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
3-64 – JLG Lift – 3121139
Bleeding
1. Install brake in system and connect pressure lines.
2. Bleed pressure release section of brake by pressur-
izing side inlet port and allowing air to escape from
top port. Pressure should not exceed 6.9 bar (100
psi) during bleeding.
3. Apply sufficient pressure to release brake and check
for proper operation in system.
Table 3-8. Troubleshooting
PROBLEM CAUSE EXPLANATION ACTION
Brake slips Excessive pressure in hydraulic system If there is back pressure in the actuation
line of the brake, holding torque will be
reduced.
Check filters, hose size, restrictions in
other hydraulic components.
Oil in brake if designed for dry use Wet linings generate 67% of the dry
torque rating. If the brake has oil in it,
check the type of oil hydraulic or gearbox.
1 . Gearbox oil
2. Hydraulic oil
Replace oil seal in brake.
Check motor seal
Check piston seals
NOTE: Internal components will
need to be inspected,
cleaned and replaced as
required.
Disc plates worn The thickness of the disc stack sets the
torque level. A thin stack reduces torque.
Check disc thickness.
Springs broken or have taken a perma-
nent set
Broken or set springs can cause reduced
torque - a rare occurrence.
Check release pressure. (See spring
replacement).
Brake drags or runs hot Low actuation pressure The brake should be pressurized to mini-
mum of 1.38 bar (20 psi) over the full
release pressure under normal operating
conditions. Lower pressures will cause
the brake to drag thus generating heat.
Place pressure gauge in bleed port &
check pressure with system on.
Bearing failure If the bearing should fail, a large amount of
drag can be generated.
Replace bearing.
Brake will not release Stuck or clogged valve Brakes are designed to come on when
system pressure drops below stated
release pressure. If pressure cannot get to
brake, the brake will not release.
Place pressure gauge in bleed port -
check for adequate pressure. Replace
inoperative line or component.
Bad o-rings If release piston will not hold pressure,
brake will not release.
Replace o-rings.
Discs frozen These brakes are designed for only lim-
ited dynamic braking. A severe emer-
gency stop or prolonged reduced release
pressure operation may result in this type
of damage.
Replace disc stack.