2000/11/13 Caterpillar

Load Haul Dump (LHD):

R2900 (PIN: BAR; 5TW)

Disassembly and Assembly, RENR4582 (9EL3678), "R2900 L.H.D. Vehicle Systems", "Wheel Brake Assembly". The information on page 171 through page 177 is incorrect. The correct information follows.

Wheel Brake Assembly

Disassemble Wheel Brake Assembly

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7574	Link Bracket	2
B	9EP3062	Spring Compressor Tool	1

Start By:

a. Remove the wheel and brake assembly from the axle housing. Refer to Disassembly and Assembly, RENR4575 (9EL3671), "R2900 L.H.D. Power Train".

b. Remove the brake assembly from the wheel assembly. Refer to Disassembly and Assembly, RENR4575 (9EL3671), "R2900 L.H.D. Power Train".

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

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Illustration 1	g00742993

1. Install the wheel brake assembly in a suitable stand or on wood blocks.

2. Remove the following items from the anchor (1) : Duo-cone seal (2), bearing (3) and spacer (4) .

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Illustration 2	g00742996

3. Remove six plugs (5) from anchor (1). Remove the O-ring seals from the plugs .

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Illustration 3	g00742997

4. Rotate the brake assembly so that the studs for the spindle are facing upward.

5. Remove 30 bolts (6) and remove the washers that hold spindle (7) to brake disc housing (8) .

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Illustration 4	g00742998

6. Loosen four special nuts (9). Loosen the nuts by turning the nuts one at a time. Loosen the special nuts until all of the spring force on spindle (7) has been released.

7. Attach a suitable hoist and lifting chains to spindle (7) and remove spindle (7) .

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Illustration 5	g00742999

8. Remove O-ring (10) from spindle (7) .

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Illustration 6	g00743001

9. Remove ten outer plates (11) and nine friction discs (12) .

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Illustration 7	g00743002

10. Remove the following items from brake disc housing (8) : plugs (16), O-ring seals (17), bleeder screws (13), adapters (14) and O-ring seals (15) .

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Illustration 8	g00743003

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Illustration 9	g00743004

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Illustration 10	g00743005

11. Use Tooling (B) in order to compress the return spring (20). Compress return spring (20) until you can remove piston locking pin (19) from guide pin (18) .

12. Release the tension on the spring by unscrewing Tooling (B) .

13. Remove guide pin (18) and return spring (20) .

14. Repeat Step 11 through Step 13 until all six locking pins, guide pins, and return springs have been removed.

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Illustration 11	g00743006

15. Remove service brake piston (21) .

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Illustration 12	g00743007

16. Remove seal (22) and seal (23) from service brake piston (21) .

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Illustration 13	g00743008

17. Remove 30 bolts (24) and the washers .

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Illustration 14	g00743009

18. Loosen special nuts (25) by turning the nuts one at a time. Loosen special nuts (25) until all the spring force on brake disc housing (8) is released.

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Illustration 15	g00743012

19. Install Tooling (A) to brake disc housing (8). Attach a suitable hoist and lifting chains to Tooling (A), as shown.

20. Remove the brake disc housing .

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Illustration 16	g00743013

21. Remove seal (26) and seal (27) .

22. Remove three seals (28) .

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Illustration 17	g00743016

23. Remove parking brake piston (29) .

24. Remove seal ring (30) .

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Illustration 18	g00743018

25. Remove 25 parking brake springs (31) .

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Illustration 19	g00743019

26. Remove bolts (33) from sleeve (32) and remove sleeve (32) .

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Illustration 20	g00743020

27. Remove O-ring seal (34) from sleeve (32) .

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Illustration 21	g00743021

28. Remove four plugs (35) and O-ring seals from anchor (1) .

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Illustration 22	g00743022

29. Remove anchor (1) from the assembly stand.

Assemble Wheel Brake Assembly

Table 2

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7574	Link Bracket	2
B	9EP3062	Spring Compressor Tool	1
C	3S-6224 -OR- 8S-8033	Electric Hydraulic Pump Group (115V) -OR- Electric Hydraulic Pump Group (230V)	1
D	9EP3036	Disc Alignment Tool	1

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in a cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. If any parts are worn or damaged, use new parts for replacement.

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Illustration 23	g00743023

1. Install anchor (1) in a suitable stand or on wood blocks.

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Illustration 24	g00743024

2. Install the O-ring seals to four plugs (2). Install the plugs in anchor (1) .

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Illustration 25	g00743026

3. Install O-ring seal (3) on sleeve (4) with 1P-0808 Multipurpose Grease .

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Illustration 26	g00743028

4. Install sleeve (4) to anchor (1) .

5. Apply 155-0695 Thread Lock Compound to the threads of bolts (5) prior to assembly. Install bolts (5) and tighten to a torque value of 135 ± 20 N·m (100 ± 15 lb ft).

