Oshkosh JLG 1500SJ, Service And Maintenance Manual

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SECTION 3 - CHASSIS & TURNTABLE
3121262 – JLG Lift – 3-71
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 Out-
put Shaft (1A). The portion of the Output Shaft (1A),
which does not have full spline, should protrude
through the Internal Gear (2) bore.
3. Install two Thrust Washers (15) and one Thrust Bearing
(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 iden-
tification 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 carrier.
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 loca-
tion 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 free-
dom 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
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 correctly
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 Lockwash-
ers (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.