Posi-Stop LCB Service Manual.book
Contents
1. SPRING PRESSURE AND EXTREME CAUTION MUST BE TAKEN WHEN REMOVING THIS COVER BRAKE COVER BOLTS MUST BE REMOVED CAU TIOUSLY AND EVENLY DO NOT REMOVE BRAKE COVER BOLTS ONE 1 AT A TIME WARNING BEFORE REMOVING COMPRESSION TOOL FROM SPINDLE MAKE SURE ALL SPRING FORCE IS OFF OF PRESSURE RING AND RING MOVES FREELY IN BRAKE HOUSING Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 25 BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS CONT REASSEMBLY 1 Install brake housing on axle 2 Install all spring sets 3 Position piston pressure ring in brake housing 4 Install spring compression tool main section over axle spindle and center in pressure ring 5 Install the bolt plate and bolts over the spindle Back the bolts out far enough so they do not contact the cylinder face 6 Install spindle nut and tighten securely against round compression tool 7 Turn the four compression tool bolts in against compression tool cylinder 8 Cautiously and evenly in a crisscross manner tighten compression tool bolts a thread or two at a time to compress spring sets and push pressure ring into brake housing Springs are compressed far enough when the tangs on the pressure ring are approximately 1 8 of an inch from being flush with face of brake housing 9 Install first steel reaction plate in pressure ring 10 Install first friction disc and lining assembly in pressure ring and against f2. which are not supplied or approved by Dana Important Always furnish serial and model numbers when ordering parts SAFETY PRECAUTIONS To reduce the chance of personal injury and or property damage the following instructions must be carefully observed Proper service and repair are important to the safety of the service technician and the safe reliable operation of the machine If replacement parts are required the part must be replaced with a Dana specified replacement part Do not use a replacement part of lesser quality The service procedures recommended in this manual are effective methods of performing service and repair Some of these procedures require the use of purpose designed tools Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended must first determine that neither their safety or the safe operation of the machine will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices that must be carefully observed in order to reduce the risk of personal injury during service or repair Improper service or repair may damage the unit or render it unsafe It is important to understand that these Cautions and Notices are not exhaustive It is impossible to warn of all possible hazardous consequences that may result from following or failing to follow these instructions Off
3. Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 2 TABLE OF CONTENTS Page 2 Foreword And Safety Precautions 3 Table of Contents 4 Description 5 Posi Stop LCB Exploded View 6 Posi Stop LCB Parts Description 7 Recommended Lubricants 8 Cleaning and Inspection 10 Posi Stop LCB Brake Pressure Test Instructions 11 Fastener Torque Chart 12 Plug and Elastic Stop Nut Torque Charts DISASSEMBLY SECTION 13 Posi Stop LCB Disassembly 13 Brake Cover Removal 14 Discs Pressure Ring and Spring Removal 15 Wear Indicator Pin Removal 16 Brake Piston Removal REASSEMBLY SECTION 18 Posi Stop LCB Reassembly 18 Wear Indicator Pin Installation 18 Slack Adjuster Installation 19 Pressure Ring and Spring Installation 20 Brake Disc Installation 21 Brake Piston Installation 21 Brake Cover Installation 23 Slack Adjuster Adjustment SPECIAL TOOL SECTION 25 Brake Spring Compression Tool Inst 27 Brake Spring Compression Tool Weldment 28 Brake Spring Compression Tool Bolt Plate Axle Model 21D 29 Brake Spring Compression Tool Bolt Plate Axle Models 53R and 48T 30 Brake Spring Compression Tool Installation 31 Brake Assembly Lifting Tool 32 Brake Piston Lifting Tool Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 3 DESCRIPTION Posi Stop LCB Liquid Cooled Brakes The liquid cooled brake is ideal for use in co
4. Stop LCB Liquid Cooled Brake Service Manual 14 Off Highway Products DANA Figure 12 Remove three slack adjuster spacers Figure 13 Remove brake cover seal ring Figure 14 Remove three slack adjuster jam nuts Figure 15 Remove three slack adjuster screws Wear Indicator Pin Removal Figure 16 Tap out brake wear indicator pin Figure 17 Remove brake wear indicator pin Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 15 Brake Piston Removal Figure 18 Place brake cover on flat surface face down Install three screws and flat washers in the brake piston puller holes CAUTION Brake cover is heavy and can cause injury and damage Figure 19 Piston with puller screws and washers installed Figure 20 Using a pry bar evenly pry piston out of the brake cover until it is no longer in contact with the piston seals Figure 21 Piston pulled out of seals Piston can be removed by hand at this point Figure 22 Remove brake piston Figure 23 Remove outer piston seal assembly 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 16 Off Highway Products DANA Figure 24 Remove inner piston seal assembly Figure 25 Remove two pressure port sealing rings Figure 26 Remove pressure ring seal ring Figure 27 Remove two brake wear indicator pin o rings Figure 28 Remove brake wear indicator pin retaining ring NOTE No
