JLG 1230ES Service Manual - Manual (Page 53)

SECTION 4 - BASE COMPONENTS
3121222 – JLG Lift – 4-17
Drive Motor - Reassembly
(See Figure 4-5.)
1. After inspection and servicing, reassemble the wir-
ing in the commutator end head (9) as originally
found. Ensure the wiring does not contact metal
parts and that it allows the brushes to move unre-
stricted in the holders. Motor terminals must be
assembled as shown (See Figure 4-8.). Torque bot-
tom terminal nut to 110-140 in-lb [12.4-15.8 N-m].
2. After the motor has been disassembled, it is recom-
mended that new bearings be installed because
bearings may have been damaged during removal.
Although the bearings may appear and feel good,
the bearing races could be "brinelled" (races or balls
deformed) and may exhibit noise and vibration prob-
lems or fail within a relatively short period of service.
Press a new bearing into the commutator end head,
pressing on the outer race only. (See Figure 4-9.)
Replace the snap ring (6) in the snap ring groove.
3. Press the armature (2) commutator end into the
commutator end head and bearing assembly, care-
fully supporting the inner-race of the bearing. (See
Figure 4-9.).
4. Carefully release the brush springs (4) allowing the
brushes to contact the commutator. Make sure
brush shunts do not interfere with spring movement.
5. Assemble the commutator end head to the frame
and field assembly (1) and tighten the screws to
120-140 in-lb [13.6-15.8 N-m]. Make sure to align
the field connection with the notch in the commuta-
tor end head. Seal wires where they exit from com-
mutator end head with a small amount of RTV
Silicone Sealant.
6. Align wires from brake assembly (11) into notch in
friction disc (10). Install both items onto shaft of
motor aligning wires with groove in commutator end
head. Secure brake assembly to commutator end
head using 3 bolts and apply small bead of RTV Sili-
cone sealant around wires between friction disc and
commutator end head and in notch in friction disc.
7. Install wire harness (8) to motor by connecting the
field and brake connectors and securing the arma-
ture terminals to the terminal studs. Refer to Figure
4-7. for proper connections. Motor terminals must
be assembled as shown (See Figure 4-8.). Always
secure the bottom nut with a wrench as you tighten
the top nut. Torque top nut to 90-110 in-lb [10.2-12.4
N-m].
8. Remove manual release screws from brake assem-
bly. Apply new o-ring (13) and affix cover (15) to
motor using the 2 manual release screws. A small
dab of RTV Silicone sealant may be used to secure
the o-ring into the o-ring groove in the cover to aid in
assembly.
9. Assemble strain relief bushing (14) around jacket of
wire harness and slide into slot in cover.
10. Align cover plate (12) with groove in frame and field
and affix using 2 screws.
11. Reinstall motor per instructions - See Page 4-28.
Figure 4-8. Motor Terminal Assembly
Figure 4-9. Bearing Replacement Procedure