81-540-007 - MICO, Inc.
Contents
1. 40 200 02 540 204 02 540 206 02 540 208 02 540 210 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 040 20 060 047 20 060 046 20 060 040 20 060 046 20 060 040 20 060 040 20 060 040 20 060 040 02 500 062 02 500 062 02 500 062 02 500 062 02 500 062 02 500 062 02 500 062 02 500 062 02 500 062 02 500 070 02 500 062 02 500 083 02 500 081 02 500 070 02 500 081 02 500 070 02 500 062 02 500 062 02 500 062 02 500 061 02 500 064 02 500 063 02 500 064 02 500 061 02 500 064 02 500 063 02 500 064 02 500 087 02 500 069 02 500 063 02 500 082 02 500 080 02 500 069 02 500 080 02 500 069 02 500 105 02 500 087 02 500 063 Same kit as 02 500 064 with the addition of seal 17 and retaining ring 19 All kits include mounting gasket NOTE Earlier models do not use spacer plate 15 Form No 81 540 007 Revised 1997 11 01 MICO Inc Model Numbers 02 540 050 02 540 068 02 540 052 02 540 074 02 540 056 02 540 076 02 540 060 02 540 200 02 540 062 02 540 206 02 540 066 02 540 208 DISASSEMBLY Refer to Figure 2 1 Remove end cover 3 from housing 18 by remov ing cap screws 1 and lock washers 2 A CAUTION Since cover is under spring tension of approximately 907 kgf 2000 Ib the six cap screws must be loosen ed evenly to relieve this force If a hydraulic press is available 2268 kgf 5000 Ib maximum the2. 5 was found in your brake during disassembly 3 Insert spacer plate 15 in housing 18 4 Starting with one of nine new steel plates 13 and alternating with eight of the ten new friction plates 14 install them on shaft 6 5 Install new bearing 16 on male end of shaft 6 and press until it shoulders on shaft 6 Insert one of two remaining new friction plates 14 in housing 18 With shaft 6 positioned vertically male end facing down place shaft assembly in housing 18 aligning tabs with slots in housing Carefully press shaft assembly into housing 18 until bearing shoulders on bottom of housing Insert the last new friction plate 14 in housing 18 7 Install new o rings 10 amp 12 on sleeve 11 Care fully push sleeve 11 into bore of housing 18 until piston bottoms on housing bore 8 Install new o ring 8 on piston 9 Carefully push piston 9 into bore of housing 18 until piston bot toms on top of lining stack 9 Insert springs 7 in piston 9 NOTE Install springs 7 in the same pattern as they were removed 10 Press new bearing 5 in end cover 3 Install new o ring 4 on flange of cover 3 11 Position cover assembly on top of springs 7 In sert cap screws 1 and lock washers 2 through cover 3 and into housing 18 Tighten screws evenly to draw cover 3 to housing 18 and bear ing 5 onto shaft 6 Torque cap screws 1 74 6 N m 55 lb ft NOTE A hydr
3. MULTIPLE DISC BRAKE liquid cooled SAE C size Service Manual MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement materials specifications and product documentation are subject to change without notice or obligation MICO is a registered trademark of MICO Inc MICO is registered in the U S Patent and Trademark Office as well as in Australia Canada Indonesia Japan Peoples Republic of China South Korea and the European Community MECO MICO Incorporated 1911 Lee Boulevard North Mankato MN U S A 56003 2507 Innovative Braking and Controls Worldwide Tel 1 507 625 6426 Fax 1 507 625 3212 Form No 81 540 007 Revised 1997 11 01 www mico com TYPICAL MULTIPLE DISC BRAKE Model 02 540 060 shown O RING O RING BACK UP RI
4. NG BACK UP RING HOUSING O RING BEARING BEARING SEAL COVER RETAINING RING SPLINE SHAFT SPACER PLATE CAP SCREW FRICTION PLATE LOCK WASHER STEEL PLATE SPRING PISTON FIGURE 1 MICO Inc 2 Form No 81 540 007 Revised 1997 11 01 DESCRIPTION AND OPERATION OF THE MICO MULTIPLE DISC BRAKE The MICO Multiple Disc Brake liquid cooled is designed specifically for use with heavy duty machin ery off highway vehicles construction materials handling mining equipment and in a multitude of winch ing applications Models are available in standard SAE mounting flange styles Other special mountings are also available Contact MICO with your requirements This multiple disc brake provides consistent braking torque positive hold and long life in rugged environ ments An oil bath protects the friction surfaces dissi pates heat efficiently and resists internal corrosion thus providing high repeatability in performance The brake will also reduce maintenance and downtime because environmental contaminants which add to brake lining wear are restricted from entering the brake Clean oil is a must for optimum lining life Braking is provided by a pack of friction discs splined to the housing and rotating discs splined to the drive shaft Force is transmitted to the disc pack through a hydraulic piston and a series of preloaded springs The brake is released by hydraulic pressure applied to the piston to compre
