& STEIGER "ST" SERIES I, Il, & III WC, BC,C& P BRAKE SYSTEM SERVICE MANUAL IMMEDIATE ACTION LETTER REFERENCE: ‘SERVICE BULLETIN REFERENCE: No/Date No/Date 1 4, 7. 1 4, 7. 2 5. 8, 2. 5. 8. 3, 6. 9. 3. 6. 9. SERVICE NEWS REFERENCE: No/Date 37-105 (5-82)Single Disc Brake System 1-16 General information ..... 6 Park brake caliper .. 8‘ Single piston hydraulic caliper .... Contents | waster cylinder ie essiensae AAS Brake disc ............. 19-45 Multi Disc Brake System,......... 17-28 General information .......... 217.18 Discs and actuator group 118-23 Master cylinder . = 2426 Slave cylinder... 2... cc ceseseesceeeeeeeevee + 26928‘Suggested Safety Practices The nature of every type of service that you do demands that you pay attention to your work all of the time. Unlike machines, you have the ability to think and reason to avoid serious risk you cannot afford. In the instructions that follow you should apply some of these standard precautions ‘+ Place the tractor in a properly equipped work area which has been furnished with the needed tooling. For ‘example, overhead hoists and chains rated to lift and carry the components you work on. ‘+ Clean the tractor before working on it. It will be safer and easier to service ‘= Let tne tractor coo! if needed before working on it, or begin working on @ non-atfected area of the tractor. * Keep your workspace organized. A clutteres shop is dangerous and will reduce your efficiency. * Remove the key so the engine cannot be started accidentally. It you don't, you may be inviting trouble. + Prevent tractor movement - block the wheels, Perform the following operations on a level surface oniy! ‘+ Follow approved metnods described herein for a sue- cessful joo. ‘+ Avoid wearing jewelry and loose clothing. They ean ‘cause you to have @ serious accident. ‘+ Always nave a tire extinguisher available ang in opera~ ting order. Know how to use it Handle heavy parts with proper lifting fixtures and with a lot of respect! cutting must be done with atorch, wear face, eye and clothing protection intended for such work. Remove and/or protect against any flammable materials DO NOT work on the tractor with the engine running Unless specifically instructed to do 0. DO NOT allow bystanders to linger near your work ‘They may be unaware of hazards, Be sure someone can help in an emergency. Ona very involved project it may be unwise to work alone. NEVER operate the tractor without brakes. DO NOT allow inexperienced personnel to operate, service or repair equipment. Brake SystemsGeneral Information: ‘The early style Steiger Single Disc Brake System is used on Series! Series! and Series Ill Steiger Tractors that are ‘equipped with the single speed transfer case ‘Mounting location and parts arrangements will vary among early and later models of tractors. therefore, only the latest Steiger Tractor Parts Manuals should be con- sulted when ordering parts. This will help ensure optimum braking performance and brake lite. Figure 1: Braking force is accomplished by means of one or two calipers mounted to utilize a single brake disc (Fig. 1) “The park brake caliperis cable operated trom the operator's ‘compartment by either an over-center lever arrangement or @ locking-type brake cable, depending on the tractor ‘model. When the park brakeis applied. 2 cam leveron the caliper compresses the pads against both sides of the brake disc by means of actuator pins in the bores of the ue Figure 2: rear casting (Fig. 2). The caliper assembly is mounted on slide rods to permit fore and alt caliper movement. therefore, allowing uniform clamping of the disc. Revised May, 191 Single Disc Brake System a Figures | l| a Figures Figure: Main Brake Caliper The single piston Hydraulic Caliper receives fluid under pressure from the brake master cylinder. Fluid pres- ‘sure then forces the piston forward to compress the linings against the disc (Fig. 3). As the brake pedal pressure is released, a retractor assembly inside the piston pulls the piston rearward for more pad to disc clearance (Fig. 4). As the brake pads wear, the pad to disc clearance still remains the same because the retractor pin will creep slightly in the collet when the spring travel limit has been obtained (Fig. 5). This