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
3-154 – JLG Lift – 3121139
Coolant Hose Replacement
REMOVAL
1. Drain the coolant.
2. Using hose clamp pliers, disconnect both hose
clamps on each hose.
3. Remove the hose from each of the fittings.
INSTALLATION
NOTE: Use hose material and lengths specified by JLG.
1. Install the hose clamps to each hose and set the
clamp back on each hose to make installation eas-
ier.
2. Fit the hose to the fittings.
3. Secure by positioning each of the clamps.
Vapor Hose Replacement
REMOVAL
1. Using hose clamp pliers disconnect both hose
clamps.
2. Remove the vapor hose from each fitting.
INSTALLATION
THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT
USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED
PARTS.
1. Install hose clamps and set back on each hose.
2. Reinstall the vapor hose to each fitting.
3. Reset clamps.
4. Start engine and check for leaks.
Engine Control Module Replacement
REMOVAL
1. Disconnect Negative battery cable.
2. Remove controller from mounting bracket.
3. Push connector lock back to unlock connector.
4. Unplug controller and remove.
INSTALLATION
THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY
YOU HAVE THE CORRECT CONTROLLER
1. Plug connector into controller.
2. Push lock into place.
3. Mount controller into mounting bracket.
4. Reconnect the battery cable.
5. Start engine.
6. Check for any DTC codes and clear.
7. Verify engine is in closed loop and no warning lights
are illuminated.
Heated Exhaust Gas Oxygen Sensor
Replacement
REMOVAL
1. Disconnect Negative battery cable.
2. Disconnect the O2 sensor electrical connector.
3. Using an O2 Sensor socket, remove the O2 Sensor
and discard.
INSTALLATION
BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH
ANTI-SEIZE COMPOUND GM P/N 5613695 OR EQUIVALENT.
AVOID GETTING COMPOUND ON THE SENSOR TIP.
1. Install O2 sensor. Tighten to 30 lb-ft (41 Nm).
2. Start engine.
3. Check for any DTC codes and clear.
4. Verify engine is in closed loop and no warning lights
are illuminated.