Service Manual
Contents
1. EEE em cee NENNEN 2 Ball Seat Wheel Mounting System rr 2 IDENTIFYING CONMET HUB ASSEMBLIES a 2 Vehicle Identification Number VIN I 2 Gasting le Le EE 2 Machining Assembly Number U a 2 Final Hub Assembly Number l llllli EEN 3 J lan Daten uru n Susa Samaq ap baca ea ve reyen a beke EE E A ide COR ass 3 S INSPECTION EE 4 HAZARD ALERT MESSAGES sea naa rikt 4 INSPECTION keier EE 4 Driver Pre Trip Visual Inspection kk kek k k keka 4 Preventative Maintenance Schedule iii kk kk kk 4 Every 12 Months or 100 000 Miles Whichever Occurs First 4 Pir parallOl cs 1 2 a u Sana 1C Bay has dee EP de ER 4 Inspect Components usu uu eet ee a d puq n r n hedning 5 Eeer tele BEE 5 Inspect for Proper Lubricant Level and Condition 5 F nctional Checks ET 5 Check End Play u luna a ee feed EEE 5 4 RECOMMENDED SERVICE r 6 HUB REMOVAL AND DISASSEMBLY beige serberne 6 COMPONENT INSPECTION AND REPLACEMENT HAZARD ALERT MESSAGES EE 7 CLEAN AND DRY COMPONENTS rr 7 Worn or Damaged Components kk kk ek kk kk kk kK k kk KAR KA 7 Hub and Component Cleaning kk SEAN 7 INSPECTIN2. 2 Preventative Maintenance Schedule Wheel end inspections should be conducted during any routine preventative maintenance on the vehicle 1 Check all items listed in the driver pre trip visual inspection 2 Lift and support the axle and rotate the wheel Check that the wheel rotates freely Listen and feel for any signs of rough bearing operation or vibration 3 On oil lubricated steer and trailer hubs place a magnet through the hubcap fill plug into the lubricant Check for any signs of metal picked up by the magnet 4 Push and pull on top of the tire or use a pry bar to lift the bottom of the tire to check for loose bearings or chucking If any of the above conditions are found the vehicle should be placed out of service until the item can be repaired 3 Every 12 Months or 100 000 Miles Whichever Occurs First Preparation Vehicles on jacks can fall causing serious personal injury or property damage Never work under a vehicle supported by a jack without supporting the vehicle with stands and blocking the wheels Wear safe eye protection 1 Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving 2 Raise the axle until the tires are off the floor 3 Place safety stands under the trailer frame or under each axle spring seat see figure 13 1003159a FIGURE 13 3 INSPECTION CONTINUED 4 Remove the tire and wheel assembly using procedures specif
3. Z NCAUTION Failure to apply grease to the bearing journals will result in fretting corrosion which may result in difficulty removing the bearing Never support the hub on the spindle with just the inner bearing and seal This can damage the seal and cause premature failure i e by cocking the seal in the bore Z NCAUTION Once the hub is on the spindle do not remove the outer bearing Removing the outer bearing may cause the seal to become misaligned resulting in premature seal failure Spindle Nut Torque a One Piece Spindle Nut System Pro Torq and Axilok For one piece spindle nut systems like the Pro Torq or Axilok torque the nut to a minimum of 250 ft lbs Do not back off the spindle nut Engage any locking device that is part of the spindle nut system If the locking device cannot be engaged when the nut is at 250 ft Ibs advance the nut until engagement takes place and the nut is locked b Double Nut or Jam Nut System If a double nut or jam nut system is being used torque the inner nut to 300 ft Ibs Do not back off the spindle nut Advance the inner nut as necessary to install the locking ring Install the outer nut with 200 ft Ibs of torque Be sure to engage any locking device ConMet does not recommend a one piece castellated type nut system for use with PreSet hubs Mounting the Hub 2 Mount the hub assembly onto the axle spindle with a smooth firm motion while holding the
4. These fill volumes were established with ConMet hubcaps and FNOK seals and are to be used as reference only Proper volumes are to the designated fill line of the hubcap used Hub casting numbers can be found cast onto the flange of the hub 105757a 8 Stud Tightening Sequence FIGURE 38 Consolidated Metco Inc 16 6 REINSTALLATION CONTINUED 1 Clean all mating surfaces on the hub drum and nuts Remove loose paint scale and any material building around the pilots of the drum hub and Do not get lubricant on the mounting face of the drum or wheel wheels Be sure paint is fully cured on recently Failure to clean lubricant from these surfaces may result in refurbished wheels decreased clamping load 4 Before installation of brake drums and wheels that utilize the hub piloted system rotate the hub so one Care should be taken to avoid damaging the hub or other of the wheel pilot bosses is at the top 12 o clock components position see figure 40 WHEEL PILOT BOSS If you plan to replace the brake drum i e cast in place of Centifuse or wheels i e aluminum in place of steel measure stud standout see figure 39 In hub piloted mounting systems the studs must be long enough for the threads to be exposed beyond the installed wheel nut In the ball seat mounting system the stud length beyond the brake drum should be from 1 31 1 44 as measured from the brake drum to the end of the stud Call Co
5. Read the manufacturer s instructions before using hot solution tanks and alkaline solutions Then carefully follow the instructions Z NCAUTION Do not use hot solution tanks or water and alkaline solutions to clean ground or polished parts Damage to parts can result CLEAN AND DRY COMPONENTS Worn or Damaged Components Do not repair or recondition wheel end components Replace damaged worn or out of specification components Do not mill or machine any components Using repaired reconditioned damaged or worn components can cause wheel end failure which can result in serious injury and property damage Hub and Component Cleaning 1 Use a cleaning solvent to clean the ground or polished parts and surfaces Kerosene or diesel fuel can be used for this purpose DO NOT USE GASOLINE Consolidated Metco Inc 4 RECOMMENDED SERVICE CONTINUED 2 Do NOT clean ground or polished parts in a hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts 3 Thoroughly clean the hub cavity with spray degreaser The cavity must be free of any contaminants 4 Toremove grease from a wheel end use a stiff fiber brush not steel and kerosene or diesel fuel not gasoline Allow the parts to dry Note that any solvent residue must be completely wiped dry since it may either dilute the grease or oil or prevent the lubricant from correctly adhering to the wheel end compo
