Service Manual Instruction Manual
Table Of Contents
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires And Wheels
- 3.2 Torque Hub
- Oil Information
- Roll and Leak Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Output Carrier Disassembly
- Input Carrier Disassembly
- Hub-Spindle Disassembly
- Spindle-Brake Disassembly
- Cover Disassembly
- Cover Assembly
- Input Carrier Sub-Assembly
- Output Planet Gear Sub-Assembly
- Spindle - Brake Sub-Assembly
- Hub-Spindle Sub-Assembly
- Cover Sub-Assembly
- Main Assembly
- Integral Brake Check
- 3.3 Free Wheeling Option
- 3.4 Drive Motor
- 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.6 Steer Adjustments
- 3.7 Swing Drive
- 3.8 Swing Bearing
- 3.9 Swing Brake - Mico
- 3.10 Rotary Coupling
- 3.11 Generator
- 3.12 Deutz D2.9 L4 Engine
- 3.13 Deutz D2011 Engine
- 3.14 Spark Arrester Cleaning Instructions
- 3.15 Glow Plugs
- 3.16 Deutz EMR 2
- 3.17 Bio Fuel in Deutz Engines
- 3.18 GM Engine General Maintenance
- 3.19 GM Engine Dual Fuel System
- Fuel Filter
- Direct Electronic Pressure Regulator (DEPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Electric Lock Off
- Engine Control Module (ECM)
- Heated Exhaust Gas Oxygen Sensor
- Gasoline Multi Point Fuel Injection System (MPFI)
- Gasoline Fuel Pump
- Gasoline Pressure And Temperature Sensor Manifold
- Fuel Filter
- Fuel Injector Rail
- Fuel Injector
- 3.20 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
- Check/Drain Oil Build-Up In 2-Stage Vaporizer
- Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
- Exhaust System And Catalytic Converter Inspection And Maintenance
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Throttle Body (ETC) Replacement
- Mixer Replacement
- Electronic Pressure Regulator (EPR) Replacement
- Regulator Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.21 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- 5.1 O-Ring Lubrication
- 5.2 Cylinders - Theory of Operation
- 5.3 Cylinder Checking Procedure
- 5.4 Cylinder Removal and Installation
- Cylinder Locations
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Boom Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- 5.5 Hydraulic Cylinder repair
- Tower Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Upright Level Cylinder
- Cleaning and Inspection
- Assembly
- Master Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Tower Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Platform Level (Slave) Cylinder
- Cleaning and Inspection
- Assembly
- Jib Lift Cylinder (AJ Only)
- Cleaning and Inspection
- Assembly
- Steer Cylinder
- Cleaning and Inspection
- Assembly
- Axle Lockout Cylinder
- 5.6 Hydraulic Pump (Gear)
- 5.7 Variable Pump
- 5.8 Hydraulic Component Start-Up
- 5.9 Pressure Setting Procedures
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics
SECTION 1 - SPECIFICATIONS
1-2 – JLG Lift – 3121616
1.3 CAPACITIES
1.4 TIRES
1.5 ENGINE DATA
Table 1-3. Capacities
Fuel Tank 30 gal (113.6 L)
Hydraulic Oil Tank 30.6 gal (115.8 L)
Hydraulic System (Including Tank) 40 gal (121 L)
Torque Hub, Drive
*
20 oz (0.6 L)
Engine Crankcase
Deutz D2011L04
De utz 2.9 L 04
GM 3.0
11 qt (10.5 L)
2.4 gal (8.9 L) w/Filter
4.5 qt (4.25 L) w/Filter
*Fill torque hubs half (1/2) full of lubricant.
Table 1-4. Tire Specifications
Size IN355/55D 625
Load Range G
Ply Rating 14
Foam Fill (Optional) Foam/Crumb
Diameter 36.9
Width 13.95
Rim Size 11.75 x 24.5
Max Tire Load 11,700 lb (5307 kg) @ 90 psi (6 bar)
Size 14 x 17.5 Airboss
Load Range G
Diameter 35.6
Width 14
Max Tire Load 11,800 lb (5443 kg)
Size 41/18LLx22.5 Turf/Sand
Load Range G
Ply Rating N/A
Foam Fill Soft
Diameter 41
Width 18.4
Rim Size 14 x 22.5
Max Tire Load 15,500 lb @ 70 psi/5 bar
Size 36x12-20FA Solidboss
Load Range G
Ply Rating N/A
Diameter 36
Width 12
Max Tire Load 11,800 lb (5443 kg)
Table 1-5. Deutz TD 2.9 Specifications
Fuel Ultra Low Sulfur Diesel (15 ppm)
Output 67 hp (50 kW)
Torque 173 ft.lbs. (234 Nm) @ 1800rpm
Oil Capacity (Crankcase) 2.4 gal (8.9 L) w/Filter
Cooling System 3.3 gal (12.5 L)
Low RPM 1200 ±50 rpm
High RPM 2600 ±50 rpm
Alternator 95 Amp
Fuel Consumption 0.65 GPH (2.48 lph)
Table 1-6. Deutz D2011L04
Fuel Diesel
Oil Capacity
Coo lin g Syst em
Cra nkc ase
To tal C apac it y
5 qt(4.5 L)
11qt (10.5 L) w/Filter
16 qt (15 L)
Idle RPM 1000
Low RPM 1800
High RPM 2500
Alternator 60 Amp, belt drive
Battery 950 Cold Cranking Amps,
205 Minutes Reserve, 12 VDC
Fuel Consumption 0.65 GPH (2.46 LPH)
Horsepower 49
Table 1-7. GM 3.0L
Fuel Gasoline or Gasoline/LP Gas
No. of Cylinders 4
BHP
Ga sol ine
LP
83 hp @ 3000 rpm
75 hp @ 3000 rpm
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 4.5 qt (4.25 L)
Minimum Oil Pressure
at idle
Ho t
6 psi (0.4 Bar) @ 1000 rpm
18 psi (1.2 Bar) @ 2000 rpm
Compression Ratio 9.2:1
Firing Order 1-3-4-2
Max. RPM 2800
Fuel Consumption N/A