JLG 510AJ Service Manual - Manual (Page 55)

SECTION 3 - CHASSIS AND TURNTABLE
3121181 – JLG Lift – 3-13
Spindle-Brake Sub-Assembly
NOTE: This procedure applies only to units with integral input
brake (2).
NOTE: For this procedure, use the Brake Assembly Drawing, which
will show the proper balloon numbers for individual brake
components. In the following instructions, if the number
has a “-” between two numbers, it refers to the Brake
Assembly Drawing only and NOT the Torque Hub Assembly
Drawing.
NOTE: The Pressure Plug (12) requires a special tool for installa-
tion. It is not recommended to remove this plug unless it is
leaking. The plug is called a Koenig Expander. The installa-
tion tool is not supplied by Fairfield manufacturing, but
can be supplied by the manufacturer of the Koenig
Expander, Sherex Industries, or one of their distributors.
1. Install Pressure Plug (12) into Spindle (1A) using follow-
ing 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
SAFETY GLASSES MUST BE WORN DURING THE NEXT STEP.
2. Place Spindle (1A) such that the splined end is facing
down. Using appropriate tool (See back of manual),
install Retaining Ring (2-1) into the spindle groove
within the 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) such that the smaller O.D. end is facing
upward.
8. Grease the large Backup Ring (2-3) and install in the
large-diameter groove at the bottom of the Piston (2-8).
9. Grease the large O-Ring (2-2) and install in the large-
diameter groove at the bottom of the Piston (2-8), on
top of the large Backup Ring (2-3).
10. Grease the small O-Ring (2-5) and install in the small-
diameter groove near the top of the Piston (2-8). Make
sure the O-Ring is seated on the bottom of the groove.
11. Grease the small Backup Ring (2-4) and install in the
small-diameter groove near the top of the Piston (2-8),
on top of the 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 the
Stator (2-9).
13. Insert appropriate number of Springs (2-13) into Piston
(2-8) counterbore. Use brake spring chart below and a
bill of materials for your particular model number to
determine number of springs.
14. Place Pressure Plate (2-7) on top of Springs (2-13).
SAFETY GLASSES MUST BE WORN DURING THE NEXT TWO STEPS.
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 that Retaining Ring (2-6) is seated properly in
the groove.
16. Remove Shipping Bolts (2-11) in brake pressure plate to
release springs in brake. Before removing bolts, use the
Coupling (9) (See Assembly Drawing at back of manual)
to center and align the Brake Rotors (2-12) with the Spin-
dle (1A).
BRAKE
CODE
BRAKE P/N
NUMBER
OF SPRINGS
A 902337 12
B 902341 10
C 902342 8
D 902343 6
E 902345 9