JLG 460SJ ANSI Service Manual - Manual (Page 141)

SECTION 3 - CHASSIS & TURNTABLE
3120788 – JLG Lift – 3-87
Rotor Replacement
1. Remove coupling guard held with two 10/32 screws.
2. Un-bolt motor mount from welder (four each 5/16-18
Screws)
3. Loosen setscrew and coupling and remove from
welder shaft.
4. Remove two each fan grids.
5. Un-bolt welder from base.
6. Remove receptacle panel.
7. Remove rails - each held with two 5/16-18 screws.
8. Remove brush holder held with one screw.
9. Remove four plastic stop nuts holding front shield
(fa housing).
10. With gear puller push out rotor from slip ring side.
11. Remove rotor assembly from stator.
12. Remove snap ring from shaft end which had cou-
pling on it.
13. Push rotor out of front shield.
14. Examine bearing and front shield to be sure it does
not need to be replaced.
15. Push new rotor into front shield.
16. Re-install small snap ring.
17. Be sure snap ring is in groove.
18. Carefully re-install rotor into stator (use rubber mallet
to tap in place).
19. Re-install four elastic stop nuts.
20. Tighten elastic stop nuts in a cris/cross manner.
21. Turn rotor by hand to make sure it turns freely.
22. If rotor seems not to turn freely, tap the casting with
a small metal hammer on the slip ring end casting.
(this will seat the bearing)
23. Apply 12 volts to the slip ring for about 20 sec-
onds.(this will make sure that the residual magne-
tism is energized)
24. Re-install brush holder.
25. Check for brush alignment to slip ring.
26. Re-install the rails.
27. Re-install the two fan grids.
28. Heat the coupling to 300 degrees.
29. Install 24mm coupling too welder shaft. The shaft
extrudes at least 1/4 of a inch threw the coupling.
30. Re-install receptacle panel.
31. Re-install welder on base plate.
32. Lift motor mount onto welder.
NOTE: Be sure coupling jaws are aligned.
33. Mount with four each 5/16-18 1 inch screws ad lock
washers.
34. Slide coupling together and tighten setscrews.
35. Re-install coupling cover with 2 10/32 screws.
Replacement of Flow Regulator
1. Remove pressure line from flow regulator.
2. Remove case drain line.
3. Remove four bolts holding flow regulator to motor.
NOTE: Be sure seals on motor are still in place
4. Push four bolts threw mounting holes on flow regu-
lator.
5. Push flow regulator onto back of motor, align four
bolts, tighten four bolts.
NOTE: Do not over tighten bolts, mounting flange is alumi-
num.
6. Re-install case drain line.
7. Re-install pressure line.
Replacement of Exciting Rectifier Bridge
1. Remove receptacle panel.
2. Remove wires from Excitation Bridge and transfer to
replacement Bridge.
NOTE: Be sure that the positive wire is on the positive termi-
nal and the AC wires are connected to the AC termi-
nals.
3. Remove defective Rectifier Bridge with one screw in
center.
4. Install new rectifier bridge with same screw.
5. Remount receptacle panel.