JLG 40H Service Manual - Manual (Page 89)

SECTION 2 - PROCEDURES
3120240 – JLG Lift –
2-69
Repair.
1. Cover Assembly.
a. Remove two bolts 26 securing disconnect cap
27 to cover 25 and remove cap.
b. Remove two bolts 26 securing cover cap 25 to
cover and remove cap.
c. Remove disconnect rod 28 from cap and
remove o-rings 29,30 from cover cap. Discard o-
rings.
d. f necessary, remove pipe plug 31 from cover.
e. Clean and inspect parts in accordance with
paragraph," Cleaning and Inspection". Replace
parts as necessary.
f. If removed, screw pipe into cover.
g. Slip o-ring 30 over cover cap and against face.
h. Place o-ring 29 into cover cap internal groove.
Disconnect rod may be used to push o-ring into
groove.
i. Place cover cap into cover with large hole
located over pipe plug. Secure cover cap to
cover with two bolts. Torque bolts to 70-80 in.
lbs. (7.9-9.0 NM).
j. Place disconnect cap over cover cap with nipple
facing out and secure with two bolts. Torque
bolts to 70-80 in. lbs. (7.9-9.0 NM).
k. Turn cover over and push disconnect rod into
cover cap. Rod will be held in place by friction
from o-ring.
2. Carrier Assembly.
a. Drive anti-roll pin 21 into planet 19 using a suit-
able punch.
b. Using a suitable press, press planet shaft from
carrier 15. After planet shaft is removed, drive
anti-roll pin from shaft.
c. Remove cluster gear 20 and thrust washers 16
from carriers.
d. Remove sixteen needle rollers 17 from cluster
gear bore.
e. Remove spacer 18 from cluster gear bore and
remove second set of sixteen needle rollers 17.
f. Repeat steps a through e for remaining two clus-
ter gears.
g. Clean and inspect all parts in accordance with
paragraph, "Cleaning and Inspection". Replace
parts as necessary.
h. Apply a coat of grease or petroleum jelly to clus-
ter gear bore.
i. Place sixteen needle rollers into cluster gear
bore.
j. Place spacer into opposite side of cluster gear
and against needle rollers.
k. Place second set of sixteen needle rollers into
cluster gear.
l. Apply grease or petroleum jelly to tang side of
two thrust washers. Place thrust washers against
bosses in carrier with washer tang fitting into slot
in carrier outside diameter.
m. While keeping thrust washers in place, slide
cluster gear into carrier with larger gear on side
with small pin hole.
n. Line up cluster gear and thrust washers with
hole in carrier and slide planet shaft through.
Ensure chamfered side of hole in planet shaft is
lined up with pin hole in carrier.
o. Drive anti-roll pin flush into carrier hole, locking
planet shaft into place.
p. Repeat steps h through o for remaining two clus-
ter gears.
3. Input Shaft Assembly.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL AND INSTALLATION.
a. Carefully remove retaining ring 33 from input
shaft 32 and discard retaining ring.
b. Remove two spacers 35 and spring 34 from
input shaft.
c. Clean and inspect all parts in accordance with
paragraph, “Cleaning and Inspection”. Replace
parts as necessary.
d. Place washer 35, spring 34, and washer 35, in
that order, onto input shaft.
e. Install retaining ring into input shaft groove to
secure spacers and spring to shaft.
Assembly.
1. 1. Using a suitable press, press new bearing cups
3,5, with large inside diameters facing out, into hub
7 counterbores.
2. Place bearing cone 4 into bearing cup 3 in small end
of hub.
3. Press new seal 2 into hub counterbore with flat
metal side facing in. Use a flat object to ensure that
seal is pressed evenly and is flush with hub face.
4. Lower hub onto spindle 1 with large open end up.