Service Manual Instruction Manual

SECTION 3 - CHASSIS & TURNTABLE
3121616 – JLG Lift – 3-39
Main Assembly
1. With Hub Shaft Subassembly resting on Shaft (1A) install
Internal Gear (2). The spline of Internal Gear (2) bore will
mesh with spline of Output Shaft (1A). This will be a
tight fit.
2. Inspect location of Internal Gear (2) on Output Shaft
(1A). A portion of Output Shaft (1A) should protrude
through Internal Gear (2) bore.
3. Install 4 Dowel Pins (13) into counter bore holes in Hub
(1G).
4. Install Thrust Washer (11) in counter bore of Carrier Sub-
assembly (Small Cluster-Gear end) Use grease to hold in
place.
5. Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place.
SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.
6. Place Carrier Subassembly on bench with large end of
Cluster Gears (3F) facing up with one at 12 o’clock posi-
tion. Find punch marked tooth on each gear at large end
and locate at 12 o'clock (straight up) from each planet
pin. Marked tooth will be located just under Carrier on
upper two gears. Check timing through slots in carrier.
(See Carrier Subassembly)
7. With longer shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) cluster gears
(3F). Be sure cluster gear timing marks (punch marks)
remain in correct location during Ring Gear (4) installa-
tion. Ring Gear (4) side with an "X" or punch mark
stamped on it should be up.
8. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
with Internal Gear (2). On Ring Gear (4), locate hole
marked "X" or punch marked over one of the marked
counter-bored holes (Step 5) in Hub (1G). Check timing
through slots in carrier. Rotate carrier in assembly to
check freedom of rotation.
NOTE: If gears do not mesh easily or Carrier Assembly does not
rotate freely, remove Carrier and Ring Gear. Check Cluster
Gear timing.
9. Install Thrust Washer (11) in counter bore on face of car-
rier. Use grease to hold in place.
10. Place O-ring (5A) into counter bore of Brake Housing (6).
Use grease to hold O-Ring in place.
SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.
11. Install Brake Housing (6). Align Pipe Plug hole (20) with
those in the Hub (1G).
12. Install Bolts (12) through Brake Housing (6) into Hub
(1G). Torque to 23 - 27 ft-lb (31-36 Nm).
13. With gearbox standing on pinion end, fill gearbox with
43 oz of ISO VG150 / VG220 gear oil.
14. Install Retaining Ring (44) in groove of Sun Gear (8).
15. Install Sun Gear (8) into mesh with Planet Gears (3F).
16. Install Pipe Plug (20) in Cover (6). Torque to 23 to 24 ft-lb
(31 - 32 Nm).
Figure 3-54. Main Assembly
44
8
20
6
11
5A
4
5
3F
11
2
13
1A