Jlg 40H Service Manual User Manual Page 97
- Page / 152
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 2 - PROCEDURES
3120240 – JLG Lift – 2-77
8. Install the power plate sub-assembly. Use a shop
press to evenly lower plate into position. There
should be no gap at the O.D. when the power plate
is properly seated against housing. If a shop press is
not available, use the assembly bolts 22. Tighten
sequentially one turn at a time until the power plate
is properly seated. Torque to 50-60 ft. lbs. (68-81
NM).
9. If replacement of pressure relief valve is necessary,
install 1/2 to 3/4 turns beyond finger tight.
10. Bleed air from brake via bleeder screw.
2.29 DRIVE BRAKE, AUSCO. (MACHINES
BUILT PRIOR TO MAY 1992) (SEE
FIGURE 2-43.)
Disassembly.
1. When shaft protruding downward, remove bolts 23
alternately and evenly to reduce spring tension.
2. Remove power plate 20, o-ring 5, stationary discs
13, springs 11, rotating discs 12, primary disc 10,
pins 9, springs 6,7 and spring retainer (if so
equipped).
3. Further disassembly is not recommended unless
necessary for the replacement of specific parts.
4. If further disassembly is required, remove snap rings
1,2, then remove shaft 8 from bearing 3 by lightly
tapping shaft with a plastic mallet.
5. Remove bearing from housing.
6. Remove piston 14 from the power plate 20 by intro-
ducing low pressure air (15 PSI) into hydraulic inlet.
Make sure piston is directed away from operator.
Remove o-rings 15,17 from the piston O.D. and I.D.
grooves. Back-up rings will be damaged and should
not be removed if replacement is not planned.
7. Bleeder 19 can be removed and inspected to assure
spring loaded ball moves freely and is free of con-
tamination.
Cleaning and 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 reused if, after thorough inspection,
they are found to be in good condition.
Assembly.
NOTE: Lubricate all seals, o-rings, cylinder of power plate
and piston with clean hydraulic oil prior to assembly.
1. Use the reverse of the disassembly procedure with
the following notes and additions.
2. Worn o-rings and damaged or worn teflon back-up
rings must be replaced prior to assembly.
3. If replacement of bleeder 19 is necessary, install 1/2
to 3/4 turns beyond finger tight.
4. Assemble piston 14 into power plate 20 using a
shop press, being careful not to damage the o-rings
or teflon back-up rings. Visually align the center of
the cutouts in the piston with the torque pin 9 holes
in the power plate.
5. Rotating discs 12 must be clean and dry, with no
presence of oil on any lining material or mating sur-
face or the stationary discs 13.
6. Install bolts 23. Tighten sequentially one turn at a
time, until power plate 20 is properly seated. Torque
to 50-60 ft. lbs. (68-81 NM).
- 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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