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 5 - HYDRAULICS
5-6 – JLG Lift – 3121139
wear ring into the applicable cylinder head gland
groove.
3. Place a new “O-ring and back-up seal in the applica-
ble outside diameter groove of the cylinder head.
4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
NOTE: Upper telescope cylinder piston has an o-ring
installed inside the spacer.
6. If applicable, correctly place a new o-ring and back-
up rings in the inner piston diameter groove.
7. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as
possible.
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
9. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and mat-
ing end of rod must be free of oil.
WHEN REBUILDING THE MASTER, SLAVE, LIFT, AXLE LOCKOUT,
OR TELESCOPE CYLINDERS, APPLY LOCTITE #242 TO TAPERED
BUSHING BOLTS, THEN TIGHTEN SECURELY. (SEE TABLE 2-1 AND
2-3. TORQUE SPECIFICATIONS).
10. Install the bolts in tapered bushing using loctite
#242. (See Table 2-1 and 2-3. Torque Specifica-
tions.)
Figure 5-7. Poly-Pak Piston Seal Installation
Figure 5-8. Wiper Seal Installation
Figure 5-9. Installation of Head Seal Kit
Figure 5-10. Piston Seal Kit Installation
Figure 5-11. Tapered Bushing Installation