JLG 3969electric Service Manual - Manual (Page 25)

SECTION 2 - PROCEDURES
3120881 – JLG Sizzor – 2-13
10. The bearing cups will remain in hub as will the inner
bearing cone. The outer bearing cone will remain on
the output shaft. The lip seal will be automatically
removed during this procedure.
NOTE: If bearing replacement is necessary, the bearing
cups can be removed with a slide hammer puller or
driven out with a punch.
11. To remove the cluster gears from the carrier, drive
the roll pin into the planet shaft. The planet shaft
may now be tapped out of the carrier. After planet
shaft has been removed, the roll pin can be driven
out.
12. The cluster gear can now be removed from the car-
rier). The tanged thrust washer will be removed from
the cluster gear.
13. The needle bearings and thrust spacer are now
removed from cluster gear.
NOTE: When rebuilding or repairing the unit, the retaining
ring (9), o-rings (22), and seal (2) should always be
replaced.
Assembly
1. With the hub shaft sub-assembly resting on the shaft
install internal gear. The spline of the internal gear.
bore will mesh with the spline of the output shaft.
2. Thrust washer (27) is installed on the face of the out-
put shaft. Sufficient grease or petroleum jelly should
be used to hold thrust washer in place.
3. Place o-ring into hub counterbore. Use petroleum
jelly to hold in place. Locate and mark the four
counter beamed holes in the face of the housing.
This is for identification later in the assembly.
4. Thrust spacer (25) is installed into the bore of the
output shaft. This should be a slip fit and the thrust
spacer should rotate in this location.
5. Place carrier assembly on a flat surface with the gear
cluster up. Find the punch marked tooth on each
large gear and locate at 12 o’clock (straight up) from
each planet pin.
6. With shoulder side of ring gear facing down, place
ring gear over (into mesh with) cluster gear. Be sure
that punch marks remain in correct location during
installation. The side of the ring gear with an “X”
stamped on it should be up.
7. While holding ring gear and cluster gear in mesh,
place small side of cluster gear into mesh with the
internal gear and sun gear. On the ring gear, locate
the hole marked “X” over one of the marked coun-
terbored holes in hub.
NOTE: If gears do not mesh easily or carrier assembly does
not rotate freely, then remove the carrier and ring
gear and check the cluster gear timing.
8. Sun gear is installed, meshing with the teeth of the
large diameter cluster gear. The counterbore on the
sun gear locates on the shoulder of the input
spacer. This is to be a slip fit and should operate
freely.
9. Thrust washer is installed onto the sun gear and
should locate on the gear teeth shoulder.
10. Thrust washer is installed into the counterbore of the
carrier.
11. Place o-ring into input cover counterbore. Use petro-
leum jelly to hold o-ring in place.
12. The input cover is now installed on this assembly.
Taking care to correctly align pipe plug hole with
those in the hub, usually 90° to one another, locate
the four counterbore holes in housing, marked in
step (3) and install four shoulder bolts. A tap with a
hammer may be necessary to align shoulder bolt
with hub counterbore.
13. Install bolts into remaining holes.
14. Pipe plugs are to be installed into input cover using
a lubricant seal.
15. Torque bolts (28 & 29) to 31- 36 NM (23 - 27 ft lbs).
16. Fill unit one-half full with EP90 lubricant.
2.18 DRIVE BRAKE ASSEMBLY
Disassembly
1. After removing brake from its installation, place
brake on a clean dry work bench with mounting
plate uppermost.
2. Unscrew the socket head bolts in equal increments
to ensure the spring pressure within the brake is
reduced gradually and evenly.
3. Remove and lay aside the shaft and mounting plate
sub-assembly. Should it be necessary to replace
ball bearings, retainer rings and press bearing off.
4. Remove friction plate and spacers and set aside.
Spacers are factory set for each brake to obtain
required air-gap and are not interchangeable
between brakes.
5. Armature and compression springs can be removed
and set aside.