5. aulic press will simplify installation of cover on housing Clamp cover in position while tightening the cap screws 12 To eliminate binding on bearings press on inner ring of bearing 5 until it shoulders on shaft 6 Form No 81 540 007 Revised 1997 11 01 A Items included in Lining Repair Kit Items included in Bearing Repair Kit m Items included in O ring Repair Kit Not used on all models Form No 81 540 007 Revised 1997 11 01 FIGURE 3 MICO Inc BLEEDING 1 Install brake in system and con nect pressure lines as well as coolant lines if flow through cooling is used BRAKE WILL NOT RELEASE Insufficient release oil pressure Damaged o rings 9 or 11 Damaged o ring 12 Figure 3 Damaged piston 10 Figure 2 Damaged bearings 5 or 16 Plates 13 amp 14 warped or welded together due to exces sive heat OaPPoh MICO Inc 2 Bleed pressure release section of brake by pressurizing side inlet port and allowing air to escape from top port Pressure should not exceed 6 9 bar 100 PSI during bleeding SERVICE DIAGNOSIS Refer to Figure 2 BRAKE WILL NOT APPLY 1 Residual oil pressure in release section of brake 2 Damaged springs 7 3 Damaged piston 10 Figure 2 4 Broken bolts 1 allowing cover 3 to move away from housing 18 3 Apply sufficient pressure to release brake and check for proper operation in system BRAKE APPLIES BUT TORQUE LOW 1 Residual oil pre
6. cover can be held in position while removing the cap screws and lock washers 2 If necessary tap cover with a soft mallet to dislodge bearing 5 from shaft 6 3 Remove o ring 4 from flange of cover 3 Press bearing 5 out of cover 3 4 Remove springs 7 from piston 10 Remove pis ton 10 from housing 18 by inserting two 1 2 13 UNC bolts into threaded holes at bottom of spring pockets in piston 10 Using appropriate puller remove piston 10 from bore of housing Note quantity and pattern of springs 7 when removed 5 Remove o ring 9 back up ring 8 o ring 11 and back up ring 12 from piston 10 6 Remove shaft assembly consisting of shaft 6 plates 13 friction plates 14 and bearing 16 from housing 18 by pressing or using a soft mallet on male end of shaft 6 7 Remove spacer plate 15 and bottom friction plate 14 from housing 18 NOTE Earlier models do not use spacer plate 15 8 Remove bearing 16 from end of shaft 6 with appropriate bearing puller Remove steel plates 13 and friction plates 14 from male end of shaft 6 9 Remove retaining ring 19 and press seal 17 from housing 18 NOTE Not all models use seal 17 and retaining ring 19 MICO Inc ASSEMBLY Refer to Figure 2 LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE SYSTEM REFER TO PAGE 3 FOR PROPER REPAIR KIT 1 Clean all parts thoroughly before ass
7. embly NOTE Follow step 2 only if seal 17 and retaining ring 19 are found in your brake during disassembly 2 Insert new retaining ring 19 in housing 18 Press new seal 17 into housing 18 until it shoulders against retaining ring 19 NOTE Follow step 3 only if spacer plate 15 was found in your brake during disassembly 3 Insert spacer plate 15 in housing 18 4 Starting with one of nine new steel plates 13 and alternating with eight of the ten new friction plates 14 install them on shaft 6 5 Install new bearing 16 on male end of shaft 6 and press until it shoulders on shaft 6 Insert one of two remaining new friction plates 14 in housing 18 With shaft 6 positioned vertically male end facing down place shaft assembly in housing 18 aligning tabs with slots in housing Carefully press shaft assembly into housing 18 until bearing shoulders on bottom of housing Insert the last new friction plate 14 in housing 18 7 Install new o rings 9 amp 11 and new back up rings 8 amp 12 on piston 10 Carefully push piston 10 into bore of housing 18 until piston bottoms on top of lining stack 8 Insert springs 7 in piston 10 NOTE Install springs 7 in same pattern as they were re moved 9 Press new bearing 5 in end cover 3 Install new o ring 4 on flange of cover 3 10 Position cover assembly on top of springs 7 In sert cap screws 1 and lock wa
