Usage:
NOTE: The procedure to remove and install the oil cooled front service brakes is the same for both the left and right front axles.
1. Position the front wheel with drain plug (1) "down" in the 6:00 position as shown.
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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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2. Position tooling (A) and a suitable stand or wooden blocks beneath the axle assembly as shown. Raise the machine until the front tire and rim to be removed is clear of the ground.
3. Position wooden blocks or suitable stands beneath frame support (2) as shown.
| NOTICE |
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The suspension cylinder rod and axle can drift downward after the tire is raised clear of the ground. Make sure the suspension cylinder rod and axle are supported before removing the tire and rim assembly or before removing the tooling used to raise the machine. |
4. Use either of the following methods to support the axle and suspension cylinder assembly:
a. Use a suitable chain positioned over the suspension cylinder and beneath the axle assembly. Remove any slack from the chain and connect the grab hook and a chain link as shown.
b. Leave tooling (A) in position on the bottom plate of the suspension cylinder.
5. Loosen nuts (3). Do not remove nuts (3) at this time.
6. Support tire and rim assembly (4) with a lift truck or suitable lifting device.
7. Remove the washers and nuts (3). For assembly purposes, the torque for nuts (3) is 1210 ± 55 N (890 ± 41 lb).
8. Remove tire and rim assembly (4). Tire and rim assembly (4) weighs 820 kg (1800 lb).
NOTE: Oil will drain from cover (5) when drain plug (1) is removed. Be prepared to catch and properly dispose of the oil.
9. Remove plug (1). Allow the oil to drain from behind cover (5). Check the condition of the O-ring seal on plug (1). Replace the O-ring seal on plug (1) with a new part if needed.
10. 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.
11. Remove bolts (7) from cover (5).
12. 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).
13. 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.
| NOTICE |
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The brake discs and plates inside brake assembly (9) can move out of position when removing wheel (8). Component damage will occur if the discs and plates move during disassembly or assembly. Be sure to follow the procedures to keep the discs and plates in position before removing wheel (8) to assure correct assembly and avoid component damage. |
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Bleeder valve (11) will allow the loss of oil from the brake assembly piston when loosened. Oil will flow from bleeder valve (11) when evenly tightening tooling (B). Do not stand in front of bleeder valve (11). Be prepared to catch and properly dispose of the oil from bleeder valve (11) while tightening tooling (B). |
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14. Use the following steps to keep the plates and discs in brake assembly (9) from moving out of position:
a. Remove two plugs (10) from the back of brake assembly (9).
b. Install tooling (B) as shown into the openings for plugs (10). Finger tighten tooling (B) only.
c. Loosen bleeder valve (11).
d. Use a wrench to evenly tighten tooling (B) to approximately 27 N·m (20 lb ft).
e. Tighten bleeder valve (11) until hand tight.
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Wheel (8) can move outward on the axle assembly when bolts (12) and plate (13) 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 (12) and plate (13). |
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15. Secure a chain onto wheel (8) with a washer and nut (3) as shown. Support wheel (8) with a hoist.
16. Remove bolts (12), plate (13) and the shim behind plate (13).
17. Remove wheel bearing (14). Check the condition of wheel bearing (14). If wheel bearing (14) is worn or damaged use a new part for replacement.
18. Use the hoist to remove wheel (8) from brake assembly (9). Wheel (8) weighs 600 kg (1320 lb).
19. Remove the bolts holding hydraulic hose (17) to support (15).
NOTE: Identify and mark all hydraulic hoses for purposes of reassembly. Plug and cap all openings to prevent contamination and debris from entering the system.
20. Disconnect hydraulic lines (16), (17) and (18) from the back of plate (19). Check the condition of the O-ring seals for the connectors on hydraulic line (16), (17) and (18). Use new parts for replacement if the O-ring seals are worn or damaged.
21. Attach a hoist to brake assembly (9) and tooling (C) as shown.
22. Remove the washers and nuts (20) holding brake assembly (9) to axle (21).
23. Use the hoist to remove brake assembly (9). Brake assembly (9) weighs 310 kg (680 lb).
24. Check the condition of the O-ring seal (22) on the back of brake assembly (9). Use a new part for replacement if the O-ring seal (22) is worn or damaged.
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.
NOTE: Use the following steps to install the brake assembly.
25. Use tooling (C) and a hoist to position brake assembly (9) onto axle (21). Hold Brake assembly (9) in position and install the washers and (2) nuts (20) finger tight.
26. Install the washers and remaining nuts (20). Use a wrench to evenly hand tighten bolts (20).
27. Remove the hoist and tooling (C) from brake assembly (9).
28. Evenly tighten bolts (20) to a torque of 790 ± 40 N·m (580 ± 30 lb ft).
29. Connect hydraulic hoses (16), (17) and (18) to the back of plate (19).
30. Install support (15). Install the bolts to hold hose (16) to support (15).
NOTE: Check for the correct amount of shim beneath plate (13) 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.
31. 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 brake assembly (9).
c. Install wheel (8) into brake assembly (9).
| NOTICE |
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Component damage can occur if the plates and discs in brake assembly (9) are not in the correct position when installing wheel (8). Do not force wheel (8) into brake assembly (9). If wheel (8) does not move easily into brake assembly (9), use tooling (D) and refer step 24 under the topic "Remove & Install Friction Discs & Plates" in this module for the proper tooling and procedure to align the discs and plates. |
32. Install wheel bearing (14)
33. Install the shim and plate (13).
34. Put 9S3263 Thread Lock on bolts (12). Use a wrench to install bolts (12) hand tight.
35. Remove the hoist supporting wheel (8).
36. Remove tooling (B). Install the O-ring seals and plugs (10). Tighten plugs (10).
37. Rotate wheel (8) while evenly tightening bolts (12) to torque of 250 ± 14 N·m (185 ± 10 lb ft).
38. Reverse the procedures and steps 2 through 11 to complete the wheel and tire assembly.
39. Fill the wheel assembly with fluid to the correct level. See the Operation & Maintenance Manual.
40. Use bleeder valve (11) 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.
Disassemble & Assemble Oil Cooled (Discs) Front Service Brakes
NOTE: The procedure to disassemble & assemble the oil cooled front service brakes is the same for both the left and right front axles.
