JLG 450A_AJ Series II Service Manual - Manual (Page 60)

SECTION 3 - CHASSIS & TURNTABLE
3-10 – JLG Lift – 3121180
SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE OR
SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION.
1. Compress 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 Pis-
ton (2-8). Tighten screws incrementally until spring
force is removed from Retaining Ring (2-6).
2. Using a small pry bar or screwdriver, pry one end of
Retaining Ring (2-6) out of groove in Spindle (1A).
Using pliers, pull Retaining Ring (2-6) out of groove.
3. Back Socket Head Cap Screws (2-11) incrementally
out of Piston (2-8) until spring force is relieved from
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).
6. Using an air hose, slowly and carefully pressurize
brake port in Spindle (1A) until Piston (2-8) comes
out of piston bore of Spindle (1A). Pull Piston (2-8)
the rest of the way out of 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).
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
SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE OR
SERIOUS INJURY. ALWAYS WEAR EYE PROTECTION.
11. Apply a liberal coat of grease to bore of Input Planet
Gear (3F).
12. Line inside of Planet Gear (3F) with 14 Needle Roll-
ers (3C).
13. Set Carrier (3A) in an upright position.
14. Insert a Planet Shaft (3E) into planet shaft hole in
end of Carrier (3A) opposite splined end.
15. Place one Thrust Washer (3B) on end of Planet Shaft
(3E). Make sure flat faces towards inside of Carrier
and make sure button fits in pocket inside Carrier (3A).
16. Place one more Thrust Washer (3B) into Carrier (3A)
and align as in Step 5.
NOTE: Grease may need to be applied to Thrust Washers
(3B) to hold them in place when installing planet
gear. Instead of grease, insert washers from ID of
carrier for buttons to fit in pockets of carrier.
17. Following thrust washers, place Planet Gear (3F)
with needle rollers, into Carrier (3A) between Thrust
Washers (3B).
18. Push Planet Shaft (3E) through Planet Gear (3F) and
other Thrust Washer (3B) until it touches other side
of Carrier (3A).
19. Press Planet Shaft (3E) to 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 small shoulder in
Carrier (3A). This shoulder is intended to keep planet
pin from working loose in that direction during oper-
ation. It is
NOT intended to keep planet pin from
being pressed through carrier.
20. On side of Carrier (3A) where Planet Shaft (3E) was
inserted, stake Carrier (3A) in 3 places using a
punch and a hammer around Planet Shaft (3E) to
ensure shaft stays in place during operation.
21. Repeat Steps 1 through 10 for remaining Planet
Gears (3F).