Service Manual Instruction Manual

SECTION 3 - CHASSIS & TURNTABLE
3-10 – JLG Lift – 3121616
Hub-Spindle Sub-Assembly
NOTE: Spray a light film of oil on all component parts during
assembly. Spray a generous amount of oil on bearings dur-
ing installation.
1. Press Bearing Cup of part (1C), position "A", into Hub
using T-158422 pressing tool.
2. Turn hub over and press Bearing Cup of part (1C), posi-
tion "B", into hub using T-158422 pressing tool.(T).
3. Place Bearing Cone of part (1C), into Bearing Cup of part
(1C), position "B".
4. Grease Seal (1B) lip and press seal into Hub (1D) using
appropriate tool until seal is flush with end of hub.(T).
5. Place Hub (1D) into pressing base. Press nine Studs (1H)
into Hub.
NOTE: Use enough pressure to press in studs. Don t use excessively
high pressure to press in studs or hub may crack.
6. Set Spindle assembly (1A) on the bench with the flange
down. Turn Hub (1D) over and lower onto Spindle (5).
Install boot (21) if applicable.
7. Install Bearing Cone of part (1C) into Bearing Cup, posi-
tion "A".
8. Apply Loctite 243 on Bearing Nut (1F) thread. Screw Nut
(1F) on top of Bearing Cone of part (1C). Leave 0.003-
0.005 inches end play to check the initial rolling torque
with the unit tied down. Then torque Bearing Nut (1F)
until rolling torque is 40 to 50 in-lbs greater than initial
rolling torque. Using tool T-206569 for the Bearing Nut.
NOTE: Final torque is initial rolling torque plus 40-50 in-lb (4.5-5.6
Nm). For example, if initial rolling torque is 30 in-lb (3.3
Nm), final rolling torque is between 70-80 in-lb (7.9-9 Nm).
Rotate hub as torque is applied to properly seat bearing. Be
sure torque wrench is tangent to the Hub (1D) OD.
9. Using appropriate tool, install two Set Screws (1G) into
Bearing Nut (1F) threaded holes. Make sure Set Screw is
driven into the spindle thread. Tighten the set screws to
damage the thread and stake the edge of the nut
around the Set Screws (1G) so the nut will not loosen.
10. Place Thrust Washer (4H) in counterbore of Spindle (1A).
11. Place Planet Gear Sub-assembly (4) into Spindle (1A)
through gap between two Studs (1H). Align the planet
gear bore with one of the planet shaft holes on the spin-
dle (1A) assembly using T-209919.
12. Insert a Planet Shaft (4E) into the planet shaft hole
described in Step (11) on Spindle (1A). Insert end of
planet shaft that does NOT have roll pin hole in Spindle
FIRST.
13. Insert Planet Shaft (4E) through first set of Thrust Wash-
ers (4B), Planet gear, then second set of Washers (4B).
Use an alignment punch or similar tool to align roll pin
holes on Spindle (1A) and Planet Shaft (4E).
NOTE: Do not hit Planet Gears (4F) when driving in Roll Pins (4G).
14. Drive new Roll Pin (4G) in aligned roll pin holes. Pin
should be flush with OD of spindle.
15. Repeat Steps (11-14) for installation of two remaining
Planet Gears (4F).
Cover Sub-Assembly
1. Grease O-Ring (6E) and insert in internal groove in Cover
(6A).
2. Assemble Disengage Cap (6B) on Cover (6A) using two
Hex Head Bolts (6C). Torque bolts to 70-80 in-lb (7.9- 9
Nm).
3. Insert Disengage Rod (6D) in hole in Cover (6A) until it
touches inside of Disengage Cap (6B).
NOTE: Disengage Rod can be inserted either end first.
4. Grease Face of Thrust Washer (2) and place in Cover (6A)
making sure tangs on washer seat into pockets in cover.
5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should
be hand tight.
Main Assembly
NOTE: All components should receive a generous amount of lubri-
cant oil as they are being assembled.
1. Place Hub-Spindle Sub-Assembly on bench.
2. Grease O-Ring (18) and place it in groove of Hub (1D).
3. Place Ring Gear (1E) on Hub (1D). Align three shipping
Cap Screw Holes on Hub (1D) and Ring Gear (1E).
4. Install three shipping Cap Screws (19) in ring gear and
hub. Torque to 15-20 ft-lb (20-27 Nm).
5. Place External Retaining Ring (5) over 13T spline to the
retaining groove on Input Shaft (9).
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over Input
Shaft (9) first, then install External Retaining Ring (5).
6. Using appropriate tool to install Retaining Ring (20) in
groove on Output Sun (11).
7. Place Input Shaft (9) spline end into mesh with Internal
Coupling (7) splines.
8. With modified spline end facing up, place Output Gear
(11) in mesh with planet gears from Hub-Spindle Sub-
Assembly.