caliper assembly is mounted to the brake hangers through studs thus allowing fore and aft caliper move- ment similar to that described previously. Later production tractors employ two (2) hydraulic calipers onasingle rotating disc. Brake SystemsSingle Disc Brake System Park Brake Caliper Pad Replacement Retaining Spring Figure 2: Hf brake pad replacement is required, the pad(s) may be changed without removing the caliper assembiy(ies) from the tractor. Loosen the cam lever lock nut and unlatch each end of the retaining spring, one per pad (Fig. 1). Slide the pads downward past the castings (Fig. 2). Install and secure the new pads. See step 5 in reassembly, installation and adjusting for adjustment procedures. Removal and Disassembly Due to wide application of the mechanical park brake caliper, removal methods may vary somewhat because of design changes of structural components (frames, weldments, etc.) and/or engine options available. Engine length will affect the park brake caliper location to nearby components. Despite the various caliper mounting arrangements, methods used for removal and installation are basically universal 1. Remove the switch key to prevent accidental start- up of the engine, and chock the wheels to prevent movement of the tractor. Figure 3: 2. Disconnect the linkage at the brake cam lever. 3. Completely remove the brake cam, washer and lock nut from the caliper assembly (Fig. 3) Figure 4: 4. Remove the cotter pins from the brake slide rods and withdraw them from their bores (Fig. 4). Brake SystemsFigure 6: 5. Remove the caliper assembly from the brake mount weldment (Fig. 6). In some cases clearance Is limited so the caliper assembly cannot be re- moved intact. When this is encountered, remove the three 12-point capscrews (Fig. 6) which fasten the caliper castings together, and remove the cast- ings individually. 6. Remove the remaining parts from the castings and inspect them (Fig. 7). Revie May, 1982 Single Disc Brake System Inspection 1. If necessary, clean all parts to be inspected, Care- fully check for cracked, broken or otherwise dam- aged parts and replace as needed. Figures: Figure 10: 2. Onthe brake caliper mounting arrangement, check. for worn pin bores of the weldment plate (Fig. 8), slide rods (Fig. 9) and slide rod bores of the caliper, castings (Fig. 10). Brake SystemsSingle Disc Brake System Figure 14: 3. In the cam side casting, inspect the actuator pins 2 and bores for excess wear (Fig. 11). ‘Threads of the brake cam stud and nut must display full thread height and depth. 1/16 inch (1.58 mm) ‘minimun thickness Figure 12: 4. If the brake pads are worn to less than 1/16 inch (1.58 MM) (Fig. 12), or worn unevenly, replace with new pads. Reassembly, Installation and Adjusting $ 4 6. 1. Fit each casting with its appropriate parts (Fig. 19). The cam may be left off at this point, Revised May, 1982 4 Figure 14: Mount the individual caliper castings to the brake mount weldment (Fig. 14). This will ensure align- ment of the brake slide rod bores before installing the three 12-point capscrews thus eliminating possible binding on the brake slide rods. Torque the three 12-point capscrews to 34 Ib. ft. (4.70 Kg/M). Figure 18: Reinstall the brake cam, washer and nut. Withdraw each brake slide rod (one at a time) to in stall the grommets (and link lever with link straps ‘on Series Ili ST 220, 250, 251, 270, 310, 320, 325) (Fig. 18). Connect the cable clevis. Completely release the park brake handle and tighten the cam lock nut Until both pads contact the disc, then loosen the nut 1/2 turn. Road test the tractor to be sure the brake pads do not rub the disc. Test braking per- formance before retuming the tractor to normal service. Brake SystemsSingle Disc Brake System Single Piston Hydraulic Brake Caliper Pad Replacement Removal and Disassembly Figure 1: Figure It replacement of only the brake pads is required, 1. Disconnect and quickly cap the brake line(s), and remove the pad retainer pins and withdraw the worn loosen the spring retainer (Fig. 3). pads (Fig. 1). Figure 2: Figure 4: Before new pads can be installed, ramove the stamped 2. Remove the pair of through-bolts at the brake cover, loosen the retracting mechanism torque nut and ‘hangers and