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
3121139 – JLG Lift – 4-19
4.2 WIRE ROPE
Each day before using the machine:
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of the fly section,
which indicates loose wire ropes.
Inspection
NOTE: The pictures in this paragraph are just samples to
show the replacement criteria of the rope.
1. Inspect ropes for broken wires, particularly valley
wire breaks and breaks at end terminations.
2. Inspect ropes for corrosion.
3. Inspect ropes for kinks or abuse.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)
5. Inspect sheaves for condition of flanges. (See
Dimension Of Sheaves for proper dimension.)
6. Inspect sheaves with a groove wearout gauge for
excessive wear.
7. Ropes passing inspection should be lubricated with
wire rope lubricant before reassembly.
Three Month Inspection
1. Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays,
abuse, or any signs of abnormalities.
2. Check rope tension by deflecting the ropes by
hand...properly tensioned ropes should have little or
no movement.
Seven Year Inspection
1. Mandatory wire rope and sheave replacement.
Additional inspection required if:
a. Machine is exposed to hostile environment or
conditions.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
e. Boom exposed to electrical arc...wires may be
fused internally.
Replacement Criteria
1. Sheaves and wire rope must be replaced as sets.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
5. Sheaves failing wearout gage inspection.
6. Ropes with 6 total broken wires in one rope lay, 3 in
one strand in one rope lay, 1 valley break, or 1 break
at any end termination.
Flexing a wire rope can often expose broken wires
hidden in valleys between strands.
A kink is caused by pulling down a loop
in a slack line during improper handling,
installation, or operation.
Observe the groove so that it may be clearly seen
whether the contour of the gauge matches the
contour of the bottom of the groove.