JLG 510AJ Service Manual - Manual (Page 105)

SECTION 3 - CHASSIS AND TURNTABLE
3121181 – JLG Lift – 3-63
8. Remove bearing (14) and Nilos Ring (13) from pinon (18)
using an external bearing puller or press.
9. Remove two bolts (4) securing motor adapter. Remove
motor adapter (37) and shim (25).
10. Remove 1/2" bolts (5) from worm cap (28) using a 3/4"
socket. Remove shIms (22, 23, 24, 25, 26) and seal (8) and
discard.
11. Remove worm (34) from housing (20) by pushing worm
from motor end using a steel rod and hammer. Bearing
cup (1) on hex end of the worm will be forced out of
housing. Once bearing cup (1) has come out of housing,
use a soft hammer to tap worm on hex end to remove
other bearing cup (1) from other end of housing.
12. Remove both bearings (2) from worm (34) using an
external bearing puller or press.
13. The bearing cup (15) can be removed from the housing
(20) by lifting it out (this is not a press fit just a close slip
fit).
14. The bearing cup (12) can be removed from the cap (27)
using a small pry bar, or by welding a small bead of weld
on the internal diameter of the cup, this IS a press fit.
Assembly
1. Press the bearing cup (12) into the cap (27).
2. Place the bearing cup (15) into the housing (20).
3. Put the face seal (38) and O-ring (10) onto the hub of the
worm gear (17).
4. Place the worm gear (17) on the press with face seal up
and press the pinion (18) into the worm gear. Place the
Nilos Ring (13) onto the pinion so that the cup shape is
up and press the bearing (14) onto the pinion tight to
the Nilos Ring.
5. Turn the assembly over and place the spacer (19) on the
pinion against the gear hub so that the hub of the
spacer is up. Press the bearing (16) onto the pinion and
tIght to the spacer and gear.
6. Place the pinion gear assembly into the housing. Place
the gear cap (27) and shims (31, 32, 33) over the gear/
pinion assembly to achieve a slight preload on the pin-
ion bearings. Remove the cap and shims and set the
shIms aside. Install a new cover plate (21) onto the cap
using 6 screws (30) and shims (35, 36) equal to or close
to equal to the total thickness of the shims just set aside.
Apply sealant (permatex number 2) to both sides of
each of these shims and tighten the screws taking care
not to twist these screws off. Set this assembly to the
side.
7. Install the bearing (2) on the bore end of the worm (34).
This IS almost a slip fit, and may have to be lightly
tapped with soft hammer.
8. Install the worm (34) into the housing, hex end first.
9. On the bore end of the worm, install the bearing cup (1)
into the worm bore of the housing. Also on bore end of
the worm, install the motor adapter (37) and 1 shim (25)
to the housing using 1/2" bolts (4) and sealant. Torque to
80 lbs-ft. (108.5 Nm).
10. Install the bearing (2) on the hex end of the worm (34).
Place the bearing cup (1) over the bearing and lightly
tap the cup into the bore using a soft hammer.
11. Install the worm cap (28) using proper shims (22 thru 26)
to achieve 0.000 to 0.001" end play. Use 3/4" bolts (5)
and sealant. Torque to 80 lbs-ft. (108.5 Nm).
12. Place the pinion/gear assembly into the housing so the
gear teeth mesh with the worm gear teeth.
You may have to turn the worm or gear set by hand to
achieve this.
13. Apply sIlIcone sealant to the surface of the housing
where the cap assembly will touch. This includes the
vertical surface.
14. Place the gear cap assembly over the pinion assembly
and place the shims set aside in step 6.
15. Install the eight 3/8" 12 point screws (3) and torque to 60
Ibs-ft. (81 Nm).
16. Install 2 small screws (29).
17. Install the seal (8) in the worm cap (28) at the hex end of
worm.
18. Install the turntable bearing using two 5/16" bolts (6)
and washers (7).
19. Fill the unit with SHC 007 grease and grease the top
bearing with Mobil SHC 460 grease.
Installation
1. Install bearing to rotation box with two capscrews, so
that fill plug of bearing is as close to gear as bolt pattern
will allow. Do not tighten capscrews.
2. Line up high spot (blue) of bearing with center tooth of
worm gear. Set backlash to 0.008 - 0.010 inch (0.20 - 0.25
mm). Tighten capscrews as shown in Figure 3-52., Swing
Bearing Torque Sequence.
3. Apply Mobiltac 375 Open Gear Compound or equiva-
lent to bearing and worm gear teeth.
4. Grease bearing. Grease fitting is on inside wall of inner
race of bearing.
NOTE: If Mobiltac 375 Open Gear Compound is not available,
Multi-Purpose Grease (MPG) can be substituted, however
the service interval will be shorter.