6. SET429 Timken General SKF Outer Cup amp Cone 107503 SET430 TN Trailer Axle Inner Cup amp Cone 107504 SET431 Timken G I SKF Outer Cup amp Cone 107501 SET427 me TP Trailer Axle Inner Cup amp Cone 107506 SET432 Timken G I SKF Outer Cup amp Cone 107506 SET432 M Consolidated Metco Inc 21 SPECIFICATIONS Wheel End Torque Specifications Item Measurement Notes Ball Seat Wheel Nut 3 4 16 450 500 Always tighten the top nut first If lubricant is used apply sparingly on threads only Do not lubricate the faces of the hub drum wheel or on the ball seats of the wheel nuts Hub Pilot Wheel Nut 22 mm x 1 5 mm 450 500 Always tighten the top nut first Apply two drops of oil between the nut and nut flange and two or three drops to the outermost 2 or 3 threads of the wheel studs Lightly lubricate the wheel pilots on the hub Drive Studs 3 4 16 70 90 Consult manufacturer s instructions for drive axle shaft Drive Studs 5 8 18 40 90 installation for all drive studs Hubcap 5 16 18 12 18 Minimum SAE Grade 5 fasteners flat washers only Oil Fill Plug 1 4 NPT 20 25 Oil Fill Plug 3 8 NPT 20 25 Oil Fill Plug 9 16 18 20 25 O ring style Consolidated Metco Inc 22 CON MET Consolidated Metco Inc 5701 SE Columbia Way Vancouver WA 98661 800 547 9473 www conmet com Part No 10005642 Rev F one or ma NS ted 4 2011 INDUSTRIES
7. be with a calibrated torquing device 106824b Torquing the Inner Wheel Nuts FIGURE 46 19 Consolidated Metco Inc SERVICE PARTS LIST PreSet Rebuild Kits Approved PreSet Oil Seals Cross Reference PatNumber 10005434 FF Steer Rebuild Kit ConMet PreSet rebuild kits include both bearing sets bearing spacer and oil seal PreSet Bearing Spacers Part Number 103592 FF Steer Bearing Spacer Seal Installation Tools Axle Designation Bearing Centering Tool Adapter Plate Universal Tool Handle Fleet Hub Tool Bearing Guide FF Steer BCT 6 847T 551 0001 551 5346 570 0020 551 0001 551 5327 570 0022 BCT 15 861T 551 0001 551 5320 570 0028 TN Trailer BCT 13 859T 551 0001 551 5412 570 0026 TP Trailer BCT 12 851T 551 0001 551 5401 570 0025 Consolidated Metco Inc 20 SERVICE PARTS LIST CONTINUED NOTE Bearing cups and cones must be replaced as a set When bearings are replaced in any PreSet hub it is recommended that the bearing spacer be replaced as well Approved Aftermarket Bearing Sets Description ConMet Number Bearing Set Number Approved Suppliers FF Steer Axle Inner Cup amp Cone 107500 SET427 Timken General SKF Outer Cup amp Cone 107501 SET428 FL Steer Axle Inner Cup amp Cone Not Available in Sets from Timken Timken Cup amp INP183330 INP107091 __________ NP183330 NP107091 R Drive Axle Inner Cup amp Cone 107502
8. damage to components can result To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands INSPECTION GUIDELINES Operating temperature can be checked as the vehicle enters the service area following a normal run If the hub is running in excess of 150 F above the ambient in normal operating conditions service is required There are three levels of inspection criteria for PreSet hub assemblies e Driver pre trip e In conjunction with preventative maintenance schedule e Every 12 months or 100 000 miles whichever comes first Follow this schedule of inspection and maintenance for PreSet hub assemblies 1 Driver Pre Trip Visual Inspection Each time prior to operating the vehicle on the road With vehicle parked on level ground and the parking brake set walk around the vehicle and visually inspect each wheel assembly for the following items e Loose damaged or missing fasteners e Loose damaged or missing hubcaps e Oil leaks at hubcap axle flange gasket or fill plug e Lubricant on the hub brake components or inside of wheel and tire e Insufficient oil level and poor oil condition If any of the above conditions are found the vehicle should be placed out of service until the item can be repaired Consolidated Metco Inc
9. inner bearing and spacer during the removal process 10 Remove the inner bearing and spacer 106804a Hub Disassembly Inner Bearing Retainer is not on Hubs equipped with CR Seals FIGURE 19 COMPONENT INSPECTION AND REPLACEMENT HAZARD ALERT MESSAGES Read and observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service Observe all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury Do not hit steel parts with a steel hammer Pieces of a part can break off Serious personal injury and damage to components can result Use a brass or synthetic mallet for assembly and disassembly procedures Solvent cleaners can be flammable poisonous and cause burns Examples of solvent cleaners are carbon tetrachloride and emulsion type and petroleum base cleaners Read the manufacturer s instructions before using a solvent cleaner then carefully follow the instructions Also follow the procedures below Wear safe eye protection Wear clothing that protects your skin Work in a well ventilated area Do not use gasoline or solvents that contain gasoline Gasoline can explode You must use hot solution tanks or alkaline solutions correctly
10. G BEARING CUPS CONES AND SPACER 9 REMOVING CUPS IN ALUMINUM HUBS rrrrorererrrnnnvrvernrrrrrsrrrrrnnnrrrrrrrrrrrnererrrrnnnnnnn 9 REMOVING CUPS IN IRON HUBS nike basere cies 9 INSTALLING A NEW CUP IN ALUMINUM HUBS 9 INSTALLING A NEW CUP IN IRON HUBS kek kk kk kK KAKA k kK 9 WHEEL STUDS uu u an nm ana tasidundttvalearactetiaatiaad a ARAT 9 STUD REMOVAL EEN 9 STUD REPLACEMENT vinene aid 10 HUB DRUM AND WHEEL INSPECTION kk kk kk k k kk kK kK KK KK KA 10 ABS TONE RING INSPECTION AS APPLICABLE 10 REMOVAL AND INSTALLATION OF POWDERED METAL ABS TONE RING Landsem eee 10 REMOVAL AND INSTALLATION OF STAMPED STEEL ABS TONE leegen eege 11 5 REASSEMBLY EE 12 PreSet WHEEL HUBS uuu u u huu a Dart babek BG ARA AR an vatn 12 6 REINSTALLATION u ic a carina i dilka Luna O bi Aa bk kw E sls 14 INSTALLING THE PreSet WHEEL HUB ASSEMBLY 14 Spindl Preparatlioh u deet Le musasasa ck ak antares 14 Mounting the Hub sien xit lan aga m lak ek kek eu e Wek ay bal EW RR War vk K eb kaw ek 14 Spindle Nut Torque iesen kek ege ke nik a i KK ken eki ene YE R He ukas hveten 14 DRIVE HUB LUBRICATION i lxxn n n kO Re K k VE KER kk tonsa Keke N ni Ya EEN 15 STEER AND TRAILER HUBS WITH OIL LUBRICANT ssssessssssssessses
