we -4087 REPAIR AND MAINTENANCE INSTRUCTIONS 15” DOUBLE ROTOR HYDROMATIC BRAKE ASSEMBLY NO. P19757-IX (TYPICAL ASSEMBLY) PawRrac, xc. Manufacturers of PARKERSBURG Products BOX 573 COFFEYVILLE, KANSAS 67337 AREA CODE (316) 251-5000 LITHO U.S.A.CONTENTS r SECTIONS PAGE | =Pieneraeee saris Wee i Replacement of Bearings and/or Seals: Cece Gt ee. 2 a 3 - Reassembly..... Rc em Sy Oe oe Hydromatic Brake Case: ue 4 = Disassembly . 2... Pe ae ea S10, (0 5 = Reassembly.. 22... eee Seas MN ales 13, 14 c 6 = Qubrlentiome ss oe Ty ILLUSTRATION DRAWINGS ‘ Checking Slope of Rotor Vane & Hating Pocket Section Vane . . 631022 Spacing Rotor with Equal Clearance Between Pocket Sections . 631017 Installation of 011 Seals (21) in Bearing Adapter (20) = U631019 C Installation of Bearing Adapter (20) and oil Seals (21) . . . 631020 Installation of Oi1 Seals (32) in Bearing Adapter (30) = U631018 : Press Set-Up to Remove Upper Rotor from Shaft... .... . U631021 General Assonbly . i). see ea ee es ea PSTST-IX HYDROMATIC, HYDROTARDER ano PARKERSBURG. REGIS [ERED TRADEMARKS OF PARMAC, INC. (OONTING SUPPORTS =) WeOROMATIC. BRAKE ‘Om HYORGTARDERLal 1.2 B-4-67 MAINTENANCE AND REPAIR INSTRUCTIONS FOR 15" DOUBLE ROTOR BC HYDROMATIC BRAKE TYPICAL ASSEMBLY P19757-1X General Part numbers given in these instructions are referred to as mark numbers and correspond to those used on the attached parts list and assembly drawing. These instructions apply to a number of similar 15" Double Rotor Hydromatic Brake assemblies, all of which are typified by the draw- ing of assembly P19757-1X. When ordering parts, always give the assembly number and serial number which are stamped on the Name Plate (43) of the Bydromatic Brake. Note: A - Principal differences between the typical assembly, P19757-1X, and similar assemblies are in shaft ex- tensions and direction of rotation "TO BRAKE" from extended shaft side. Most simtlar assemblies have the shaft extension on one side only (like the typical assembly), although the diameter of the shaft extension and its length may vary. A few similar assemblies have the shaft extended on both sides. Some similar assemblies with single shaft extension (like the typical assembly) have the shaft extended for clockwise rotation "TO BRAKE” from the extended shaft side instead of for counter-clockwise rotation "TO BRAKE" from the extended shaft side as is the case for the typical assembly, P19757-1x. In similar assemblies with the shaft extended for clockwise rotation "TO BRAKE" from the extended shaft side, the Shaft (1) extends from R. H. Cap (14) in- stead of L.H. Cap (15) as shown for the typical assembly. Likewise Bearing Adapter (30) and Cover Plate (35) for the large Bearing (33) are installed in R.H. Cap (14) for similar assemblies with the Shaft (1) extended for clockwise rotation "TO BRAKE" from the extended shaft si Some similar assenblies, typified by assembly P19757-1x, are equipped with special cover plates on one or both sides to meet specific requirements.1.3 1.4 1.5 1.6 1.8 HB-4-67 For any repair job, disassembly should proceed only to the point permitting replacement of damaged part or parts. All disassembly and assembly procedures must be undertaken with the shaft of the Hydromatic Brake vertical. Bearings (24) and (33), Outer Oil Seals (45), and Inner Oil Seals (21) and (32), are the only parts subject to mechanical wear. Normally these parts are the only ones requiring occasional replace- ment. Rotors (3) and (4) and Pocket Sections (8), (9), and (16) are subject to erosion and cavitation from the action of the braking fluid and may, after long periods of use, require replacement. Te will be noted that No. 1 Permatex (36) is used as a sealing com- pound on many joints in this assembly. whenever such a joint is broken in disassembly, both surfaces comprising the joint must be scraped free of hardened Permatex (36), washed with solvent, and thoroughly dried before being reassembled with new Permatex’ (36). In all cases where joints are to be made up using Permatex (36), the coating should be evenly applied and allowed to air dry about five minutes before being made up. As disassembly proceeds, the various parts removed should be thoroughly cleaned, wrapped and stored. 