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
4-18 – JLG Lift – 3121139
Lift Cylinder Removal
1. Elevate the boom enough to gain access to the lift
cylinder lower pivot pin.
2. Use an adequate supporting device to support the
weight of the boom and associated components as
shown below.
NOTE: The supporting device must be able to support
approximately 5350 pounds (2430 kg).
3. Tag and disconnect the hydraulic hoses from the lift
cylinder.
4. Use an adequate lifting device to support the lift cyl-
inder.
NOTE: The lift cylinder weighs approximately 618 pounds
(280 kg).
5. Remove the bolt and keeper pin securing the upper
lift cylinder pivot pin and remove the pivot pin.
6. Remove the bolt and keeper pin securing the lower
lift cylinder pivot pin and remove the pivot pin.
7. Using the lifting device, slide the lift cylinder back
enough to allow the cylinder end to clear the attach-
ment point on the boom.
8. Slide the lift cylinder sideways enough to remove it
from the machine.
Lift Cylinder Installation
1. Using an adequate lifting device, position the lift cyl-
inder in the machine in the same manner that it was
removed.
2. Install the lower pivot pin and secure it in place with
the keeper pin and bolt.
3. Connect the hydraulic lines to the cylinder as tagged
during removal.
4. Extend the cylinder rod until it aligns with the attach-
ment point on the boom. Take care not to extend the
cylinder rod too far.
5. Install the upper lift cylinder pivot pin and secure it in
place with the keeper pin and bolt.
6. Remove the supporting device and function check
the boom to make sure the lift cylinder operates
properly and there are no leaks.