mount bar (Fig. 4). The caliper assem- bottom the piston in its bore (Fig. 2) bly with hangers will then be free for removal. Install the new pads and retainer pins as per instruc tions given in Reassembly, Installation and Adjusting Figures; 3. Remove the brake pad retainer pins and brake pads (Fig. 8). Revised May, 1982 5 Brake SystemsSingle Disc Brake System Capscrews Capserews Figure 6: 4. Using @3/8 inch 12-point socket, remove the four (4) capserews which fasten the caliper castings together (Fig. 6). Figure 7: 5. For removal of the piston, remove the stamped cover, the retracting mechanism torque nut and collet with its washer from the rear of the piston side casting (Fig. 7). Figure 8: 6. Ifthe piston cannot be grasped and pulled from its bore, usea soft punch and CAREFULLY tap on the retractor pin end of the piston. As the piston is re- ‘moved, slide the dust boot toward the casting (Fig. 8) Revised May, 1982 Figure 8: ee Figure 10: 7. Using an O-ring pick, remove the O-rings from the retractor pin bore of the piston side casting (Fig. 9) and also from the outside diameter of the piston (Fig. 10). NOTE: DO NOT disassemble the piston, for it is under high spring pressure. Inspection If necessary, clean all parts to be inspected. Care- fully check for cracked, broken or otherwise dam- aged parts and replace as needed. NOTE: The piston side casting is not serviced separately. If replacement is required, a new sub-assembly should be used. Replace the piston side casting if the piston bore pitted, scratched, grooved or out of round. Brake SystemsFigure 11: 3. Examine the piston assembly, and replace as an assembly if it is pitted in the O-ring groove area (Fig. 11), out of round, if the retractor pin is scored (or bent or if the retractor spring in the piston is broken. ‘Check for Wear hh Figure 12: 4. On the brake caliper mounting group, check the stud surfaces and brake hanger bores for wear (Fig. 12). If worn more than .016 inch (.38 MM) from new dimensions, replacement is needed. 030 inch (76mm) Inspect holes, ‘minimum, fordamage thickness Figure 12: 5. If the brake pads are worn to less than .090 inch (76 MM), worn unevenly or otherwise damaged, new brake pads must be installed (Fig. 13). Revised May, 1982 Single Disc Brake System Reassombly, Installation and Adjusting Figure 14: 1. Lubricate the bores of the piston side casting with brake fluid (00 NOT USE OIL OR GREASE). Care- fully insert a new O-ring in the groove of the re- tractor pin bore (Fig. 14) Figure 18: 2. Fit the lip of the dust boot into the groove near the edge of the piston bore (Fig. 15) Figure 16: Install the O-ring and back-up washer in the seal groove of the piston, with the back-up washer nearest the pad end of the piston (Fig. 16). Brake SystemsSingle Disc Brake System Figure 17: 4. Lubricate the piston and its seals with brake fluid and start it in the bore of the piston side casting while repositioning the dust boot over the piston (Fig. 17). (D0 NOT USE OIL OR GREASE!) Figure 18: 5. Bottom the piston in its bore and fit the outer lip of the dust boot into the small groove near the pad end of the piston (Fig. 18). Figure 19: 6. From the rear of the piston/casting subassembly, install the flat washer, collet and torque nut over the retractor pin (Fig. 19). Torque the nut to 40 Ib. ft. (6.5 Kg/M) and replace the cover. Revised May, 1982 Figure 20: On each of the new pad retainer pins, assemble a flat washer, then a rubber bushing and then guide both pins through the two inside holes of the bridge plate (Fig. 20). Rest the piston side assembly on a clean flat sur face, with the six through holes on top. Figure 21: Insert the pins (already intact with the bridge plate) through the two innermost holes of the piston side assembly. The bridge plate will fit in only one cor- rect position; its contours match those of the pis- ton side housing. The threaded ends of the pins will be on the same side as the carrier side casting (Fig. 21). Brake SystemsFigure 22: 10. Install the two new pads and holder assemblies ‘onto the pins with the friction faces in contact with each other (Fig. 22). 