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 – 3-117
3.19 FORD EFI ENGINE
Performing Diagnostics
1. Verify the complaint and determine if it is a deviation
from normal operation.
2. Once the complaint has been verified, preliminary
checks can be done. Conduct a thorough visual
inspection, be alert for unusual sounds or odors,
and gather diagnostic trouble code information.
3. Perform a system check that will verify the proper
operation of the system in question and check for
recent information updates.
4. If a diagnostic trouble code (DTC) is stored, contact
a JLG distributor to make an effective repair.
5. If no DTC is stored, select the symptom from the
symptom tables and follow the diagnostic path or
suggestions to complete the repair.
6. After the repair has been made and validated for
proper operation, the old part should be momen-
tarily re-installed to verify that it was indeed the
source of the problem.
If no matching symptom is available, analyze the com-
plaint and develop a plan for diagnostics utilizing the wir-
ing diagrams, technical assistance, and repair history.
Intermittent conditions may be resolved by using a check
sheet to pinpoint the circuit or electrical system compo-
nent. Some diagnostic charts contain Diagnostic Aids
which give additional information about a system. Be sure
to use all of the information that is available to you.
VISUAL/PHYSICAL ENGINE INSPECTION
CHECK
Perform a careful visual and physical engine inspection
before performing any diagnostic procedure. Perform all
necessary repairs before proceeding with additional diag-
nosis, this can often lead to repairing a problem without
performing unnecessary steps. Use the following guide-
lines when performing a visual/physical inspection check:
• Inspect engine for modifications or aftermarket equip-
ment that can contribute to the symptom; verify that all
electrical and mechanical loads or accessory equip-
ment is "OFF" or disconnected before performing diag-
nosis.
• Inspect engine fluids for correct levels and evidence of
leaks.
• Inspect vacuum hoses for damage, leaks, cracks,
kinks and improper routing, inspect intake manifold
sealing surface for a possible vacuum leak.
• Inspect PCV valve for proper installation and operation.
• Inspect all wires and harnesses for proper connections
and routing; bent or broken connector pins; burned,
chafed, or pinched wires; and corrosion. Verify that
harness grounds are clean and tight.
• Inspect engine control module (ECM), sensors, and
actuators for physical damage.
• Inspect ECM grounds for cleanliness, tightness, and
proper location.
• Inspect fuel system for adequate fuel level, and fuel
quality (concerns such as proper octane, contamina-
tion, winter/summer blend).
• Inspect intake air system and air filter for restrictions.
• Inspect battery condition and starter current draw.
If no evidence of a problem is found after visual/physical
engine check has been performed, proceed to MIL DTC
retrieval procedure.
EFI Diagnostics
The EFI diagnostics are designed to assist in locating a
faulty circuit or component. When a malfunction is
detected by the Engine Control Module (ECM), a diagnos-
tic trouble code (DTC) is set and will be displayed on the
JLG Control System Analyzer. Refer to Section 6 - JLG
Control System.
CLEARING TROUBLE CODES
To clear the trouble codes from the ECM, the electrical
current running to the ECM must be shut off. To do this,
disconnect the negative terminal from the battery for a
period of approximately 15 minutes.