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 – 3-165
Ignition System Checks Verify that the spark plugs are correct for use with LPG (R42LTS)
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks Check the engine thermostat for always being open or for the wrong heat range
Additional Check Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition
may be severe enough to stall the engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating.
The sensor will result in a high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel
delivered to the engine causing a severe driveability problem.
Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring
the oxygen sensors will help identify the problem.
Check for a sticking mixer air valve.
Verify proper operation of the EPR.
Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
Check mixer module assembly for proper installation and connection.
Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
Verify that the spark plugs are correct for use with LPG (R42LTS)
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over
30,000 ohms, replace the wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake man-
ifold leakage than the gasoline fuel supply system.
Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
Check the ECM grounds for being clean, tight, and in their proper locations.
Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor
readings to be skewed resulting in poor idle quality.
Table 3-13. Symptom Diagnosis
Checks Action