JLG 400S Caught Fire - Need Wiring Help

[gdai]

Hi, I hope somebody can help, I'm pretty well stuck!

So, this lift caught fire, the upper fuel line from the filter blew off and boom! Anyway, I've replaced most of what burned, including the main wiring harness, fuel lines, map sensor etc. and now have it so that I can get it to start and sometimes idle for awhile, but it usually kills right away after starting or when trying to increase engine speed.

So, I didn't replace the full engine wiring harness, but have spliced where I know the connections go. I'm hoping that if I can get the rest of the wiring cleaned up that it will run, but the schematic that I have doesn't show these connections.

This is a 2001 JLG 400S Dual Fuel without ADE with the Ford LRG-425 engine.
Lift Serial number is 030056378

The engine Serial # is 84014-1-07-00
The engine model # is JLG-425I-6005-A
the base engine code is OC-1870AA EFI

Mostly what is left is the wiring that sits on the top of the engine near the exhaust. The wires are still there and intact, but most of the connectors melted and it looks like the wiring colors don't match through the connectors, so I have no way of knowing where to splice them.

If you think you can help I would be very very very grateful & I'll post pictures & what info I already know.

Thanks!

Gordon

 

[barklee]

Hi, I hope somebody can help, I'm pretty well stuck!

So, this lift caught fire, the upper fuel line from the filter blew off and boom! Anyway, I've replaced most of what burned, including the main wiring harness, fuel lines, map sensor etc. and now have it so that I can get it to start and sometimes idle for awhile, but it usually kills right away after starting or when trying to increase engine speed.

So, I didn't replace the full engine wiring harness, but have spliced where I know the connections go. I'm hoping that if I can get the rest of the wiring cleaned up that it will run, but the schematic that I have doesn't show these connections.

This is a 2001 JLG 400S Dual Fuel without ADE with the Ford LRG-425 engine.
Lift Serial number is 030056378

The engine Serial # is 84014-1-07-00
The engine model # is JLG-425I-6005-A
the base engine code is OC-1870AA EFI

Mostly what is left is the wiring that sits on the top of the engine near the exhaust. The wires are still there and intact, but most of the connectors melted and it looks like the wiring colors don't match through the connectors, so I have no way of knowing where to splice them.

If you think you can help I would be very very very grateful & I'll post pictures & what info I already know.

Thanks!

Gordon

Funny stuff..... I am just going through the same thing with a genie s65 that burned. We replaced the engine harness and the machine starts and everything works but the throttle wont increase with the petal and the engine will only run for about 20 seconds. The diagrams are terrible and i got tired of messing with it so i took mine to the ford industrial dealer. I bet you have the same problem as mine (at least one of them). My Genie has a diagnostic system on it that was reading low oil pressure, so i replaced the oil pressure sensor with no luck. The dealer says that they cant figure it out either but can make it run by grounding the oil pressure sensor. They put a guage on mine and determined it was making the proper oil pressure so im gonna go with it as i dont have endless time and money to spend on it. They also figured out the throttle problem but im not sure what it was...... I would start there if i were you. You may also have melted or damaged the engine computer.... By the age of your machine i would guess that it is the obsolete computer and needs updated anyway, as there is no replacement for the older computers (as i understand). I have a spare computer if you find you need one.... Good Luck, and if i can help further PM me.

 

[gdai]

Funny stuff..... I am just going through the same thing with a genie s65 that burned. We replaced the engine harness and the machine starts and everything works but the throttle wont increase with the petal and the engine will only run for about 20 seconds. The diagrams are terrible and i got tired of messing with it so i took mine to the ford industrial dealer. I bet you have the same problem as mine (at least one of them). My Genie has a diagnostic system on it that was reading low oil pressure, so i replaced the oil pressure sensor with no luck. The dealer says that they cant figure it out either but can make it run by grounding the oil pressure sensor. They put a guage on mine and determined it was making the proper oil pressure so im gonna go with it as i dont have endless time and money to spend on it. They also figured out the throttle problem but im not sure what it was...... I would start there if i were you. You may also have melted or damaged the engine computer.... By the age of your machine i would guess that it is the obsolete computer and needs updated anyway, as there is no replacement for the older computers (as i understand). I have a spare computer if you find you need one.... Good Luck, and if i can help further PM me.

Thanks barklee,

Funny stuff indeed -- Your experiences gives me some things to try. I don't think the ECM is damaged because it was on the opposite end away from the fire, but I guess it's a possibility. If I get to that point I'll let you know and take a look at picking up your computer. I did find a better schematic also from Genie -- even though this is a JLG, the Genie's with the Ford installed from about the same timeframe have the same wiring harness/setup. Unfortunately I've about broken the bank on this & it's in a fairly remote area so I can't get it to a dealer and they're about 150 miles away and want a grundle to come take a look at it. I have no good way to move it without getting it running either, the only local guys who could move it from where it is want around $2K. If it comes to that maybe I'll just take it out a piece at a time and sell it off.

Thanks again!

 

[kevinc1650]

You can go to JLG website and Genie's site and get all the diagrams off them.

 

[gdai]

You can go to JLG website and Genie's site and get all the diagrams off them.

Thanks Kevinc. I scoured the JLG site for the schematics and they do have the schematic for the main wiring harness that helped when I was installing that, but for the engine wiring harness schematic they tell you to contact Ford Power Products. Ford Power Products referred me to my local Ford Power Products dealer who I contacted and didn't get what I needed. I did find the schematic on the Genie website that's close to the same as what I have but it's not exactly the same. Not sure if it's a difference between Genie and JLG, or just variations in production by Ford.

Anyway, I think that I have the wiring in place now but it still won't run. I can get it to start and idle if I start it with a spray of ether and with one of the vacuum tubes that tees off from the MAP sensor disconnected from the fuel rail then it just kills after 20 seconds or so. If the MAP sensor to fuel rail vacuum tube is connected it won't idle at all. I tried grounding the oil pressure sending wire like barklee suggested and that didn't make any difference either.

Not sure where to look next, but will look closer at the MAP sensor & wiring to see if something there may be the problem, but this is a new MAP sensor. Am also wondering if the throttle actuator may have been damaged with the heat, but I pulled the intake off and watched it & it appears to be working as it should. When it's idling it stays steady at slightly open and when it starts to kill it opens like I would think it should trying to keep itself running. When it starts to kill a spray of ether keeps it running so it seems to be starving for fuel. I tested fuel pressure and it stays right at 60psi constantly...

Also, not sure what I've done now, but it no longer tries to increase speed with the pedal or when the generator is kicked on like it normally would.

Any other insights anyone might have would be great. Thanks.