Service Manual Instruction Manual
Table Of Contents
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires And Wheels
- 3.2 Torque Hub
- Oil Information
- Roll and Leak Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Output Carrier Disassembly
- Input Carrier Disassembly
- Hub-Spindle Disassembly
- Spindle-Brake Disassembly
- Cover Disassembly
- Cover Assembly
- Input Carrier Sub-Assembly
- Output Planet Gear Sub-Assembly
- Spindle - Brake Sub-Assembly
- Hub-Spindle Sub-Assembly
- Cover Sub-Assembly
- Main Assembly
- Integral Brake Check
- 3.3 Free Wheeling Option
- 3.4 Drive Motor
- 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.6 Steer Adjustments
- 3.7 Swing Drive
- 3.8 Swing Bearing
- 3.9 Swing Brake - Mico
- 3.10 Rotary Coupling
- 3.11 Generator
- 3.12 Deutz D2.9 L4 Engine
- 3.13 Deutz D2011 Engine
- 3.14 Spark Arrester Cleaning Instructions
- 3.15 Glow Plugs
- 3.16 Deutz EMR 2
- 3.17 Bio Fuel in Deutz Engines
- 3.18 GM Engine General Maintenance
- 3.19 GM Engine Dual Fuel System
- Fuel Filter
- Direct Electronic Pressure Regulator (DEPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Electric Lock Off
- Engine Control Module (ECM)
- 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
- 3.20 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
- Check/Drain Oil Build-Up In 2-Stage Vaporizer
- Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
- Exhaust System And Catalytic Converter Inspection And Maintenance
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Throttle Body (ETC) Replacement
- Mixer Replacement
- Electronic Pressure Regulator (EPR) Replacement
- Regulator Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.21 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- 5.1 O-Ring Lubrication
- 5.2 Cylinders - Theory of Operation
- 5.3 Cylinder Checking Procedure
- 5.4 Cylinder Removal and Installation
- Cylinder Locations
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Boom Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- 5.5 Hydraulic Cylinder repair
- Tower Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Upright Level Cylinder
- Cleaning and Inspection
- Assembly
- Master Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Tower Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Platform Level (Slave) Cylinder
- Cleaning and Inspection
- Assembly
- Jib Lift Cylinder (AJ Only)
- Cleaning and Inspection
- Assembly
- Steer Cylinder
- Cleaning and Inspection
- Assembly
- Axle Lockout Cylinder
- 5.6 Hydraulic Pump (Gear)
- 5.7 Variable Pump
- 5.8 Hydraulic Component Start-Up
- 5.9 Pressure Setting Procedures
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics
SECTION 3 - CHASSIS & TURNTABLE
3-40 – JLG Lift – 3121616
Motor and Brake Assembly
1. Insert Stator (8K) (O.D. lobes) in bore of Brake Housing
(6). Alternate Rotors (8J) (I.D. splines) and Stators, ending
with a Stator (8K).
2. Grease O-rings (8F) & (8D) and Back-up rings (8H) & (8E).
Place them in their respective grooves in Brake Housing
(6) and Piston (8A). Make sure Back-up rings are correctly
positioned.
3. Apply grease sparingly to Piston O.D. (8A) and bore of
Brake Housing (6). Insert Piston (8A) in Brake Housing (6).
Do not damage O-rings.
4. Install Springs (8L) in Piston (8A) spring pockets.
5. Test brake and perform roll test. Remove Brake Test
Plate.
6. Install O-ring (26) on pilot of Motor (31). Use grease to
keep O-ring in place.
7. Place Motor (31) in Brake pilot and line up holes. Check
timing sheet.
8. Assemble Lift Lugs (28) on Hex Bolts (29). Assemble Hex
Bolts (29) with Lift Lugs (28) through Motor (31) and
Brake (6) against Motor flange. Torque to 80-100 ft-lb
(108-135 Nm).
Figure 3-55. Motor and Brake Assembly
Motor Control Valve Assembly
1. Lay assembly down with motor ports facing up. Remove
two plastic plugs in the motor ports. Do not to lose O-
ring in each port. Assemble Motor control Valve (32) on
Motor (31) with Bolt (21) and Lock Washers (22). Torque
Bolts (21) to 23-27 ft-lb (31-36 Nm).
NOTE: Align holes in control valve with motor ports.
2. Install Elbow Fittings (30) in Brake (6). Do not tighten jam
nuts.
3. Install Elbow Fittings (30) in Motor Control Valve (32). Do
not tighten jam nuts.
4. Assemble Tube (35) in Elbow Fittings (30). Torque jam
nuts to 13-15 ft-lb (17-20 Nm).
5. Install one O-ring Plug (23) in Motor Control Valve (32).
Torque to 30-31 ft-lb (40-42 Nm).
6. Pressure test brake, tube, and control valve connections
by applying 3000 psi (207 bar) pressure to open port in
Motor Control Valve (32) and holding for one minute.
Check for leaks at control-valve-motor interface and
tube connections. Release pressure and install remain-
ing O-ring Plug (23) in Motor Control Valve (32). Torque
to 30-31 ft-lb (40-42 Nm).
Figure 3-56. Motor Control Valve Assembly
6
8K
8J
8K
8K
8K
8K
8J
8J
8J
8H
8F
8D
8E
8A
8L
26
31
28
29
Brake Port
31
1P
35
32
23
22
21
6