Usage:
1. Position the machine on a flat, clear, clean surface which will allow the machine to remain in a stationary position without the use of the brake.
 |
Accident or injury could result if the machine is not blocked while working on the brake. |
 |
2. Place blocks under both tires and the drum to prevent any movement while working on the secondary brake.
3. Attach a hoist to the secondary brake mounting bracket.
4. Remove one nut and washer holding clip (2) which holds hydraulic brake hose (1) to the drum yoke.
5. Remove two bolts, nuts and washers (3) which holds the secondary brake to the drum yoke. Weight of the secondary brake is 24 kg (53 lb).
|
Ensure that the machine is completely blocked prior to starting the machine. Accident or injury may result from operating a machine which is not properly blocked. |
|
6. Start machine and release secondary brake on the operators counsel. This will allow the secondary brake to release from the brake disc plate. With the machine still running, grasp the strap holding the secondary brake and move it forward so that the brake is clear of the brake disc plate.
7. Shut machine off. The secondary brake will now close, but will now be separated from the brake disc plate.
8. Disconnect and plug hydraulic brake hose (4).
9. Lower the secondary brake to the bottom of the drum, and remove the hoist.
NOTE: The following steps are installation of the secondary brake.
10. Set the secondary brake in the bottom outer edge of the drum.
11. Route a lifting strap down between the drum and the drum yoke, and attach to the secondary brake. See Photo C33142P1.
12. Raise the secondary brake to the approximate level at which it will be connected to the yoke.
13. Unplug and connect the hydraulic brake hose to the secondary brake.
|
Ensure that machine is completely blocked prior to starting machine. Accident or injury may result from operating a machine which is not properly blocked. |
|
14. Start machine and release hydraulic brake on the operators console. The piston within the secondary brake will retract and allow the the secondary brake to be slipped onto the brake disc plate.
15. While the machine is still running, move the secondary brake mounting bracket into position so that the two holes in the bracket line up with the two holes in the drum yoke. Insert two bolts (3) through the drum yoke and through the secondary brake mounting bracket.
16. Shut the machine off. The secondary brake should now be attached to the brake disc plate and the drum yoke.
17. Install two washers and nuts to bolts (3) which hold the secondary brake to the drum yoke.
18. Install one nut and washer to clip (2) which holds hydraulic brake hose (1) to the drum yoke.
19. Fill hydraulic oil tank to the correct level. See "Hydraulic Tank" in the Operation & Maintenance Manual for the correct filling procedure.
20. Remove the blocks from in front of and behind the drum and the tires.
21. Start the machine and operate the brake several times to ensure that it not only stops the machine but that it also does not drag. There should be .508 mm (.020 in.) clearance between brake disc plate and brake pad on each side of the disc plate.
Disassemble And Assemble Secondary Brake (CS-431B)
Start By:
a. remove secondary brake (CS-431B)
1. Thoroughly clean the outside of the brake valve prior to disassembling it.
2. Put alignment marks on brake housing (1) and brake mounting bracket (3) to ensure proper assembly.
3. Remove two clips (4) from two caliper mounting pins (2) and remove the two caliper mounting pins. This will release the brake housing (1) from brake mounting bracket (3).
NOTE: Stud (6) and nut (8) have left handed threads.
4. Remove cotter pin (9), nut (8) and washer (7) from threaded stud (6).
5. Using a depth gauge, measure the depth which spring retaining cap (5) is threaded into the brake housing. Record this dimension. This measurement will be necessary during reassembly.
6. Using tooling (A), unscrew spring retaining cap (5) from the brake housing. There are springs behind the retaining cap; however they will be relaxed prior to the cap releasing from the brake housing.
7. Grasp threaded stud (6), and remove the internal portion of the brake from the brake housing. If the internal portion does not easily release, it is being held by the rubber o-rings. Place the housing in a vice. Use a small pry bar between the two brake pads. Apply pressure upward, and at the same time, pull upward on the threaded stud.