5. and reassembly spring compression tool be fabricated before disassembling any part of this brake a drawing of the tool is included on pages 83 85 3 Install spring compression tool main section over axle spindle through brake discs and against the piston pressure ring 4 Install the bolt plate and bolts over the spindle Back the bolts out far enough so they do not contact the cylinder face 5 Install spindle nut and tighten securely against compression tool 6 Tighten the four compression tool bolts against compression tool cylinder This will hold the springs in position while removing the brake cover and brake discs 7 With the spring compression tool securely in place remove the brake cover bolts evenly Do not remove bolts one at a time 8 Remove brake cover and piston from brake housing 9 Remove the friction and reaction discs 10 Cautiously and evenly turn out a thread at a time the compression tool bolts The compression springs will push the piston pressure ring out of the brake housing 11 Remove spindle nut and remove two piece compression tool Refer to pages 49 amp 65 for detailed disassembly and reassembly instructions for servicing the internal components of the brake housing and cover WARNING DO NOT ATTEMPT TO MAKE ANY REPAIRS ON THE BRAKE UNTIL THIS TEXT IS COMPLETELY READ AND UNDERSTOOD AND ALL SAFETY PRE CAUTIONS COMPLIED WITH WARNING OUTER BRAKE HOUSING COVER IS UNDER 72 000 LBS COMPRESSED
6. made with piston Figure 58 Back three adjusting screws off 1 5 turns While maintaining position of adjusting screws tighten jam nuts Figure 59 Tighten three adjusting screw jam nuts to 50 to 75 LBF FT 67 8 to 101 7 Nm Figure 60 Install two pressure port plugs Tighten to 84 to 120 LBF IN 10 to 14 Nm Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 23 Air Pressure Test Figure 61 Air pressure test Refer to pressure test instructions on page 9 Figure 62 Hydraulic pressure test brake Refer to pressure test instructions on page 9 Final Assembly Figure 63 One at a time remove the 24 brake cover screws Apply Loctite 262 or equivalent to the threads reinstall and tighten to 175 to 190 LBF FT 240 to 260 Nm IMPORTANT Do not remove more than one screw at a time Figure 64 Install two warning sticker covers with four screws and tighten to 15 to 240 LBF IN 24 to 27 Nm 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 24 Off Highway Products DANA BRAKE SPRING COMPRESSION TOOL INSTRUCTIONS DISASSEMBLY 1 Disassemble wheel end from spindle up to and including the removal of the wheel hub from the brake discs NOTE If axle spindle or axle housing is to be replaced remove brake as an assembly by removing brake to spindle screws and washers 2 Remove brake assembly from spindle It is imperative that a special disassembly
7. Service Manual 25150 amp 26150 Posi Stop Liquid Cooled Brake LCB ASM 0104 May 2009 Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual NOTES Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 1 FOREWORD This manual has been prepared to provide the customer and maintenance personnel with information and instructions on the maintenance and repair of Dana Products Extreme care has been exercised in the design and selection of materials and manufacturing of these units The slight outlay in personal attention and cost required to provide regular and proper lubrica tion inspection at stated intervals and such adjustments as may be indicated will be reimbursed many times in low cost operation and trouble free service In order to become familiar with the various parts of the product its principle of operation trouble shooting and adjustments it is urged that mechanics study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations Whenever repair or replacement of component parts is required only Dana approved parts as listed in the applicable parts manual should be used Use of will fit or non approved parts may endanger proper operation and performance of the equipment Dana does not warrant repair replacement parts or failures resulting from the use of parts
