JLG 500RTS ANSI Service Manual - Manual (Page 40)

SECTION 2 - PROCEDURES
2-24 – JLG Sizzor – 3121103
c. Insert roll checker into spindle/brake. If brake is
not working properly, roll checker should not
turn.
d. Set hand pump to PUMP.
e. Increase hydraulic pressure in brake by pump-
ing gradually. At the same time, try to turn roll
checker. If brake is set correctly, roll checker
should turn when pump pressure reaches 140 to
160 psi (10-11 bar).
f. Roll test brake in both clockwise and counter-
clockwise directions. Perform same number of
turns in each direction as ratio of unit. This num-
ber is the same as the last two digits of the
model number found on the units ID tag. For
example, if units model number is W1BJ4U318,
then it should be rolled 18 times in both direc-
tions.
g. Set hand pump to RELEASE and check to see if
brake has reset itself. If brake has reset roll
checker should not be able to turn.
h. Remove roll checker from spindle/brake.
i. Remove hydraulic line from its brake port.
j. Remove bleeder valve from its brake port.
3. Leak test unit at a pressure of 5 psi (0.4 bar) for 2 to
3 minutes.
4. Remove the twelve grade 8 bolts and four shoulder
bolts from cover.
5. Remove flat washers from cover.
6. Remove cover from hub.
7. If necessary, disassemble cover as follows:
a. Remove pipe plug from cover if it has not
already been removed.
b. Set cover down so that its open end faces up.
Remove o-ring from counterbore in cover. Dis-
card o-ring.
c. Turn cover over. Remove two bolts that hold dis-
connect cap in place.
d. Remove disconnect cap from cover.
e. Remove two remaining bolts that hold cover cap
in place.
f. Remove cover cap from cover.
g. Remove disconnect rod from cover cap.
h. Remove o-ring from groove inside cover cap.
Discard o-ring.
i. Remove o-ring from outside of cover cap.
8. Remove thrust washer from carrier assembly.
9. Remove thrust spacer from input shaft assembly.
10. Remove ring gear from mesh with carrier assembly.
11. Remove carrier assembly from hub.
12. If necessary, disassemble carrier assembly as fol-
lows:
a. Locate roll pin in carrier housing. Drive roll pin
down into planet shaft until it bottoms against
carrier housing. If roll pin is not completely
driven into planet shaft, damage to carrier could
occur when shaft is removed.
b. Drive roll pin out of planet shaft. Roll pin must
come out through side of planet shaft that it orig-
inally went into.
c. Remove planet shaft from carrier housing. Two
tongued thrust washers and cluster gear will
slide off.
d. Remove needle rollers and spacer from inside
cluster gear.
e. Repeat steps (a) through (d) to remove two
remaining cluster gears.
13. Remove input gear from input shaft assembly.
14. Remove thrust spacer from input shaft assembly.
15. Remove input shaft assembly from spindle/brake.
16. If necessary, disassemble input shaft as follows:
a. Remove retaining ring from input shaft.
Discard retaining ring.
b. Slide thrust spacer, spring, and other
thrust spacer off of input shaft.
17. Remove thrust washer from bottom of internal gear.
18. Remove internal gear from hub.
19. Remove o-ring from counterbore in hub. Discard o-
ring.
20. Using a screwdriver or chisel and hammer,
straighten out tang on lock washer which has been
bent into notch in locknut.
21. Using an N-13 locknut wrench (tool no. T-141863),
loosen locknut. Remove locknut from spindle/brake
and discard.
22. Remove lock washer from spindle/brake and dis-
card.
23. Remove tongued washer from spindle/brake.
24. Lift bearing cone out of hub.
25. Lift hub off of spindle/brake.
26. Using a slide hammer, remove seal from small end
of hub. Discard seal.
27. Lift bearing cone off of spindle/brake.
28. Using a soft punch and hammer, remove bearing
cup from deep end of hub.