11. ONTINUED REMOVING CUPS IN ALUMINUM HUBS 1 Ifrequired on an aluminum hub remove the bearing cup by welding a large bead around the bearing surface of the steel cup letting the assembly cool and removing the bearing cup see figure 21 If a welder is not available heat the hub in an oven to a temperature not to exceed 300 F and pound out the bearing cups with a hammer and drift being careful not to damage the hub 106856a Welding Bead FIGURE 21 2 Inspect the bearing cup bore for evidence of cup rotation or spun cups e If cup rotation exists replace the hub REMOVING CUPS IN IRON HUBS 1 On an iron hub remove the bearing cup using a large hammer and a heavy drift or a hydraulic press Take precaution to avoid damaging the bearing cup bore and shoulder 2 Inspect the bearing cup bore for evidence of cup rotation or spun cups e f cup rotation exists replace the hub INSTALLING A NEW CUP IN ALUMINUM HUBS To install a new cup in an aluminum hub it is recommended that the hub be heated in boiling water 212 F or in an oven at a temperature not to exceed 300 F Cooling the cup in a freezer to 32 F or below will further ease the installation if desired Do not overheat the hub as it may degrade the heat treated strength of the hub Remove the aluminum hub from the oven or water and carefully drop in the new bearing cup being certain it is fully seated If the cup is loose allow a few second
12. Service Manual Lal for PreSet Hub Assemblies PreSet Hubs for Drum Brakes Australian Operating Environment Only A ef oN Aluminum PreSet Iron PreSet Hub Assembly Hub Assembly Pre Adjusted Bearings ABOUT THIS MANUAL e Read this manual carefully providing extra attention to its explanations and instructions e To ensure safe continuous trouble free operation understand your wheel hub system and keep all components in proper operating condition e Pay particular attention to all NOTES CAUTIONS WARNINGS and DANGERS to avoid the risk of personal injury or property damage and realize these statements are not exhaustive ConMet cannot possibly know or evaluate all conceivable methods in which service may be performed or the possibly hazardous consequences of each method Accordingly those who use a procedure not recommended by ConMet must first satisfy themselves that neither their safety nor the safety of the product will be jeopardized by the service method selected e Use only ConMet approved replacement parts Do not attempt to use damaged parts e DISC WHEEL INSTALLATION PROCEDURES ConMet part number 103282 OIL DECALS ConMet part number 106873 and SEMI FLUID DECALS ConMet part number 107383 are available upon request Before You Begin 1 Read and understand all instructions and procedures before you begin to service components 2 Read and observe all Warning and Caution haz
13. ameter and the hub seal bore with the same lubricant as will be used in the hub The Stemco Endeavor seal is installed dry and should not be lubricated 5 Position the seal into the hub bore The Outrunner and Stemco Endeavor seals require the proper tool for installation Refer to the Service Parts List on page 20 of the manual to identify the correct installation tool 6 When installing the Outrunner or Stemco Endeavor seal tap the adapter plate of the installation tool around the outer edge to postition the seal Drive the wheel seal into place see figure 30 Once the tool bottoms out the seal is installed correctly 7 When installing the SKF Scotseal Plus XL press the seal evenly into the bore by hand see figure 30 If additional force is needed use a flat plate and a small mallet to install the seal Install the seal 12 5 REASSEMBLY CONTINUED OUTRUNNER OR SKF SCOTSEAL PLUS XL STEMCO ENDEAVOR SEAL 106811b FIGURE 30 8 Check to be certain the seal is not cocked and that the seal inner diameter and the inner bearing turn freely Failure to lubricate the inner diameter of the seal and the seal journal may result in premature seal failure 9 Lubricate the inner diameter of the seal with a light film of the same lubricant as will be used in the hub 10 Turn the hub over and place it seal end down For all drive and trailer hubs install a bearing spacer If the spacer has a tapered end it
14. ard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both 3 Follow your company s maintenance and service installation and diagnostics guidelines 4 Use special tools when required to help avoid serious personal injury and damage to components Hazard Alert Messages A danger note is associated with a hazard that will result in death or serious personal injury if the advisory is not followed Serious personal injury may be equated to career ending injury A Warning alerts you to a hazard that will result in death or serious injury if not avoided A Caution alerts you to an instruction or procedure that you must follow exactly to avoid minor injury or damage to components A note includes additional information that may assist the technician in service procedures How to Obtain Additional Maintenance and Service Information On the Web Visit www conmet com to access ConMet s product sales service and maintenance literature ConMet Customer Service Call ConMet s Customer Service at 1 800 547 9473 NOTES TABLE OF CONTENTS 1 INTRODUCTION snert S i e ja W n ky HEC r e aa DEH an ek AA n 1 PreS t Hub Assemblies uuu d da ay keke an Kulik tenes b na k REK K K Kek DERS eka geed 1 2 IDENTIFICATION ebessen yiy kal kar EEEE 2 WHEEL MOUNTING SYSTEMS Zubin Y Kuye ke KOYA ek eW EEN 2 Hub Pilot Wheel Mounting