8. Remove eight springs (12) and two washers (11), one on each end of the spring group from between piston (10) and spring retaining cap (5). The springs are bevel washer type in a series of two each facing each other.
| NOTICE |
|---|
Do not remove filister head screw (16) and button snap (15) unless they are damaged or if piston (10) is to be replaced. |
9. Remove o-rings (13) and (14) from piston (10). Both o-rings fit in the same groove but are different types. The flat o-ring (14) will be the furthest down toward the brake pad, while the round rubber o-ring will be directly behind it. Remove brake pad (17) from piston (10) by gently prying between the two. If necessary, remove filister head screw (16) and button (15).
| NOTICE |
|---|
If stud (6) must be removed from piston (10), it will be necessary to heat the piston to soften the threadlock. It is not advisable to remove stud (6) unless absolutely necessary. Stud (6) has threads which run in two different directions. The upper portions, toward the springs, is left hand threads. The lower portion, into the piston, is right hand. Grasp the stud in only the center where there are no threads. |
10. If necessary remove stud (6) from piston (10).
11. Remove two rubber o-rings (18) and (19) from inside the brake housing. Both o-rings fit in the same groove but are different types. The flat o-ring (18) will be the farthest down toward the brake pad, while the round rubber o-ring (19) will be directly behind it.
| NOTICE |
|---|
Do not remove filister head screw (20) and button snap (21) unless housing (1) is to be replaced. |
12. Remove brake pad (22) from housing (1) by gently prying between the two. If necessary, remove filister head screw (20) and button (21).
NOTE: The following steps are for the assembly of the secondary brake.
13. Thoroughly clean all parts of the secondary brake prior to assembly.
14. Install filister head screw (20 and button snap (21) into housing (1) if they were removed.
15. Install brake pad (22) into housing (1). The locating pin on the back of the brake must seat in the corresponding hole in the housing. The brake pad will snap into place when correctly installed.
16. Lubricate and install two o-rings (18) and (19). Both will fit into the same groove with the flat o-ring (18) being the furthest down with the round rubber o-ring (19) directly behind it.
NOTE: If threaded stud (6) was removed from piston (10) it will be necessary to use 9S3263 Thread Lock to reassemble.
17. Put a thin coat of 9S3263 Thread Lock on the threads of stud (6) and install threaded stud (6) into piston (10).
18. Lubricate and install two o-rings (13) and (14). Both will fit into the same groove with the flat o-ring (14) being the furthest down with the round rubber o-ring (13) directly behind it. Install snap button (15) and filister head screw if they were removed.
| NOTICE |
|---|
Do not install brake pad onto piston (10) until the the piston has been assembled into the brake housing (1). The sharp edges of the brake pad may damage the two o-rings (18) and (19) as the piston is inserted into the brake housing. |
19. Lubricate piston (10) with a light coat of hydraulic oil. Grasp the piston by threaded rod (6), and insert the piston into the brake housing. Push the piston down into the housing until the brake pad end of the piston is exposed opposite the other brake pad.
20. Assemble two washers (11) and the eight beveled springs (12). One washers will be on each end of the springs, while the springs will be assembled in groups of two each facing each other. Refer to Photo C32930P1. Slide the washers and the springs onto spring retaining cap (5).
21. Set the spring retaining cap on a bench with the springs and washers stacked on top of it. Grasp the brake housing with both hands and slowly lower it onto the spring assembly until threaded stud (6) is through the center of spring retaining cap (5).
22. Turn the brake assembly over, and screw the spring retaining cap into the brake housing approximately two turns.
23. Install brake pad (17) into piston (10). The locating pin on the back of the brake must seat in the corresponding hole in the piston. The brake pad will snap into place when correctly installed.
24. Place brake housing in a vise to prevent it from turning. Using tooling (A) and a depth gauge, screw the spring retaining cap into the brake housing until the same depth as recorded in Step 5 is reached.
25. Install washer (7), nut (8) and cotter pin (9) into threaded stud (6). The nut should only be screwed onto the stud far enough so that the cotter pin can lock the nut into a fixed position. Threaded stud (6) and nut (8) have left hand threads.
26. Place brake housing unit (1) in the brake housing bracket (3). Check alignment marks placed on brake during disassembly. Install two pins (2) through the brake housing unit and the brake housing bracket. Attach two clips (4) to pins (2).
End By:
a. install secondary brake (CS-431B)