JLG Skytrak 6036 Service Manual page 77

c. Cleaning and Drying
1. Disassemble and clean all parts using an
approved cleaning fluid.
2. Remove any burrs or rough spots from any
machined surfaces.
d. Inspection and Replacement
1. Individually inspect each cross, bearing caps
and needle bearings for signs of wear or
missing parts.
NOTE: If all parts of the cross assemblies check
to be in good condition, pack the bearing caps with
a good grade of MP grease. Reassemble equal
numbers of needle bearings into each cap and
reassemble the cross assembly into the drive shaft
yokes.
2. Replace the cross assembly as a complete
assembly if any parts are worn or missing.
3. Replace the felt seal if worn or damaged.
4. Replace the sleeve or shaft assemblies if they
are severely dented or damaged.
5. Cross assemblies should flex and be free from
excessive bind. A slight drag is desirable on a
new cross assembly. Excessive looseness
causes unbalance.
e. Assembly
1. Install dust cap, Fig. 6.1, split retaining ring,
and felt seal on the shaft assembly.
2. Slide the sleeve assembly onto the splines of
the drive shaft and tighten the dust cap.
IMPORTANT: Be sure that the arrows or marks on
the shaft and sleeve assemblies are aligned, since
the yokes on both ends of the drive shaft must be
in the same plane to prevent excessive vibration.
3. Install the cross and both bearings in the yoke.
4. Install the two retaining rings in their grooves in
the yoke.
5. Repeat steps 3 and 4 for the other cross
assembly.
6. Using the grease fitting on the sleeve assem-
bly, lubricate the shaft assembly spline with a
multi-purpose lithium-based grease.
7. Temporarily tape the two loose bearing caps to
the cross so they do not fall off during assem-
bly of drive shaft onto the forklift.
f. Installation
Model 6036 S/N 9B0499 and Before
Section 6. Drive Shafts and Drop Box
Drive Shaft–Transmission to Drop Gear Box
1. Position the drive shaft assembly on the forklift
so slip joint mounts to the drop box, Fig. 6.1.
2. Remove tape and secure this end of the drive
shaft cross assembly to the transmission
output shaft yoke with a cap and bolt assembly
or bearing straps. Torque the cap and bolt
assembly to 30 to 35 lb-ft (41 to 48 N m) or the
bearing strap to 55 to 60 lb-ft (75 to 82 N m).
3. Slide slip joints as far as possible onto drive
shaft, remove taps and secure the drive shaft
cross assembly to the drop box input shaft
yoke with a U-bolt assembly or bearing strap.
Torque the U-bolt assembly to 20 to 24 lb-ft (27
to 37 N m) or the bearing strap to 55 to 60 lb-ft
(75 to 82 N m).
4. Install the transmission cover on the forklift.
Drive Shafts–Drop Gear Box to Axle
1. Position the drive shaft on supports under the
fork lift so slip joint mounts to the drop box,
Fig. 6.1.
2. Secure this end of the drive shaft cross
assembly to the axle input shaft yoke with a U-
bolt assembly. Torque the U-bolt assembly to
20 to 24 lb-ft (27 to 37 N m).
3. Slide slip joint as far as possible into drive
shaft, remove tape and secure the drive shaft
cross assembly to the drop box output shaft
yoke with a U-bolt assembly. Torque the U-bolt
assembly to 20 to 24 lb-ft (27 to 37 N m).
4. Remove supports from under the forklift.
6.2 DROP GEAR BOX
6.2.1 End Yokes
a. Inspection
Replace end yoke (3, Fig. 6.4) if worn or damaged.
b. Removal
To remove end yoke, remove screw (1, Fig. 6.4),
washer (2) and end yoke (3).
c. Installation
To install end yoke, press yoke (3, Fig. 6.4) on
shaft and secure with washer (2) and screw (1).
6.2.2 Oil Seals
6-3