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 1 - SPECIFICATIONS
1-12 – JLG Lift – 3121139
INSTALLATION
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-
ING BEFORE INSTALLING NEW SEAL
1. Install the mounting plate to lock off O-ring seal.
2. Install the retaining bolt seal.
3. Install the housing seal.
4. Drop the magnet into the bottom of the filter hous-
ing.
5. Install the filter into the housing.
6. Install the retaining bolt into the filter housing.
7. Install the filter up to the bottom of the electric lock
off.
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).
9. Open manual shut-off valve. Start the vehicle and
leak check the propane fuel system at each serviced
fitting. Refer to Propane Fuel System Leak Test.
Propane Fuel System Pressure Relief
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
SURE (WHERE APPLICABLE) BEFORE SERVICING THE
PROPANE FUEL SYSTEM COMPONENTS.
To relieve propane fuel system pressure:
1.Close the manual shut-off valve on the propane fuel
tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
BEFORE DISCONNECTING ANY FUEL LINE.
1.12 SERIAL NUMBER LOCATION
A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing,
the machine serial number is stamped on the left side of
the frame.
Figure 1-3. Serial Number Locations