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Illustration 27	g00743030

6. Install 25 parking brake springs (6) in the machined holes of the anchor .

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Illustration 28	g00743031

7. Install parking brake piston (7). Ensure that the springs enter the machined holes correctly.

8. Install seal ring (8) to anchor (1) with 1P-0808 Multipurpose Grease .

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Illustration 29	g00743032

9. Install seal (10) and seal (11) to brake disc housing (13) with 1P-0808 Multipurpose Grease. Ensure that the flat portion of the seals are toward the bottom of the groove in the brake disc housing .

Note: It may be necessary to stretch seal (10) and seal (11) in order to ensure that the seals remain seated during the assembly process.

10. Install three seals (12) to brake disc housing (13) with 1P-0808 Multipurpose Grease .

11. Obtain two 1/2 inch - 16 x 6 guide pins. Install two guide pins (9) to brake disc housing (13) .

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Illustration 30	g00743033

12. Install Tooling (A) to brake disc housing (13). Attach a hoist and suitable lifting chains to Tooling (A), as shown.

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NOTICE
Do not install brake disc housing (13) without fitting retaining studs and special nuts (14) .

13. Install four special nuts (14) .

14. Check for correct alignment and install the brake disc housing to the anchor .

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Illustration 31	g00743034

15. Tighten four special nuts (14). Tighten nuts (14) in order to pull brake disc housing (13) even on the anchor. Remove Tooling (A) and the hoist.

16. Remove two guide pins (9) .

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Illustration 32	g00743035

17. Apply 155-0695 Thread Lock Compound to the threads of bolts (15) prior to assembly. Install 30 bolts (15) and the washers. Tighten the bolts to a torque value of 135 ± 20 N·m (100 ± 15 lb ft).

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Illustration 33	g00743036

18. Install seal (17) and seal (18) to service brake piston (16) with 1P-0808 Multipurpose Grease. Ensure that the flat portion of the seals are toward the bottom of the grooves in the service brake piston .

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Illustration 34	g00743037

19. Apply clean hydraulic oil to seal surfaces. Check for correct alignment and carefully install service brake piston (16), as shown.

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Illustration 35	g00743039

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Illustration 36	g00743040

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Illustration 37	g00743041

20. Install return spring (19) and guide pin (20). Use Tooling (B) in order to compress the spring. Compress the spring until guide pin (20) is in a position that allows you to install piston locking pin (21) .

21. Release the tension on the spring by unscrewing Tooling (B) .

22. Repeat Step 20 and Step 21 until all six of the following items have been installed: return springs, guide pins and locking pins .

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Illustration 38	g00743045

23. Install the following items to brake disc housing (13) : O-ring seals (25), plugs (26), O-ring seals (22), adapters (23) and bleeder screws (24) .

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Illustration 39	g00743046

24. Connect a suitable pressure gauge and relief valve to the supply port for the parking brake. Connect Tooling (C). Use Tooling (C) in order to pressurize the port to a pressure of 4140 kPa (600 psi). Turn off the tap and check the pressure gauge for leakage.

Note: Do not exceed 4140 kPa (600 psi).

Note: If a drop in pressure is noticed, the seal for the parking brake should be checked.

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Illustration 40	g00743048

25. With the service brake piston in the fully released position, install ten outer plates (27), and nine friction plates (28) in alternating order. Start with an outer plate and end with an outer plate. Lubricate the plates with clean oil when you are installing the plates .

Note: When all plates are installed the plates should sit below the level of the splines in brake disc housing (13). If this is not the case then the pressure in the parking brake port should be checked.

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Illustration 41	g00743049

26. Install O-ring (30) on spindle (29) .

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NOTICE
Do not install spindle (29) without fitting retaining studs and special nuts (32) .

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Illustration 42	g00743050

27. Obtain two 1/2 inch - 16 x 6 guide pins. Install two guide pins (31) to the brake disc housing .

28. Install four special nuts (32) to spindle (29) .

29. Use a suitable lifting device in order to lower spindle (29) in position, as shown.

30. Evenly tighten special nuts (32) to a torque value of 120 ± 10 N·m (90 ± 7 lb ft).

31. Remove two guide pins (31) .

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Illustration 43	g00743051

32. Apply 155-0695 Thread Lock Compound to the threads of bolt (33) prior to assembly. Install 30 bolts (33) and the washers. Tighten the bolts to a torque value of 135 ± 15 N·m (100 ± 10 lb ft).

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Illustration 44	g00743052

33. Rotate the brake assembly so that anchor (1) is facing upward.

34. Install the O-ring seals to six plugs (34). Install the six plugs, as shown.

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Illustration 45	g00743053

35. Install Tooling (D) in order to align the nine friction discs. Release the oil pressure from the parking brake. Remove Tooling (C) and the pressure gauge. Remove Tooling (D) .

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Illustration 46	g00743054

36. Install spacer (35), bearing (36) and Duo-cone seal (37) .

End By:

a. Install the brake assembly to the wheel assembly. Refer to Disassembly and Assembly, RENR4575 (9EL3671), "R2900 L.H.D. Power Train".

b. Install the wheel assembly and the brake assembly to the axle housing. Refer toDisassembly and Assembly, RENR4575 (9EL3671), "R2900 L.H.D. Power Train".