11. Install the carrier side casting onto the pins and ‘secure it by installing two of the twelve-point retaining bolts with washers at the outermost two holes of the caliper assembly (Fig. 23). Tighten only atter al bolts have been started. Figure 24: Revised May, 1982 Single Disc Brake System Figure 25: 12, Install the remaining two twelve-point bolts (with- ‘out washers) through the outermost two holes of the bridge plate (Fig. 24). After carefully aligning 0 avoid binding of the bolt threads, torque the bolts to 44 Ib. ft. (6.08 Kg/M). The inner set of twelve-point bolts should be torqued before the outer set (Fig. 25). Figure 26: 18. Install a rubber bushing and a flanged nut on each Of the threaded ends of the pad retaining pins pro- truding through the carrier side casting. The rubber bushing will fit in a recess in the cartier side cast- ing (Fig. 26). Brake SystemsSingle Disc Brake System Figure 30: ‘Observe the rubber bushings as the flanged nut is tightened on the pin, and tighten the nut until the rubber bushing starts to extrude past the flanged nut face (Fig. 27). There will be a slight bulging of the rubber bushing on the opposite end of the pin (Fig. 28) 14, Install the brake assembly with through bolts and hangers (Fig. 29), and ensure that the plunger, spring and retainer plate are fitted to the brake bar. Revised May, 1982 16. After making the necessary line connections, bleed air from the brake system and refill the master cylinder fluid as required (Fig. 20). 16. After pumping the pedal hard several times to ensure that the brake is functioning correctly, test drive the tractor and check braking performance. Recheck the caliper for leakage and/or dragging, and correct if needed before returning the tractor to normal service. brakes! Always block the wheels on each ‘axle to avold accidental rolling of the vehicle and possible personal injury. Brake SystemsSingle Disc Brake System Master Cylinder Removal and Disassembly Figure 1: Figure 4 1. Disconnect electrical wiring at the brake pressure 4. Using a snap ring pliers or screwdriver (depending switch, the brake line from the fitting (and cap the fon the type of snap ring used), remove the snap line) (Fig. 1). Loosen the fill cap with a wrench if ring while holding the piston inward against spring necessary. pressure (Fig. 4). Figure 2: a Figure 8: 2, Remove the three (3) self-locking hexagon nuts 5. The piston should be free to come out (Fig. 6). If it from the cylinder mount flange (Fig. 2), and pull does not, light tapping on the cylinder body or the unit forward. working the piston in and out should gradually treet. Figure 3: 3. Remove the fill cap and pour the fluid into a waste ‘container. Remove the rubber dust boot from the rear of the cylinder to expose the snap ring and piston (Fig. 8). Revised May, 1982 ct Brake SystemsSingle Disc Brake System Inspection and Repair ev ; ©) Figure 6: 1. Thoroughly clean the master cylinder housing and {ill cap, then blow dry with compressed air. 2. Examine the bore of the master cylinder (Fig. 6) If only light scratches or pitting are present, they may be removed with a small brake cylinder hone. IMPORTANT: After honing operations, again thor- oughly clean and dry the master ovlinder. If the scratches or pitting cannot be removed by light honing, replace the housing or entire assem- bly. Reassembly and installation 1. Lubricate the housing bore and the piston/seal assembly with clean brake fluid. (DO NOT USE OL OR GREASE.) Figure 7: 2. Carefully install the spring and piston seal assem- bly into the cylinder bore. As the piston seal ap- proaches the snap ring groove of the cylinder housing (Fig. 7), wobble the piston until the seal ‘works into the bore. Revised May, 1982 12 Figure 8: Figure 9: 3. Hold the piston in the bore while installing the snap ring (Fig, 8). Install the rubber dust boot (Fig. 9). Figure 1 Guide the pedal push rod through the dust boot and fasten the cylinder to the cab (Fib. 10). Re- connect the push rod and clevis at the brake pedal, i it was previously removed Brake SystemsSingle Disc Brake System oa Adjust Pedal Free Travel Figure 11: Figure 73 5. Reconnest the brake line and brake switeh wires 2, Adjust the pushrod to allow some free play be- (Fig. 11). tween the pedal and piston. After zero clearance, ‘one full turn of the pushrod into the yoke is appro- 6. Fill the master cylinder fluid reservoir and bleed priate (Fig. 13). the brake system. Refill the reservoir after bleed- ing is completed Brake Dise Testing and Adjusting Inspection, Inspect the brake disc with the disc mounted on its ‘rive flange to determine if replacement is needed. Figure 12; 1. Apply moderate pedal pressure for several minutes to see if the piston seal will leak. If leakage is present it can be observed when the rubber dust Figure 1: boot is loosened from the rear of the cylinder (Fig. 12). 