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
3-46 – JLG Lift – 3121139
Spindle-Brake Sub-Assembly
NOTE: This procedure applies only to units with integral
input brake (2).
NOTE: For this procedure, use the Brake Assembly Drawing
(Figure 3-36.), which will show the proper balloon
numbers for the individual brake components. In the
following instructions, if the number has a “-”
between two numbers, it refers to the Brake Assem-
bly Drawing only and NOT the Torque Hub Assembly
Drawing.
NOTE: The Pressure Plug (12) requires a special tool for
installation. It is not recommended to remove this
plug unless it is leaking. The plug is called a Koenig
Expander. The installation tool is not supplied by
Fairfield manufacturing, but can be supplied by the
manufacturer of the Koenig Expander, Sherex Indus-
tries, or one of their distributors.
1. Install Pressure Plug (12) into Spindle (1A) using fol-
lowing procedure:
• Clean hole in spindle using appropriate Loctite spray
• Dip collar of plug in Loctite 290 or 680 (keep
unplugged portion of hole free of Loctite)
• Using appropriate tool, install plug flush with surface of
spindle
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
2. Place Spindle (1A) such that the splined end is fac-
ing down. Using appropriate tool (See back of man-
ual), install Retaining Ring (2-1) into the spindle
groove within the splines.
3. Place Washer (2-10) on top of Retaining Ring (2-1).
4. Place Stator (2-9) on top of Washer (2-10).
5. Place Rotor (2-12) on top of Stator (2-9).
6. Repeat steps 3 & 4 until there are a total of 8 Stators
(2-9) and 7 Rotors (2-12) installed.
7. Place Piston (2-8) such that the smaller O.D. end is
facing upward.
8. Grease the large Backup Ring (2-3) and install in the
large-diameter groove at the bottom of the Piston (2-
8).
9. Grease the large O-Ring (2-2) and install in the
large-diameter groove at the bottom of the Piston (2-
8), on top of the large Backup Ring (2-3).
10. Grease the small O-Ring (2-5) and install in the
small-diameter groove near the top of the Piston (2-
8). Make sure the O-Ring is seated on the bottom of
the groove.
11. Grease the small Backup Ring (2-4) and install in the
small-diameter groove near the top of the Piston (2-
8), on top of the small O-Ring (2-5).
NOTE: If piston comes pre-assembled with shipping bolts
(2-11), skip to Step 15.
12. Insert Piston (2-8) into Spindle (1A) until it contacts
the Stator (2-9).
13. Insert the appropriate number of Springs (2-13) into
Piston (2-8) counterbore. Use the brake spring chart
below and a bill of materials for your particular
model number to determine the number of springs.
14. Place Pressure Plate (2-7) on top of Springs (2-13).
SAFETY GLASSES MUST BE WORN DURING THE NEXT TWO
STEPS.
15. Using snap ring pliers, install Retaining Ring (2-6)
into groove in Spindle (1A) and on top of Pressure
Plate (2-7). Make sure that Retaining Ring (2-6) is
seated properly in the groove.
16. Remove Shipping Bolts (2-11) in brake pressure
plate to release springs in brake. Before removing
bolts, use the Coupling (9) (See Assembly Drawing
at back of manual) to center and align the Brake
Rotors (2-12) with the Spindle (1A).
BRAKE
CODE
BRAKE P/N
NUMBER
OF SPRINGS
A 902337 12
B 902341 10
C 902342 8
D 902343 6
E 902345 9