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
3-80 – JLG Lift – 3121139
17. A metal plug, with seal, plugs a machining hole in
the housing. It is not necessary to remove plug and
replace seal unless leakage occurs around plug. To
remove plug, insert 5 mm (.187 in.) hex key through
port opening and push it out. The 009 plug is not
interchangeable with 007 and 008 plugs.
Inspection and Cleaning
Check all mating surfaces. Replace any parts with
scratches or burrs that could cause leakage or damage.
Clean all metal parts in clean solvent. Blow dry with air. Do
not wipe parts with cloth or paper towel because lint or
other matter could get into the hydraulic system and
cause damage.
Check around key slot and chamfered area of shaft for
burrs, nicks or sharp edges that could damage seals dur-
ing reassembly. Remove nicks or burrs with hard smooth
stone (such as an Arkansas stone). Do not file or grind
motor parts.
NOTE: Lubricate all seals with petroleum jelly. Use new
seals when reassembling motor.
DO NOT STRETCH SEALS BEFORE INSTALLING THEM.
Cleanliness is extremely important in the successful appli-
cation of Loctite. Before Loctite can be applied, the parts
should be cleaned as follow:
NOTE: Fully cured Loctite resists most solvents, oils, gaso-
line and kerosene and is not affected by cleaning
operations. It is not necessary to remove cured Loc-
tite that is securely bonded in tapped holes; however,
any loose particles of cured Loctite should be
removed.
a. Wash the housing with solvent to remove oil,
grease and debris. Pay particular attention to
four tapped holes on flanged end.
b. Blow dry with compressed air. Clean and dry
tapped holes.
c. Wire brush screw threads to remove cured Loc-
tite and other debris. Discard any screws that
have damaged threads or rounded heads.
d. Wash screws with non-petroleum base solvent.
Blow dry with compressed air.
Assembly
SHAFT END
1. If you remove plug and seal, lubricate seal and
install on plug. Some plugs have two o-ring grooves
but require only one o-ring. Install o-ring in groove
closest to end of plug. Push plug into housing. Be
careful not to damage seal.