2. Disassembly For Replacement of Bearings and/or Seals Instructions in this section are given in sequence, assuming that bearings and/or seals in either or both sides of the Hydromatic Brake are to be replaced, or that the Hydromatic Brake is to be completely disassembled. Note: A - If Roller Bearing (33) and/or seals in side containing Roller Bearing (33) only are to be replaced, proceed as outlined in Paragraphs 2.2 to 2.10. Then refer to Paragraphs 3.15 to 3.28 for reassembly instructions. B- If Ball Bearings (24) and/or seals in side containing Ball Bearing (24) only are to be replaced, start dis- assembly with instructions in Paragraphs 2.11 to 2.18. ‘Then refer to Paragraphs 3.1 to 3.14 for reassembly instructions.2.2 2:3) 2.5 2.6 2.7 HB-4-67 Remove eight Socket Cap Screws (29) and slide Cover Plate (35) with its pressed-in outer Oil Seal (45) off the end of Shaft (1). Note: A - Caution: Tf outer Oil Seal (45) is not to be replaced, the keyways in the end of the Shaft (1) should be filled with wood blocks or the shaft wrapped with shim stock to prevent cutting the lip of the Seal (45) on the edges of the keyways. B - If only outer O{1 Seal (45) is to be replaced, this is as far as disassembly should proceed. Refer to Para. graph 1.3. See Paragraph 3.26 for replacement instructions. Insert two 3/8" eye bolts into any two of the eight tapped holes in the exposed face of the Bearing Adapter (30). Then lift the Bearing Adapter (30) out of the base of Side cap (15). Note: A - Seals (32) and Roller Bearing (33), minus the inner race, will remain in the Bearing Adapter (30) and be removed with it. Apply heat to inner race of Roller Bearing (33) and remove it from its seat on Shaft (1). Note: A - If Roller Bearing (33) is not to be replaced, the inner race should be left undisturbed from its seat on Shaft (1) as removal of it will render it unfit for further service. The Roller Bearing (33) is a sliding fit in the bore of Bearing Adapter (30) and can be easily removed by bumping the bearing bore end of Adapter (30) against a solid object or by light tapping on the inner race. Note: A - If Roller Bearing (33) is not to be replaced, it should be thoroughly washed in solvent, greased lightly, and well wrapped for storage until needed for reassembly. O11 Seals (32) may be removed from Bearing Adapter (30) per the following instructions if they are to be replaced. If Oil Seals 2) are not to be replaced, do not remove them from Bearing Adapter (30) as such removal will distort the seal cases and elements and render them unfit for further service. See Paragraphs 3.18 through 3.21 for replacement instructions. Remove the first Oil Seal (32) from Bearing Adapter (30) by placing the Bearing Adapter (30), seal end down, on parallels to provide about 5/8" clearance between the end of the Bearing Adapter (30) and the work bench top and, using a chisel, punch, screw driver, or similar tool, working from the bearing bore end of Bearing Adapter G0), to drive the Of1 Seal (32) out of Bearing Adapter (30).HB-4-67 ees 2.8 Remove the second Oil Seal (32) from Bearing Adapter (30), after operation in Paragraph 2.7, by placing Bearing Adapter (30), bearing bore end down, on the work bench and driving O{1 Seal (32) into the bearing bore of Bearing Adapter (30). 2.9 To remove Sleeve (5) for replacement will necessitate the removal of Side Cap (15). Refer to Paragraph 4.3 for removal procedures. 2.10 Procedures outlined in Paragraphs 2.1 through 2.9 will completely disassemble one side of the Hydromatic Brake and permit replacement of all parts normally requiring such service. Refer to Paragraphs 1.3 and 1.8. Note: A - If replacement of one or more of these parts is the objective, new parts required should be installed and the disassembled side completely reassembled per Section 3 before turning the Hydromatic Brake over to effect the disassembly of the other side of the Hydromatic Brake. B - If the Hydromatic Brake is to be further or completely disassembled, do not reassemble the Roller Bearing (33) side. Turn the partially disassembled Hydromatic Brake over and proceed with the disassembly as per following instructions. Both sides of the Hydromatic Brake must be completely disassembled per this section before starting disassembly of the case per Section 4. 