Jlg 40H Service Manual User Manual Page 103
- Page / 152
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 2 - PROCEDURES
3120240 – JLG Lift – 2-83
2.32 DRIVE BRAKE, MICO. (MACHINES BUILT
FROM S/N 33476 TO PRESENT)
(SEE FIGURE 2-46.)
Disassembly.
1. Remove end cover 2 from housing 19 by removing
capscrews 1.
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
2000 POUNDS (907 KG). THE FOUR CAPSCREWS SHOULD BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP-
SCREWS.
2. Remove case seal 4 from housing 19 then remove
bleeder screw 3 from end cover 2.
3. Remove piston 7 from end cover 2.
4. Remove o-ring 5, back-up ring 6,o-ring 8,and back-
up ring 9 from piston 7.
5. Remove stack assembly, consisting of shaft 10, sta-
tors 11,return plate 13, and rotors 12, from housing
19.
6. Remove dowel pins 20, springs 14,15 and spring
retainer 16 from housing 19.
7. Remove retaining ring 17 from housing 19.
8. Remove shaft by pressing or using a soft mallet on
male end of shaft 10.
9. Remove retaining ring 21 and bearing 18 from shaft
10.
10. Press rotary oil seal 22 from housing 19.
Inspection.
1. Clean all parts thoroughly.
2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.
3. Discard seals and o-rings.
4. Closely inspect bearings and bearing contact sur-
faces. Replace as necessary.
NOTE: Bearings may be re-used if, after thorough inspec-
tion, they are found to be in good condition.
Assembly.
NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
1. Clean all parts thoroughly before assembly.
2. Press new rotary oil seal 22 into housing 19. Note
direction of seal.
3. Install new bearing 18 and retaining ring 21 on shaft
10.
4. Insert shaft assembly and retaining ring 17 in hous-
ing 19.
5. Insert dowel pins 20, spring retainer 16 and springs
14,15 in housing 19.
6. Position new large diameter return plate 13 in hous-
ing with tab guided by dowel pins 20 until disc rests
on springs 14,15.
DISC 11,12 AND RETURN PLATE 13 SHOULD REMAIN DRY DUR-
ING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO
CONTAMINATE DISC SURFACES.
7. Place a new friction disc 12 on shaft 10 until it con-
tacts return plate 13.
8. Add additional new discs 11 and new friction discs
12 as required to complete assembly.
9. Install new o-ring 5, new back-up ring 6, new o-ring
8 and new back-up ring 9 on piston 7. Note order of
o-rings and back-up rings. Insert piston 7 into end
cover 2 being careful not to shear o-rings or back-up
rings.
10. Install new case seal 4 in housing 19 then install
bleeder screw 3 in end cover 2.
11. Position end cover 2 on housing 19 aligning dowel
pins 20 with holes in end cover.
12. Install capscrews 1 and tighten evenly to draw end
cover 2 to housing 19. Torque capscrews to 55 ft.
lbs. (75 NM).
NOTE: If available a hydraulic press will simplify installation
of end cover on housing. Clamp cover in position
while tightening the capscrews.
13. If hydrostatic bench testing is performed on the
brake assembly, release pressure should not
exceed 2000 psi (137 Bar) unless two additional
bolts are used for supplemental clamping.
- October 11, 2001 1
- PRECAUTIONS 3
- REVISON LOG 4
- TABLE OF CONTENTS 5
- (Continued) 6
- SECTION 3 - TROUBLESHOOTING 6
- LIST OF FIGURES 6
- FIGURE NO. TITLE PAGE NO 6
- (INTENTIONAL BLANK PAGE) 8
- SECTION 1. SPECIFICATIONS 9
- 1-2 – JLG Lift – 3120240 10
- 3120240 – JLG Lift – 1-3 11
- SECTION 1 - SPECIFICATIONS 12
- Deutz F3L912/F3L1011 Engine 12
- Wisconsin VG4D Engine 12
- 1-8 – JLG Lift – 3120240 16
- 3120240 – JLG Lift – 1-9 17
- SECTION 2. PROCEDURES 21
- 2-2 – JLG Lift – 3120240 22
- 3120240 – JLG Lift – 2-3 23
- 2-4 – JLG Lift – 3120240 24
- 3120240 – JLG Lift – 2-5 25
- 2-6 – JLG Lift – 3120240 26
- 3120240 – JLG Lift – 2-7 27
- 2.9 CYLINDER REPAIR 29
- Disassembly 29
- Cleaning and Inspection 30
- Assembly 30
- 2.10 CYLINDER REMOVAL AND 32
- INSTALLATION 32
- Telescope Cylinder Removal 32
- 2-14 – JLG Lift – 3120240 34
- Inspection 36
- 3120240 – JLG Lift – 2-19 39
- 2-20 – JLG Lift – 3120240 40
- 3120240 – JLG Lift – 2-21 41
- 2-22 – JLG Lift – 3120240 42
- Linkage 43
- Mounting-Controller 44
- Power Distribution 44
- Troubleshooting 48
- 2.17 THROTTLE CHECKS AND 49
- ADJUSTMENTS - DEUTZ F2L511 49
- ENGINE. (SEE FIGURE 2-8.) 49
- 3120240 – JLG Lift – 2-33 53
- 3120240 – JLG Lift – 2-35 55
- ADJUSTMENT 78
- 2.23 SWING BEARING 79
- Wear Tolerance 80
- Installation 81
- Swing Bearing Torque Values 82
- Repair 85
- 2.26 SWING DRIVE BRAKE, MICO 91
- (MACHINES BUILT PRIOR TO MAY 91
- 1992). (SEE FIGURE 2-39.) 91
- 2-72 – JLG Lift – 3120240 92
- Bleeding 94
- 3120240 – JLG Lift – 2-75 95
- 3120240 – JLG Lift – 2-77 97
- 3120240 – JLG Lift – 2-79 99
- SECTION 2 - PROCEDURES 100
- 3120240 – JLG Lift – 2-81 101
- 3120240 – JLG Lift – 2-83 103
- 3120240 – JLG Lift – 2-85 105
- 3120240 – JLG Lift – 2-87 107
- 3120240 – JLG Lift – 2-89 109
- INSPECTION SCHEDULE 110
- 2-92 – JLG Lift – 3120240 112
- SECTION 3. TROUBLESHOOTING 113
- SECTION 3 - TROUBLESHOOTING 114
- JLG Worldwide Locations 152
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