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 4 - BOOM & PLATFORM
4-14 – JLG Lift – 3121139
Installation
1. Using a suitable lifting device, position boom
assembly on upright so that the pivot holes in both
boom and upright are aligned.
2. Install boom pivot pin, ensuring that location of hole
in pin is aligned with attach point on upright.
3. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.
4. Connect all wiring to the ground control box.
5. Connect all hydraulic lines running along side of
boom assembly.
6. Using all applicable safety precautions, operate lift-
ing device in order to position boom lift cylinder so
that holes in the cylinder rod end and boom struc-
ture are aligned. Insert the lift cylinder pin, ensuring
that location of hole in pin is aligned with attach
point on boom.
7. Align holes in boom structure with hole in master
cylinder. Insert the master cylinder pin, ensuring that
location of hole in pin is aligned with attach point on
boom.
8. Adjust retract and extend cables to the proper
torque. Refer to Section 4.3, Boom Rope Torquing
Procedures.
9. Using all applicable safety precautions, operate
machine systems and raise and extend boom fully,
noting the performance of the extension cycle.
10. Retract and lower boom, noting the performance of
the retraction cycle.
Telescope Cylinder/Boom Cable Removal
1. Make sure the machine is on a firm, level surface.
2. Raise the boom to a horizontal position.
3. Extend the boom approximately 2 feet (0.6 m). This
will enable access to the bolts that secure the cable
mount block to the boom fly section.
4. Tag and disconnect all hydraulic hoses running to
the telescope cylinder. Cap or plug all openings to
prevent any foreign matter from entering the hydrau-
lic system.
5. Using a 3/8 drive extension approximately 4 feet (1.2
m) long, remove the bolts and washers securing the
cable mount block to the boom fly section.
6. Remove the four bolts, shims, and attachment
blocks that secure the telescope cylinder barrel to
the boom mid section.