2.11 Remove six Socket Cap Screws (29) and Cover Plate (28). Note: A - Shim Set (22) exposed by this operation should be kept with Cover Plate (28) removed. 2.12 Remove three Cap Screws (26), Lock Washers (27), and Retainer Plate (25). 2.13. Insert four jack screws (3/8" bolts or cap screws having at least 2-1/4" of thread) into the four tapped holes in the exposed face of the Bearing Adapter (20). By tightening up evenly all around on these four jack screws, the Bearing Adapter (20) will be drawn out of the bore of Cap (14) at the same time pulling Bearing (24) off its seat on Shaft (1). Note: A - Seals (21) and Ball Bearing (24) will remain in Bearing Adapter (20) and be removed with it. B - Shim Set (22) exposed by this operation should be kept with Bearing Adapter (20) removed. C - Clean the Permatex (36) and Packing (23) out of the corner of the Bearing Adapter (20) shoulder. Refer to Paragraph 1.7.21s 2.15 2.16 2.17 2.18 2.19 HB-4-67 Ball Bearing (24) is a sliding fit in the bore of Bearing Adapter (20) and can be easily removed by bumping the bearing bore end of Adapter (20) against a solid object or by light tapping on the inner race. Note: A - If Ball Bearing (24) is not to be replaced, it should be thoroughly washed in solvent, greased lightly, and well wrapped for storage until needed for reassembly. Oil Seals (21) may be removed from Bearing Adapter (20) per the following instructions if they are to be replaced. If Oil Seals (21) are not to be replaced, do not remove them from Bearing Adapter (20) as such removal will distort the seal cases and elements and render them unfit for further service. Remove the first Oil Seal (21) from Searing Adapter (20) by placing the Bearing Adapter (20), seal end down, on parallels to provide about 5/8" clearance between the end of the Bearing Adapter (20) and the work bench top, using a chisel, punch, screw driver, or similar tool, working from the bearing bore end of Bearing Adapter (20), to drive the O11 Seal (21) out of the Adapter (20). Remove the second {1 Seal (21) from Bearing Adapter (20), after operation in Paragraph 2.16, by placing Bearing Adapter (20), bear- ing bore end down, on the work bench and driving Oil Seal (21) into the bearing bore of Bearing Adapter (20). Procedures outlined in Paragraphs 2.11 through 2.17 will completely disassemble that side of the Hydromatic Brake containing the Ball Bearing (24). (Refer to Paragraph 1.3.) All disassembly procedures covered in this section must have been performed before starting disassembly of the Hydromatic Brake Case per Section 4. 3. Reassembl; For Replacement of Bearings and/or Seal: Assuming that both sides of the Hydromatic Brake have been disassembled as per Section 2, or the Hydromatic Brake Case has been completely reassembled per Section 5, follow procedures in this section to re- assemble both sides of the Hydromatic Brake in their respective order. Refer to Paragraph 2.1. Ball Bearing (24) is the locking bearing. This bearing locates and holds the Rotors (3) and (4) in the center of Pocket Sections (8) and (9) and (16), with equal clearance on each side of the rotors. The locked bearing side of the Hydromatic Brake ould always be assembled first.HB-4-67 3.2 Before any reassembly procedures are begun, all parts to be used, either those removed in disassembly or new parts, should be thor- oughly cleaned, all Permatex removed, washed with solvent and dried thoroughly. All parts should be inspected and any nicks and/or burrs filed smooth. Refer to Paragraph 1.7. 3.3. To properly center the Rotors (3) and (4) with equal clearance between Pocket Sections (8), (9), and (16), the following procedure must be performed with accuracy. Refer to Drawing U631017. 