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 3 - CHASSIS & TURNTABLE
3-62 – JLG Lift – 3121139
3.8 DRIVE BRAKE, 2WD - MICO (PRIOR TO
S/N 83331)
Disassembly
1. Remove pressure plate (3) from cover plate (16) by
removing cap screws (1) and washers (2).
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI-
MATELY 907 KGF (2000 IBS). THE TWO CAP SCREWS MUST BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE, 1361 KGF (3000 IBS) MINIMUM, THE
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING
THE CAP SCREWS. COVER PLATE (16) MUST BE SUPPORTED AS
SHOWN IN FIGURE 3-50.
2. Remove case seal (4) from cover plate (16).
3. Remove piston (7) from pressure plate (3).
4. Remove O-ring (5), back-up ring (6), O-ring (8) and
back-up ring (9) from piston (7).
5. Remove stator disc (11), rotor disc (12) and return
plate (13) from cover (16).
NOTE: Not all models use the same number of springs or
spring pattern.
6. Remove dowel pins (15) and springs (14) from cover
plate (16). Record this information for assembly pur-
poses.
7. Remove retaining ring (19) from cover plate (16).
8. Remove shaft (10) by pressing or using a soft mallet
on male end of shaft (10).
NOTE: Cover plate (16) must be supported as shown in FIG-
URE 3-50.
9. Remove retaining ring (20) from cover plate (16) and
press out oil seal (17) and bearing (18) if required.
NOTE: Cover plate (16) must be sup¦ported as indicated in
Figure 3-50.
Assembly
LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH
CLEAN TYPE FLUID USED IN THE SYSTEM.
1. Use an alkaline wash to clean parts before assem-
bly.
2. Press oil seal (17) into cover plate (16) until it is flush
with bearing shoulder. Note direction of seal.
3. Press bearing (18) into position until it bottoms out
on borestep.
NOTE: Cover plate (16) must be supported as indicated in
Figure 1.
4. Install retaining ring (20) in cover plate (16).
5. Press shaft (10) into bearing (18) until it bottoms on
shoulder.
NOTE: Bearing (18) inner race and cover plate (16) must be
supported as indicated in Figure 1 during this opera-
tion.
6. Install retaining ring (19) on shaft (10).
7. Insert dowel pins (15) and springs (14) in cover plate
(16).
NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
8. Position return plate (13) on springs (14).
NOTE: Discs (11 & 12) and return plate (13) must remain
dry during installation. No oil residue must be
allowed to contaminate disc surfaces.
9. Install rotor disc (12) and stator disc (13).
10. Install o-ring (5), back-up ring (6), O-ring (8) and
back-up ring (9) on piston (7). Note order of O-rings
and back-up rings. Insert piston (7) into pressure
plate (3).
NOTE: Be careful not to shear o-rings or back-up rings. Be
careful not to scratch or mar piston.
11. Install new case seal (4) in cover plate (16).
12. Position pressure plate (3) on cover plate (16) align-
ing dowel pins (15) with holes in pressure plate.
13. Install cap screws (1) and washers (2) and tighten
evenly to draw pressure plate (3) to cover plate (16).
Torque cap screws 65.1-67.8 N-m (48-50 Ib-ft).
NOTE: A hydraulic press will simplify installation of pressure
plate on cover. Clamp pressure plate in position
while tighten¦ing the cap screws. Cover plate (16)
must be supported as indicated in Figure 3-50.
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED
134.5 BAR (500 PSI).