Start By:
a. remove oil cooled front service brake
1. Position the brake assembly on a bench as shown.
2. Install tooling (B) to plate (1) and attach a hoist.
3. Remove the washers and bolts (2) from ring (3) and anchor plate (4).
4. Use the hoist to lift plate (1) from ring (3). Check the condition of the O-ring seals on ring (3). Use new parts for replacement if the O-ring seals are worn or damaged.
5. Position plate (1) on a bench. Remove the hoist and tooling (B) from plate (1).
6. Attach a hoist and strap to plate (1). Turn plate (1) over and position on the bench with guides (5) and springs (6) contacting the bench as shown.
| NOTICE |
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Use extra care not to damage the highly finished surfaces of piston (8) and the bore of plate (1). |
7. Use the following steps to remove piston (8) from plate (1):
a. Depress springs (6) by using "C" clamps or a press to push piston (8) sightly into plate (1).
b. Remove pins (7) from twenty guides (5).
c. Use two pry bars to work piston (8) free of the bore in plate (1). Lift piston (8) from plate (1) and guides (5).
8. Lift plate (1) off of twenty springs (6) and guides (5).
9. Remove damper (9) and the twelve friction discs and twelve plates from ring (3).
10. Remove two spacers (10) from anchor plate (4).
11. Reposition (turn over) ring (3) and anchor plate (4) on the bench.
12. Check the condition of studs (11). Replace studs (11) with new parts as needed. For assembly purposes, the torque for studs (11) is 230 ± 30 N·m (170 ± 22 lb ft).
13. Remove the washers and four bolts (12) that hold anchor plate (4) to ring (3).
14. Attach a hoist to anchor plate (4) using tooling (B). Lift anchor plate (4) from ring (3).
15. Check the condition of the O-ring seals on anchor (4). Use new parts for replacement if the O-ring seals are worn or damaged.
| NOTICE |
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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 diameters of all components before starting reassembly. |
NOTE: The following steps are for the assembly of the oil cooled front service brake assembly.
16. Position ring (3) on a bench with the surface that contacts plate (4) facing up.
17. Support anchor plate (4) with tooling (B) and a hoist.
18. Put 1U6396P1 O-Ring Compound on the O-Ring seals seated on the surface of anchor plate (4).
19. Lower anchor plate (4) onto ring (3). Install and evenly tighten the washers and bolts (12).
20. Reposition assembled anchor plate (4) and ring (3) on the bench with ring (3) facing up as shown.
| NOTICE |
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Spacers (10) should move freely in anchor plate (4). |
21. Install spacers (10).
| NOTICE |
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Tool (C) is used to assure the correct alignment of the friction discs and plates. |
22. Install tool (C) into the bore of ring (3).
23. Install the twelve friction discs, twelve plates and damper (9) over tool (C) and into ring (3).
24. Check the condition of O-Ring seals (13) and (14) on piston (8). Use new parts for replacement if O-Ring seals (13) and (14) are worn or damaged. Put 1U6396P1 O-Ring Compound on O-Ring seals (13) and (14).
| NOTICE |
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It is necessary to hold guides (5) and springs (6) in position while assembling piston (8) into plate (1). Use a cotter pin or wire of a suitable diameter and the following procedures to aid in the assembly. |
25. Do the following to assemble plate (1), springs (6) and guides (5):
a. Install springs (6) onto guides (5) as shown.
b. Install assembled guides (5) and springs (6) into plate (1). Position the guides and springs so that the springs are located on the outside (tire side) of ring (1).
c. Position ring (1), guides (5) and springs (6) on the bench as shown.
d. Install a cotter pin or wire (15) of suitable diameter into the center most hole of twenty guides (5). It may be necessary to push down on ring (1) to provide the necessary clearance to insert wire (15) into hole in guide (5).
26. Position piston (8) onto ring (1). Use a soft hammer to seat piston (8) into the bore of ring (1). Use care not to cut or damage O-Ring seals (13) and (14).
26. Install pins (7) through the remaining hole in twenty guides (5).
27. Install tooling (A) into the two forcing screw holes in plate (1). Evenly tighten tooling (A) until guides (5) move far enough to free retaining wires (15). Use pliers to remove wires (15) from the center most hole in twenty guides (5).
28. Remove tooling (A).
29. Put 1U6396p1 O-Ring Compound on the O-Ring seals seated on the face of ring (3).
30. Use tooling (B) attached to a hoist to install plate (1) onto ring (3). Install the washers and bolts (2). Evenly tighten bolts (2) to a torque of 300 ± 15 N·m (220 ± 10 lb ft).
31. Remove the hoist and tooling (B).
| NOTICE |
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Tool (C) should move freely from the friction discs and plates after evenly torquing bolts (2) and tooling (A). Tooling (A) is used to put pressure on spacers (10) and the friction discs and plates. This procedure allows the friction discs and plates to be locked into position and stay properly aligned after tooling (C) has been removed. |
32. Install tooling (A) into anchor plate (4) through the access holes for spacers (10). Tighten tooling (A) to a torque of 27 N·m (20 lb ft).
33. Remove tool (C).
End By:
a. install oil cooled front service brakes