1 = Securely fasten dial indicator to Side Cap (14), with the dial registering on the shaft end. Zero the indicator dial and lift shaft and rotor assembly to its limit of travel. The dial indicator will indicate the total movement of the shaft and rotor assembly. Call this dimension "W" and note it down for later use. 2 - Lower shaft and rotor assembly to its lowest position. If dial indicator does not return to zero, repeat procedure in Step 1 above and continue until actual shaft and rotor assembly move- ment has been determined. 3 - Install Bearing Adapter (20) in Side Cap (14). Secure in position with 4 Screws (29). 4 - Use illustration drawing U631017 as a guide for performing the following steps. Measure from bearing shoulder on Shaft (1) to top surface of Bearing Adapter (20). Call this dimension "A' Be sure shaft is in lowest position. 5 - Measure from bearing shoulder in Bearing Adapter (20) to top surface of Bearing Adapter (20). Call this dimension "B". 6 - Subtract dimension "B" from dimension "A", Call this dimension ne. 7 = Subtract dimension "C" from one-half of dimension "M", the answer being the total thickness of Shims (22) to be used between Bearing Adapter (20) and Side Cap (14). 8 - Remove Bearing Adapter (20) from Side Cap (14) and proceed as follow 3.4 Wipe small coves of No. 1 Permatex (36) into corners of Bearing Adapter (20) formed by the abutment against which Oil Seals (21) seat. See Drawing U631017. 3.5 From the bearing bore end of Bearing Adapter (20), press one Oil Seal (21) into place, seating solidly against the shoulder of Bearing Adapter (20). Note that the pressure for this operation is applied to the back or heel side of Oil Seal (21). See Drawing U631019Z101g9N SNOILOSS 130d NIIML3E SONVYV3STD 1VNO3 HLIM YOLOY ONIOVdS (8-v)- z =(22) SWIHS 40 SS3NNOIHL "03137dWO9 N33S S¥H HOSHD ONIOVES: SIML Y3L4¥ TANN (02) HaLdvaY NI (12) S138 SS3ud LON OG TSLON ‘WOLVIIGN IWIG NO... NOISNBWIG OV3Y ‘noiliséd dol 01 avis 3SIVY "NOILISOd 1$3K01 NI LAVHS H1IM YOLVOIGN! OU3Z “(b!) dvd OL N3LSV4 YOLVOIONI vid NOILISOd 1S3MO7_ S, 11 NI (1) LaVHS HLIM ,¥, NOISNANIG aurisvaW (1) LavHS (02) waLavay (e1)dvo3.6 3.7 3.8 3.9 3.10 3. 3.12 3.13 HB-4-67 he Note: A - Take every precaution to avoid damaging or distorting the seal case in this procedure. Always use a flat steel plate as shown on Drawing U631019 to distribute Pressure evenly. Turn over the Bearing Adapter (20), after operation in Paragraph 3.6, and press the other Oil Seal (21) into place against the shoulder of Bearing Adapter (20). Note that the pressure for this operation is applied to the front or lip side of Seal (21). See Note "A" of Para- graph 3.5. Wipe around lips of both installed Oil Seals (21) with a small quantity of No. 2 Calcium Base Grease (37). Also fill space between Seals (21). Wrap one strand from a piece of 1/4" diameter twisted asbestos valve stem packing 36” long (23) twice around the small diameter of Bearing Adapter (20) against the shoulder. Cover this double strand of packing (23) with a small cove of No. 1 Permatex (36). See Drawing U631019. Place correct amount of Shims (22) (Per Paragraph 3.3) on Side Cap (14) and lower Bearing Adapter (20) (with Seals (21) in place), into bore of Side Cap (14). Be sure to line up the four holes in Bearing Adapter (20) with the four holes in Side Cap (14). Note: A - As there are four holes in Bearing Adapter (20), and x holes for Screws (29), it is possible to line up the screw holes while the Adapter (20) holes are blocked. ~ B - Always use a sleeve for this operation as shown on Drawing 631020 to avoid damaging lips of Seals (21) on shoulders of Shaft (1). Install Ball Bearing (24) on Shaft (1) and in Bearing Adapter (20). Press on inner race of Bearing (24). Support shaft from the opposite end during this operation. The Bearing should be packed with No. 2 Calcium Base Grease (37) for initial lubrication. Install Keeper Plate (25) and secure in place with three Cap Screws (26) and Lockwashers (27). Place Cover Plate (28) on Bearing Adapter (20). Check with feeler gauge between Cover Plate (28) and Bearing Adapter (20) to determine the thickness of Shim (22) required