4-4.3 Replacement Of Brake Assembly - Big Joe PPT 45 Series Operation, Maintenance, Repair Parts

4-4.3 Replacement of Brake Assembly

1. Disconnect battery.
2. Jack up the truck so the drive wheel is off the
ground; then securely block the truck to prevent
movement.
3. Remove screws (5, 7 and 9, Figure 4-6), lock-
washers, flat washers, upper and lower motor
compartment covers (6, 8 and 10).
4. Remove the four screws (1) securing the guard
ring (3) and slide the guard ring upwards as much
as possible.
CAUTION
Removing the mounting screws will loosen the
steering arm. Support the arm to prevent injury
from falling steering arm.
5. Remove the four screws (23, Figure 4-4) securing
the steering arm to the drive motor assembly.
NOTE: Use caution when removing the steering
arm that brake and control head cables
are not disconnected or damaged.
6. Remove the three brake assembly mounting bolts
(1, Figure 4-12).
1
2
4
Figure 4-12. Brake Parts
PPT0104-901336
7. Trace the wire harness to the Creep and Deadman
switches.
Note connections before removing wires.
Remove the wires from the two switches and dis-
connect the three wire connector.
8. Cut the red and blue wires as close to the crimp-on
connector as possible.
NOTE: A new crimp-on connector is included with
9. Remove the old brake assembly (2, Figure 4-12).
10. Install new brake assembly and secure with the
three cap screws (1, Figure 4-12).
11. Using the provided crimp-on connector connect the
red and blue wires to the wiring harness.
12. Adjust the brake air gap. See Section 4-4.1 Brake
Pad Adjustment.
13. Reinstall the steering arm assembly. Secure the 4
mounting bolts (23, Figure 4-4).
NOTE: Make sure to route the electric control
14. Reposition the guard ring (63) and secure with the
four mounting screws (3, Figure 4-6).
15. Reinstall motor compartment covers (6, 8 and 10).
16. Remove blocking and lower truck
17. Reconnect the battery.
3
I-7015
IMPORTANT
the replacement brake assembly.
cable through the semi-circular notch in
the brake assembly mounting plate on top
of the drive motor assembly.
4-11