JLG GRADALL 522, Owner'S/Operator'S Manual

Page: 89 / 288

Table of Contents
Section 1: Introduction
Description ......................................................................................................................................................1
Identification
Section 2: Removal and Disassembly
Remove Axle ..................................................................................................................................................2
Disassemble Ball and Ramp Brake
Disassemble Trumpet Assembly ....................................................................................................................3
Disassemble Planetary System and Axle Shaft ..............................................................................................4
Disassemble Hydraulic Apply Wet Disc Brake................................................................................................5
Disassemble Three Function Wet Disc Brake
Disassemble Main Housing ............................................................................................................................7
Disassemble Differential Case ........................................................................................................................8
Disassemble Pinion Bearing Cage ................................................................................................................10
Section 3: Prepare Parts for Assembly
Clean Ground and Polished Parts ................................................................................................................13
Clean Parts With Rough Finish
Clean Axle Assemblies
Dry Cleaned Parts
Prevent Corrosion
Inspect Parts
Inspect Tapered Roller Bearings ..................................................................................................................14
Inspect Hypoid Pinion and Ring Gear Sets ..................................................................................................15
Inspect Main Differential Assembly
Inspect Axle Shafts
Inspect Main Housing ..................................................................................................................................16
Inspect Yoke
Inspect Planetary System Parts
Inspect Brakes
Repair or Replace Parts
Repair Welding
Liquid Adhesive ............................................................................................................................................17
Disassemble Locked Sets
Cleaning
Reassembly
Application
Apply Silicone Gasket Material ....................................................................................................................18
Duo-Cone Oil Seal: Mount and Install
Section 4: Assembly and Installation
Assemble Differential Case ..........................................................................................................................23
Check Rotating Resistance of Differential Gears (Not Limited Slip) ............................................................26
Assemble Drive Pinion and Bearing Cage ....................................................................................................27
Adjust Pinion Bearing Preload (Without Press) ............................................................................................28
Adjust Thickness of Pinion Bearing Cage Shim Pack (Depth of Pinion) ......................................................29
Install Pinion Bearing Cage Assembly on Main Housing ..............................................................................31
Install Differential Housing Assembly into Main Housing (With Shims) ........................................................32
Install Differential Housing Assembly into Main Housing (With Adjusting Ring 2 Sides)..............................33
Assemble Axle Shaft ....................................................................................................................................34
Assemble Trumpet Assembly ......................................................................................................................35
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