JLG 500RTS ANSI Service Manual - Manual (Page 43)

SECTION 2 - PROCEDURES
3121103 – JLG Sizzor – 2-27
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 36 - 49 in lb (4 - 5
Nm) 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.
h. Place two remaining bolts into bolt holes in dis-
connect cap and tighten.
i. Using a torque wrench, apply 36 - 49 in lbs (4 - 5
Nm) torque to both bolts.
j. Grease o-ring.
k. Place o-ring into counterbore around edge of
cover.
BEWARE OF BURRS AND SHARP EDGES AROUND COUNTER-
BORE WHEN INSTALLING O-RING.
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.
l. Apply a light coat of never-seize to pipe plug.
m. Tighten pipe plug into pipe plug hole in cover.
20. Place cover assembly onto ring gear. Align pipe
plug holes in cover and hub as shown in Figure 2-
10. Make sure shoulder bolt holes in cover and ring
gear are aligned.
21. Place sixteen flatwashers on top of bolt holes in
cover assembly.
22. Place shoulder bolts into four shoulder bolt holes in
cover and tighten by hand.
23. Place grade 8 bolts into twelve bolt holes in cover
and tighten.
24. Apply 18 - 25 ft lbs (25 - 35 Nm) of torque to all bolts.
25. Leak test unit at a pressure of 5 psi (0.4 bar) for 2-3
minutes..
2.23 DRIVE BRAKE - 2WD/4WD REAR
Disassembly
1. Remove end cover from housing by removing
washer head cap screws.
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
2000 LBS. (907 KG). THE FOUR WASHER HEAD CAP SCREWS
SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A
HYDRAULIC PRESS IS AVAILABLE (3000 LBS. MIN.) (1361 KG
MINIMUM), COVER CAN BE HELD IN POSITION WHILE REMOVING
WASHER HEAD CAP SCREWS.
2. Remove case seal from housing, then remove
bleeder screw from end cover.
3. Remove piston from end cover.
4. Remove o-ring, back-up ring, o-ring and back-up
ring from piston.
5. Remove separators from housing.
6. Remove stack assembly, consisting of stator friction
discs, return plate, and rotor discs from housing.