JLG 450A_AJ Series II Service Manual - Manual (Page 64)

SECTION 3 - CHASSIS & TURNTABLE
3-14 – JLG Lift – 3121180
Spindle-Brake Sub-Assembly
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-
OUS INJURY. ALWAYS WEAR EYE PROTECTION.
This procedure applies only to units with integral input
brake (2).
NOTE: For this procedure, use Brake Assembly Drawing,
which shows proper balloon numbers for individual
brake components. In the following instructions, if
the number has a “-” between two numbers, it refers
to Brake Assembly Drawing only and NOT Torque
Hub Assembly Drawing.
NOTE: The Koenig Expander Pressure Plug (12) requires a
special installation tool. It is not recommended to
remove this plug unless it is leaking. The installation
tool is available from KVT Solutioneering Group
(http://www.kvt-koenig.us) or their distributors as of
the date of this manual.
1. Install Pressure Plug (12) into Spindle (1A) using the
following procedure:
• Clean hole in spindle using appropriate Loctite spray
• Dip collar of plug in Loctite 290 or 680 (keep
unplugged portion of hole free of Loctite)
• Using appropriate tool, install plug flush with surface of
spindle
2. Place Spindle (1A) with splined end facing down.
Using appropriate tool (See back of manual), install
Retaining Ring (2-1) into spindle groove within
splines.
3. Place Washer (2-10) on top of Retaining Ring (2-1).
4. Place Stator (2-9) on top of Washer (2-10).
5. Place Rotor (2-12) on top of Stator (2-9).
6. Repeat steps 3 & 4 until there are a total of 8 Stators (2-9)
and 7 Rotors (2-12) installed.
7. Place Piston (2-8) with smaller O.D. end facing up.
8. Grease large Backup Ring (2-3) and install in large-
diameter groove at bottom of Piston (2-8).
9. Grease large O-Ring (2-2) and install in large diame-
ter groove at bottom of Piston (2-8), on top of large
Backup Ring (2-3).
10. Grease small O-Ring (2-5) and install in small diame-
ter groove near top of Piston (2-8). Make sure O-
Ring is seated in bottom of groove.
11. Grease small Backup Ring (2-4) and install in small
diameter groove near top of Piston (2-8), on top of
small O-Ring (2-5).
NOTE: If piston comes pre-assembled with shipping bolts
(2-11), skip to Step 15.
12. Insert Piston (2-8) into Spindle (1A) until it contacts
Stator (2-9).
13. Insert appropriate number of Springs (2-13) into Pis-
ton (2-8) counterbore. Use brake spring chart below
and a bill of materials for your particular model num-
ber to determine number of springs.
14. Place Pressure Plate (2-7) on top of Springs (2-13).
15. Using snap ring pliers, install Retaining Ring (2-6)
into groove in Spindle (1A) and on top of Pressure
Plate (2-7). Make sure Retaining Ring (2-6) is seated
properly in groove.
16. Remove Shipping Bolts (2-11) in brake pressure plate
to release springs in brake. Before removing bolts,
use Coupling (9 - Figure 3-11.) to center and align
Brake Rotors (2-12) with Spindle (1A).
BRAKE
CODE
BRAKE P/N
NUMBER
OF SPRINGS
A 902337 12
B 902341 10
C 902342 8
D 902343 6
E 902345 9