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
3-14 – JLG Lift – 3121139
Disassembly
NOTE: Removal of the endcap voids warranty.
During assembly, coat all moving parts with a film of
clean hydraulic oil. This assures that these parts will
be lubricated during start-up.
Replace all O-Rings and gaskets.
It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.
1. Using a 11/16 in wrench remove plug (1) and (2).
2. Using a 5/8 in hex wrench remove plug (3).
3. Remove O-rings (4, 5, and 6).
4. Using pliers, remove centering springs (7, 8, and 9).
5. Remove spring retaining washers (10 and 11).
6. Remove shift spool (12).
7. Remove orifice poppet (13).
8. Remove all fittings from the unit. Discard any O-rings
on the fittings.
9. Using an 11/16 inch hex wrench, loosen the speed
sensor lock nut (14) if equipped. Then remove the
speed sensor using a Vi inch hex wrench. Units with-
out speed sensor have an O-ring plug (15) installed
in that location; remove it with a Va inch internal hex
wrench.
10. Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm
hex wrench, remove cavity plug (18, if equipped with
two-line control) from X2 cavity.
11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.
12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard
O-rings.
5
3
7
13
2
6
9
11
1
4
8
10
12
1. Plug
2. Plug
3. Plug
4. O-ring
5. O-ring
6. O-ring
7. Spring
8. Spring
9. Spring
10. Washer
11. Washer
12. Shift Spool
13. Orifice Poppet
Figure 3-6. Loop Flushing Spool
15
20
16
16
19
17
18
21
14
14. Lock Nut
15. O-ring Plug
16. Control Line Plug
17. Control Line Plug
18. Cavity Plug
19. Drain Plug
20. Drain Plug
21. Work Port Plug
Figure 3-7. Plugs, Fittings, and Speed Sensor