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
3-44 – JLG Lift – 3121139
Output Carrier Sub-Assembly
1. Place Spring (4I) into the deep counterbore of the
Output Carrier (4A).
2. Place Washer (4J) on top of Spring (4I).
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
3. With Retaining Ring (4K) installed on snap ring pli-
ers, place on top of Washer (4J) and compress
Spring (4I) until Retaining Ring (4K) is seated com-
pletely in groove.
4. Apply a liberal coat of grease to the bore of one Out-
put Planet Gear (4F).
5. Line the inside of the Planet Gear (4F) with 15 Nee-
dle Rollers (4C).
NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in
between the ends of the two rollers that form the
space, and then slid, parallel to the other rollers, into
place.
6. Place Thrust Washer (4H) into the shallow counter-
bore of the Output Carrier (4A).
7. Set Carrier (4A) in an upright position.
8. Insert a Planet Shaft (4E) into one of the planet shaft
holes on the Carrier (4A). The end of the planet shaft
that does NOT have the roll pin hole should be
inserted in the carrier FIRST.
9. Place one Thrust Washer (4B) onto the end of Planet
Shaft (4E). Make sure the flat faces towards the
inside of the carrier and make sure the button fits in
the pocket inside the Carrier (4A).
10. Following the thrust washer, place Planet Gear (4F)
with needle rollers, onto Planet Shaft (4E).
11. Following the planet gear, place one more Thrust
Washer (4B) onto Planet Shaft (4E). Align the Thrust
Washer (4B) in the same manner described in Step
6.
12. Now insert Planet Shaft (4E) through the opposite
planet shaft hole on Carrier (4A). Use an alignment
punch or similar tool to align the roll pin holes on
Carrier (4A) and Planet Shaft (4E).
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
13. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with OD of carrier.
14. Repeat Steps 4,5, & 8-13 for the installation of the
two remaining Planet Gears (4F).