to lock outer race of Bearing (24) in place. With Shims (22) thickness determined, remove Cover Plate (28). Place correct amount of Shims (22) (per Paragra ph 3.12) on Cover Plate (28). Secure Cover Plate (28) to Bearing Adapter (20) with six Socket Cap Screws (29).23 PACKING (23) & PERMATEX: (36) PER PARAGRAPH 3.9 PRESSURE FOR INSTALLATION SECOND SEAL. PRESSURE FOR INSTALLATION OF ee aa FIRST SEAL. NOTE— SEALS (2!) IN THIS SKETCH ARE SHOWN PARTIALLY INSTALLED IN BEARING ADAPTER (20) WHEN FULLY INSTALLED, BOTH SEALS (21) SEAT SOLIDLY AGAINST SHOULDER. INSTALLATION OF OIL SEALS IN BEARING ADAPTER 15" D.R. HYDROMATIC BRAKE U631019NOTE LINE UP OF HOLES PACKING (23) AND PERMATEX (36) USE LIGHT MACHINE OIL OR GREASE ON SHAFT AND SLEEVE BEARING ADAPTER (20) AND SEALS (11) INSTALL IN PROPER POSITION BEARING ADAPTER(20) AND SEALS(2I) READY TO INSTALL IN BORE OF CAP (14) NOTE USE OF SLEEVE TO PREVENT DAMAGING LIPS OF SEALS ON SHOULDER OF SHAFT (1). INSTALLATION OF BEARING ADAPTER AND SEALS 15" _D. R. HYDROMATIC BRAKE U631020HB-4-67 3.14 Instructions given in paragraphs 3.1 through 3.13 will completely reassemble the Ball Bearing (24) side of the Hydromatic Brake. Turn the partially assembled Hydromatic Brake over and proceed per the following instructions. 3.15 Apply a small bead of No. 1 Permatex (36) around Shaft (1) in the corner formed by the shaft shoulder against which Sleeve (5) will seat. 3.16 Heat Sleeve (5), then drop in place against the shoulder of Shaft (1) and allow to shrink on its seat. Hold the Sleeve (5) firmly against the shaft shoulder until cooled to about room temperature before proceeding. 3.18 Wipe small coves of No. 1 Permatex (36) into corners of Bearing Adapter (30) formed by the abutment against which O{1 Seals (32) at. See Drawing 631018. 3.19 From the bearing bore end of Bearing Adapter (30), press one Of] Seal (32) into place, seating solidly against the shoulder of Bearing Adapter (30). Note that the pressure for this operation is applied to the back or heel side of Oil Seal (32). See Drawing U631018. Note: A - Take every precaution to avoid damaging or distorting the seal case in this procedure. Always use a flat steel plate as shown on Drawing U631018, to distribute pressure evenly. 3.20 Turn over the Bearing Adapter (30), after operation in Paragraph 3.19, and press the other Oil Seal (32) into place against the shoulder of Bearing Adapter (30). Note that the pressure for this operation is applied to the front or lip side of Seal (32). See Note "A" of Paragraph 3.19. 3.21 Wipe around lips of both installed Oil Seal (32) with a small quan- tity of No. 2 Calcium Base Grease (37). Also fill space between Seals (32). 3.22 Place Gasket (31) on shoulder in bore of Side Cap (15) and lower Bearing Adapter (30) (with Seale (32) in place), into bore of Side cap (15). Secure in place with four Cap Screws (34). 3.23 Heat the inner race of Roller Bearing (33) in ofl to approximately 250° F., drop in place against Sleeve (5) on Shaft (1), and allow to shrink on its seat. Hold the inner race of Roller Bearing (33) firmly against Sleeve (5) on Shaft (1) until cooled to about room temperature before proceeding. 3.24 Press Roller Bearing (33) into bore of Bearing Adapter (30). Bear- ing should be packed with No. 2 Calcium Base Grease (37) for initial lubrication.PACKING (23) & PERMATEX: (36) PER PARAGRAPH PRESSURE FOR INSTALLATION Of SECOND SEAL. ~~ ° PRESSURE FOR INSTALLATION OF FIRST SEAL, NOTE— SEALS (32)IN THIS SKETCH ARE SHOWN PARTIALLY INSTALLED IN BEARING ADAPTER (30). WHEN FULLY INSTALLED, BOTH SEALS (32) SEAT SOLIDLY AGAINST SHOULDER. INSTALLATION OF OIL SEALS IN BEARING ADAPTER 15"D.R. HYDROMATIC BRAKE U6 310183.25 3.27 3.28 4a 4.2 HB-4-67 25. Place Cover Plate (35) on Bearing Adapter (30), make sure Cover Plate (35) is seated firmly against outer race of Roller Bearing (G3). Check with feeler gauge between Cover Plate (43) and Bearing Adapter (33) to determine the thickness of Shim (47) required to lock outer race of Roller Bearing (33) in place. With Shim (47) thickness determined, remove Cover Plate (35) and Press Oil