Input Carrier Sub-Assembly; Output Planet Gear Sub-Assembly; Spindle - Brake Sub-Assembly - JLG 600A Service And Maintenance Manual

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 which 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. The end
of the planet shaft that does NOT have the roll pin hole
should be inserted into the carrier FIRST.
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
on the inside of the carrier (3A) towards the OD.
6. Following the thrust washer, place planet gear (3F) with
needle rollers, onto planet shaft (3E).
7. Following the planet gear, place one more thrust washer
(3B) onto planet shaft (3E). Align the thrust washer (3B)
in the same manner described in Step 5.
8. Now insert planet shaft (3E) through the opposite
planet shaft hole on carrier (3A). Use an alignment
punch or similar tool to align the roll pin holes on carrier
(3A) and planet shaft (3E).
NOTE: Be sure not to hit the Planet Gears (3F) when driving in the
Roll Pins (4G).
9. Drive roll pin (4G) down into the aligned roll pin holes.
pin should be flush with the flat of carrier.
10. Repeat steps 1-9 for the installation of the two
remaining planet gears (3F).
NOTE: Some grease may need to be applied to the thrust washers
(3B) to hold them in place while installing the planet gears.

Output Planet Gear Sub-Assembly

1. Apply a liberal coat of grease to the bore of one Output
planet gear (4F).
2. Line the inside of the planet gear (4F) with 14 Needle
rollers (4C).
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 which form the space, and then slid,
parallel to the other rollers, into place.
3. Place spacer (4D) into the bore of the output planet (4F).
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SECTION 3 - CHASSIS & TURNTABLE
4. Repeat Step 2 to put in second roll of needle rollers (4C).
5. Apply grease to hold two thrust washers (4B) together
and onto output planet gear (4F) counterbore. Do the
same to the other side.
6. Repeat steps 1-5 to finish the assembly of the two
remaining output planet gears (4F).

Spindle - Brake Sub-Assembly

1. Place spindle (1A) such that the flange side is up.
2. Place stator (8K) into the spindle (1A) scallop cuts.
3. Place rotor (8J) on top of stator (8K).
4. Repeat steps 2 & 3 until there are a total of 9 stators (8K)
and 8 rotors (8J) installed.
5. Place piston (8A) such that the smaller O.D. end is facing
upward. Grease the two O-rings and the two backup
rings.
6. Install large backup ring (8E) in the large-diameter
groove at the bottom of the piston (8A).
7. Install large O-ring (8D) in the large-diameter groove at
the bottom of the piston (8A), on top of the large
backup ring (8E).
8. Install small O-ring (8F) in the small-diameter groove
near the top of the Piston (8A). Make sure the O-ring is
seated on the bottom of the groove.
9. Install small backup ring (8H) in the small-diameter
groove near the top of the piston (8A), on top of the
small O-ring (8F).
10. Insert piston (8A) into spindle (1A) until it contacts the
stator (8K).
11. Insert the appropriate number of springs (8L), based on
the assembly print, into piston (8A) counterbore.
12. Place spring (1L) into coupling (7) counterbore. Place the
pressure plate (1M) on top of spring (1L).
13. Use appropriate tool to install retaining ring (1K) into
the retaining ring groove in the coupling (7)
counterbore.
14. Insert coupling sub-assembly (7) through rotors (8J).
15. Place pressure plate (8B) on top of springs (8L).
16. Use two ¼ -20 x 0.625 in. flat head capscrews (22) by
bolting the pressure plate (8B) and piston (8A) together
or some other appropriate tools to install retaining ring
on top of pressure plate (8B) until retaining ring (8C) is
seated.
NOTE: Remove 2 Screws from units when done, otherwise brake
will not function.
17. Install pipe plug (21) if applicable.
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