JLG 120HX ANSI Service Manual - Manual (Page 57)

SECTION 2 - PROCEDURES
3120686 – JLG Lift – 2-37
b. Remove two bolts (303) securing cover cap
(306) to cover and remove cap.
c. Remove disconnect rod (305) from cover cap
and remove o-rings (306 and 307) from cover
cap. discard o-rings.
d. If necessary, remove pipe plug (309) from cover.
4. Remove two thrust washers (15) and thrust bearing
(16) from carrier counterbore. One thrust washer
may stick to cover. Inspect thrust washers and bear-
ing for wear and replace if necessary.
5. Lift carrier assembly (3) from hub and spindle
assembly (1).
6. Disassemble carrier as follows:
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL.
a. Remove retaining (208) from planet shaft (205).
b. Remove spacer (207) from planet shaft, then,
using a suitable drift, drive planet shaft from car-
rier, shearing off roll pin. Tap remaining roll pin
from carrier using a suitable punch.
c. Remove cluster (206) gear from carrier and
remove bearing cones (204) from cluster gear.
d. If necessary, press bearing cups (203) from clus-
ter gear.
7. Lift ring gear (4) from housing (107). Remove o-ring
(5) from counterbore of ring gear and discard.
8. Remove input spacer (12), input (sun) gear (13),
input spacer (14), and input shaft (11) from spindle
(101).
9. Remove two thrust washers (15) and thrust bearing
(16) from end of spindle. One thrust washer may
stick in carrier counterbore. Inspect thrust washers
and thrust bearing for wear and replace if necessary.
10. Lift internal gear (2) out of hub.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL.
11. Remove ring keeper (21), retaining ring (106), and
thrust washer from end of spindle. Remove hub from
spindle.
12. Remove bearing cone (104) and seal (102) from
spindle (101). Seal will possibly hold bearing cone
into hub. If so, remove both from hub. If bearing
cups (103) require replacing they can be driven out
of hub counterbores. Discard seal and replace with
new seal.
EYE PROTECTION SHOULD BE WORN DURING RETAINING RING
REMOVAL.
13. To remove cluster gear (206) from carrier, remove
retaining ring (208) from planet shaft (205) and drive
planet shaft out of carrier.
14. Cluster gear and bearings (203, 204) can now be
slid out of carrier and spacer (207) removed from
carrier bore. If bearing cups (203) require replacing
they can be driven out of cluster gear counterbores.
15. Repeat steps (12) and (13) for remaining cluster
gears.
WHEN REBUILDING THE UNIT, O-RINGS AND RETAINING RINGS
SHOULD ALWAYS BE REPLACED.
Cleaning and Inspection
1. Thoroughly clean all parts in an approved cleaning
solvent.
2. Inspect geared or splined components in primary
and secondary planet carriers, input and output sun
gears, ring gear, coupling and input shaft for
chipped or broken teeth, and excessive or uneven
wear patterns. Replace components as necessary.
3. Inspect all thrust washers for scoring, pitting, ero-
sion, discoloration or excessive wear. Replace thrust
washers as necessary.
4. Inspect all bearing cones and cups for scoring, pit-
ting or excessive wear. If necessary, using a suitable
press, remove bearing cups from hub and replace
bearings as a set.
5. Inspect all needle rollers for scoring, pitting or
excessive wear. Replace all rollers as necessary.
6. Inspect planet gear pins for grooves, scoring or
excessive wear. Replace pins as necessary.
7. Inspect all threaded components for damage includ-
ing stretching, thread deformation, or twisting.
Replace as necessary.
8. Inspect oil seal surfaces in hub and spindle for burrs
or sharp edges. Dress applicable surfaces or
replace components as necessary.
9. Inspect mating surfaces of hub, ring gear and cover
for burrs and sharp edges. Dress applicable sur-
faces or replace components as necessary.