JLG 340AJ, Service And Maintenance Manual

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SECTION 3 - CHASSIS & TURNTABLE
3-60 – JLG Lift – 3121259
7. Remove bearing (15) and Nilos Ring (16) from pinion
(21) using external bearing puller or press.
8. Remove motor and motor adapter (22) and shims (28).
9. Remove ¾" bolts (7) from Worm Cap (20) using ¾"
socket. Remove shim (29) and seal (9) and discard.
10. Remove worm (32) from housing (25) by pushing worm
from motor end using steel rod and hammer. Bearing
cup (3) on hex end of worm will be forced out of hous-
ing. Once the bearing cup (2) has come out of housing
use soft hammer to tap worm on hex end to remove
other bearing cup (2) out the other end of housing.
11. Remove both bearings (2) from worm (32) from worm
using external bearing puller or press.
12. Bearing cup (17) can be removed from housing (25) by
lifting out (this is not a press fit just a close slip fit).
13. Bearing cup (15) can be removed from cap (18) using
small pry bar. Or by welding a small bead of weld on
internal diameter of cup, this is a press fit.
Assembly
1. Press bearing cup (15) into cap (18).
2. Place bearing cup (17) into housing (25).
3. Put face seal (23) on to hub of worm gear (31) with flap
of seal pointing away from gear.
4. Place worm gear (31) on press with face seal up and
press pinion (21) into worm gear. Place Nilos Ring (16)
on to pinion so that cup shape is up and press bearing
(15) on to pinion tight to Nilos Ring.
5. Turn assembly over and place spacer (24) on pinion
against gear hub so that large chamfer on I.D. of spacer
is against Bronze gear. Press Bearing (17) on to pinion
tight to spacer and gear.
6. Place pinion/gear assembly into housing. Place gear cap
(18) and shims (26) over gear/pinion assembly to
achieve a slight preload on pinion bearings. Remove cap
and shims and set shims aside. Install new cover plate
(19) on to cap using 6 screws (30) and shims (26) equal
to or close to equal to total thickness of shims just set
aside. Apply sealant (LocTite #515) to both sides of each
of these shims and tighten screws take care not to twist
these screws off. Clean extra sealant from surfaces of
cover plate. Apply a small amount of grease to this flap.
Set this assembly to the side.
7. Install bearing (2) on bore end of worm (32) only. This is
almost a slip fit, may have to be lightly tapped with soft
hammer.
8. Install worm (32) into housing (25), hex end first.
9. On bore end of worm, install bearing cup (2) into worm
bore of housing. Also on bore end of worm (32) install
motor adapter (22) and 1 shim (28 yellow) to housing
using ¾-13 x 1" bolts (6) and sealant. Torque to 75 ft-lbs.
(3.1 Nm) (these bolts will be replaced with motor bolts
when motor is mounted).
10. Install bearing cone (2) on hex end of worm (32). Place
bearing cup (2) over bearing and lightly tap cup into
bore using soft hammer.
11. Install worm cap (20) using proper shims (29) to achieve
0.000 to 0.001" (0.0000 to 0.0254 mm) end play. Apply
LocTite 242 to end of ¾-13 x 1.25" grade 5 bolts (7) and
LocTite #515 sealant to shims. Torque bolts to 75 ft-lbs.
(3.1 Nm).
12. Place pinion/gear assembly into housing so gear teeth
mesh with worm gear teeth. May have to turn worm or
gear set by hand to achieve this.
13. Apply LocTite #515 to surfaces of housing where cap
assembly will touch. This includes the vertical surfaces.
14. Place gear cap assembly and shims set aside in step 6,
over pinion assembly.
15. Apply LocTite 242 to end of eight 5/16" 12 point screws
(4) and torque to 20 ft-lbs. (0.84 Nm)
16. Install 4 small screws (30) through cover plate (18) and
into housing (25) tighten screws take care not the twist
these screws off.
17. Install seal (9) in worm cap at hex end of worm.
18. Install slew ring (14) using two 1/4" bolts (5) and washer
(1). Adjust backlash with pinion to 0.008/0.012" (0.203/
0.305 mm) and torque bolts to 10 ft-lbs. (0.42 Nm).
19. Fill unit with SHC 007 grease and grease pinion bearing
(15) thru fitting (11) with Mobil SHC 460 grease.