15. b and seat the ball seat of the nut into the ball socket of the wheel see figure 44 18 6 REINSTALLATION CONTINUED INNER CAP NUTAT Use the appropriate nuts with the above technique to install the 12 O CLOCK POSITION front and outer dual wheels Follow your shop practice to locate the valve stems 8 Installthe outer wheel and nuts and tighten to 450 500 ft Ibs see figure 47 The last nut rotation must be with a calibrated torque device 106815a Tightening the Inner Cap Nuts FIGURE 44 6 To properly center the wheel snug the remaining wheel nuts Verify the drum is in place over the drum pilots see figure 45 106824b Torquing the Outer Wheel Nuts FIGURE 47 9 Inspect the brake and wheel installation by checking the seating of the wheel s and drum at the pilots and by turning the wheel s and check for any irregularity Excessive or inadequate wheel nut torque can cause a failure of the wheel mounting system and a wheel separation resulting in 105756a 10 Stud Tightening Sequence severe personal injury or death and property damage Always use FIGURE 45 a device that measures the torque being applied After the first 50 100 miles retorque all the nuts to 450 500 ft Ibs Loosen the 7 Starting with the top nut first and using a staggered outer nuts to retorque the inner nuts pattern torque the inner wheel nuts in stages to 450 500 ft Ibs see figure 46 The last nut rotation must
16. bearing failure and possible loss of the wheel 15 Consolidated Metco Inc 6 REINSTALLATION CONTINUED 1 Remove the fill hole plug REINSTALLING BRAKE DRUMS AND WHEELS 2 Loosen the hubcap bolts to allow air to escape while the hub is filling Hub Pilot Wheel Mounting System 3 Fill the hub with the OEM recommended amount of room temperature 60 F minimum semi fluid grease The brake drum must be fully seated on the drum pilot and against through the fill hole in the hub see figure 36 the hub face during and after installation of the wheel s If your shop practice requires the use of lubricant or anticorrosion material to the threads and or the drum pilot area avoid getting lubricant on the flat mating surfaces of the hub drum and wheels Always snug the top nut first to fully seat the brake drum on the drum pilot and against the hub face See the adjacent diagram for bolt tightening sequence and tighten in order from 1 through 8 or 10 depending on the bolt pattern see figure 37 and figure 38 105755a Filling Hub with Semi Fluid Grease FIGURE 36 4 Retorque the hubcap bolts to 12 18 ft Ibs 5 Reinstall and tighten the fill plug to 20 25 ft Ibs Semi Fluid Grease Volumes CASTING VOLUME NUMBERS FL OZ 10017979 102035 102610 19 10001896 100164 101143 10020219 10003636 10016225 105756a 10 Stud Tightening Sequence FIGURE 37 10016620 10009758 10003654
17. ce FIGURE 9 MOUNTING FLANGE DIAMETER SS 106825a Mounting Flange Diameter FIGURE 10 MOUNTING FLANGE BACKFACE 106826a Mounting Flange Backface FIGURE 11 BARREL OF HUB 106827a Barrel of Hub FIGURE 12 Final Hub Assembly Number This number is stamped on one of the following e Mounting flange face see figure 9 e Diameter of the mounting flange see figure 10 e Back side of the mounting flange see figure 11 The final hub assembly number identifies the hub assembly hub machining studs bearings spacer seal and ABS ring Julian Date Both the machining and the final assembly have Julian dates stamped into the hub assembly in the same location as the assembly numbers see figures 9 10 11 and 12 A Julian date appears as the day of the year plus the last two digits of the calendar year e g July 4 2008 would appear as 18508 This number provides the date when the hub was machined and assembled at the factory and may be used for warranty purposes Consolidated Metco Inc 3 INSPECTION HAZARD ALERT MESSAGES Read and observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both Do not work under a vehicle supported only by jacks Jacks can slip and fall over Serious personal injury and
18. commended service interval is 5 years 500 000 miles or every second brake service for on highway vocations In more severe duty Ifthe hub to be disassembled is a drive hub remove the drive axle shaft and capture the oil see figure 17 applications this service may be required more often Your 12 month inspection criteria will give you an indication whether this service is required In order to ensure optimum wheel hub performance ConMet recommends that only approved PreSet service parts be used to replace all critical components of the system Refer to the back of this manual for a listing of approved parts HUB REMOVAL AND DISASSEMBLY 1 Remove the tires and wheels by following steps 1 4 sss under the Inspection Guidelines section entitled Removing the Drive Axle Shaft 3 Every 12 Months or 100 000 Miles Whichever FIGURE 17 Occurs First on page 4 4 Place a container under the hubcap or drive axle shaft for a drive hub to receive the draining oil then remove the hubcap or drive axle shaft Do not reuse Sudden release of compressed air can cause serious personal the oil Correctly dispose of the lubricant injury and damage to components Before you service a spring chamber carefully follow the 5 Examine the spindle nut to determine the type of manufacturer s instructions to compress and lock the spring to locking system Disengage the locking device completely release the brake Verify that no air pressure
19. faces on the hub drum wheels and nuts Remove loose paint scale and any material building around the pilots of the drum hub and wheels Be sure paint is fully cured on recently refurbished wheels When dual wheels are mounted the stud length beyond the brake drum standout should be from 1 31 1 44 as measured from the brake drum to the end of the stud see figure 42 When mounting dual aluminum wheels use ALCOA inner cap nuts 5978R and 5978L or the equivalent These nuts can also be used with longer studs up to 1 88 standout For special single aluminum wheel applications on drive and trailer hubs use ALCOA single cap nuts 5995R and 5995L or 5554R and 5554L or the equivalent depending on the stud thread length see Table A For single steel wheel applications use BATCO 13 3013R and 13 3013L or the equivalent see Table B BRAKE gt DRUM 106812a Stud Standout FIGURE 42 Consolidated Metco Inc Rotate the hub to bring a drum pilot to the top 12 o clock position see figure 43 Position the inner wheel and tire assembly over the studs against the drum Rotating the Wheel Pilot to 12 O Clock FIGURE 43 4 Beginning in the 12 o clock position install the inner cap nuts by hand to ensure they are not cross threaded Do not tighten any nuts at this time 5 Apply sufficient torque about 50 ft Ibs to the inner top cap nut to draw the brake drum up on the drum pilot and against the hu
