

450A Series II/450AJ Series II (See Section 3 for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109286 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109286 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109286 to Present without UGM & with Arctic Package) Tier 3 & 4 interim 3.0L Complete Engine (Machines Prior to SN 0300160835 with UGM) Tier 3 & 4 interim 3.0L Complete Engine (Machines SN 0300160835 to Present with UGM)

Ref Ref

600A/600AJ (See Section 3 for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109298 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109298 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109298 to Present without UGM & with Arctic Package) Tier 3 & 4 interim 3.0L Complete Engine (Machines with UGM)

Ref Ref

600S/600SJ/660SJ/680SJ (See Section 3 for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109245 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109245 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109245 to Present without UGM & with Arctic Package) (Note: Not available for purchase) Tier 3 & 4 interim 3.0L Complete Engine (Machines with UGM)

GM Engine Parts Supplement

Ref Ref Ref Ref

Ref Ref Ref Ref

Ref Ref Ref Ref Ref Ref Ref Ref

1-1

SECTION 1

USAGE CHART

USAGE CHART Part Number 2000354 1001091583 1001111353 1001114595

2000354 1001091583 See Note 1001114595

Description 800A/800AJ (See 3.0L ENGINE SECTION for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109494 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109494 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109494 to Present without UGM & with Arctic Package) Tier 3 & 4 interim 3.0L Complete Engine (Machines with UGM) 800S/860SJ (See 3.0L ENGINE SECTION for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0300109494 without UGM) Tier 2 3.0L Complete Engine (Machines SN 0300109494 to Present without UGM & without Arctic Package) Tier 2 3.0L Complete Engine (Machines SN 0300109494 to Present without UGM & with Arctic Package) (Note: Not available for purchase) Tier 3 & 4 interim 3.0L Complete Engine (Machines with UGM) JLG Scissors Lift Models:

2000360 1001091585 1001102398 1001114604

1-2

3394RT/4394RT (See 3.0L ENGINE SECTION for Breakdown) Tier 1 3.0L Complete Engine (Machines Prior to SN 0200166823) Tier 2 3.0L Complete Engine (Machines SN 0200166823 to SN 0200191606) Tier 2 3.0L Complete Engine (Machines SN 0200191606 to SN 0200198947) Tier 3 & 4 interim 3.0L Complete Engine (Machines SN 0200198947 to Present)

GM Engine Parts Supplement

Qty Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref Ref

3121245

SECTION 2 .97L ENGINE

3121245

GM Engine Parts Supplement

2-1

SECTION 2 .97L ENGINE FIGURE 2-1. SHORT BLOCK COMPONENTS

3

4

1 2

4

6 5

5

5

5

21

5

20

18 17

19

23 15 16

14 309

302

13

7 12 301 303 22 106

108 107

102 103

104 105

2-2

101

GM Engine Parts Supplement

3121245

SECTION 2 .97L ENGINE

209 210

208 211

204 203

201 212

202

205 426

206 213 207

214

428 427 417

215 216

410

425 408 409 404

419 413

424 403 402

411 419

412

416

407 409 404 401

406

421

420

423 422

414

9

415 405 10

8

11

418

3121245

GM Engine Parts Supplement

2-3

SECTION 2 .97L ENGINE FIGURE 2-1. SHORT BLOCK COMPONENTS ITEM #

1 2 3 4 5

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

PART NUMBER

70003244 70003245 70003246 70003247 70003248 70003249 70003250 70003251 70003252 70003253 70003254 70003255 70003256 70003257 70003258 70003259 70003260 70003261 70003262 70003263 70003264 70003265 70003266 70003267 See Note Use I70003253

QTY.

DESCRIPTION

Ref

PISTON/CRANKSHAFT COMPONENTS

4 4 4 8 4 8 8 8 1 1 1 1 1 1 2 10 1 2 1 1 2 1 4 1 1 1 Ref

101 102 103 104 105 106 107 108

201 202 203 204 205 206 207

2-4

See Note 70003268 70003269 70003270 70003271 70003272 70003273 70003274

70003275 70003276 70003277 70003278 70003279 70003280 70003281

1 1 18 1 1 1 1 2

REV.

Ring, Piston Piston Pin, Piston Clip Rod, Connecting Bolt, Connecting Rod Nut, Connecting Rod Nut Bearing, Rod Crankshaft Bolt Ring Gear, Timing Washer Key Bearing Bearing, Crankshaft Gasket Pin, Dowel Gasket, Rear Oil Seal Housing Housing, Rear Oil Seal Bolt Seal, Rear Oil Bolt Seal, Front Oil Ring (Note: Not available for purchase) Washer OIL PAN COMPONENTS Pan, Oil (Note: Not available for purchase) Gasket, Oil Pan Bolt Plug, Oil Pan (Note: See Dress Kit before ordering parts) Seal, Oil Pan Plug Gasket, Strainer Strainer, Sump Bolt

Ref

OIL PUMP COMPONENTS

1 1 1 1 1 1 1

Block, Oil Pump Plug Gear, Oil Pump Inner Gear, Oil Pump Outer Valve, Oil Pressure Relief Spring, Oil Pressure Relief Plug, Oil Pressure Relief

GM Engine Parts Supplement

3121245

SECTION 2 .97L ENGINE FIGURE 2-1. SHORT BLOCK COMPONENTS (CONTINUED) ITEM #

PART NUMBER

QTY.

208 209 210 211 212 213 214 215 216

70003282 70003283 70003284 70003285 70003286 70003287 70003288 70003289 70003290

1 6 1 2 5 1 2 1 1

Cover, Oil Pump Rear Screw Gasket, Oil Pump Pin, Dowel Bolt Bolt Bolt Washer Bolt

Ref

FLYWHEEL COMPONENTS

301 302 303 304 to 308 309

See Note 70003403 70003404 70003405 Not Used 70003406

1 1 6 1

Flywheel (Note: Not available for purchase) Ring Gear Bolt, Flywheel Pin, Dowel

1

Bearing

Ref 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428

3121245

70003342 70003343 70003344 70003345 70003346 70003347 70003348 70003349 70003350 70003351 70003352 70003353 70003354 70003355 70003356 70003357 70003358 70003359 70003360 70003361 70003362 70003363 70003364 70003365 70003366 70003367 70003368 70003369

DESCRIPTION

1 1 1 4 2 6 2 2 4 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1

REV.

TIMING COMPONENTS Cover, Joining Cover, Front Gasket, Front Bolt & Washer Support, Long Bolt Grommet Grommet Spacer Gasket Gasket Gasket Gasket Ring, Front Cover Plug, Front Cover Window Pulley, Camshaft Timing Key Support, Short Bolt & Washer Belt, Timing Bolt Washer Washer Tensioner Spacer, Torsion Bar Bar, Torsion Bolt Washer, Torsion Bar

GM Engine Parts Supplement

2-5

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