National Crane Published 5-27-2018 Control # 039-06 7-9
800D SIDE SHIMMING OF BOOM SECTIONS
10. Remove race (12) from input planet set (13).
11. Remove input planet set (13) from gear housing (7) by
pulling straight up and out of the housing.
12. Remove retaining ring (41), press out the planet pins
(40), remove the planet gear (38), and needle bearings
(39), inspect for unusual wear. Replace as required.
13. Remove race (12) from output planet set (10).
14. Remove the output sun gear (11), from the output planet
carrier (10). Lift the output planet set out of the housing
(7).
15. Remove the retaining ring (48). Press out the planet pins
(47); remove the planet gear (45) and needle bearings
(44). Inspect for unusual wear. Replace as required.
16. Remove bearing lock nut (35) and lock washer (34).
17. Remove the pinion shaft (1) from the housing (7) inspect
the pinion shaft, seal, and bearing for wear and replace if
necessary. Remove the inboard bearing (9) and inspect
for wear.
18. Remove outboard seal (2) and bearing (3) Inspect for
wear and replace if necessary.
Assembly Procedure
1. Press the inboard and outboard bearing cup (4 & 8,
Figure 7-1) into the gear housing (7) if replaced.
2. Grease pack the bearing cones (9 & 3) with EP-2 before
installation.
3. Install the outboard cone (3) into the outboard cup (4).
Press the seal (2) into the gear housing (7) from the
outboard side.
4. Slide the output pinion (1) into the housing (7) from the
outside.
5. Install the inboard bearing cone (9).
6. Apply Loctite® to pinion shaft and locknut.
7. Install the bearing lockwasher (34) then the bearing
locknut (35). Torque locknut to 50 lb-ft. Loosen and
rotate pinion 90 degrees, re-torque locknut to 50 lb-ft.
(repeat this process 4 times) then re-tighten locknut to
20 lb-ft. If the locknut is between tabs on the lockwasher
always tighten until tabs align with slots in locknut.
Secure locknut by bending tabs on lockwasher so that it
engages locknut to prevent locknut from backing off.
NOTE: Install a 5/8-11 bolt into the end of the pinion
shaft on the outboard side and check the rolling torque.
Preload of the bearing torque should be 50-75 lb-in.
8. Install the output carrier (10) into the gear housing (7).
Install sun gear (11) and then the race (12) into output
carrier (10).
9. Install the input carrier section (13) with race (12).
10. Assemble the brake section by first installing the o- ring
(14) on the brake housing (15). Install eight capscrews
(18) to the brake housing (15) and torque to 10 ft. lbs.
NOTE: Notice the position of the brake port in
conjunction with the drain and fill holes in the housing.
11. If applicable install piston (36) into brake housing (15).
NOTE: Apply a slight film of oil on the o-rings and back-
up rings before installation.
12. Insert the brake driver (27) into the assembled brake
housing (15).
13. Install the stator plates (19) and friction disks (20)
starting with one stator plate and alternating between
friction disk and stator plate until six stator plates and
five friction disks are used. NOTE: Soak friction disk in
EP-90 oil before installation.
14. Carefully press the assembled piston (25) into the brake
housing (15), taking care not to damage the o- rings.
NOTE: Notice the position of the dowel pin hole in piston
with the brake release port for correct assembly.
15. Install six springs (33) into the holes in the piston (
25).
16.
Mount the motor adapter (30) to the brake housing (15)
with eight caps crews (32) checking to make sure the roll
pin (26) is in line with the dowel hole in piston (25).
NOTE: Notice the position of the motor mounting hole in
relation to the brake release port for correct re-
assembly.
17. Mount the motor to the adapter (30).
18. Fill the gearbox to desired level with EP-90 gear lube.
Fo
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