JLG 40RTS Service Manual - Manual (Page 55)

SECTION 2 - PROCEDURES
3120826 – JLG Sizzor – 2-39
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 as shown in diagram below.
14. With squared shoulder side down, place internal
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 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 counter bore 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 degrees apart on cover cap and tighten.
f. Using a torque wrench, apply 4- 5 Nm (36 to 49
in. lbs) 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 4 - 5 Nm (36 - 49
in. lbs. ) torque to both bolts.
j. Grease o-ring.
k. Place o-ring into counter bore 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 counter bore. If an o-
ring has been stretched too much, simply squeeze o-
ring together bit by bit while placing it around counter
bore. 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. Make sure shoulder bolt
holes in cover and ring gear are aligned.
21. Place sixteen flat washers 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 25 - 35 Nm (18 - 25 ft. lbs.) of torque to all
bolts.
25. Leak test unit at a pressure of 0.4 bar (5 psi) for 2-3
minutes.