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 – 3-19
BALL GUIDE AND SLIPPER RETAINER
Inspect the ball guide and slipper retainer for damage,
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not reuse.
VALVE PLATE
The condition of the valve plate is critical to the efficiency
of the motor. Inspect the valve plate surfaces carefully for
excessive wear, grooves, or scratches. Replace or resur-
face grooved or scratched valve plates. Measure the valve
plate thickness and replace if worn beyond the minimum
specification. Valve plates may be resurfaced to the speci-
fications shown in the drawing, provided resurfacing will
not reduce the thickness below the minimum specifica-
tion.
SWASHPLATE AND JOURNAL BEARINGS
Inspect the running face, servo ball-joint, and swashplate
journal surfaces for damage or excessive wear. Some
material transfer may appear on these surfaces and is
acceptable providing the surface condition meets specifi-
cations shown. Measure the swashplate thickness from
the journals to the running face. Replace swashplate if
damaged or worn beyond minimum specification.
Replace swashplate if the difference in thickness from one
side to the other exceeds specification.
Inspect the journal bearings for damage or excessive
wear. Replace journal bearings if scratched, warped, or
excessively worn. The polymer wear layer must be
smooth and intact.
SHAFT BEARINGS
Inspect bearings for excessive wear or contamination.
Rotate the bearings while feeling for uneven movement.
Bearings should spin smoothly and freely. Replace bear-
ings that appear worn or do not rotate smoothly.
SHAFT
Inspect the motor shaft. Look for damage or excessive
wear on the output and block splines. Inspect the bearing
surfaces and sealing surface. Replace shafts with dam-
aged or excessively worn splines, bearing surfaces, or
sealing surfaces.
Slipper retainer
Ball guide
3.83 mm [0.151 in] min.
0.025 mm
[0.001 in]
0.0076 mm
[0.00030 in]
convex max
LV
25.8 mm
[1.015 in]
24.6 mm
[0.969 in]
KV
Thickness equality
side to side:
0.05 mm [0.002 in]
0.0025 mm
[0.0001 in]