8. an provide useful information but an axle should not be removed from service based solely on this analysis Vehicles which are prone to high levels of ingested water in the axle or water as a result of condensation should not use extended drain intervals Friction Modifiers Friction modifiers may be used with the lubricant to reduce Posi Torq limited slip differential noise or liquid cooled brake noise If friction modifiers are used follow instructions on TSB 278E The use of aftermarket lubricant additives other than those specified is not recommended and may reduce the life of the axle and void the warranty Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 7 CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using solvent type cleaning fluid It is recommended that parts be immersed in cleaning fluid and agitated slowly until parts are thoroughly cleaned of all old lubricants and foreign materials CAUTION Care should be exercised to avoid skin rashes fire hazards and inhalation of vapors when using solvent type cleaners BEARINGS Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to dislodge solidified particles of lubricant Immerse again in cleaning fluid to flush out particles Repeat above operation until bearings are thoroughly clean Dry bearings using moisture free compressed air Be careful to direct air stream acro
9. assemble the brake IMPORTANT If the brake spring compression tool is not going to be used the following procedure must be followed to avoid personal injury and component damage CAUTION The brake cover is under 72 000 psi pounds square inch of pressure created by the brake apply springs It is recommended that the capscrew heads be numbered to assist in following the loosening tightening sequence Refer to figure 52 In a crossing or star pattern loosen the 24 brake cover capscrews turning no more than one quarter 1 4 turn at a time in sequence Continue this process until all pressure on the cover has been relieved Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 13 Figure 6 After all spring force has been relieved from cover remove the 24 cover screws and washers Figure 7 Install two eye bolts to assist in handling the brake cover in opposite warning plate holes Figure 8 Remove brake cover Discs Pressure Ring and Spring Removal Figure 9 Remove brake friction and reaction discs NOTE If discs are to be reused they need to be reinstalled in the exact order and direction in which they were removed Figure 10 Remove brake piston pressure ring Figure 11 Remove brake springs NOTE Inner and outer springs are matched sets and must remain together As each set is removed it is recommended that they be wired together to prevent mixing sets 25150 26150 Posi
10. cts DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 11 PLUG AND ELASTIC STOP NUT TORQUE CHARTS O RING PLUGS Size P N LBF FT Nm 5 16 24 24K 1 5 7 3 8 24 24K 2 8 11 7 16 20 24K 3 10 14 1 2 20 24K 4 13 18 9 16 18 24K 5 15 20 3 4 16 24K 6 25 34 7 8 14 24K 7 35 47 1 1 16 12 24K 8 50 68 1 3 16 12 24K 9 60 81 1 5 16 12 24K 10 75 102 1 5 8 12 24K 11 85 115 1 7 8 12 24K 12 85 115 PIPE PLUGS Size NPTF LBF FT Nm 1 16 27 7 9 1 8 27 10 14 1 4 18 20 27 3 8 18 30 41 1 2 14 35 47 3 4 14 45 61 1 11 1 2 55 75 1 1 4 11 1 2 65 88 ELASTIC STOP NUTS Size LBF FT Nm 1 20 200 270 1 1 4 18 250 340 1 1 2 18 350 475 1 3 4 12 450 610 Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 12 DISASSEMBLY Posi Stop LCB Brake Disassembly Figure 1 Remove four warning sticker cover screws Figure 2 Remove two warning sticker covers Note Warning Figure 3 Note warning cast into brake cover Figure 4 Remove two pressure port plugs Brake Cover Removal Figure 5 This disassembly procedure is tedious and time consuming Due to the potential for injury and damage any shortcuts should be avoided A spring compression tool drawing and instructions are included on pages 24 and 26 It is recommended the compression tool be used to disassemble and re
11. d and free Maintain pressure for 30 seconds minimum without drop Repeat twice If brake will not maintain pressure tear down and determine cause of leak rebuild and retest Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 10 FASTENER TORQUE CHART STANDARD FASTENERS Lubricated and Plated Bolts CapScrews and Studs Grade 5 Grade 8 3 Radial Dashes on Bolt Head 6 Radial Dashes on Bolt Head Size LBF FT Nm LBF FT Nm 1 4 20 10 14 11 15 1 4 28 11 15 13 18 5 16 18 16 22 30 41 5 16 24 20 27 32 43 3 8 16 25 34 36 49 7 16 14 41 56 57 77 7 16 20 45 61 64 87 1 2 13 63 85 88 119 1 2 20 70 95 99 134 9 16 18 100 136 141 191 5 8 11 124 168 175 237 5 8 18 141 191 198 268 3 4 10 220 298 310 420 3 4 16 245 332 347 470 METRIC FASTENERS Lubricated and Plated Bolts CapScrews and Studs Class 8 8 Class 10 9 Class 12 9 8 8 on Bolt Head 10 9 on Bolt Head 12 9 on Bolt Head Size LBF FT Nm LBF FT Nm LBF FT Nm M4 2 2 3 3 2 4 4 7 4 10 M5 4 4 5 9 6 4 8 7 7 4 10 M6 7 4 10 11 15 13 18 M8 18 25 26 36 32 43 M10 36 49 51 72 62 84 M12 63 85 92 125 107 145 M14 100 135 147 200 173 235 M16 155 210 229 310 269 365 M18 221 300 317 430 369 500 M20 313 425 450 610 524 710 M22 428 580 605 820 708 960 M24 538 730 774 1050 900 1220 Off Highway Produ