8. g two 1 2 13 UNC bolts into threaded holes at bottom of spring pock ets in piston 9 Using appropriate puller remove piston 9 from bore of housing Note quantity and pattern of springs 7 when removed 5 Use appropriate puller to remove sleeve 11 Re move o rings 10 amp 12 from sleeve 11 6 Remove o ring 8 from piston 9 7 Remove shaft assembly consisting of shaft 6 plates 13 friction plates 14 and bearing 16 from housing 18 by pressing or using a soft mallet on male end of shaft 6 8 Remove spacer plate 15 and bottom friction plate 14 from housing 18 NOTE Earlier models do not use spacer plate 15 9 Remove bearing 16 from end of shaft 6 with appropriate bearing puller Remove plates 13 and friction plates 14 from male end of shaft 6 10 Remove retaining ring 19 and press seal 17 from housing 18 NOTE Not all models use seal 17 and retaining ring 19 MICO Inc ASSEMBLY Refer to Figure 3 LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE SYSTEM REFER TO PAGE 3 FOR PROPER REPAIR KIT 1 Clean all parts thoroughly before assembly NOTE Follow step 2 only if seal 17 and retaining ring 19 are found in your brake during disassembly 2 Insert new retaining ring 19 in housing 18 Press new seal 17 into housing 18 until it shoulders against retaining ring 19 NOTE Follow step 3 only if spacer plate 1
9. shers 2 through cover 3 and into housing 18 Tighten screws evenly to draw cover 3 to housing 18 and bear ing 5 onto shaft 6 Torque cap screws 1 74 6 N m 55 lb ft NOTE A hydraulic press will simplify installation of cover on housing Clamp cover in position while tightening the cap screws 11 To eliminate binding on bearings press on inner ring of bearing 5 until it shoulders on shaft 6 Form No 81 540 007 1997 11 01 A Items included in Lining Repair Kit Items included in Bearing Repair Kit m Items included in O ring Repair Kit x Not used on all models Form No 81 540 007 Revised 1997 11 01 FIGURE 2 MICO Inc Model Numbers 02 540 054 02 540 078 02 540 064 02 540 204 02 540 070 02 540 210 02 540 072 DISASSEMBLY Refer to Figure 3 1 Remove end cover 3 from housing 18 by remov ing cap screws 1 and lock washers 2 A CAUTION Since cover is under spring tension of approximately 907 kgf 2000 Ib the six cap screws must be loosen ed evenly to relieve this force If a hydraulic press is available 2268 kgf 5000 Ib maximum the cover can be held in position while removing the cap screws and lock washers 2 If necessary tap cover with a soft mallet to dislodge bearing 5 from shaft 6 3 Remove o ring 4 from flange of cover 3 Press bearing 5 out of cover 3 4 Remove springs 7 from piston 9 Remove piston 9 from housing 18 by insertin
10. ss the springs The brake is self applying since any function which reduces the hydraulic system pressure below the release pressure Repair Kits of the brake will start to initiate a brake application Zero pressure produces maximum brake torque Brake cooling is normally provided by one of the follow ing methods Sump Method Oil is added at the time of installation to a level of 1 4 1 2 capacity 118 3 236 6 mL 4 8 fl oz A breather must be installed on the top cooling port to compensate for expansion due to heat This method of cooling is used where the operation of the brake is strictly for parking or emergency use i e either on or off with minimal dragging through the brake Also the maximum shaft speed must not exceed 1500 rpm in this mode due to fluid viscous shear Flow Through Method A continuous flow of oil between 3 79 and 30 3 L min 1 and 8 GPM from the vehicles hydraulic system is used for cooling This method is required where the ap plication may involve dragging through the brake such as in a winch application for positioning a load Internal cooling pressure should be maintained below 6 9 bar 100 PSI This method is also ideal for higher shaft speed applications Model Lining Kit Bearing Kit O ring Kit Number Number Number Number 02 540 050 02 540 052 02 540 054 02 540 056 02 540 060 02 540 062 02 540 064 02 540 066 02 540 068 02 540 070 02 540 072 02 540 074 02 540 076 02 540 078 02 5
11. ssure in release section of brake 2 Springs 7 have taken perma nent set due to excessive heat 3 Friction plates 14 worn out OIL LEAKS EXTERNALLY FROM BRAKE 1 Damaged rotary oil seal 17 2 Damaged o ring 4 Form No 81 540 007 Revised 1997 11 01
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