20. g device 17 Consolidated Metco Inc 6 REINSTALLATION CONTINUED Table A Single Aluminum Wheel Applications Aluminum Wheels ALCOA Cap Nut Number 3 4 16 Threaded 5995R and 5995L or 5554R and 5554L depending on stud length Use the appropriate nuts with the above technique to install the front and outer dual wheels Follow your shop practice to locate the valve stems 9 Inspect the brake and wheel installation by checking the seating of the wheel s and drum at the pilots and by turning the wheel s and checking for any irregularity Table B Single Steel Wheel Applications Steel Wheels BATCO Cap Nut Number 3 4 16 Threaded 13 3013R and 13 3013L Studs 2 When installing the inner wheel and tire assembly verify the inner nuts being used are suitable for the application aluminum wheels steel wheels brake drum thickness etc Excessive or inadequate wheel nut torque can cause a failure of the wheel mounting system and a wheel separation resulting in severe personal injury or death and property damage Always use a device that measures the torque being applied After the first 50 100 miles retorque all the nuts to 450 500 ft Ibs Loosen the outer nuts to retorque the inner nuts Inner cap nuts must be deep enough to ensure the stud will not bottom inside the nut and must be of a configuration approved by wheel manufacturer Ball Seat Wheel Mounting System 1 Clean all mating sur
21. g through the bearing rollers and that the ends of the bearing are lubricated Check to be sure there are no signs of contamination present If additional grease is required use the fill hole in the barrel of the hub to add additional grease until grease flows from the outboard bearing Use caution not to overfill the hub as it could lead to improper venting and seal leaks Functional Checks Rotate the hub and check for free smooth and quiet rotation If rotation is hampered PreSet hubs should be serviced immediately Check End Play 1 Remove the hubcap or drive axle shaft Use an appropriate container to catch the lubricant Attach the magnetic base of the dial indicator to the spindle Touch the dial indicator stem to the hubcap mounting surface see figure 15 105735a FIGURE 15 2 Grasp two wheel studs across from each other Pull and push while oscillating the hub 3 Measure the end play by calculating the difference between the minimum and maximum dial indicator readings Unless the end play measurement exceeds 006 no additional service is necessary If the spindle nut is correctly locked do not adjust or retighten the spindle nut Z NCAUTION If end play exceeds 0 006 inch 0 15 mm service the hub All components replaced under warranty must be returned for consideration of reimbursement Contact the OEM for their warranty return policy Consolidated Metco Inc 4 RECOMMENDED SERVICE The re
22. ied by the wheel manufacturer see figure 14 103160a FIGURE 14 Inspect Components Check for the following e Loose damaged or missing fasteners e Loose damaged or missing hubcaps Inspect for Leaks 1 Check that no lubricant is present around the hubcap or on the wheel e If lubricant is present investigate the cause and take corrective action 2 Check that no lubricant is present on the hub brake hardware or brake shoes e f lubricant is present check the inboard seal and replace as necessary Inspect for Proper Lubricant Level and Condition 1 Allow any air in the lubricant to escape prior to inspection Visually inspect the lubricant for discoloration Under normal conditions the lubricant will darken A white or milky appearance indicates water contamination 2 Visually inspect the lubricant for foreign materials such as metal shavings rust or other contaminants A magnet can be used to detect any metallic materials that may be present in the lubricant 3 Ifthe inspection indicates contamination service the wheel hub according to instructions outlined later in this manual Do not mix different types of lubricants Only use lubricants approved by the seal manufacturer For a complete list refer to the Lubricant Compatibility Listing in the Literature section on www conmet com On wheel ends filled with semi fluid grease remove the hubcap and verify that sufficient grease is flowin
23. il bath system do not pack the bearing with grease Grease will prevent the proper circulation of axle lubricant and can cause premature wheel seal and bearing failure 1 Place the hub seal end up on a clean work bench surface If you are working on a drive or trailer hub go to step 3 If you are working on a steer hub proceed as follows 2 Forsteer hubs install the tubular bearing spacer with the tapered end down see figure 28 106809a Bearing Cone Assembly for Steer Hub FIGURE 28 3 Lubricate the inner bearing cone with the same lubricant as will be used in the hub and install it into the inner bearing cup see figure 29 106810a Bearing Cone Assembly for Drive Hub FIGURE 29 Consolidated Metco Inc The seal must be replaced every time the hub is removed from the spindle Do not apply any gasket sealant to the seal outer or inner diameter Always use the seal installation tool specified by the seal manufacturer Using an improper tool can distort or damage the seal and cause premature seal failure If using the Outrunner wheel seal place the seal with the air side facing the adapter plate of the installation tool If using the SKF Scotseal Plus XL wheel seal no special installation tools are required If using the Stemco Endeavor seal be sure to use the Stemco installation tool 4 When installing the SKF or Outrunner wheel seal lubricate the seal outer di
24. ing can be removed by see figure 27 gripping the ring with a pair of locking pliers and tapping the pliers upward with a rubber mallet Work around the ring to keep the ring from cocking see figure 25 Drive axle and trailer tone rings can be removed by gripping the ring with a pair of locking pliers and prying against the head of a wheel stud to lift the ring off the hub Work around the ring to prevent cocking see figure 26 Stamped Steel ABS Ring on Steer Axle 105744a FIGURE 25 Installing the ABS Tone Ring FIGURE 27 5 Press the ring on the hub lf a press is not available drive the ring on with a hammer or mallet until the ring seats on the hub see figure 28 A swift initial blow with an 8 lb hammer may be necessary to start the ring onto the hub Stamped Steel ABS Ring on Drive Axle FIGURE 26 2 Thoroughly clean and degrease the ABS ring seat on the hub with a nonflammable solvent Replace the hub if the ABS ring seat is damaged 105745a The ABS ring must be fully seated with a maximum of 0 008 axial runout to ensure the ABS system functions properly FIGURE 28 NOTE 6 Inspect the ring to ensure proper seating If the ring with the ring installation tool until it is completely seated Using a Hammer to Install the Ring 3 Place the hub in a press and place the ABS ring on the hub ring seat 11 Consolidated Metco Inc 5 REASSEMBLY PreSet WHEEL HUBS Z NCAUTION When using an o
