Service Manual Instruction Manual

SECTION 3 - CHASSIS & TURNTABLE
3121616 – JLG Lift – 3-9
Input Carrier Sub-Assembly
1. Apply a liberal coat of grease to bore of one Input Planet
Gear (3F).
2. Line inside of Planet Gear (3F) with 14 Needle Rollers
(3C).
NOTE: The last roller installed must be installed end wise. That is,
the end of the last roller must be placed in between ends of
the two rollers which form the space, and then slid, parallel
to the other rollers, into place.
3. Set Carrier (3A) in an upright position.
4. Insert a Planet Shaft (3E) in planet shaft hole in end of
Carrier (3A) opposite splined end. End of planet shaft
that does NOT have the roll pin hole should be inserted
into carrier FIRST.
5. Place one Thrust Washer (3B) on end of Planet Shaft (3E).
Make sure the flat faces towards inside of carrier and
make sure button fits in the pocket on inside of Carrier
(3A) towards the OD.
6. Following the thrust washer, place Planet Gear (3F) with
needle rollers, on Planet Shaft (3E).
7. Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align Thrust Washer
(3B) in same manner described in Step 5.
8. Now insert Planet Shaft (3E) through opposite planet
shaft hole on Carrier (3A). Use an alignment punch or
similar tool to align roll pin holes on Carrier (3A) and
Planet Shaft (3E).
NOTE: Do not to hit Planet Gears (3F) when driving in Roll Pins
(4G).
9. Drive Roll Pin (4G) down into aligned roll pin holes. Pin
should be flush with flat of carrier.
10. Repeat Steps 1-9 for installation of two remaining Planet
Gears (3F).
NOTE: Some grease may need to be applied to the Thrust Washers
(3B) to hold them in place while installing the planet gears.
Output Planet Gear Sub-Assembly
1. Apply a liberal coat of grease to the bore of one Output
Planet Gear (4F).
2. Line inside of the Planet Gear (4F) with 14 Needle Rollers
(4C).
NOTE: 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 which form the space, and then slid, parallel
to the other rollers, into place.
3. Place Spacer (4D) in bore of Output Planet (4F).
4. Repeat Step 2 to put in second roll of Needle Rollers
(4C).
5. Apply grease to hold two Thrust Washers (4B) together
and on Output Planet Gear (4F) counterbore. Do the
same to the other side.
6. Repeat Steps 1-5 to finish assembly of two remaining
Output Planet Gears (4F).
Spindle - Brake Sub-Assembly
1. Place Spindle (1A) with flange side up.
2. Place Stator (8K) in Spindle (1A) scallop cuts.
3. Place Rotor (8J) on top of Stator (8K).
4. Repeat steps 2 & 3 until there are a total of 9 Stators (8K)
and 8 Rotors (8J) installed.
5. Place Piston (8A) with smaller O.D. end facing up. Grease
two O-Rings and two Backup Rings.
6. Install large Backup Ring (8E) in large-diameter groove
at bottom of Piston (8A).
7. Install large O-Ring (8D) in large-diameter groove at bot-
tom of Piston (8A), on top of large Backup Ring (8E).
8. Install small O-Ring (8F) in small-diameter groove near
top of Piston (8A). Make sure O-Ring is seated on the
bottom of the groove.
9. Install small Backup Ring (8H) in small-diameter groove
near top of Piston (8A), on top of small O-Ring (8F).
10. Insert Piston (8A) in Spindle (1A) until it contacts Stator
(8K).
11. Insert appropriate number of Springs (8L), based on
assembly print, into Piston (8A)counterbore.
12. Place Spring (1L) in Coupling (7) counterbore. Place Pres-
sure plate (1M) on top of Spring (1L).
13. Use appropriate tool to install Retaining Ring (1K) in
retaining ring groove in coupling (7) counterbore.
14. Insert Coupling sub-Assembly (7) through Rotors (8J).
15. Place Pressure Plate (8B) on top of Springs (8L).
16. Use two ¼ -20 x 0.625 flat head Cap Screws (22) by bolt-
ing Pressure Plate (8B) and Piston (8A) together or some
other appropriate tools to install Retaining Ring on top
of Pressure Plate (8B) until Retaining Ring (8C) is seated.
NOTE: Remove 2 Screws from units when done or brake will not
function.
17. Install Pipe Plug (21) if applicable