JLG 3246E2 Service Manual - Manual (Page 31)

SECTION 2 - PROCEDURES
3120855 – JLG Sizzor – 2-19
Assembly
NOTE: Before assembly, inspect all parts and replace if nec-
essary.
Before assembly, lubricate all parts with hydraulic oil
and grease rubber parts with Vaseline.
1. Turn motor housing so the rear end faces upwards.
Press shaft seal into housing.
2. The bearing race can be fitted in any position.
3. Place the needle bearings in the outer ring and hold
them in place with grease. Place the whole bearing
into the housing. Press the bearing into position
using pressure equipment if necessary.
4. Carefully insert shaft through bearing housing.
5. Place O-ring (greased) in bearing housing O-ring
recess.
6. Place spring washer on balance plate, insert O-ring
in recess and lubricate with grease. Place balance
plate lightly in position so that it engages. Be careful
not to damage the O-ring.
7. Place the disc valve on the shaft with channels
upwards so that the long tab on the disc valve
engages with the slot in the shaft.
8. If there is a difference in the spline length, fit the car-
dan shaft with he long spline end in the output shaft.
Mark the bottom of the cardan spline that lies adja-
cent to the long tab on the disc valve.
9. Place the needles in the outer ring and hold them in
place with grease. Carefully place the distributor
plate on the bearing housing so that the shaft enters
the bearing. Press the distributor plate until it stops
on the housing and line up the screw holes.
10. Place the O-rings (greased) in the gearwheel O-ring
recesses. If there is a recess on one end of the
splined hole, position the gearwheel with recess on
the same side as the smallest screw hole (stage
hole) in the gearwheel rim. Fit the gearwheel set with
this side facing the motor.
11. Clockwise Revolution:
Fit the gearwheel set on the cardan shaft so that the
top of a tooth in the external teeth of the gearwheel
is vertically over the mark on the cardan shaft. Turn
the gearwheel set counterclockwise until the cardan
shaft and gearwheel engage (15°). Turn the gear-
wheel rim to line up the screw holes.
12. Counterclockwise Revolution:
Fit the gearwheel set on the cardan shaft so that the
top of a tooth in the external teeth of the gearwheel
is vertically over the mark on the cardan shaft. Turn
the gearwheel set clockwise until the cardan shaft
and the gearwheel engage (15°). Turn the gearwheel
to line up the screw holes.
13. Rotate the end cover to line up the screw holes.
14. Use new washers and a 13 mm socket spanner.
Torque to 330-380 lb in (3.75 - 4.25 daNm).
15. Screw in plastic plugs.
16. Turn the motor over and strike the dust seal into
place with a plastic hammer and suitable mandrel.
17. Secure the key in place with tape.
2.16 DRIVE MOTOR (REXROTH)
Disassembly
1. Place the drive motor vertically in a vice with the out-
put shaft pointing downwards.
2. Using a 17mm spanner wrench loosen the 7 cover
bolts. remove the cover with the bolts.
3. Lift off the displacer and the intermediate disk.
4. Remove the cardan shaft.
5. Remove the control sleeve.
6. Remove the check valves consisting of ball, limit,
stop and filler (filler only when one valve is installed).
7. Turn the drive around in the vise so that the output
shaft is facing up. Remove the keyed shaft.
8. Loosen the 8 socket head cap screws on the flange
mounting using a 4mm allan wrench.
9. Withdraw the flange from the shaft while holding the
flange in a special fixture.
10. Turn the motor around again. Attach a mandrel and
press the output shaft with bearing out of the motor
housing with the help of a lever press.
Assembly
1. The output shaft with pressed on and adjusted
tapered roller bearing and cylindrical shaft is to be
centrically positioned onto the housing edge. Press
the complete assembly into the housing to the limit
stop with the help of the press.
NOTE: Do not jam.
2. Before mounting the flange, put a mounting sleeve
onto the shaft.
NOTE: Be sure that the seal is thoroughly oiled.
3. Position the flange with slight pressure into the
housing. Take care to avoid damage to the seals.