25. innsssssrsrrnnrreneene 15 TRAILER HUBS WITH SEMI FLUID GREASE LUBRICANT J 15 TABLE OF CONTENTS REINSTALLING BRAKE DRUMS AND WHEELS kk kk eke keke k 16 Hub Pilot Wheel Mounting System AEN 16 Ball Seat Wheel Mounting System AEN 18 SERVICE PARTS LIST ie cient ana bas mam N bark Y R ER EE EE ee 20 SPECIFICATIONS naii 5ixul arin k en H lkan D k H a basis Arda H RA deeg HA w r Ru L AA 22 Wheel End Torque Specifications kk renne 22 1 INTRODUCTION Consolidated Metco Inc is recognized as the leader in the design and manufacture of lightweight low maintenance components for the commercial vehicle industry ConMet PreSet wheel hub technology offers a better solution to prevent premature wheel hub failures PreSet Hub Assemblies ConMet PreSet hub assemblies include precision machined hubs premium seals specially 106818a toleranced roller bearings and unique PreSet Drive Hub precision machined bearing spacers This combination FIGURE 3 eliminates the need to manually adjust wheel end play These components are delivered as a complete assembly reducing the potential for premature failures due to incorrect end play settings and or improper installation practices LUBRICANT ABS RING ea OPTIONAL 106819a INNER PreSet TN Trailer Hub BEARING CONE FIGURE 4 INNER BEARING CUP SPACER SECTIONED OIL SEAL BEARING CONE 106817a FIGURE 1 106820a PreSet TP Trai
26. ler Hub ConMet offers a complete family of aluminum and FIGURE 5 ductile iron PreSet wheel hub assemblies for steer drive and trailer axles 106304a PreSet Steer Hub FIGURE 2 1 Consolidated Metco Inc 2 IDENTIFICATION WHEEL MOUNTING SYSTEMS ConMet PreSet wheel hubs are available in both hub pilot and ball seat nut configurations Hub Pilot Wheel Mounting The hub pilot wheel mounting system makes use of a single two piece flange nut on each wheel stud for both single and dual wheel applications see figure 6 The hub pilot wheel mounting system is also known as the Uni Mount 10 10 stud WHD 10TM 10 stud WHD 8 8 stud and ISO system SINGLE 106821a Hub Pilot Mounting Systems FIGURE 6 Ball Seat Wheel Mounting System The ball seat wheel mounting system makes use of the spherical contact area between the nut and wheel to both locate the wheel and hold the wheel tight against the brake drum see figure 7 The ball seat wheel mounting system is also known as the stud piloted ball seat cap nut BCN and double cap nut DCN system SINGLE mon 106822a Ball Seat Mounting Systems FIGURE 7 Consolidated Metco Inc IDENTIFYING CONMET HUB ASSEMBLIES Identifying your hub assembly is important for many reasons It will enable you to properly service the hub assembly and purchase the appropriate replacement parts if needed Plus if a warrant
27. nMet at 1 800 547 9473 for the correct stud part number for your application If you plan to replace the brake drum verify the new drum has the same drum pilot diameter as the one that has been removed 105758a Rotating the Hub FIGURE 40 5 Position the brake drum over the hub so it seats on the drum pilot and against the hub face 6 Place the wheel s into position One or more nuts can be started in order to hold wheel s and drum into position 7 Snug the top nut first Apply 50 ft Ibs torque to 106812a draw the brake drum up fully against the hub see Measuring Stud Standout figure 41 FIGURE 39 2 In environments where a corrosion inhibitor is beneficial ConMet recommends the use of Corrosion Block a product of Lear Chemical Research 905 564 0018 In severely corrosive environments a light coat of Corrosion Block on the drum and wheel pilots has proven beneficial 3 In addition to the above preparation apply two drops of oil to a point between the nuts and nut flange washer and two drops to the last two or three threads at the end of each stud Also lightly lubricate the pilots on the hub to ease wheel installation and removal 106824b Reinstalling the Wheel FIGURE 41 8 Install the remaining wheel nuts and using the sequence as shown torque all the nuts to 50 ft Ibs then retorque to 450 500 ft Ibs see figure 37 and figure 38 The last nut rotation must be with a calibrated torquin
28. nents 5 Clean and inspect the wheel bearings race spindle bearing and seal journals and hub Bearings should be cleaned in a suitable non flammable solvent and dried with either compressed air or a lint free rag If compressed air is used do not spin dry the bearings as the rollers may score due to lack of lubricant Ensure that the air line is moisture free 6 Parts must be dried immediately after cleaning Dry parts with clean paper towels or rags or compressed air Do not dry bearings by spinning with compressed air 7 Apply a light oil to cleaned and dried parts that are not damaged and are to be immediately assembled Use only the type of oil used by the manufacturer Do NOT apply oil to the brake linings or the brake drums 8 Ifthe parts are to be stored apply a good corrosion preventative to all surfaces Do NOT apply the material to the brake linings or the brake drums Store the parts inside special paper or other material that prevents corrosion INSPECTING BEARING CUPS CONES AND SPACER 1 After components have been properly cleaned visually inspect the cups and cones Reference materials for proper inspection procedures are available from the bearing manufacturers If removal or replacement is required follow the steps outlined on the next page Consolidated Metco Inc If you choose to reuse existing bearings at this service they must be inspected in accordance with the bearing manufacturers rec
