JLG 1100S Service Manual - Manual (Page 90)

SECTION 3 - CHASSIS & TURNTABLE
3-48 – JLG Lift – 3121256
Main Assembly
1. With the Hub Shaft Sub-Assembly resting on the
Shaft (1A) install Internal Gear (2). The spline of the
Internal Gear (2) bore will mesh with the spline of the
Output Shaft (1A).
2. Inspect the location of the Internal Gear (2) on the
Output Shaft (1A). The portion of the Output Shaft
(1A), which does not have full spline, should pro-
trude through the Internal Gear (2) bore.
3. Install two Thrust Washers (15) and one Thrust Bear-
ing (16) on the portion of Output Shaft (1A) which
protrudes through Internal Gear (2).
4. Center the Input Gear (13) on the end of the Output
Shaft (1A) opposite the gear with the large diameter
down.
5. Place O-ring (5) into Hub counter-bore. Use grease
to hold O-ring in place.
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE
SEATING THIS O-RING.
6. Also at this time locate and mark the four counter
reamed holes in the face of the Hub (1G). This is for
identification later in the assembly.
7. Place Carrier (3A) Subassembly on bench with the
large end of Cluster Gears (3F) up with one at the 12
o clock position. Find the punch marked tooth on
each gear at the large end and locate at 12 o'clock
(straight up) from each planet pin. Marked tooth will
be located just under the Carrier on upper two
gears. Check the timing through the slots in the car-
rier.
8. With large shoulder side of Ring Gear (4) facing
down, place Ring Gear (4) over (into mesh with)
large end of gears. Be sure that punch marks remain
in correct location during Ring Gear (4) installation.
The side of the Ring Gear (4) with an "X" or punch
mark stamped on it should be up.
9. While holding Ring Gear (4) and Cluster Gears (3F)
in mesh, place small end of Cluster Gears (3F) into
mesh with the Internal Gear (2) and Input Gear (13).
On the Ring Gear (4) locate the hole marked "X", or
punch marked, over one of the marked counter-
bored holes (Step 5) in Hub (1G). Check timing
through the slots in the carrier. Rotate carrier in
assembly to check for freedom of rotation.
NOTE: NOTE: If gears do not mesh easily or Carrier Assem-
bly does not rotate freely, then remove the Carrier
and Ring Gear and check the Cluster Gear timing
10. Install Thrust Washer (15)/Thrust Bearing (16) set
into the counter-bore in the face of the carrier. Use
grease to hold in place.
11. Place O-ring (5) into Cover (6) counter-bore. Use
grease to hold O-Ring in place.
CAUTION: BEWARE OF SHARP EDGES OF THE COUNTER-BORE
WHILE SEATING THIS O-RING.
12. Using sufficient grease to hold in place, install Thrust
Washer (8) into the counter-bore of the interface of
the Cover (6).
13. The Cover (6) is now installed, taking care to cor-
rectly align Pipe Plug hole (20) with those in the Hub
(1J). Check timing sheet.
14. Locate the 4 counter-bored holes in Hub (1G)
[marked in Step 5] and install 4 Shoulder Bolts (18)
with Lockwashers (19). Start the shoulder bolts by
hand.
15. Install Grade 8 Bolts (17) with Lockwashers (19) into
remaining holes.
16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65
Nm) and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to
65 Nm). Roll and leak test the assembly.
17. With gearbox standing on the pinion end fill gearbox
with GEAROIL 80W90, to bottom of plug hole in
cover at Pipe Plug (20).
18. Install Pipe Plug (20) into Cover (6) using thread
sealant.