1. With the upper driveline disconnected, mount a dial indicator on one of the brake mount bars (Fig. 1) and tum the brake disc to check for excessive runout. If runout exceeds .030 inch (.76 MM), re- place the brake disc. 13 Brake SystemsSingle Disc Brake System Minimum thickness 400 inch (10.16 mm) Maximum wear per side (038 inch (.96 mm) per side 4 038 inch (.96 mm) | | = EA Figure 2: 2. Measure the brake disc for wear (Fig. 2), and if worn to less than .400 Inch (10.16 MM), tapered more than .098 inch (.96 MM) along its wear path, or displays large grooves deeper than .038 inch (.96 MM), then replace the brake disc. Figure 3: Figure 4: 3. Observe the finish of the brake disc. It should be smooth enough to eliminate a grinding action on the brake pads. The finish of the brake disc should be uniform throughout the entire circumference (Fig. 3). f spotted heavily with “welded” brake pad ‘material (Fig. 4), replace the brake disc. Revised May, 1982 Figure 5: Remove the brake mount bar(s) intact with caliper assemblies and lines still connected (Fig. 5) Figure 6: 2. Disconnect the upper driveline at the transmission ‘output flange and swing it aside (Fig. 6). Figure 7: 3. Loosen the cam lock nut on the park brake caliper to allow extra clearance when removing the disc (Fig. 7) 14 Brake SystemsSingle Disc Brake System Figure 8: 4. Remove the capscrews that retain the disc to the transmission output yoke. Pull the bottom of the disc rearward then lower it enough to clear the park brake caliper (Fig. 8). Installation 1. After installation of the brake disc, driveline, brake mount bars and calipers, adjust the park brake (see Park Brake Caliper, Reassembly in- stallation and Adjusting, step 5). 2. If the brake disc (and/or brake pads) were re- placed, the pistons in the hydraulic calipers must be bottomed in their bores. (See Single Piston Hydraulic Brake Caliper section.) Revised May, 1982 15 Brake SystemsSeries III "ST" BC, C&P Multi Disc Brake System General Information Under Serial No 2001 — oe SS * eS s Figure 2: ‘The Steiger Multi-Disc Brake System Is used only on do not (Fig. 2). Though design variations are present, the Steiger Tractors that employ the two-speed transfer operating principles and repair procedures are case. The brake design will depend on the transfer case Identical. All repair procedures on the brake can be ‘model used. For instance, in comparing the models C, done with the transfer case in the tractor. E and F transfer cases, note that the model C unit has an offset center shaft (Fig. 1) while the models E and F Revised May, 1982 7 Brake SystemsSeries III "ST" BC,C & P Multi Disc Brake System Under Serial No 2001 Outer Brake Plate Te AO Teanetee ase Sie r tt _ Center Shaft eC, Hi Figure 4: Actuator ~ Figure 5: The stationary brake disc arrangement, Including the actuator, is supported by pins mounted on the center shaft bearing cap/brake plate (Fig. 3). The rotating brake discs fit the protruding spline center shaft and are stacked alternately with the stationary dises (Fig, 4). The actuator assembly is located in the center of the brake disc arrangement (Fig. 5), and is connected mechanically to a hydraulic slave cylinder. Whenever the slave cylinder is activated, the actuator plates spread and contact the brake discs. As further pressure is applied, braking forces are greatly increased due to the self-energizing effect of the actuator assembly. Revised May, 1982 18 Figure 7: The Steiger Multi-Disc Brake Assembly functions as the park brake as well as the main brake. Application of the park brake is done by a locking-type cable and sliding yoke/ bracket connected to the mechanical link- lage to the actuator. Note the early type (Fig. 6) linkage ‘compared to the later type (Fig. 7) Discs and Actuator Group Removal and Disassembly 1. Disconnect the actuator yoke and push rod clevis from the lever (Fig. 1). Brake SystemsFigure 4: Revised May, 1982 19 Series Ill “ST” BC,C & P Multi Disc Brake System Under Serat No 2001 2. Remove the brake shields if the bolt-on type is used (Fig. 2). Remove the park brake cable and bracket from the outer brake plate (Fig. 3), then remove the outer brake plate. If the slip-in type brake shields are used (Fig. 4), remove at this time. 3. Carefully remove the brake discs individually to maintain the same order if they are to be reused. Figure 5: 4, Remove the anchor pin and inner wear plate (Fig 5) from the bearing cap/ brake plate assembly. Figure 6: 5, Release the actuator return springs (Fig. 6), then Brake SystemsSeries Ill "ST" BC, C &P Multi Disc Brake System Under Serial No 2001 baits Figure 7: Figure 8: remove the clevis pin at the actuator link ends (Fig. 7). The actuator plates can now be separated (Fig. 8). 6. If removal of the support pins is required, the brake plate/bearing cap assembly must be re- moved from the transfer case before capsorews ccan be loosened to remove the pins. Refer to the Steiger two-speed transfer case service manual for repair procedures, however, repairs may be done with the transfer case in the tractor chassis. Revised May, 1982 20 Inspection and Repair 1. Mount a dial indicator to check bearing clearance of the transfer case center shaft. If the bearing clearance is out of the specified range, or if the center shaft oil seal Is leaking, refer to the Stelger Two-Speed Transfer Case Service Manual for re- pair procedures. Figure 9: 2. Inspect the splines of the protruding center shaft for wearing atthe four (4) diso fitting areas (Fig. 9). | wearing is severe enough to let the brake discs hang-up, the center shaft must be replaced. if center shaft replacement is needed, refer to the Steiger Two-Speed Transfer Case Service Manual Figure 10: 3. Inspect the surface of the anchor pin at point of stationary brake plate contact (Fig. 10). Replace if wearing is severe enough to cause the stationary brake plates to hang-up. Brake SvstomsInspect, Finish Condition Figure 11: 4. Inspect the stationary brake plates for cracks, wear and finish appearence. If cracked or worn far enough so new brake discs will not fit properly on the used stationary plates, replace the stationary plates. The finish should be smooth and uniform throughout the disc wear faces (Fig. 11). If the Wear surfaces are heavily grooved or display rough ess which would grind the lining material from the rotating dises, replacement of the stationary diso(s) is required. ‘Check Spline Condition, (Check lining thickness ) Figure 12: 5. Inspect the rotating brake discs for lining thick- ‘ness and splined hub condition. Disc(s) should be replaced when lining material surface is less than 1/16 inch (1.58 MM) from the disc backing plate (Fig. 12), or if the hub splines are worn to the point of excess looseness on the center shaft. Revised May, 1882 21 Series Ill “ST” BC, C & P Multi Disc Brake System Under Serial No 2001 Cheok all ramps fortrusness and uniformity Figure 13: 6. With the actuator disassembled, inspect the wear faces a5 described in step 4. Proceed by inspect- ing the ramps of actuator plates (Fig. 13). If “pockets” are worn into the ramp surfaces, replace the disc(s) as required. Figure 14: 7. Measure the actuator balls to insure roundness and equal size (Fig. 14). If out of round or badly pitted, replace all the balls in the actuator assem- bly. Brake SystemsSeries Ill "ST" BC, C & P Multi Disc Brake System Under Serial No 200% Reassembly, Installation and Adjusting =. °* inner Wea Plate Figure 15: 1. With the brake plate/bearing cap with support pins already mounted, install the anchor pin and inner wear plate with its grooved side facing the trans- fer case (Fig. 15) Figure 16: ‘Anchor pin slots Figure 17: 2. Assemble the actuator by laying the first plate face down. Install the balls in the ramps (Fig. 18). Posi- tion the second plate onto the balls ensuring that the anchor pin slots are near each other (Fig. 17) Revised May, 1982 22 Figure 18: Install the actuator