JLG 510AJ Service Manual - Manual (Page 51)

SECTION 3 - CHASSIS AND TURNTABLE
3121181 – JLG Lift – 3-9
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE STEPS 1-3 IN THIS
PROCEDURE.
1. Compress the Compression 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
Piston (2-8) and tightening incrementally until spring
force has been taken off of the Retaining Ring (2-6).
2. Using a small pry bar or screwdriver, pry one end of the
Retaining Ring (2-6) out of the groove in Spindle (1A),
then, using pliers, pull Retaining Ring (2-6) the rest of
the way out of the groove.
3. Back Socket Head Cap Screws (2-11) incrementally out
of Piston (2-8) until spring force is relieved from the 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).
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN
THIS PROCEDURE.
6. Using an air hose, slowly and carefully pressurize the
brake port in the Spindle (1A) until the Piston (2-8)
comes out of piston bore of Spindle (1A), Then pull the
Piston (2-8) the rest of the way out of the 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 Spindle
(1A).
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE NEXT STEP IN
THIS PROCEDURE.
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
1. Apply a liberal coat of grease to the bore of one Input
Planet Gear (3F).
2. Line the inside of the Planet Gear (3F) with 14 Needle
Rollers (3C).
NOTE: The last roller installed must be installed end wise. That is,
the end of the last roller must be placed in between the
ends of the two rollers that form the space, and then slid,
parallel to the other rollers, into place.
3. Set Carrier (3A) in an upright position.
4. Insert a Planet Shaft (3E) into the planet shaft hole in the
end of the Carrier (3A) opposite the splined end.
5. Place one Thrust Washer (3B) onto the end of Planet
Shaft (3E). Make sure the flat faces towards the inside of
the carrier and make sure the button fits in the pocket
inside the Carrier (3A).
6. Place one more Thrust Washer (3B) into the Carrier (3A).
Align the Thrust Washer (3B) in the same manner
described in Step 5.
NOTE: Some grease may need to be applied to the Thrust Washers
(3B) to hold them in place while installing the planet gear.
Instead of using grease, washers can be inserted from the
ID of the carrier for buttons to fit in pockets of the carrier.
7. Following the thrust washers, place Planet Gear (3F)
with needle rollers, into the Carrier (3A) between the
Thrust Washers (3B).
8. Push the Planet Shaft (3E) through the Planet Gear (3F)
and the other Thrust Washer (3B) until it touches the
other side of the Carrier (3A).
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
9. Press the Planet Shaft (3E) until it is pressed to the
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 the small shoulder in Carrier (3A). This
shoulder is intended to keep the planet pin from working
loose in that direction during proper operation of the unit.
It is NOT intended to keep the planet pin from being
pressed through the carrier.
10. On the side of the Carrier (3A) where the Planet Shaft
(3E) was inserted, stake the Carrier (3A) in 3 places using
a punch and a hammer around the Planet Shaft (3E) to
assure the shaft stays in place during operation of the
unit.
11. Repeat Steps 1 through 10 for the installation of the two
remaining Planet Gears (3F).