JLG 800S Service Manual - Manual (Page 88)

SECTION 3 - CHASSIS & TURNTABLE
3-42 – JLG Lift – 3121139
1. Compress the Compression Springs (2-13) by
installing a minimum of three M4 x 16mm Socket
Head Cap Screws (2-11) equally spaced through
End Plate (2-7) and into Piston (2-8) and tightening
incrementally until spring force has been taken off of
the Retaining Ring (2-6).
2. Using a small pry bar or screwdriver, pry one end of
the Retaining Ring (2-6) out of the groove in Spindle
(1A), then, using pliers, pull Retaining Ring (2-6) the
rest of the way out of the groove.
3. Back Socket Head Cap Screws (2-11) incrementally
out of Piston (2-8) until spring force is relieved from
the End Plate (2-7).
4. Remove Socket Head Cap Screws (2-11) and End
Plate (2-7) from brake cavity in Spindle.
5. Remove Compression Springs (2-13) from Piston (2-
8).
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE
NEXT STEP IN THIS PROCEDURE.
6. Using an air hose, slowly and carefully pressurize
the brake port in the Spindle (1A) until the Piston (2-
8) comes out of piston bore of Spindle (1A), Then
pull the Piston (2-8) the rest of the way out of the
Spindle (1A) by hand.
7. Remove Backup Rings (2-3) & (2-5) and O-rings (2-
2) & (2-4) from Piston (2-8).
8. Remove Rotors (2-12) and Stators (2-9) from Spin-
dle (1A).
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE
NEXT STEP IN THIS PROCEDURE.
9. Invert Spindle (1A) and, using retaining ring pliers,
remove Retaining Ring (2-1).
10. Remove Spacer (2-10) from Spindle.
Input Carrier Sub-Assembly
1. Apply a liberal coat of grease to the bore of one
Input Planet Gear (3F).
2. Line the inside of the Planet Gear (3F) with 14 Nee-
dle Rollers (3C).
NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in
between the ends of the two rollers that form the
space, and then slid, parallel to the other rollers, into
place.
3. Set Carrier (3A) in an upright position.
4. Insert a Planet Shaft (3E) into the planet shaft hole in
the end of the Carrier (3A) opposite the splined end.
5. Place one Thrust Washer (3B) onto the end of Planet
Shaft (3E). Make sure the flat faces towards the
inside of the carrier and make sure the button fits in
the pocket inside the Carrier (3A).
6. Place one more Thrust Washer (3B) into the Carrier
(3A). Align the Thrust Washer (3B) in the same man-
ner described in Step 5.
NOTE: Some grease may need to be applied to the Thrust
Washers (3B) to hold them in place while installing
the planet gear. Instead of using grease, the washers
could be inserted from the ID of the carrier for the
buttons to fit into pockets of the carrier.
7. Following the thrust washers, place Planet Gear (3F)
with needle rollers, into the Carrier (3A) between the
Thrust Washers (3B).
8. Push the Planet Shaft (3E) through the Planet Gear
(3F) and the other Thrust Washer (3B) until it
touches the other side of the Carrier (3A).
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
9. Press the Planet Shaft (3E) until it is pressed to the
appropriate depth.
NOTE: If planet shaft locating tooling is not available, press
lightly on Planet Shaft (3E) and make sure not to
press Planet Shaft (3E) through the small shoulder in
Carrier (3A). This shoulder is intended to keep the
planet pin from working loose in that direction during
proper operation of the unit. It is
NOT intended to
keep the planet pin from being pressed through the
carrier.
10. On the side of the Carrier (3A) where the Planet
Shaft (3E) was inserted, stake the Carrier (3A) in 3
places using a punch and a hammer around the
Planet Shaft (3E) to assure the shaft stays in place
during operation of the unit.
11. Repeat Steps 1 through 10 for the installation of the
two remaining Planet Gears (3F).