JLG 680S, Service And Maintenance Manual

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SECTION 3 - CHASSIS & TURNTABLE
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Main Drive Assembly
NOTE: Refer to Figure 3-68., Main Drive 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). This will be a tight fit.
2. Inspect the location of the Internal Gear (2) on the Out-
put Shaft (1A). The portion of the Output Shaft (1A)
should protrude through the Internal Gear (2) bore.
3. Install 4 Dowel Pins (13) into counterbore holes in Hub
(1G).
4. Install Thrust Washer (11) in counterbore 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.
BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS
ORING.
6. Place Carrier Sub-Assembly on bench with the large end
of Cluster Gears (3F) facing 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 carrier (See Carrier Sub-Assem-
bly).
7. With large shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) cluster gears
(3F). Be sure that cluster gear timing marks (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.
8. 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). 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: If gears do not mesh easily or Carrier Assembly does not
rotate freely, then remove the Carrier and Ring Gear and
check the Cluster Gear timing.
9. Install Thrust Washer (11) into the counterbore on the
face of the carrier. Use grease to hold in place.
10. Place O-ring (5A) into counterbore of Brake Housing (6).
Use grease to hold o-ring in place.
BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING THIS O-
RING.
11. Install the Brake Housing (6), taking care to correctly
align Pipe Plug hole (20) with those in the Hub (I G).
12. Install Bolts (12) through the Brake Housing (6) into the
Hub (1G) and torque to 23-27 ft. lbs. (31-37 Nm).
13. With gearbox standing on the pinion end fill gearbox
with 43 oz. of ISO VG150/VG220 gear Oil.
14. Install Retaining Ring (44) into the groove in the Sun
Gear (8).
15. Install the Sun Gear (8) into mesh with the Planet Gears
(3F).
16. Install Pipe Plug (20) into Cover (6) torque to 23-24 ft. lbs.
(31-32 Nm).