Main Assembly - JLG 400S Service And Maintenance Manual

SECTION 3 - CHASSIS & TURNTABLE

Main Assembly

Refer to Figure 3-45.
1. Slightly tap the Internal Gear (2) with spline side down
onto Output Shaft (1A) splines to ensure Internal Gear
(2) is properly seated.
2. Grease and install O-ring (5) onto Housing (1G) o-ring
groove.
3. Grease and install Thrust Spacer (11) into counterbore of
Carrier Sub-assembly on smaller diameter cluster gear
side. The grease should hold the Thrust Spacer (11) in
place for assembly.
4. Place Carrier Sub-assembly onto table oriented as
shown above, with large end of Cluster Gear (3F) facing
up. Position all three punch-marks on the face of the
large gears at 12 o'clock. Timing marks on the two upper
Cluster Gears will be visible through the slots in the Car-
rier if the Cluster Gears are correctly marked. Secure gear
teeth using timing fixture.
5. Place Ring Gear (4) in to large end of Cluster Gear to
secure timing.
6. Remove Carrier sub-assembly and Ring Gear (4) from
the table and assemble into the Internal gear (2) being
careful to keep the ring gear, or sun gear, in mesh with
the cluster gears.
3-52
7. After engaging internal gear teeth and before rotating
carrier, look at the Carrier sub-assembly in the main
assembly and insure the timing is correct by locating the
timing marks in the slots in the carrier and at 12 o'clock
on the gear that the timing mark is visible in the carrier
bore.
8. Grease and install O-ring (5A) onto Brake Housing (6)
counterbore.
9. Install Brake Housing (6) onto Ring Gear (4) by aligning
the bolt holes in brake housing with ring gear holes.
10. Ensure the pipe plugs in Housing (1G) and Brake Hous-
ing (6) are timed as shown.
11. Pull one Cover Bolt (12) and place into the bolt hole and
repeat for remaining bolts.
12. Torque Bolts (12) in star pattern to 23-27 ft. lbs.
(31-36.5 Nm).
13. Install Input Shaft (8) with spline side up into housing
bore. Insure the input shaft gear teeth and planet gears
are engaged.
14. Install O-ring plugs (1P) into Brake Housing (6) and
Housing (1G). Torque 23 to 24 ft. lbs. (31 to 32.5 Nm).
15. The unit should now be leak and roll checked as per
instructions in this section.
16. Fill oil through the opening in Brake Housing (6) with
43 oz. (1.3 L) of 80W90 gear oil.
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