12. d providing they meet API GL 5 MT 1 qualifications The highest viscosity grade must be used given the prevailing ambient temperatures from the chart below In general synthetic oils have a lower pressure viscosity response than mineral oil lubricants as the contact pressure between the gears increases This produces a thickening of the mineral oil at the contact point This increase in viscosity helps to maintain lubricant film thickness reducing the possibility of surface and spalling fatigue Synthetic lubricants do not thicken as much under pressure unless specifically formulated to do so Before using a synthetic lubricant in heavy applications the customer must check with the lubricant supplier on the issue of high pressure lubricant applica tions Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature and very dusty atmospheric conditions will result in accelerated deteriora tion or contamination Judgment must be used to determine the required change intervals for extreme conditions Extended Oil Change Interval Extended oil service may result when using synthetic lubricants Appropriate change intervals must be determined for each application by measuring oxidation and wear metals over time to determine a baseline Wear metal analysis c
13. d wrap in clean lint free cloth or paper to protect them until installed OIL SEALS GASKETS AND RETAINING RINGS Replacement of spring loaded oil seals gaskets and retaining rings is more economical when unit is disassembled than to risk premature overhaul to replace these parts at a future time Loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly Sealing member should be handled carefully partic ularly when being installed Cutting scratching or curling under lip of seal seriously impairs its efficiency At reas sembly lubricate lips of oil seals with Multipurpose Lithium grease Grade 2 Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 8 CLEANING AND INSPECTION CONT GEARS AND SHAFTS If Magna Flux or a dye penetrant process is available use this process to check parts Examine teeth and the ground polished surfaces of all gears and shafts carefully for wear pitting chipping nicks cracks or scoring If gear teeth are cracked or show spots where case hardening is worn through replace with new gear Small nicks may be removed with suitable hone stone Inspect shafts to make certain they are not sprung bent or have twisted splines HOUSINGS COVERS AND CAPS Inspect housings covers and caps to be certain they are thoroughly cleaned and that mating surfaces bearing bores etc are free from nicks or burrs Check all part
14. e Manual 27 Off Highway Products DANA Brake Spring Compression Tool Bolt Plate Axle Model 21D 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 28 Off Highway Products DANA Brake Spring Compression Tool Bolt Plate Axle Models 53R and 48T 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 29 Off Highway Products DANA Brake Spring Compression Tool Installation Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 30 Brake Assembly Lifting Tool 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 31 Off Highway Products DANA Brake Piston Lifting Tool For product inquiries or support visit www dana com or call 419 887 6445 For other service publications visit www SpicerParts com literature asp For online service parts ordering visit www SpicerParts com order asp Copyright 2010 Dana Holding Corporation All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or otherwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES
15. ew 24 21 Warning Sticker 2 22 Sticker Cover Plate 2 23 Capscrew 4 24 Snap Ring 1 25 Seal Ring 1 26 Seal Ring 1 27 Seal Ring 2 28 Name Plate 1 29 Rivet 2 30 Plug 2 1 Brake Housing 1 2 Plug 1 3 Plug 1 4 Brake Cover 1 5 Bleeder Screw 1 6 Plug 1 7 Spring Set 15 8 Piston Pressure Ring 1 9 Reaction Plate 6 10 Disc and Lining Assembly 6 11 Brake Piston 1 12 Outer Piston Seal 1 13 Inner Piston Seal 1 14 Slack Adjuster Spacer 3 15 Slack Adjuster Screw 3 16 Pin Wear Indicator 1 17 Nut 3 18 O Ring Seal 2 19 Washer 24 20 Capscrew 24 21 Warning Sticker 2 22 Sticker Cover Plate 2 23 Capscrew 4 24 Snap Ring 1 25 Seal Ring 1 26 Seal Ring 1 26 Seal Ring 2 28 Name Plate 1 29 Rivet 2 30 Plug 2 ITEM DESCRIPTION QTY Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 6 RECOMMENDED LUBRICANTS Recommendations Extreme pressure gear lubricant is recommended for use in all drive steer and rigid drive axles except where explicitly stated differently by Spicer Off Highway Products Engineering Mineral Based Acceptable lubricants must meet API GL 5 MT or MIL PRF2105E qualifications The highest vis cosity grade must be used given the prevailing ambient temperatures from the chart below Synthetics Synthetic lubricants are recommende
