Usage:
Start By:
a. remove wheel
b. remove drive chains
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Do not disconnect the air line to the brake and wheel spindle housing until the air pressure is zero. Failure to do so can result in personal injury. |
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1. Remove bolts (2) and guard (1).
2. Remove tube assembly (3).
3. Install tool (A) and a hoist on brake and wheel spindle housing (4). Remove bolts (5) that fasten the brake and wheel housing to the tandem housing.
NOTE: Do not remove the four bolts (6) [opposite side of each other] that holds the brake and wheel spindle housing to the cover inside the tandem housing.
4. Remove the brake and wheel spindle housing. Weight is 240 kg (530 lb.).
5. Be sure the O-ring seal on the brake and wheel spindle housing is not damaged.
NOTE: The following steps are for the installation of the brake and wheel spindle housing.
6. Fasten a hoist and tool (A) to the brake and wheel spindle housing. Install it on the tandem housing.
7. Install bolts (5) and remove tool (A).
8. Install tube assembly (3). Put guard (1) in position and install bolts (2).
End By:
a. install drive chains
b. install wheel
Disassemble Brake And Wheel Spindle Housing
NOTE: Gear configuration on the 16G is slightly different in this area. From this point on, the brake and wheel spindle housing is the same as the 14G.
Start By:
a. remove brake and wheel spindle housing
1. Remove three bolts and retainer (1).
2. Remove shims (2) from the top of spindle.
3. Use two straps and a hoist to remove sprocket (3). The weight of the sprocket is 33 kg (72 lb.).
4. Remove O-ring seal (5) from cover. Remove bearing cone (4) from bearing cup.
5. Install tooling (A) and a hoist on cover (6) and remove the four bolts that fasten cover to housing. Remove cover (6). Weight of the cover is 36 kg (80 lb.).
6. Remove bearing cup from cover with a press and tooling (B).
7. Remove O-ring seal (8) and hub (7) from housing.
8. Remove seven discs (9) and six disc assemblies (10) from housing.
9. Install tooling (A) and a hoist and remove housing (11) from the spindle. The weight of the housing is 73 kg (160 lb.).
10. Turn the housing over and remove Duo-Cone seal (12) from housing.
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Spring (14) is under compression. To prevent personal injury, support bolt (13) until all compression of spring (14) is released. |
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11. Remove bolts (13) and springs (14).
12. Install tooling (C) and wooden blocks in position and remove piston (15) from housing.
13. Remove seals (16) and (17) from piston.
14. Use a hammer and a punch to remove bearing cup (18) from housing.
15. Install tooling (D) and remove bearing cone (20) from spindle (19).
16. Remove spacer (21) from spindle (19).
17. Remove Duo-Cone seal (22).
Assemble Brake And Wheel Spindle Housing
NOTE: Inspect all seals before assembly and make replacements if needed.
1. Install spacer (21) on spindle (19) with the chamfer side up as shown.
2. Heat bearing cone (20) to a temperature of 135° C (275° F) and install it on spindle (19). Make sure the bearing is in contact with the spacer.
NOTE: The rubber toric rings of the Duo-Cone seal group and all surfaces that come in contact with them must be clean and dry at assembly. Make an application of a thin film of oil to the contact surfaces of the metal seals just before assembly.
3. Use tool (C) to install Duo-Cone on the spindle.
4. Lower the temperature of bearing cup (18) and install it in housing (11). Use tooling (B) to make sure the bearing cup is against the housing.
5. Install seals (17) on piston. Put a thin layer of oil on seals with the type of oil that is to be sealed.
6. Find the punch mark on surface (23) on the piston.
7. If the original disc assemblies are to be used, the punch mark on surface (23) of piston must be in alignment with plug opening in housing (11). See illustration B56986P1 for the location of plug (24) in housing.
8. If new disc assemblies are to be installed, the piston must be turned so that the punch mark is not in alignment with the hole that housing plug was removed from.
9. Turn housing over (11) and install piston (15). The weight of the housing is 73 kg (160 lb.).
10. Install springs (14), washers and bolts (13) to fasten piston to housing. Tighten bolts to a torque of 41 ± 7 N·m (30 ± 5 lb.ft.).
11. Turn the housing assembly over and install Duo-Cone seal with tool (C).
12. Install tooling (A) and a hoist on housing (11) and install it in position on the spindle. Remove tooling (A).
13. Install hub (7) on the spindle with the flat face of the hub down.
14. Put clean SAE 30 oil on plates (10). Install discs (9) and plates (10) in the housing. Start with a disc.
15. Lower the temperature of bearing cup (25) and install it in cover (6).
16. Install seal (26) on housing.
17. With tooling (A) and a hoist in position, install cover (6) on housing. Remove tooling (A). Weight of cover is 36 kg (80 lb.).
18. Install bearing cone (4) and seal (5) on cover.
19. Make an attachment of two nylon straps and a hoist and install sprocket (3) in position on the spindle. The weight of the sprocket is 33 kg (72 lb.).
20. Install retainer (1) and bolts (21) without shims. Tighten bolts to a torque of 54 N·m (40 lb.ft.) while a rotation of the housing is made.
21. Remove bolts and retainer, but do not turn housing. Use a straight edge and feeler gauge. Measure the distance between the end of the spindle shaft and the sprocket hub. Install a shim pack with a thickness equal to this measurement less 0.254 to 0.381 mm (.010 to .015 in.). If the shim pack is over 1 mm (.039 in.), include a 6J1881 Shim. If the required shim pack thickness is over 1.5 mm (.059 in.), use two 6J1881 Shims.
22. Install retainer (1) and bolts (27). Earlier models have lockwire through the bolts. Tighten these bolts to a torque of 350 ± 47 N·m (265 ± 35 lb.ft.). On later models with no lockwire, tighten the bolts to a torque of 461 ± 20 N·m (340 ± 15 lb.ft.).
23. If new disc assemblies were installed, use the following procedure to mark the piston.
24. After the "END BY" step, mark the machine and engage the brakes. Put a punch mark on the piston with tool (D). This mark will be in the center of the plug assembly on machines with new brakes.
25. Brake wear is checked by the installation of tool (E) in housing. As the disc assemblies wear, with the brake engaged, the mark on the piston will move toward the side of tool (E). When the mark can not be seen, the friction material on the disc assembly is worn more than the recommended amount and must be replaced.
End By:
a. install brake and wheel spindle housing.