JLG 500RTS Service Manual - Manual (Page 42)

SECTION 2 - PROCEDURES
2-26 – JLG Sizzor – 3120829
NOTE: O-rings may be stretched to fit counterbore. If an o-
ring has been stretched too much, simply squeeze o-
ring together bit by bit while placing it around coun-
terbore. It can be made to fit exactly.
3. Oil exposed surfaces inside hub.
4. Mark four shoulder bolt holes on hub so for align-
ment with shoulder bolt holes in ring gear and cover.
5. Place internal gear into hub so its internal splines
mesh with external splines of spindle/brake.
6. Oil internal gear.
7. Place thrust washer onto spindle/brake so it rests on
bottom of internal gear.
8. Assemble input shaft as follows:
a. Place one thrust spacer, spring, and other
spacer, IN THAT ORDER, onto smooth end of
shaft.
SAFETY GLASSES SHOULD BE WORN DURING FOLLOWING
PROCEDURE.
b. Place retaining ring onto input shaft. Using
retaining ring pliers, insert retaining ring into
groove on input shaft by compressing spring
and spacers together.
9. With large, splined end down, place input shaft
assembly into spindle/brake.
10. Place thrust spacer onto input shaft.
11. With internal splines facing up, place input gear into
mesh with input shaft assembly.
12. Assemble carrier as follows:
a. Apply grease to inside of one cluster gear.
b. Line one half of cluster gear with 16 needle roll-
ers.
c. Place one thrust spacer inside cluster gear so it
rests on top of needle rollers.
d. Line remaining half of cluster gear with 16 nee-
dle rollers.
e. Insert a planet shaft into one of the planet shaft
holes in the carrier housing which has a roll pin
hole. End of planet shaft that does not have a
roll pin hole should be inserted into carrier hous-
ing first.
f. Place one thrust washer onto end of planet shaft
which has been inserted through planet shaft
hole. Notice that thrust washer has a tang on it.
Tang should point straight so as to fit in slot on
inside edge of planet shaft hole.
g. Following thrust washer, place cluster gear, with
needle rollers, onto planet shaft. Large end of
cluster gear should go onto shaft first.
h. Following cluster gear, place one more thrust
washer onto planet shaft. Align thrust washer in
same manner as described in step (f).
i. Insert planet shaft through opposite planet shaft
hole in carrier housing. Use an alignment punch
or similar tool to align roll pin holes in carrier
housing and planet shaft.
j. Drive roll pin down into aligned roll pin holes.
k. Repeat steps (a) through (j) to install two remain-
ing cluster gears.
13. Set carrier assembly on work surface so that large
end of cluster gears face up. Locate punch marks
on face of each cluster gear and position them at 12
o’clock.
14. With squared shoulder side down, place ring gear
into mesh with cluster gears in carrier. If ring gear is
on correctly, the X marking a shoulder bolt hole
should face up.
NOTE: Make sure punch marks on cluster gears remain in
their correct positions when installing ring gear.
15. Place carrier assembly and ring gear together into
mesh with internal gear. Align shoulder bolt hole in
ring gear marked with an X over one of the shoulder
bolt holes in the hub.
NOTE: Ring gear may be lifted off hub to align shoulder bolt
holes. Ring gear and carrier need to be installed
together initially only so that punch marks on carrier
remain aligned.
16. Oil all exposed surfaces inside hub.
17. Place thrust spacer onto input shaft assembly.
18. Place thrust washer into counterbore in carrier.
19. Assemble cover as follows:
a. Place o-ring onto cover cap so it rests against
flange of cover cap.
b. Insert o-ring into groove inside cover cap.
c. Insert disconnect rod into cover cap.
d. Place cover cap into cover. Align pipe plug hole
in cover cap over pipe plug hole in cover.
e. Place two cover cap bolts into any two bolt holes
180° apart on cover cap and tighten.
f. Using a torque wrench, apply 4 - 5 Nm (36 - 49
in lb) torque to both bolts.
g. With large end down, place disconnect cap onto
cover. Align pipe plug hole in disconnect cap
over pipe plug hole in cover cap.