16. ing and assembly Figure 50 Mark location of pressure ports on brake cover and housing Align ports and install cover on alignment pins Figure 51 Remove two alignment pins and install 24 brake cover screws and washers NOTE Run screws down only Finger Tight Figure 52 Mark screws with numbers from 1 to 24 in a criss crossing pattern Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 21 Figure 53 Carefully recheck alignment of reaction disc teeth and teeth in the brake housing IMPORTANT This is a critical step If the teeth are not properly aligned they will not enter the brake housing without damage as the springs are compressed Figure 54 Tighten the 24 brake outlet cover screws in a criss cross pattern by turning each screw NO MORE THAN 1 4 TURN As springs are compressed check alignment of reaction disc teeth as they enter the brake housing When cover contacts brake housing the screws should be tightened to 175 to 190 LBF FT 240 to 260 Nm Slack Adjuster Installation Figure 55 Install three slack adjuster screws with silicone on threads Figure 56 Install three slack adjuster jam nuts Refer to slack adjuster adjustment procedure for proper adjustment 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 22 Off Highway Products DANA Slack Adjuster Adjustment Figure 57 Turn three slack adjuster screws inward until contact is
17. irst steel plate 11 Install second steel reaction plate 12 Install second friction disc aligning the four oil grooves in the second disc with the oil grooves in the first friction disc 13 Alternate steel plates and friction discs until five plates and five discs are installed First plate installed is steel and last disc installed is friction NOTE Always align friction disc oil grooves and careful alignment of friction disc teeth at this time will facilitate wheel hub spline alignment in discs at wheel hub assembly in brake 14 Install a new square cut sealing ring in groove in brake housing 15 Position brake cover on brake housing aligning fluid hole marks on cover with holes in housing Refer to Posi Stop brake reassembly on page 65 16 Install cover to housing bolts and washers If there is a slight gap between cover and housing carefully and evenly tighten bolts to specified torque 17 Install cover to housing bolts and washers If there is a slight gap between cover and housing carefully and evenly tighten bolts to specified torque 18 Carefully and evenly loosen bolts in compression tool When bolts are away from compression cylinder remove spindle nut Remove compression tool and cylinder from spindle and brake 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 26 Off Highway Products DANA Brake Spring Compression Tool Weldment 25150 26150 Posi Stop LCB Liquid Cooled Brake Servic
18. ntaminated or temperature sensitive environments and in machines where extra long maintenance intervals are required Braking action of the Posi Stop LCB is achieved through the application of the hydraulic piston and brake apply springs with the rotating friction surfaces which react with stationary stator plates The stator plates are retained by scalloped tangs at the outside diameter which in turn transfer the reaction torque to the rigid outside housing Hub splines are long enough to engage all friction discs before bearings or seals are set This provides ease of service reassembly Wheel bearings are serviced as in any normal bearing service procedure Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 4 POSI STOP LCB EXPLODED VIEW 2515 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 5 Off Highway Products DANA 25150 POSI STOP LCB PARTS DESCRIPTION 26150 POSI STOP LCB PARTS DESCRIPTION ITEM DESCRIPTION QTY 1 Brake Housing 1 2 Plug 1 3 Plug 1 4 Brake Cover 1 5 Bleeder Screw 1 6 Plug 1 7 Spring Set 15 8 Piston Pressure Ring 1 9 Reaction Plate 5 10 Disc and Lining Assembly 5 11 Brake Piston 1 12 Outer Piston Seal 1 13 Inner Piston Seal 1 14 Slack Adjuster Spacer 3 15 Slack Adjuster Screw 3 16 Pin Wear Indicator 1 17 Nut 3 18 O Ring Seal 2 19 Washer 24 20 Capscr
