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
3121139 – JLG Lift – 3-65
3.9 RE-ALIGNING TORQUE HUB INPUT
COUPLING
The following procedure applies to torque hubs with inte-
gral brakes.
Equipment Required
1. Hydraulic power supply (hand pump) capable of
producing 200 psi (13.8 bar).
2. Hydraulic fittings to adapt hydraulic supply to brake
release port on hub.
Procedure
1. Using appropriate fittings, connect a line from the
hydraulic power supply to the brake port.
2. Pressurize the brake release port 155 to 200 psi
(10.6 to 13.8 bar) to release the brake.
3. Verify that the brake is released by rotating the input
coupling or hub spindle.
4. Once the brake is released, the input coupling will
be free to re-align with the drive motor.
5. Install the drive motor on the hub, then release the
hydraulic pressure at the brake release port. The
coupling will remain in position.
6. Disconnect the hydraulic power supply and recon-
nect the line going into the brake release port.
3.10 OSCILLATING AXLE BLEEDING
PROCEDURE AND LOCKOUT TEST
Lockout Cylinder Bleeding
ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN-
TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PRO-
CEDURE.
ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS
ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.
1. Make sure machine is on a level surface.
2. Center boom over rear axle to make sure the cam
valve in the rotary coupling is depressed.
3. Place chocks under the tires to ensure the machine
does not move. Disable the machine brakes by dis-
connecting the brake solenoid on the dual select
valve.
4. Use suitable containers to catch any excess hydrau-
lic fluid. Place the containers under each lockout cyl-
inder.
5. Open one bleeder screws at a time.
6. Start the engine, position drive control lever on the
main hydraulic pump forward or reverse.
7. Close bleeder screws when all air is dissipated
(bled).
8. Reconnect the brake solenoid and remove the
wheel chocks.
9. Perform oscillating axle lockout test.
10. If necessary, repeat steps 1 thru 7.