JLG 800S Service Manual - Manual (Page 73)

SECTION 3 - CHASSIS & TURNTABLE
3121139 – JLG Lift – 3-27
Repair
1. Cover Assembly.
a. Remove two bolts (25) securing disconnect cap
(26) to cover (23) and remove cap.
b. Remove two bolts (25) securing cover cap (24)
to cover and remove cap.
c. Remove disconnect rod (27) from cap and
remove o-rings (28, 29) from cover cap. Discard
o-rings.
d. If necessary, remove pipe plug (30) from cover.
e. Clean and inspect parts in accordance with
Cleaning and Inspection procedures. Replace
parts as necessary.
f. If removed, screw pipe plug into cover.
g. Slip o-ring (29) over cover cap and against face.
h. Place o-ring (28) into cover cap internal groove.
Disconnect rod may be used to push o-ring into
groove.
i. Place cover cap into cover with large hole
located over pipe plug. Secure cover cap to
cover with two bolts. Torque bolts to 70-80 in.
lbs. (7.9-9.0 Nm).
j. Place disconnect cap over cover cap with nipple
facing out and secure with two bolts. Torque
bolts to 70-80 in. lbs. (7.9-9.0 Nm).
k. Turn cover over and push disconnect rod into
cover cap. Rod will be held in place by friction
from o-ring.
2. Carrier Assembly.
a. Drive anti-roll pin (19) into planet shaft (17) using
a suitable punch.
b. Using a suitable press, press planet shaft from
carrier (13). After planet shaft is removed, drive
anti-roll pin from shaft.
c. Remove cluster gear (18) and thrust washers
(14) from carriers.
d. Remove sixteen needle rollers (15) from cluster
gear bore.
e. Remove spacer (16) from cluster gear bore and
remove second set of sixteen needle rollers (15).
f. Repeat steps (a) through (e) for remaining two
cluster gears.
g. Clean and inspect all parts in accordance with
Cleaning and Inspection procedures. Replace
parts as necessary.
h. Apply a coat of grease or petroleum jelly to clus-
ter gear bore.
i. Place sixteen needle rollers into cluster gear
bore.
j. Place spacer into opposite side of cluster gear
and against needle rollers.
k. Place second set of sixteen needle rollers into
cluster gear.
l. Apply grease or petroleum jelly to tang side of
two thrust washers. Place thrust washers against
bosses in carrier with washer tang fitting into slot
in carrier outside diameter.