JLG 45e ANSI Service Manual - Manual (Page 69)

SECTION 2 - PROCEDURES
3120743 – JLG Lift – 2-45
Assembly.
1. With the hub shaft sub-assembly resting on the spin-
dle (1) install internal gear (13). The spline of the
internal gear (13). The spline of the internal gear (13)
bore will mesh with the spline of the output shaft (1).
2. Thrust washer (27) is installed on the face of the
spindle (1). Sufficient grease or petroleum jelly
should be used to hold thrust washer (27) in place.
3. Place o-ring (22) into hub counterbore. Use petro-
leum jelly to hold in place. Locate and mark the four
counter beamed holes in the face of the housing (7).
This is for identification later in the assembly.
4. Thrust spacer (25) is installed into the bore of the
spindle (1). This should be a slip fit and the thrust
spacer should rotate in this location.
5. Place carrier assembly (14) on a flat surface with the
cluster gears (19) 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 (21) facing down,
place ring gear over (into mesh with) large gears. 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 (21) and cluster gears (19) in
mesh, place small side of cluster gears into mesh
with the internal gear (13) and input gear (24). On
the ring gear, locate the hole marked “X” over one of
the marked counterbored holes in assembly (7).
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. Input gear (24) is installed, meshing with the teeth of
the large diameter cluster gear (19). The counter-
bore on the input gear (24) locates on the shoulder
of the input spacer (25). This is to be a slip fit and
should operate freely.
9. Thrust washer (26) is installed onto the input gear
(24) and should locate on the gear teeth shoulder.
10. Thrust washer (27) is installed into the counterbore
of the carrier.
11. Place o-ring (22) into input cover (23) counterbore.
Use petroleum jelly to hold o-ring in place.
12. The input cover (23) is now installed on this assem-
bly. Taking care to correctly align pipe plug hole (30)
with those in the housing (7), usually 90 degrees to
one another, locate the four counterbore holes in
housing (7), marked in step (3) and install four
shoulder bolts (29). A tap with a hammer may be
necessary to align shoulder bolt with hub counter-
bore.
13. Install bolts (28) into remaining holes.
14. Pipe plugs (30) are to be installed into input cover
(23) using a lubricant seal.
15. Torque bolts (28 and 29) to 23 - 27 ft. lbs. (31- 36
Nm).
16. Fill unit one-half full with EP90 lubricant.
2.18 DRIVE BRAKE ASSEMBLY.
(SEE FIGURE 2-35.)
Disassembly.
1. After removing brake from its installation, place
brake on a clean dry work bench with mounting
plate uppermost.
2. Unscrew capscrews (9) in equal increments to
ensure the spring pressure within the brake is
reduced gradually and evenly.
3. Remove and lay aside the shaft (3) mounting plate
(4) sub-assembly. Should it be necessary to replace
ball bearings (11), remove circlips (12 and 13) and
press bearing off.
4. Remove friction plates (5, 6, 7) and spacers (8) and
set aside. Spacers are factory set for each brake to
obtain required air-gap and are not interchangeable
between brakes.
5. Armature (2) and coil springs (10) can be removed
and set aside.
Inspection.
1. Inspection the friction plates (5, 6) and the mating
surfaces on the armature (2) and mounting plate (4)
for wear and/or damage.
2. Examine the coil springs (10).
3. Examine the friction plates and the shaft (3) for wear
and/or damage to the spline.
4. Examine the pole faces of the magnet (1) and the
armature (2) for bruises, swellings or damage. Any
bruises, swellings or damage should be stoned flat.
5. Examine input and output splines of shaft for wear
and/or damage.
6. Check ball bearing (11) for axial float and/or wear.
NOTE: It is essential when replacing plates (5, 6, 7) that
spacers (8) are also replaced.