Seal (45) into bore of Cover Plate (35). Note direction of sealing lip. (Refer to Typical Assembly Drawing P19757-1X.) Note: A -Take every precaution to avoid damaging or distorting the seal case in this procedure. Always use a flat steel plate to distribute pressure evenly. Place correct amount of Shims (47) (Per Paragraph 3.25) on Cover Plate (35), then assemble Cover Plate (35) to Bearing Adapter (30) and secure in place with eight Cap Screws (29). Exercise care to avoid damaging the sealing lip of Seal (45). Install Grease Fittings (38) and Relief Fittings (39) in their respective locations in Cover Plate (28), Side Cap (14), and Bearing Adapter (30). Procedures contained in Section 3 will completely reassemble both sides of the Hydromatic Brake. Lubricate bearings and seals as per lubrication instructions, Section 6. 4. Disassembly Hydromatic Brake Case Procedures under this section should not be undertaken unless replace- ment of Rotors (3) and/or (4) and Pocket Sections (8), (9), and/or (16) are required. Refer to Paragraphs 1.3, 1.6, 1.7, and 2.19, Procedures under this section must not be undertaken until both sides of the Hydromatic Brake have been completely disassembled per Section a Starting on either side of the Hydromatic Brake case, remove the thirteen Cap Screws (18) on the outside edge of Side Cover (14) or (15). Do not remove the six Cap Screws (17) located on the inner bolt circle of the Side Cover (14) or (15). Note: A - Insert four of Cap Screws (18) into the four tapped holes in the flange of Cap (14) or (15) just outside of the four mounting bosses and use as jack screws to remove Cap (14) or(15) and its associated Pocket Section (8) or (16) and "0" Ring (46) from the Center Ring (13).44 HB-4~67 -10- Note: B - Clean the tapped holes in Cap (14) or (15) well before inserting Screws (18). If available, run a 3/8"-L6NC tap to the bottom of the hole: © - Remove "0" Ring (46) from Pocket Section (8) or (16). ‘The Center Ring (13) may be separated from the Adapter (6) by using a soft hammer or a wood block and driving against the outer flange of Center Ring (13). Note: A - Procedures in Paragraphs 4.3 and 4.4 will expose one Rotor (3) or (4). B- Turn the Hydromatic Brake over and repeat operations in Paragraphs 4.3 and 4.4 to expose the other Rotor @) or (4) before proceeding. Support the remaining assembly by parallels under the flange of Adapter (6) and press on end of Shaft (1) to remove one Rotor (3) or (4) from Shaft (1). Not! : A - When properly set for this operation, the upper Rotor (3) or 4) is supported by the Adapter (6), bearing on the parallels on the press bed, and Shaft (1) is Pressed through it. See Sketch 631021. B - The Shaft (1) and lower Rotor (3) or (4) will move downward a distance of 3" in this press operation to remove the upper Rotor (3) or (4). At least 3" of clearance must be provided below the end of Shaft (1) and the face of lower Rotor (3) or (4) before starting to press. € - Removal of one Rotor (3) or (4) per this paragraph frees Adapter (6) and its assembled Pocket Sections (8) and (9). This adapter and pocket section sub- assembly should be removed from Shaft (1) before proceeding. To remove Rotor (3) or (4) remaining on Shaft (1) after operation in Paragraph 4.5, support Rotor (3) or (4) on press bed, long end of shaft down, and press Shaft (1) through Rotor (3) or (4). Note: A - The Shaft (1) will move downward a distance of 3" in this operation and clearance must be provided below the end of Shaft (1) before starting to press. Procedures to this point will have completely disassembled the Hydromatic Brake except:a — 4i¢$___ = ‘SUPPORT — CLEAR| = 7 66 UPPER ROTOR PRESS TABLE ADAPTER N N es SUPPORT PRESS SET UP TO REMOVE UPPER ROTOR (3) FROM SHAFT (I) WHEN DISASSEMBLING BRAKE. U63102148 4.10 5.1 53 HB-4-67 St 1 - Keys (2) have not been removed from Shaft (1). 