JLG 45e Service Manual - Manual (Page 66)

SECTION -
-40 – JLG Lift – 3120861
9. The spindle (1) may now be pressed out of the
housing (7).
10. The bearing cups (3 and 5) will remain in housing (7)
as will bearing cone (6). Bearing cone (4) will remain
on the spindle (1). The seal (2) 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 (19) from the carrier
(14), drive the roll pin (20) into the planet shaft (18).
The planet shaft may now be tapped out of the car-
rier. After planet shaft has been removed, the roll pin
(20) can be driven out.
12. The cluster gear (19) can now be removed from the
carrier (14). The tanged thrust washer (15) will be
removed from the cluster gear.
13. The needle bearings (16) and thrust spacer (17) are
now removed from cluster gear (19).
NOTE: When rebuilding or repairing the unit, the retaining
ring (9), o-rings (22), and lip seal (2) should always
be replaced.
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.