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 1 - SPECIFICATIONS
1-2 – JLG Lift – 3121139
1.3 CAPACITIES
1.4 COMPONENT DATA
Engine Data
Table 1-3. Capacities
Fuel Tank Approx. 31 gallons (117 liters)
Hydraulic Tank Approx. 47.8 gallons (181 liters)
Engine Oil Capacity
Fo rd
Deutz
C ooling Syst em
C rankcase
Tot al Capaci ty
Cater pil lar
GM
4.5 Quarts (4.25 L) w/Filter
5 Quarts (4.5 L)
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L)
10.6 quarts (10 L)
4.5 Quarts (4.25 L) w/Filter
Table 1-4. Ford LRG-425 Specifications
Type Water-cooled
Fuel Gasoline
Oil Capacity 4.5 Quarts (4.25 L) w/Filter
Idle RPM 1000
Low RPM 1800
High RPM 2800
Alternator 95 Amp, Belt Drive
Fuel Consumption
Low RP M
Hig h RP M
3.45 GPH (13.06 lph)
4.60 GPH (17.41 lph)
Horsepower 74 @ 3000 RPM, full load
Cooling System 16 Quarts (15.14 L)
Spark Plug AWSF-52-C
Spark Plug Gap 0.044 in. (1.117 mm)
Table 1-5. Deutz F4M2011 Specifications
Type Liquid Cooled (Oil)
Fuel Diesel
Oil Capacity
Cooli ng Syst em
Crankcase
Total Capacity
5 Quarts (4.5 L)
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L)
Idle RPM 1000
Low RPM 1800
High RPM 2800
Alternator 55 Amp, belt drive
Fuel Consumption
Low RPM
Hig h RP M
1.90 GPH (7.19 lph)
2.50 GPH (9.46 lph)
Horsepower 66 @ 3000 RPM, full load
Table 1-6. Deutz D2011L04 Specifications
Type Liquid Cooled (Oil)
Fuel Diesel
Oil Capacity
Cooli ng Syst em
Crankcase
Total Capacity
5 Quarts (4.5 L)
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L)
Idle RPM 1000
Low RPM 1800
High RPM 2600
Alternator 55 Amp, belt drive
Fuel Consumption
Low RPM
Hig h RP M
1.90 GPH (7.19 lph)
2.50 GPH (9.46 lph)
Battery 1000 Cold Cranking Amps, 210
minutes Reserve Capacity, 12 VDC
Horsepower 64 @ 2600 RPM, full load