2- Pocket Sections (8), (9), and (16) have not been removed from Caps (14) and (15) or Adapter (6). NOTE: A - These parte (keys and pocket sections) should not be removed from theit associated parts unless replacement is necessary. Refer to Paragraph 1.3. To replace Pocket Section (8) or (16) assembled with Cap (14) or (15), remove the six 3/8" X 1/2" Socket Cap Screws (17) and the four Socket Cap Screws (19) or (34) from Gap (14) or (15). Tap the Pocket Section (8) or (16) through the bore of Cap (14) or (15) using a soft hammer or wood block. NOTE: A - Attention is directed to the four Locating Pins (7) in each Pocket Section (8) or (16). These Pins (7) are snug fit in reamed holes in both Pocket Section (8) or (16) and Cap (14) or (15) and, at separation, are apt to remain in either piece. To replace Pocket Section (8) and/or (9), assembled with Adapter (6), remove "oO" Ring (46) from Pocket Section (8) or (9), the six 3/8" Hex Nuts (12) from Studs (11) or six 3/8" Hex Head Cap Screws (11) Lf applicable, and the four 3/8" X 5/8" Socket Cap Screws (10), holding each Pocket Section to the Adapter (6). Jar the Pocket Section with a soft hammer or wood block, and work around the joint with a screw driver or similar tool to pry the pieces apart. Avoid burring either piece. See Note "A" of Paragraph 4.8. Procedures covered in Sections 2 and 4 will completely disassemble the Hydromatic Brake. 5. Reassembly Hydromatic Brake Case (Refer to Paragraphs 1.2 and 1.5) Before any reassembly work is started, whether the Hydromatic Brake Case has been completely or partially disassembled per Section 4, all parts must be thoroughly cleaned and readied for reassembly. Refer to Paragraph 1.7 and 1.8. Assuming the Hydromatic Brake Case has been completely disassembled per Section 4, procedures in this section will reassemble it. All work outlined in this section must be completed before attempting to assenble either side of the Hydronatic Brake per Section 3.5.3 5.4 5.5 5.8 5.9 5.10 su Baiz' HB-4-67 -12- Install four Locating Pins (7) in reamed holes in one face of Adapter (6). Apply a thin even coat of No. 1 Permatex (36) to each joint surface, both inner and outer. Determine whether R.H. Pocket Section (8) or L.H. Pocket Section (9) assembles with the prepared face of Adapter (6). NOTE: A - The spacing of the Studs (11) or Hex Head Cap Screws (11) and Locating Pins (7) will permit each Pocket Section (8) or (9) to properly assemble on only one face of Adapter (6). Apply a thin coat of No. 1 Permatex (36) to each joint surface of the proper Pocket Section (8) or (9) to assemble with the face of Adapter (6) prepared per Paragraph 5.3. NOTE: A - Allow all Permatex No. 1 (36) coated surfaces to air dry at least 5 minutes before assembling. Assemble Pocket Section (8) or (9) per Paragraph 5.5 with Adapter (6) Prepared per Paragraph 5.3, using six Hex Nuts (12) for Studs (11), or 3ix Hex Head Cap Screws (11) and four Socket Head Cap Screws (10). Scrape all No. 1 Permatex (36) from exposed flange of Adapter (6). Install "o" Ring (46) around Pocket Section (8) or (9). Turn assembly per Paragraph 5.6 over and repeat procedures in Paragraphs 5.3 through 5.6 to complete the Adapter (6) and Pocket Section (8) and (9) Install four Locating Pins (7) in R.H. Cap (14) and apply a thin, even coat of No. 1 Permatex (36) on each joint surface, both inner and outer. See Note A of Paragraph 5.5. Apply a thin, even coat of No. 1 Permatex (36) to each joint surface of R.H. Pocket Section (8). NOTE: A - The spacing of the Locating Pins (7) will permit only R.H. Pocket Section (8) to assemble with R.H. Cap (14). Assemble R.H, Pocket Section (8) with R.H. Cap (14), prepared per Paragraphs 5.8 and 5.9, using six Cap Screws (17) and four Cap Screws (10). Scrape all No. 1 Permatex (36) from exposed flange of Cap (14). Install "0" Ring (46) around Pocket Section (8). Repeat procedures in Paragraphs 5.8 through 5.10 to assemble L.H, Pocket Section (16) with L.H. Cap (15). Install two Keys (2) in Shaft (1) at one rotor seat and press either Rotor (3) or (4) on Shaft (1). Note that the extended hub, seating against center shoulder of the shaft, properly locates the Rotor (3) or (4) on Shaft (1).5.13 5.14 5.15, 5.16 5.18 5.19 5.20 5.21 5.22 HB-4-67 Etigte. With Shaft (1) and one Rotor (3) or (4) assembled per Paragraph 