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 – 3-25
20. Install orifice poppet (30).
21. Install shift spool (31).
22. Install spring retaining washers onto springs (32 and
33).
23. Carefully install centering springs (34, 35, and 36).
24. Install new O-rings (37, 38, and 39).
25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs.
(27 Nm).
26. Using a 11/16 in wrench, torque plugs (41 and 42) to
27 ft.lbs. (37 Nm).
Initial Start-up Procedures
Follow this procedure when starting-up a new motor or
when installing a motor that has been removed.
Prior to installing the motor, inspect for damage incurred
during shipping. Make certain all system components
(reservoir, hoses, valves, fittings, heat exchanger, etc.) are
clean prior to filling with fluid.
1. Fill the reservoir with recommended hydraulic fluid.
Always filter fluid through a 10 micron filter when
pouring into the reservoir. Never reuse hydraulic
fluid.
2. Fill the inlet line leading from the pump to the reser-
voir. Check the inlet line for properly tightened fit-
tings and be certain it is free of restrictions and air
leaks.
3. Fill the pump and motor housing with clean hydrau-
lic fluid. Pour filtered oil directly into the upper most
case drain port.
4. To ensure the pump and motor stay filled with oil,
install case drain lines into the upper most case
drain ports.
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the
charge pressure gauge port of the pump to monitor
system pressure during start up.
6. While watching the pressure gauge, run the engine
at the lowest possible speed until system pressure
builds to normal levels (minimum 160 psi [11 bar]).
Once system pressure is established, increase to full
operating speed. If system pressure is not main-
tained, shut down the prime mover, determine
cause, and take corrective action.
7. Operate the hydraulic system for at least fifteen min-
utes under light load conditions.
8. Check and adjust control settings as necessary after
installation.
9. Shut down the prime mover and remove the pres-
sure gauge. Replace plug at the charge pressure
gauge port.
10. Check the fluid level in the reservoir; add clean fil-
tered fluid if necessary. The motor is now ready for
operation.
39
40
34
30
41
37
36
33
42
38
35
32
31
(27 Nm)
20 ft.lbs.
5/8 in
(37 Nm)
(37 Nm)
27 ft.lbs.
27 ft.lbs.
11/16 in
11/16 in
30. Orifice Poppet
31. Shift Spool
32. Spring
33. Spring
34. Spring
35. Spring
36. Spring
37. O-ring
38. O-ring
39. O-ring
40. Plug
41. Plug
42. Plug
Figure 3-25. Loop Flushing Spool