JLG 120-SXJ ANSI Service Manual - Manual (Page 40)

SECTION 3 - CHASSIS & TURNTABLE
3-12 – JLG Lift – 3121105
i. Align roll pin holes in both shaft (15) and carrier
(10) with chamfered portion of shaft hole upper-
most.
j. Position new roll pin (16) in hole in carrier (10)
and drive pin into hole until end of pin is flush
with carrier surface.
k. Repeat steps (a) through (j) for remaining two
cluster gears.
3. Position internal gear (19) on inner end of output
shaft (30).
4. Time carrier cluster gears as follows:
a. Place carrier assembly on a flat surface, posi-
tioning two top gears at ten o’clock and two
o’clock, and one bottom gear at six o’clock as
shown in Figure 3-8., Torque Hub Carrier Timing.
b. Find marked (punch mark) teeth on large gears.
Rotate gears until punch mark is located in a
straight up, 12 o’clock, position. Punch marks at
ten o’clock and two o’clock will be located just
under edge of carrier and not readily visible.
5. Place ring gear (7) over cluster gears (11), with
raised shoulder of ring gear facing down.
6. While holding ring gear (7) in position, invert carrier
assembly (10) so that ring gear and larger diameter
of cluster gears (11) are facing down.
7. Apply a light coating of petroleum jelly or multi-pur-
pose grease to inner thrust washer (8) and thrust
bearing (9).
8. Position thrust washer (8), thrust bearing (9), and
thrust washer (8) into applicable groove of carrier
assembly (10).
9. Apply a light coating of petroleum jelly or multi-pur-
pose grease to new inner o-ring (6).
10. Position o-ring (6) in groove in hub (24).
11. While holding ring gear (7) and carrier assembly
(10), insert smaller diameter of cluster gears (11)
into internal gear (19).
12. Rotate ring gear (7) until hole marked “X” is located
over hub shaft assembly (24).
13. Insert input gear (18) into carrier assembly (10) so
that input gear and larger diameter of cluster gears
(11) are in mesh. Check that carrier assembly (10)
rotates freely.
14. Position thrust washer (17) on shaft of input gear
(18).
15. Apply a light coating of petroleum jelly or multi-pur-
pose grease to new outer o-ring (6).
16. Position o-ring (6) into groove of cover (1).
17. Apply a light coating of petroleum jelly or multi-pur-
pose grease to outer thrust washers (8) and thrust
bearing (9).
18. Position outer thrust washer (8), thrust bearing (9)
and thrust washer (8) in cover (1).
19. Position cover (1) on ring gear (7) with oil check
plug (5) in cover located at 90° from oil fill plugs (25
and 26) in hub (24).
20. Install four shoulder bolts (3) and lockwashers (4)
into appropriate counterbored holes in hub (24).
21. Install eight bolts (2) which attach cover (1) to ring
gear (7) and hub (24) and tighten to a torque of 23-
27 ft.lbs. (3.2-3.7 kgm).
22. Carefully install hub pinion gear on splined output
shaft. If necessary, gently tap into position with a soft
headed mallet.
23. Apply No. 2 Lift Grade Loctite to pinion gear retain-
ing plate screws.
24. Position gear retaining plate and install attaching
screws.
25. Remove oil fill plug (25 or 26) and fill hub assembly
with approximately one quart of approved extreme
pressure gear lubricant. Install fill plug.
3.4 SWING BRAKE
1. Separate end cover (2) from housing (21) by remov-
ing capscrews (1).
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO
RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE
(3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN
POSITION WHILE REMOVING THE CAPSCREWS AND LOCK-
WASHERS.
2. Remove case seal (4) from the housing (21), then
remove bleeder screw (3) from the end cover (2).