Usage:
NOTE: The friction discs and plates can be removed and installed with the brake assembly either on or off of the machine. Use the following procedures to measure friction disc wear and to remove and install the friction discs with the brake assembly on the machine. If some brake components are worn or damaged, it may be practical to replace the friction discs and plates with the brake assembly off of the machine. To make replacement of components off of the machine, see the topics "Remove & Install Oil Cooled (Discs) Front Service Brakes" and "Disassemble & Assemble Oil Cooled (Discs) Front Service Brakes" in this module for further information.
NOTE: The procedure to remove and install the friction discs and plates is the same for both the left and right front axles.
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Personal injury or death can result from a machine falling from a jack or supports. Make sure the machine is stopped on flat level ground. Apply the parking and secondary brakes. Block the tires to prevent the machine from rolling. |
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1. Use steps 1 through 8 under the topic "Remove & Install Front Wheel Bearings And Duo-Cone Seals" in this module to support the machine and remove the tire and wheel for the brake assembly to be worked on. Do not drain the oil from the wheel assembly at this time.
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Bleeder valve (3) will allow the loss of oil from the brake assembly piston when loosened. Oil will flow from bleeder valve (3) when evenly tightening tooling (A). Do not stand in front of bleeder valve (3). Be prepared to catch and properly dispose of the oil from bleeder valve (3) while tightening tooling (A). |
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NOTE: When measuring for wear on the friction discs and plates, take both measurements (step c and step f) from the same spot face and tool (B).
2. Do the following to measure the wear on the friction discs and plates to determine the need for replacement:
a. Remove plugs (1) and (2) from the brake assembly and install tooling (B) into the holes for plugs (1) and (2) as shown. Tighten tooling (A) finger tight.
b. Apply the service brake. Tighten tooling (B) to a torque of 27 N·m (20 lb ft) while keeping the service brake applied.
c. Choose either tool (B) to make a measurement. Use a vernier caliper or depth micrometer to measure from the top of the bolt head on tooling (B) to the spot face around the hole for plug (1) or plug (2). Record this measurement (L1).
d. Release the service brake.
e. Loosen bleeder valve (3). Evenly tighten tooling (B) to torque of 27 N·m (20 lb ft). Tighten bleeder valve (3).
f. Again measure from the top of the same (as used in step c) bolt head on tool (B) to the spot face for plug (1) or plug (2). Record this measurement (L2).
g. Find the difference in the measurements in steps f and c (L1 - L2 = L). This measurement (L) is the amount of wear on the friction discs and plates.
h. Use the measured dimension (L) found in step g and the chart below to determine the percentage of remaining service life for the friction discs and plates.
NOTE: The following steps are for removing and installing the friction discs and plates after determining the need for replacement.
3. Remove plug (4). Allow the oil to drain from behind cover (5). Check the condition of the O-ring seal on plug (4). Replace the O-ring seal on plug (4) with a new part if needed.
4. Remove plug (6) and make sure all of the oil has drained from cover (5). Check the condition of the gasket beneath plug (6). Replace the gasket beneath plug (6) with a new part if needed.
5. Remove bolts (7) from cover (5).
6. Install two of the bolts (7) into the forcing screw holes of cover (5) as shown. Evenly tightly the bolts until cover (5) is free from wheel (8).
7. Check the condition of the O-ring seal on cover (5). If the O-ring seal on cover (5) is worn or damaged use a new part for replacement.
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Wheel (8) can move outward on the axle assembly when bolts (9) and plate (10) are removed from the end of the axle. To prevent component damage and possible personal injury, make sure wheel (8) is properly supported before removing bolts (9) and plate (10). |
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8. Secure a chain onto wheel (8) with a washer and nut as shown. Support wheel (8) with a hoist.
9. Remove bolts (9), plate (10) and the shim behind plate (10).
NOTE: Check the condition of all components including bearing cups, cones and seals for wear or damage. If the Duo-Cone seals or wheel bearings are worn or damaged, refer to the topic "Remove & Install Wheel Bearings & Duo-Cone Seals" in this module for further information.
10. Remove wheel bearing (11).
11. Use the hoist to remove wheel (8) from the brake assembly. Wheel (8) weighs 600 kg (1320 lb).
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For purposes of reassembly, mark the position of plate (12) and the brake assembly housing. |
12. Remove two bolts (13) from plate (12). Install two guide bolts in the holes for the two bolts (13).
13. Remove the remaining bolts (13) from plate (12).
14. Install screws into the two forcing screw holes in plate (12). Evenly tighten the forcing screws to free plate (12) from the brake assembly.
