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 – 3-79
13. Reposition motor in vise. Clamp across ports as
shown above. Do not clamp side of housing. Exces-
sive clamping pressure on side of housing causes
distortion.
14. Remove cap screws from mounting flange. These
screws are assembled with Loctite to hold them in
place.
The screws will require 35-45 Nm (300 - 400 in/lbs)
of torque to break loose and 11 Nm (100 in/lbs)
torque to remove. Do not use impact wrench on
screws that have been secured with Loctite. This
could result in rounded heads or broken sockets.
NOTE: If torque higher than given above is required to break
screws loose, apply heat according to following
instructions.
NOTE: When heated, Loctite partially melts. This reduces
the torque required to remove screw. Use small
flame propane torch to heat small area of housing
where screw enters (see figure below). Be careful
not to overheat housing and damage motor. Gradu-
ally apply torque to screw with socket wrench as
heat is applied for 8 to 10 seconds. As soon as
screw breaks loose, remove heat from housing. Con-
tinue turning screw until it is completely removed.
15. Carefully remove flange from housing.
SOME MOTORS MAY HAVE A QUAD SEAL AND BACK-UP RING IN
PLACE OF THE PRESSURE SEAL. THE QUAD SEAL AND BACK-UP
RING ARE NO LONGER AVAILABLE AND ARE REPLACED BY THE
PRESSURE SEAL. THEY ARE INTERCHANGEABLE, BUT SOME
PRECAUTIONS MUST BE TAKEN TO INSURE PROPER INSTALLA-
TION. FOLLOW THE REASSEMBLY INSTRUCTIONS.
16. Exclusion seal, back-up ring, pressure seal and seal
will come off with flange. Use seal removal tool as
shown to remove exclusion and pressure seals.
BE CAREFUL NOT TO SCRATCH SEAL CAVITY O.D. THIS COULD
CREATE A LEAK PATH.