5.12, set up on a press frame, long end of shaft up, place Adapter (6) and Pocket Section (8) and (9) sub-assembly, per Paragraph 5.7, over shaft and against Rotor (3) or (4). Note: A - It is possible to install the adapter and pocket section sub-assembly in reverse position. Use care to see that the adjacent vanes of Pocket Section (8) or (9) and Rotor (3) or (4) slope in the same direction. When properly mated, any rotor pocket vane will fall in line with any adjacent pocket section vane. See Drawing 631022, illus- trating proper relation of rotor and pocket section vanes. Install two Keys (2) in exposed rotor seat of Shaft (1) and press other Rotor (3) or (4)into position, extended hub against shoulder of Shaft (1). Remove assembly to this point from press and set up, shaft vertical, for following procedures. Scrape off all No. 1 Permatex (36) squeezed out of joint between Pocket Section (8) or (9) and Adapter (6). Apply a thin, even coat of No. 1 Permatex (36) to flange of Adapter (6) and to mating face of one Center Ring (13). See Note "A" of Paragraph 5.5 Install Center Ring (13) over Pocket Section (8) or (9) and against flange of Adapter (6). Position Center Ring (13) by inserting a 3/8" x 6" headless screw in one of tapped holes in Adapter (6) and align- ing bottom or inlet portions of Center Ring (13) and Adapter (6). Scrape off all No, 1 Permatex (36)squeezed out of joints between Caps (24) and (15) and Pocket Sections (8) and (16). Select Cap (14) or (15) and Pocket Section (8) or (16) sub-assembly, prepared per Paragraph 5.10 or 5.11 to assemble properly with Center Ring (13) and apply a thin, even coat of Permatex No. 1 (36) to face of Center Ring (13) and flange of Cap (14) or (15). See Note "A" of Paragraph 5.5, Note: A = Only one of the cap-pocket section sub-assemblies will install properly to line up with the inlet portion of Center Ring (13). Install prepared Cap (14) or (15) and Pocket Section (8) or (16) sub- assenbly, using thirteen Cap Screws (18) to secure. Position sub- assembly by the 3/8" x 6" headless screw in Adapter (6) and align the bottom or inlet portions of Center Ring (13) and Cap (14) or (15). Turn assembly to this point over and repeat instructions contained in Paragraphs 5.16 through 5.21 to complete assembly of case.VANE OF POCKET SECTION (8) OR (9) STRAIGHT EDGE —NOTE= VANES OF ROTOR AND ADJOINING POCKET SECTIONS MUST CHECK AS SHOWN VANE OF ROTOR (3) OR (4) DIRECTION, OF ROTOR ROTATION" TO BRAKE” CHECKING SLOPE OF ROTOR VANE AND MATING POCKET SECTION VANE U6310225.23 6.1 6.3 6.4 6.5 6.6 6.7 HB-4-67 nee Operations to this point complete assembly of the Hydromatic Brake case. Procedures in Section 3 may now be undertaken to assemble the seals and bearings on each side of the Hydromatic Brake. Lubri. ion Install one Grease Fitting (38), at the top, and one Relief Fitting (39) at the bottom, in Cover Plate (28). This lubricates Bearing (24). Install one Grease Fitting (38) at the top on vertical centerline, and one Relief Fitting (39) at the bottom, on R.H. End Cap (14). This lubricates Seals (21). Install one Grease Fitting (38) at the top, and one Grease Fitting (38) on the horizontal centerline of Bearing Adapter (30). These Locations are designated on Typical Assembly P19757. Install one Relief Fitting (39) on the horizontal centerline and one Relief Fitting (39) at the bottom of Adapter (30). The top Grease Fitting (38) lubricates Bearing (33) and the Grease Fitting (38) on the horizontal centerline lubricates Seals (32). Lubricate each Bearing (24) and (33) of newly assembled Hydromatic Brake with about six strokes from a 9 oz. Hydraulic Grease Gun, using No. 2 water resistant Calcium Base Cup Grease (37), (Texaco Novatex No. 2 or equivalent). In service, lubricate each Bearing (24) and (33) with about six strokes before each trip. Lubricate between Seals (21) and (32) of newly assembled Hydronatic Brake with about twelve strokes from a 9 oz, Hydraulic Grease Gun, using No. 2 Calcium Base Grease (37). In service, lubricate between seals (21) and (32) before and after each trip with about nine strokese