29. ommended guidelines If this inspection indicates that existing bearing component s must be replaced bearing cups and cones must be replaced as a set Whenever new bearings are installed replacement of the bearing spacer is also recommended After properly cleaning the components visually inspect spacer for wear or damage It can be difficult to determine if the spacer is worn and needs replacement It is recommended that the spacer be replaced anytime the hub is disassembled and there is evidence of bearing cone rotation Cone rotation can result in spacer wear Therefore if the spacer is reused unsafe preload of the bearings could occur To inspect for cone rotation e Visually inspect spacers for signs of wear or damage Carefully inspect the machined ends of the bearing spacer Wear to the bearing spacer can appear as a sharp ring of standing metal at either edge of the machined surfaces See figure 20 e Inspect bearing cone ID for visual evidence of rotation and wear e Inspect spindle bearing journal for visual evidence of rotation and wear 106864a Bearing Spacer Wear FIGURE 20 If unsure of the condition of components PreSet bearing kits can ensure bearing adjustment and optimum bearing life The PreSet bearing kit consists of both bearing sets and a bearing spacer The kits are available from both ConMet and approved bearing suppliers Some kits also include a wheel seal 4 RECOMMENDED SERVICE C
30. outer bearing in place Use care to maintain alignment between the bearing cones spacer and spindle and to avoid seal damage see figure 33 106831a The hubcap bolt holes must be free of debris such as silicone gasket sealer to ensure the bolts will tighten properly to avoid leaks Silicone trapped in the hubcap screw holes can create hydraulic pressures during hubcap screw installation leading to premature hub failure through the hubcap holes The vent should also be clean and free of debris Remove any burrs or sharp edges Always use new gaskets Mounting the Assembly FIGURE 33 Consolidated Metco Inc 14 6 REINSTALLATION CONTINUED 4 Installthe hubcap or drive axle A ConMet PreSet hubcap is required for trailer hubs not equipped with tire inflation systems Torque the hubcap bolts to 12 18 ft Ibs using a star pattern Torque the drive axle per the axle manufacturer s recommendations Use SAE Grade 5 bolts or stronger Do not use star washers Use only flat washers or split washers DRIVE HUB LUBRICATION 105753a Drive hubs can be lubricated by installing one quart of oil through the fill plug in the barrel of the hub Filling the Hub with Oil FIGURE 34 Z NCAUTION 2 Be certain the hubcap is properly filled to the oil level mark on the face of the cap see figure 35 If no fill plug is present the drive hub can be lubricated Allow the initial fill amount to settle for 10 min
31. r or recondition wheel end components Replace damaged worn or out of specification components Do not mill or machine any components Using repaired reconditioned damaged or worn components can cause wheel end failure which can result in serious injury and property damage Consolidated Metco Inc ABS TONE RING INSPECTION AS APPLICABLE The Anti Lock Braking System ABS signals acts like any signal generator where the magnet passes a coil and generates a current On hubs the toothed ring passes a sensor and generates a signal that is sent to the ABS computer There are two types of ABS rings used on ConMet hubs powdered metal and stamped steel see figure 23 POWDERED METAL STAMPED STEEL OR MACHINED ABS RING ABS RING 106805a FIGURE 23 If the tone ring is damaged for example if it is dropped bent chipped or dinged it must be replaced REMOVAL AND INSTALLATION OF POWDERED METAL ABS TONE RING For a powdered metal ring remove using a chisel making sure not to damage the hub Reinstall by heating the ring to 350 F in an oven and installing it on the hub see figure 24 106806a Powdered Metal ABS Ring FIGURE 24 10 4 RECOMMENDED SERVICE CONTINUED REMOVAL AND INSTALLATION OF 4 Using ConMet ring installation tool part number STAMPED STEEL ABS TONE RING 107119 center the tool over the ABS ring Each j type of ring fits a corresponding diameter on the tool 1 The steer axle tone r
32. remains in the service chamber before you proceed 2 If the axle is equipped with spring brake chambers Do not loosen the axle spindle nuts by either striking them directly carefully compress and lock the springs so that they with a hammer or striking a drift or chisel placed against them cannot actuate see figure 16 Damage to the parts will occur causing possible loss of axle wheel end components and serious personal injury 6 Remove the spindle nut system 103161a FIGURE 16 3 Remove the brake drum Support the drum during the removal process to prevent damage to the axle spindle threads Consolidated Metco Inc 6 4 RECOMMENDED SERVICE CONTINUED Slide the hub off the spindle Remove and save the outer bearing cone Be careful when you remove the hub that you do not damage the outer bearing by dropping it on the floor e If the hub is difficult to remove because the seal is stuck on the spindle use a mechanical puller to remove the hub see figure 18 e f part of the seal remains on the spindle carefully remove the part of the seal that remains on the spindle o o o oan ell IEN ge dm 00 105740a FIGURE 18 Place the hub on its outboard end and remove and discard the seal If present remove and discard the inner bearing retainer The stamped steel retainer secures the inner cone during shipment and has no purpose in service see figure 19 Be careful not to damage the
33. s for it to heat up and secure itself before moving the hub Use a 0 001 to 0 002 feeler gauge to ensure the cup is fully seated against the shoulder of the bearing bore INSTALLING A NEW CUP IN IRON HUBS Iron hubs do not need to be heated for bearing cup installation Press the bearing cup into the hub being certain that it is fully seated see figure 22 Use a 0 001 to 0 002 feeler gauge to ensure the cup is fully seated against the shoulder of the bearing bore 105742a Bearing Cup Pressed into Hub FIGURE 22 WHEEL STUDS Replace all wheel studs that have damaged or distorted threads are broken or bent or are badly corroded Also replace both studs adjacent to the damaged stud If two or more studs have damage replace all the studs in the hub Broken studs are usually an indication of excessive or inadequate wheel nut torque STUD REMOVAL Observe all warnings and cautions for press operation provided by the press manufacturer to avoid serious personal injury and damage to components 1 Place the clean hub in a shop press with the hub supported evenly around and adjacent to the stud being removed Consolidated Metco Inc 2 4 RECOMMENDED SERVICE CONTINUED Failure to adequately support the hub can result in physical injury and or damage to the hub Some hubs are configured so it is impractical to have supports to prevent the hub from tipping when force is applied to the stud In this case
