JLG M600 Service Manual - Manual (Page 44)

SECTION 3 - CHASSIS & TURNTABLE
3-6 – JLG Lift – 3121813
Assembly of end cover unit (8)
1. Press sleeve (52) into cover (8).
2. Install "o" ring (54) into groove of cover (8).
3. Install shift rod (56) into cover (8).
4. Install the cover (51) into cover (8) and fix cover (51)
with hex bolts (53). Tighten bolts with torque wrench
to 6.3 ft. lbs. (8.5 Nm).
Final Assembly
1. Install thrust washer (29) in spindle (60).
2. Install "o" ring (19) into groove of support ring (6).
3. Install planet gears (1) onto planet pins which are
part of spindle (60).
4. Install snap rings (15) on planet pins of spindle (60)
in order to fix the planet gears (1).
5. Put ring gear (30) onto support ring (6) and fix ring
gear (30) with hex head bolts (23). Tighten bolts with
torque wrench to 15.5 ft. lbs.(21.1 Nm).
6. Insert the first stage planetary assembly (7) into
drive.
7. Install “o” ring (33) in groove of ring gear (30).
8. Install end the cover unit (8) on shoulder ring gear
(30) and fix with snap ring (34).
9. Install seal rings (21) and screw plugs (22).
10. Before installation of motor, CHECK THAT THERE IS
1-2mm OF CLEARANCE BETWEEN THE MOTOR
SPLINE SHAFT SHOULDER AND THE COUPLER
(62).
11. Install the motor and reconnect hydraulic lines.
12. Roll motor so that one fill plug is at 12 o’clock posi-
tion, and the other is at 3 o’clock. Fill to bottom of 3
o’ clock plug with gear oil. reinstall plugs
Initial Start-Up and After Repairs
Before operating the machine, make sure that the drive is
filled with clean oil, approximately 0.2 us gallons (0.8 L).
An accurate oil level is determined by the oil level plug,
which should be removed before oil fill.
With the gear case filled to their proper levels, start the
machine and allow sufficient time for run-in at moderate
pressure and speed before running at full speed. After 4
hours of operation, recheck oil level.Maintenance
Daily: - Check for oil leakage
Weekly: - Check oil level
Monthly: - Check mounting bolt torque
Oil Change Interval-Gear Drive
1. Perform the first oil change after approximately 150
hours.
2. Subsequent changes, every 1500 hours or annually,
whichever occurs first.
NOTE: Flush the drive before filling with new oil.
3.3 DRIVE HUB (S/N 115723 TO PRESENT)
Roll and Leak Testing
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure
that the unit’s gears, bearings and seals are working
properly. The following information briefly outlines what
to look for when performing these tests.
THE ROLL TEST
The purpose of the roll test is to determine if the unit’s
gears are rotating freely and properly. You should be
able to rotate the gears in your unit by applying con-
stant force to the roll checker. If you feel more drag in
the gears only at certain points, then the gears are not
rolling freely and should be examined for improper
installation or defects. Some gear packages roll with
more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
THE LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to
fall after the unit has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs,
the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be
detected by brushing a soap and water solution
around the main seal and where the o-rings or gaskets