JLG 3969electric ANSI Service Manual - Manual (Page 26)

SECTION 2 - PROCEDURES
2-14
– JLG Sizzor– 3120768
3. Place o-ring into hub counterbore. Use petroleum
jelly to hold in place. Locate and mark the four
counter beamed holes in the face of the housing.
This is for identification later in the assembly.
4. Thrust spacer (25) is installed into the bore of the
output shaft. This should be a slip fit and the thrust
spacer should rotate in this location.
5. Place carrier assembly on a flat surface with the gear
cluster 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 facing down, place
ring gear over (into mesh with) cluster gear. 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 and cluster gear in mesh,
place small side of cluster gear into mesh with the
internal gear and sun gear. On the ring gear, locate
the hole marked “X” over one of the marked coun-
terbored holes in hub.
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. Sun gear is installed, meshing with the teeth of the
large diameter cluster gear. The counterbore on the
sun gear locates on the shoulder of the input spacer.
This is to be a slip fit and should operate freely.
9. Thrust washer is installed onto the sun gear and
should locate on the gear teeth shoulder.
10. Thrust washer is installed into the counterbore of the
carrier.
11. Place o-ring into input cover counterbore. Use petro-
leum jelly to hold o-ring in place.
12. The input cover is now installed on this assembly.
Taking care to correctly align pipe plug hole with
those in the hub, usually 90 degrees to one another,
locate the four counterbore holes in housing,
marked in step (3) and install four shoulder bolts. A
tap with a hammer may be necessary to align shoul-
der bolt with hub counterbore.
13. Install bolts into remaining holes.
14. Pipe plugs are to be installed into input cover using
a lubricant seal.
15. Torque bolts (28 & 29) to 23 - 27 ft. lbs. (31- 36 NM).
16. Fill unit one-half full with EP90 lubricant.
2.17 DRIVE BRAKE ASSEMBLY
Disassembly
1. After removing brake from its installation, place
brake on a clean dry work bench with mounting
plate uppermost.
2. Unscrew the socket head bolts in equal increments
to ensure the spring pressure within the brake is
reduced gradually and evenly.
3. Remove and lay aside the shaft and mounting plate
sub-assembly. Should it be necessary to replace
ball bearings, retainer rings and press bearing off.
4. Remove friction plate and spacers and set aside.
Spacers are factory set for each brake to obtain
required air-gap and are not interchangeable
between brakes.
5. Armature and compression springs can be removed
and set aside.
Inspection
1. Inspect the friction plate and the mating surfaces on
the armature and mounting plate for wear and/or
damage.
2. Examine the compression spring.
3. Examine the friction plate and the shaft for wear and/
or damage to the spline.
4. Examine the pole faces of the magnet and the arma-
ture 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 for axial float and/or wear.
NOTE: It is essential when replacing the friction plate that
spacers are also replaced.
Assembly
1. Clean all parts thoroughly.
2. Reverse disassembly procedure above, taking par-
ticular care with the assembly sequence of the fric-
tion plate.
NOTE: Assemble friction plate with two center-punches fac-
ing towards mounting plate.
3. If a new plate has been fitted, then new spacers will
have to be adjusted for air gap of 0.014 - 0.024
inches (0.35 - 0.60 mm).
4. After checking air gap, connect power supply.