34. should face towards the outboard end of the hub see figure 31 105748a Installing the Spacer FIGURE 31 11 Lubricate the outer bearing cone with the same lubricant as will be used in the hub and install it into the hub assembly see figure 32 105749a Installing the Outer Bearing Cone FIGURE 32 Consolidated Metco Inc 6 REINSTALLATION INSTALLING THE PreSet WHEEL HUB ASSEMBLY Z NCAUTION On the ball seat wheel mounting system always use left handed threaded studs which are gold in color and have an L stamped on the end in the hub on the driver s side of the equipment and use right handed threaded studs which are silver in color and have an R stamped on the end in the hub on the passenger s side of the equipment The ConMet part number is located on the head of the stud The same part number must be used for replacement unless changing the drum or wheel type Spindle Preparation 1 Light corrosion fretting that forms on spindles is normal and should be removed with a fine abrasive When the residue is cleaned away the bare spindle is again subject to corrosion and must be covered with a film of grease for corrosion protection making sure both the bearing journals and the seal journals are well coated Standard Grade 2 greases work well in normal environments The lubricant being used in the wheel end may also be used In severe environments a Moly grease may provide added protection
35. support the hub on wood blocks on the floor and use a heavy hammer to drive the studs out with several sharp blows Be careful to avoid damaging the hub and components particularly the seal bore and the ABS tone ring Press the stud out of the hub STUD REPLACEMENT On the ball seat wheel mounting system always use left handed threaded studs on left handed hubs and use right handed threaded studs on right handed hubs The ConMet part number is located on the head of the stud The same part number must be used for replacement unless changing the drum or wheel type To install a new stud support the hub evenly around and adjacent to the stud being installed Press the new stud all the way into the hub Be sure the stud is fully seated and that the stud head is not embedded into the hub Excessive force can cause the stud head to be embedded into the hub which can create a crack in the hub resulting in serious injury and property damage If a stud head is imbedded in a hub replace the hub HUB DRUM AND WHEEL INSPECTION 2 Inspect the drum pilots wheel pilots and mounting face on the hub for damage A damaged drum pilot is usually caused by improper drum mounting A damaged wheel pilot could be the result of inadequate wheel nut torque allowing the wheels to slip in service Also inspect other surfaces of the hub for signs of cracks or damage Inspect the wheels and brake drum for damage Do not repai
36. utes by lifting the opposite side of the axle 8 to allow the Repeat the fill procedure until the oil is at the fill line lubricant to run down the axle housing and into the hub on the hubcap assembly Elevate the axle for two minutes to allow the lubricant time to fill the hub Repeat the process for the opposite side of the vehicle The rear axle carrier should be filled to the proper level to ensure adequate lubricant is available to fill the entire hub Refill the carrier to the proper level after this procedure is completed STEER AND TRAILER HUBS WITH OIL LUBRICANT 105754a Only use oil approved by the seal manufacturer see approved list Fill to Oil Level Line from the seal manufacturer or on www conmet com FIGURE 35 Some hubs are provided with a fill hole located in the barrel and between the bearings for adding lubricant 3 Be sure to put the fill hole plug back into the hubcap 1 Fill the hub through the hubcap or the fill hole with and hati he venir ls Working propery oil It may be necessary to add lubricant more than once to adequately fill the hub see figure 34 TRAILER HUBS WITH SEMI FLUID GREASE LUBRICANT If you are using semi fluid grease in trailer applications special procedures must be followed as outlined in the Semi Fluid Grease Lubricant section Failure to fill and maintain the hub with the correct amount of semi fluid grease may cause premature failure of the wheel hub system
37. y issue arises you ll then be able to provide details on all aspects of the ConMet hub This section is devoted to finding and understanding the different identification numbers associated with ConMet hubs Vehicle Identification Number VIN The quickest and easiest method of identifying your hub assembly is to note the vehicle identification number VIN and call the truck dealership The dealership can then tell you what hubs were installed on your vehicle If this is not possible there is a variety of identification numbers located on a ConMet hub assembly Casting Number This number is physically cast into the hub and appears in large characters usually on the back side of the mounting flange near the stud head see figure 8 gt Z CASTING NUMBER ONTHE BACK SIDE OFTHE MOUNTING FLANGE 10001280 E A mn o o a amp amp amp amp N 106829a Casting Number on the Back Side of the Mounting Flange FIGURE 8 Machining Assembly Number This number is stamped on one of the following e Mounting flange face see figure 9 e Diameter of the mounting flange see figure 10 Back side of the mounting flange see figure 11 Barrel of the hub see figure 12 The machining number represents the way the hub is machined e g hub pilot vs ball seat 8 78 vs 8 53 vs 9 brake drum pilot diameter 2 IDENTIFICATION CONTINUED MOUNTING FLANGE FACE 106828a Mounting Flange Fa
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