19. re 40 Install reacting disc Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 19 Figure 41 Identify the rounded edges on teeth of friction discs Rounded edges should be installed facing UP Figure 42 Install friction disc Alternately install the remaining reaction and friction discs NOTE Align the friction disc oil grooves missing teeth with the previously installed friction disc Alignment of friction disc teeth at this time will ease spline engagement during hub installation Figure 43 Line up the reaction disc teeth with the internal teeth in brake housing Figure 44 Install two alignment pins in brake housing 180 apart NOTE Alignment pins can be made by using bolts with heads cut off Brake Piston Installation Figure 45 Install outer piston seal assembly Figure 46 Install inner piston seal assembly NOTE Use caution not to over stretch the inner o ring and seal ring 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 20 Off Highway Products DANA Figure 47 Lightly lubricate inner and outer piston seals and piston with grease install piston in brake cover Figure 48 Evenly press piston into brake cover until it bottoms out C clamps can be used as shown to ease this process Brake Cover Installation Figure 49 Install two pressure port seal rings NOTE Use grease to retain seal rings in grooves during handl
20. s carefully for evidence of cracks or conditions which can cause oil leaks or failures Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 9 POSI STOP LCB BRAKE PRESSURE TEST INSTRUCTIONS 1 Air Pressure Decay Test and Criteria a After completing assembly and with bleeder plugged apply 12 PSI 83 kPa air pressure to the brake fluid actuation port Shut off air at inlet to hold pressure on brake b Let pressure stabilize for 30 seconds This is to compensate for temperature change piston movement and seating of seal lips c Re pressure to 12 PSI 83 kPa if required and hold for 15 seconds with no pressure drop d Repeat re pressuring until 12 PSI 83 kPa holds for 15 seconds minimum but not over 3 repressurings e If after 3 re pressurings brake will still not hold pressure tear down and determine cause of leak rebuild and retest 2 Air and Hydraulic Pressure Test a After completing assembly and with bleeder plugged apply 100 PSI 689 kPa air pressure to the brake fluid actua tion port Shut off air at inlet to hold pressure on brake Brake should maintain pressure for 30 seconds without drop b Apply 1500 50 00 PSI 10342 344 000 kPa hydraulic pressure using mineral oil to brake actuation port shut off pressure at inlet to hold pressure on brake Inspect to insure that pressure plate has moved against housing stop and that friction discs are release
21. ss bear ings to avoid spinning Bearings may be rotated slowly by hand to facilitate the drying process HOUSINGS COVERS AND CAPS Clean interior and exterior of housings bearing caps etc thoroughly Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces Parts should remain in solution long enough to be thoroughly cleaned and heated This will aid the evaporation of the cleaning solution and rinse water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Cast parts may also be cleaned with steam cleaner CAUTION Care should be exercised to avoid skin rashes and inhalation of vapors when using alkali cleaners Thoroughly dry all cleaned parts immediately by using moisture free compressed air or soft lintless absorbent wip ing rags free of abrasive materials such as metal filings contaminated oil or lapping compound INSPECTION The importance of careful and thorough inspection of all parts cannot be overstressed Replacement of all parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date BEARINGS Carefully inspect all rollers cages and cups for wear chipping or nicks to determine fitness of bearings for further use Do not replace a bearing without replacing the mating cup or cone at the same time After inspection dip bear ings in clean light oil an
22. t necessary to remove unless replacement is required Clean and inspect all components Repair or replace components as required Off Highway Products DANA 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 17 REASSEMBLY Posi Stop LCB Brake Reassembly Figure 29 Clean cured thread locking compound from holes with a 625 11 UNRC 2A tap Use compressed air to remove residue from holes Use appropriate eye protection when using compressed air Figure 30 Position brake housing on blocks as shown to allow clearance for the wear indicator pin Pin will protrude through bottom of housing Wear Indicator Pin Installation Figure 31 Install wear indicator pin retaining ring Figure 32 Install two wear indicator pin o rings and lubricate Figure 33 Install wear indicator pin in housing Pressure Ring and Spring Installation Figure 34 Lubricate pressure ring o ring sealing surface with grease 25150 26150 Posi Stop LCB Liquid Cooled Brake Service Manual 18 Off Highway Products DANA Figure 35 Install brake spring sets Figure 36 Install three slack adjuster spacers Figure 37 Lubricate brake cover seal ring with grease and install Figure 38 Lubricate seal ring with grease and install on pressure ring Figure 39 Set pressure ring into position A lifting device similar to the one shown can ease installation Refer to tool drawing on page 31 Brake Disc Installation Figu
Download Pdf Manuals
Related Search