Jlg 40H Service Manual User Manual download pdf (Page 92)

SECTION 2 - PROCEDURES

2-72 – JLG Lift – 3120240

Cleaning and Inspection.

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks,

and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly.

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Insert new o-ring 25, dowel pins 23, and springs

21,22 in housing 26.

2. Install new bearing 24 in housing and press until

bearing bottoms on shoulder in housing.

3. Position new large diameter disc 20 in housing with

tabs guided by dowel pins 23 until disc rests on

springs 21,22.

DISCS 16 & 20 AND FRICTION DISCS 18 SHOULD REMAIN DRY

DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED

TO CONTAMINATE DISC SURFACES.

4. Place a new friction disc 18 on bottom disc 20 cen-

tering it as closely as possible. Insert one spring 17

on each dowel pin 23.

5. Add additional new disc 16, and friction disc 18 and

springs 17 as required for specific model.

6. Install snap ring 14 on shaft 15. Insert shaft 15 thru

friction discs 18 until shaft contacts bearing 24.

Press shaft 15 until it shoulders on inner race of

bearing 24. A small preload will exist on snap ring 14

at this point.

7. Insert separators 19 over spiral pins in housing 26.

Separators will contact top of bottom disc 20 when

properly installed.

8. Install new o-ring 8, new back-up ring 9, new o-ring

11 and new back-up ring 12 on piston 10. Insert pis-

ton 10 into end cover 4 being careful not to shear o-

rings or back-up rings. Inserting 1/4-20UNC bolts in

piston may simplify installation.

9. Install new o-ring 6, new bearing 7, new square ring,

pipe plug 3, and bleeder screw 13 in end cover.

10. Position end cover 4 on housing, aligning dowel

pins 23 with holes in end cover.

11. Install capscrews 1 and lockwashers 2. Tighten

evenly to draw end cover 4 to housing and bearing 7

onto shaft 15. Torque capscrews to 55 ft. lbs. (75

NM).

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position

while tightening capscrews.

12. Press on inner ring of bearing 7 until it shoulders on

shaft 15 to eliminate binding on bearings. Be certain

to restrain opposite end of shaft to avoid excessive

thrust loading on bearing 24.

PRESS FORCE SHOULD BE LIMITED TO 2000 LBS (907.2 KG)

MAXIMUM TO AVOID POSSIBLE DAMAGE TO SNAP RING 14.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE

BRAKE ASSEMBLY. RELEASE PRESSURE SHOULD NOT EXCEED

2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE

USED FOR SUPPLEMENTAL CLAMPING.

Bleeding.

1. Install brake and connect pressure lines.

2. Bleed pressure release section of brake by pressur-

izing side inlet port and allowing air to escape from

top port. Pressure should not exceed 100 psi (6.9

Bar) during bleeding.

3. Apply sufficient pressure to release brake and check

for proper operation.

2.27 DRIVE BRAKE, MICO. (MACHINES BUILT

PRIOR TO MAY 1992)(SEE FIGURE 2-40.)

Disassembly.

1. Remove end cover 29 from housing 50 by removing

capscrews 26 and lockwashers 27.

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY

1500 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE

LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC

PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE

COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP-

SCREWS AND LOCKWASHERS.

2. Tap cover with a soft mallet in order to dislodge bearing 32 from cover.

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