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
3-124 – JLG Lift – 3121139
ELECTROSTATIC DISCHARGE DAMAGE
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic compo-
nents are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can
cause damage to some electronic components. By com-
parison, It takes as much as 4000 volts for a person to feel
the spark of a static discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and induction.
An example of charging by friction is a person sliding
across a seat.
Charge by induction occurs when a person with well-insu-
lated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same polar-
ity are drained off, leaving the person highly charged with
the opposite polarity. Static charges can cause damage,
therefore it is important to-use care when handling and
testing electronic components.
To prevent possible electrostatic discharge damage, fol-
low these guidelines:
• Do not touch the ECM connector pins or soldered
components on the ECM board.
• Do not open the replacement part package until the
part is ready to be installed.
• Before removing the part from the package, ground
the package to a known good ground on the equip-
ment.
• If the part has been handled while sliding across a
seat, while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
Fuel System
FUEL INJECTOR
The Electronic Fuel Injection (EFI) fuel injector is a sole-
noid-operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow fuel
delivery.
The fuel is injected under pressure in a conical spray pat-
tern at the opening of the intake valve. Excess fuel not
used by the injectors passes through the fuel pressure
regulator before being returned to the fuel tank.
A fuel injector which is stuck partly open will cause a loss
of fuel pressure after the engine is shut down, causing
long crank times.
FUEL METERING SYSTEM COMPONENTS
The fuel metering system is made up of the following
parts:
•The fuel injectors
•The fuel rail
• The fuel pressure regulator/filter assembly
• The electronic governor
•The ECM
• The crankshaft position (CKP) sensor
• The camshaft position (CMP) sensor
•The fuel pump
• The fuel pump relay
BASIC SYSTEM OPERATION
The fuel metering system starts with the fuel in the fuel
tank. The fuel is drawn up to the fuel pump through a pre-
filter. The electric fuel pump then delivers the fuel to the
fuel rail through an inane fuel filter. The pump is designed
to provide fuel at a pressure above the pressure needed
by the injectors. A fuel pressure regulator in the fuel filter
assembly keeps fuel available to the fuel injectors at a
constant pressure. A return line delivers unused fuel back
to the tank.