JLG 660SJ Service Manual - Manual (Page 64)

SECTION 3 - CHASSIS & TURNTABLE
3-14 – JLG Lift – 3121202
Cover Sub-Assembly
1. Grease O-Ring (6E) and insert into internal groove in
Cover (6A).
2. Assemble Disengage Cap (6B) onto Cover (6A)
using two Hex Head Bolts (6C). Torque bolts to 70-
80 in-lbs.
3. Insert Disengage Rod (6D) into hole in Cover (6A)
until it touches the inside of the Disengage Cap (6B).
NOTE: The Disengage Rod can be inserted either end first.
4. Grease Face of Thrust Washer (2) and place in
Cover (6A) making sure that tangs on washer seat
into pockets in cover.
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The
plugs should be hand tight.
Main Assembly
NOTE: All components should receive a generous amount
of lubricant oil as they are being assembled.
1. Place Hub-Spindle Sub-Assembly on the bench.
2. Grease O-Ring (18) and place it into groove of Hub
(1D).
3. Place Ring Gear (1E) onto Hub (1D). Align the three
shipping Cap Screw Holes on Hub (1D) and Ring
Gear (1E).
4. Install three shipping Cap Screws (19) into ring gear
and hub. Torque them to 15-20 ft-lbs.
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)
into groove on Output Sun (11).
7. Place Input Shaft (9) spline end into mesh with Inter-
nal Coupling (7) splines.
8. With the modified spline end facing up, place the
Output Gear (11) into mesh with the planet gears
from the Hub-Spindle Sub-Assembly.
9. Place Input Carrier Sub-Assembly (3A) onto Output
Sun Gear (11) splines. Drop Input Sun (10) into
mesh with planet gears for specific ratios, if
required. (No timing required).
10. Grease O-Ring (17) and insert into groove in Cover
Sub-Assembly (6).
11. Install Cover Sub-Assembly (6) into Ring Gear (1E)
counterbore and install Retaining Ring (6G) into
groove in Ring Gear (1E).
12. Attach ID Tag (15) onto unit using Drive Screws (16).
13. Check disconnect, roll and air check unit, leak check
brake, and record release pressure.
14. Insert Plastic Plug (12) into place if applicable.
Integral Brake Check
1. Using appropriate fittings, connect hydraulic line
from hand pump to brake port.
2. Check to see that brake is set by trying to rotate
Input Shaft (9). This can be accomplished by install-
ing an appropriate tool (any tool that can locate on
the splines of the Input Coupling (7), such as a mat-
ing splined shaft) into Input Coupling (7).
3. Bleed brake. Increase hydraulic pressure gradually
while trying to rotate the input until brake just starts
to release. Note this pressure. Make sure the pres-
sure falls into the appropriate range below.
4. Increase pressure to 1,000 psi and hold for 30 sec-
onds to check for leaks. Repair leaks if necessary.
NOTE: Make sure that brake re-engages when pressure is
released.
NOTE: When done, make sure Input Coupling (7) is cen-
tered in Spindle (1A) to make installation of motor
possible without release of brake.
BRAKE
CODE
JUST RELEASE
PRESSURE RANGE
PSI BAR
A 200-260 13.7-17.9
B 170-220 11.7-15.1
C 140-185 9.6-12.7
D 130-155 8.9-10.6
E 115-145 7.9-9.9