Jlg 40H Service Manual User Manual Page 85
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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SECTION 2 - PROCEDURES
3120240 – JLG Lift – 2-65
Repair.
1. Cover Assembly.
a. Remove two bolts (38) securing disconnect cap
(37) to cover (32) and remove cap.
b. Remove two bolts (38) securing cover cap (34)
to cover and remove cap.
c. Remove disconnect rod (36) from cap and
remove o-rings (33,35) from cover cap. Discard
o-rings.
d. If necessary, remove pipe plug (39) from cover.
e. Clean and inspect parts in accordance with
paragraph b. Replace parts as necessary.
f. If removed, screw pipe into cover.
g. Slip o-ring (33) over cover cap and against face.
h. Place o-ring (35) into cover cap internal groove.
Disconnect rod may be used to push o-ring into
groove.
i. Place cover cap into cover with large hole
located over pipe plug. Secure cover cap to
cover with two bolts.Torque bolts to 70-80 in. lbs.
(7.9-9.0 NM).
j. Place disconnect cap over cover cap with nipple
facing out and secure with two bolts. Torque
bolts to 70-80 in. lbs. (7.9-9.0 NM).
k. Turn cover over and push disconnect rod into
cover cap. Rod will be held in place by friction
from o-ring.
2. Carrier Assembly.
a. Drive anti-roll pin (24) into planet (23) using a
suitable punch.
b. Using a suitable press, press planet shaft from
carrier (22). After planet shaft is removed, drive
anti-roll pin from shaft.
c. Remove cluster gear (28) and thrust washers
(25) from carriers.
d. Remove sixteen needle rollers (26) from cluster
gear bore.
e. Remove spacer (27) from cluster gear bore and
remove second set of sixteen needle rollers (26).
f. Repeat steps (a) through (e) for remaining two
cluster gears.
g. Clean and inspect all parts in accordance with
paragraph b. Replace parts as necessary.
h. Apply a coat of grease or petroleum jelly to clus-
ter gear bore.
i. Place sixteen needle rollers into cluster gear
bore.
j. Place spacer into opposite side of cluster gear
and against needle rollers.
k. Place second set of sixteen needle rollers into
cluster gear.
l. Apply grease or petroleum jelly to tang side of
two thrust washers. Place thrust washers against
bosses in carrier with washer tang fitting into slot
in carrier outside diameter.
m. While keeping thrust washers in place, slide
cluster gear into carrier with larger gear on side
with small pin hole.
n. Line up cluster gear and thrust washers with
hole in carrier and slide planet shaft through.
Ensure chamfered side of hole in planet shaft is
lined up with pin hole in carrier.
o. Drive anti-roll pin flush into carrier hole, locking
planet shaft into place.
p. Repeat steps h through o for remaining two clus-
ter gears.
3. Input Shaft Assembly.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL AND INSTALLATION.
a. Carefully remove retaining ring 17 from input
shaft 14 and discard retaining ring.
b. Remove two spacers 17 and spring 16 from
input shaft.
c. Clean and inspect all parts in accordance with
paragraph b. Replace parts as necessary.
d. Place washer 15, spring 16, and washer 15, in
that order, onto input shaft.
e. Install retaining ring into input shaft groove to
secure spacers and spring to shaft.
Assembly.
1. Using a suitable press, press new bearing cups 5,9,
with large inside diameters facing out, into hub 8
counterbores.
2. Place bearing cone 4 into bearing cup 5 in small end
of hub.
3. Press new seal 3 into hub counterbore with flat
metal side facing in. Use a flat object to ensure that
seal is pressed evenly and is flush with hub face.
4. Lower hub onto spindle 2 with large open end up.
5. Place bearing cone 10 over end of spindle and into
bearing cup 9.
6. Place bearing shim 11 over end of spindle and
against bearing cone.
- 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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