15. Use a strap to remove plate (12) from the guide bolts and the brake assembly. Plate (12) weighs 190 kg (420 lb). Check the condition of the seals and O-ring seals beneath plate (12) and replace with new parts if worn or damaged.
16. Remove damper (14) and the twelve friction discs and twelve plates from the brake assembly housing.
17. Remove tooling (B) from the back of the brake assembly housing.
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Spacers (15) should move freely in the brake assembly anchor. If spacers (15) do not move freely, use a soft punch or drift positioned through the holes for plugs (1) and (2) to remove them from the bores. Be sure all parts are clean and free of dirt and debris. Remove any scratches or burrs from brake components. |
18. Use a soft hammer to push (reseat) two spacers (15) into brake assembly anchor. Make sure the outer face of spacers (15) are flush (even) with the inside face of the brake assembly anchor as shown.
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Be sure all parts are thoroughly clean and free of dirt and debris. If any components are worn or damaged use new parts for replacement. Thoroughly clean the inside of the brake assembly housing before starting reassembly. |
NOTE: The following steps are for installing the friction discs and plates.
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Tooling (C) must be used to keep the friction discs and plates aligned and allow for the proper installation of wheel (8). Before installing the friction discs and plates onto tooling (C) and into the brake assembly, thoroughly coat or immerse each disc and plate in transmission oil. |
19. Position tooling (C) into the brake assembly housing.
20. Install the brake friction discs, plates and damper (14) over tooling (C) and into the brake assembly as shown.
21. Support plate (12) with a strap and hoist. Position plate (12) onto the two guide bolts installed and the brake assembly (see step 12).
22. Install plate (12) as follows:
a. Reposition the strap as shown and again support plate (12) with the hoist. Use the hoist to keep plate (12) aligned with the bore of the brake assembly.
b. Start twenty seven bolts (13) into plate (12) and the brake assembly.
c. Remove the two guide bolts and install the remaining two bolts (13).
d. Use a wrench to evenly tighten (snug) all twenty nine bolts (13).
e. Install tooling (B) into the holes for plugs (1) and (2). Tighten tooling (B) to a torque of 27 N·m (20 lb ft).
f. Evenly torque bolts (13) to 300 ± 15 N·m (220 ± 10 lb ft).
23. Remove the hoist and strap from plate (12).
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Tool (C) should move freely from the friction discs and plates after evenly torquing bolts (13). If tool (C) will not move freely in and out of the brake assembly, the friction discs are not aligned correctly. Component damage can occur if the plates and discs in the brake assembly are not in the correct position when installing wheel (8). To avoid component damage, use tool (C) and the following procedures to assure proper friction disc and plate alignment. |
24. Remove tool (C) from friction discs and plates and the brake assembly. If tool (C) does not move freely from the brake assembly and plates (14) do the following:
a. Loosen tooling (B).
b. Install tooling (C) all the way into the brake assembly, making sure all friction discs and plate are resting on tool (C).
c. Hold tooling (C) centered while tightening tooling (B) to a torque of 27 N·m (20 lb ft).
d. Remove tooling (C).
NOTE: Check for the correct amount of shim beneath plate (9) after removing wheel (8) or replacing any components in the wheel assembly. See the illustrations and step 34 under the topic "Remove & Install Front Wheel Bearings And Duo-Cone Seals" in this module for the procedure to adjust the wheel bearings.
25. Install wheel (8) as follows:
a. Support wheel (8) with a hoist.
b. Align the splines of wheel (8) with the discs and plates of the brake assembly as shown.
c. Install wheel bearing (11).
d. Position wheel (8) into discs and plates (14) and the brake assembly.
e. Install the spacer and plate (9).
f. Put 9S3263 Thread Lock on bolts (10). Use a wrench to install bolts (10) hand tight.
g. Remove the hoist supporting wheel (8).
h. Remove tooling (B) from the brake assembly.
i. Rotate wheel (8) while evenly tightening bolts (12) to torque of 250 ± 14 N·m (185 ± 10 lb ft).
26. Install cover (5) and bolts (7). Install plug (4).
27. Reverse the procedures and steps 1 through 8 under the topic "Remove & Install Front Wheel Bearings And Duo-Cone Seals" in this module to install the tire and wheel and lower the machine from tooling (A).
28. Fill the wheel assembly with fluid to the correct level. See the Operation & Maintenance Manual.
29. Use bleeder valve (3) to bleed the brakes. See the topic "Removing Air from Hydraulic Brakes System (Bleed the Brakes)" in the Systems Operation/Testing & Adjusting Manual for this information.