Service Manual Owner's manual
Table Of Contents
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires & Wheels
- 3.2 Wheel Drive Assembly, 2WD
- 3.3 Drive Motor - 2WD (Prior to S/N 83331)
- 3.4 Drive Motor (S/N 83331 to Present)
- 3.5 Torque Hub
- 3.6 Wheel Drive Assembly, 4WD
- 3.7 Torque Hub (4WD Machines W/ Integral Brake)
- Roll, Leak and Brake Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Input Carrier Disassembly
- Output Carrier Disassembly
- Housing-Spindle Disassembly
- Spindle-Brake Disassembly
- Input Carrier Sub-Assembly
- Output Carrier Sub-Assembly
- Spindle-Brake Sub-Assembly
- Housing-Spindle Sub-Assembly
- DW2B Integral Brake Check
- Main Assembly
- 3.8 Drive Brake, 2WD - Mico (Prior to S/N 83331)
- 3.9 Re-Aligning torque hub input coupling
- 3.10 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.11 Swing Drive Hub
- 3.12 Swing Brake - Mico (Prior to S/N 66417)
- 3.13 Swing Motor (Prior to S/N 66417)
- 3.14 Swing Motor (S/N 66417 to Present)
- 3.15 Procedure For Setting Gear Backlash
- 3.16 Swing Bearing
- 3.17 Rotary Coupling
- 3.18 Generator
- 3.19 Ford EFI Engine
- 3.20 Deutz EMR 2 (S/N 85332 to Present)
- 3.21 GM Engine General Maintenance
- 3.22 GM Engine Dual Fuel System
- Fuel Filter
- Electric Lock Off
- EPR Assembly
- Low Pressure Regulator (LPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Engine Control Module
- 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
- 3.23 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Electronic Pressure Regulator (EPR) Assembly Replacement
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Electronic Throttle Control Replacement
- Mixer Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.24 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- Section 6. JLG Control System
- Section 7. Basic Electrical information & schematics
SECTION 3 - CHASSIS & TURNTABLE
3121139 – JLG Lift – 3-107
Wear Tolerance
1. From the underside of the machine, at rear center,
with the main boom fully elevated and fully retracted,
and tower boom stowed, as shown in Figure 3-57.,
Swing Bearing Tolerance Boom Placement. (Sheet 1
of 2), using a magnetic base dial indicator, measure
and record the distance between the swing bearing
and turntable. See Figure 3-60., Swing Bearing Tol-
erance Measuring Point.
2. At the same point, with the main boom at horizontal
and fully extended, and the tower boom fully ele-
vated and fully retracted as shown in Figure 3-58.,
Swing Bearing Tolerance Boom Placement.(Sheet 2
of 2). Using a magnetic base dial indicator, measure
and record the distance between the swing bearing
and turntable. See Figure 3-60., Swing Bearing Tol-
erance Measuring Point.
3. If a difference greater than 0.079 in. (2.00 mm) is
determined, the swing bearing should be replaced.
4. If a difference less than 0.079 in. (2.00 mm) is deter-
mined, and any of the following conditions exist, the
bearing should be removed, disassembled, and
inspected for the following:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble
and return to service.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON
AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING
ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE
OF THIS, PROPER MAINTENANCE OF THE SWING BEARING
BOLTS IS A MUST FOR SAFE OPERATION.
Swing Bearing Removal
1. From Ground Control station, operate the boom
adequately to provide access to frame opening to
rotary coupling.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING
BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD
SLING SUPPORT AND/OR BLOCKING.
2. Attach an adequate support sling to the boom and
draw all slack from sling. Prop or block the boom if
feasible.
3. From inside turntable, remove mounting hardware
which attach rotary coupling retaining yoke brackets
to turntable.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
4. Tag and disconnect the hydraulic lines from the fit-
tings on the top of the rotary coupling. Use a suit-
able container to retain any residual hydraulic fluid.
Immediately cap lines and ports.
5. Attach suitable overhead lifting equipment to the
base of the turntable weldment.
6. Use a suitable tool to scribe a line on the inner race
of the swing bearing and on the underside of the
turntable. This will aid in aligning the bearing upon
installation. Remove the bolts and washers which
attach the turntable to the bearing inner race. Dis-
card the bolts.
7. Use the lifting equipment to carefully lift the com-
plete turntable assembly from the bearing. Ensure
that no damage occurs to the turntable, bearing or
frame-mounted components.
Figure 3-59. Swing Bolt Feeler Gauge Check.
Figure 3-60. Swing Bearing Tolerance Measuring Point.