JLG M600 Service Manual - Manual (Page 78)

SECTION 3 - CHASSIS & TURNTABLE
3-40 – JLG Lift – 3121813
Main Assembly
(See Figure 3-21., Main Disassembly)
1. With the Housing-Shaft Subassembly resting on the
Shaft (1A) install one Dowel Pin (14) into each of the
four counter-bored holes in the Housing (1G) (See
assembly drawing) until they bottom out. Also at this
time, mark the four Dowel Pin (14) holes on the O.D.
of the Housing (1G) (See assembly drawing). This is
for identification later in the assembly.
2. Install Thrust Spacer (28) into counter-bore in
splined end of the Output Shaft (1A).
3. Place O-Ring (5) into Housing (1G) counter-bore.
Use grease to hold O-ring in place.
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE
SEATING THIS O-RING.
4. Install Carrier Subassembly with splined end down
so that the spline of the Carrier Subassembly is in
mesh with the spline of the Housing-Shaft Subas-
sembly. Rotate carrier in assembly to check for free-
dom of rotation.
5. With large shoulder side of Ring Gear (2) facing
down, place Ring Gear (2) onto Housing-Shaft Sub-
assembly with gear teeth in mesh with the Planet
Gears (3f) in the Carrier (3A). The side of the Ring
Gear (4) with an "X" or punch mark stamped on it
should be up and the marked hole should be at a
Dowel Pin (14) location.
Motor-Brake Subassembly
(See Figure 3-19., Motor and Brake Disassembly)
1. Place Brake Housing (6) on bench with flange end
down. Either block Brake Housing (6) up or place
over hole in bench large enough for the shoulder of
the Sun Gear (9) to rest on the bottom of the Brake
Housing (6). Then install Sun Gear (9) with gear end
down into Brake Housing (6).
2. Place Spacer (8-5) into Brake Housing (6) in bottom
of small counter bore below splines.
3. Install brake disks, starting with an Outer Plate (8-3),
then alternating Inner Plates (8-4) and Outer Plates
(8-3) into splined bore.
4. Grease the O Rings (8-1A) & (8-1C) and Backup
Rings (8-1B) & (8-1D), and place them in their
respective grooves in the Piston (8-2). Make sure the
backup-rings are correctly positioned as per the
assembly print.
NOTE: Be sure that Backup Rings (8-1B) & (8-1D) are
located as tightly into the grooves in the Piston (8-2)
as possible to prevent them from being “shaved”
when Piston (8-2) is installed into Brake Housing (6).
5. Apply grease sparingly to Piston (8-2) O.D. and the
cylinder bore of Brake Housing (6). Insert Piston (8-
2) into cylinder of Brake Housing (6), be sure not to
cut the O Rings (8-1A) & (8-1C) or Backup Rings (8-
1B) & (8-1D).
6. Install Compression Springs (8-6) into spring pock-
ets in Piston (8-2).
7. Install Compression Springs (8-7) into Compression
Springs (8-6) in spring pockets in Piston (8-2).
8. Grease O-Ring (26) and install into counter-bore in
Brake Housing (6).
9. Assemble Test Cover (See Tools at back of manual
for drawing) to Brake Housing (6) using four Bolts
(15) evenly tightening Bolts (15) to 80-100 ft-lbs.
10. Check the brake for release. Apply pressure to
brake port in side of Brake Housing (6) while trying
to rotate Sun Gear (9) by hand. The brake should
release between 200-255psi. Remove Test Cover.
11. Assuming that Brake passed the Brake Test, place
Motor (10) into Brake Housing (6) with splines of
Motor (10) meshing with splines of Sun Gear (9).
12. Attach Motor (10) to Brake Housing (6) with four
Bolts (15) and torque to Bolts (15) to 80–100 ft-lbs.
13. 13. Install O-Ring Plug (13) and torque to 13–15 ft-
lbs.
Motor-Brake Assembly
(See Figure 3-19., Motor and Brake Disassembly)
1. Grease Thrust Washer (11) and install into counter-
bore of Carrier Subassembly, which should already
be installed into the Main Subassembly.
2. Grease O-Ring (5A) and install into counter-bore of
the Brake Housing (6) in the Motor-Brake Subas-
sembly.
3. Install Motor-Brake Subassembly onto Main Assem-
bly using twelve Bolts (12). Torque bolts to 23 – 27 ft-
lbs.