retum springs and reconnect the link ends with the clevis pin and yoke block (Fig. 18). Figure 19: Figure 20: 3. Install a brake disc, stationary plate, brake disc, actuator assembly (Fig. 19), disc, stationary plate brake disc, slip-in shields, if used and outer brake plate in the order given (Fig. 20). If reassembly is, done with reusable parts, maintain the order in which they were removed. Connect the brake lever, slave cylinder and park brake cable. If the slip-in ‘ype brake shields are used, install at this time. Brake SystemsFigure 21: 4. After installing the outer brake plate, the brake is adjusted to a minimum clearance of .080 inch (2.28 MM) between the brake disc stack and the outside plate (Fig. 21) by adjusting the length of the threaded rod on the slave cylinder. Figure 22: NOTE: Later production brakes have shorter support ins to allow the use of shims to compensate for disc and plate wear (Fig. 22). It an entire new brake is being installed along with the shim kit, then five shims are installed on each pin, If the shim kit is being installed with a used brake then a shim adjustment may already be necessary. Assemble the brake using five shims on each pin and follow the brake adjustment instructions. Revised May, 1982 23 Series III “ST” BC, C&P Multi Disc Brake System Under Seria! No 2001 Figure 22: 8. The brake should be adjusted by removing shims when the travel distance measured between the actuating discs (Fig. 23) is from .170 ineh (4.31 MM) to a maximum of .200 inch (6.08 MM) when the brake is activated from a fully relaxed position to a fully applied position. The park brake can be ‘applied to hold the brake in the applied position. Normally, the removal of one shim from each pin should be sufficient to restore the brake to the optimum working range. There are a total of five shims that can eventually be removed. At no time should the shim removal result in a travel distance of less than .080 inch. When using shims on the support pins, they must be of equal total thickness on ALL pins. If bolt-on brake shields are used, i stall at this time. rma Figure 24: 6. Torque the outer brake plate capscrews to 8 Ib. ft. (8.02 Kg/M). After shim removal and reassembly hhave been completed, the brake should be adjust- ed to. minimum clearance of .090 inch (2.28 MM) between the outside plate and brake disc stack by adjusting the length of the threaded rod on the slave cylinder (Fig. 24), 7. Test drive the tractor after repairs and/or adjust- ments have been completed to ensure proper brake ‘operation and performance. Brake SystemsSeries III "ST" BC, C & P Multi Disc Brake System Under Serial No 2001 Master Cylinder Removal and Disassembly Figure 1: 1. Disconnect the electrical wiring at the brake pres- sure switch, and the brake line from the fitting (then cap the line) (Fig. 1). Loosen the fill cap with, ‘wrench if necessary. foe Figure 2: - 2. Remove the three (3) self-locking hexagon nuts from the cylinder mount flange (Fig. 2) and pull the unit forward. Figure 3: 3. Remove the fil cap and pour the fluid into a waste container. Remove the rubber dust boot from the roar of the cylinder to expose the snap ring and piston (Fig. 3). Revised May, 1982 Figure 4: 4, Using a snap ring pliers or screwariver (depending on the type of snap ring used), remove the snap ring while holding the piston inward against spring pressure (Fig. 4). Figure §: 5 The piston should be free to come out (Fig. 8). If it does not, light tapping on the cylinder body or working the piston in and out should gradually free it. Brake SystemsInspection 1. Thoroughly clean the master cylinder housing and fill cap, then blow dry with compressed air. L Figure 6: 2. Examine the bore of the master cylinder (Fig. 6). If only light scratches or pitting are present, they may be removed with a small brake cylinder hone. IMPORTANT: After honing operations, again thorough- Jy clean and dry the master cylinder. If the scratches or pitting cannot be removed by light honing, replace the housing or entire assem- bly. Reassembly and Installation 1. Lubricate the housing bore and the piston/seal assembly with clean brake fluid. (DO NOT USE OILOR GREASE.) Figure 7: 2. Carefully install the spring and piston seal assem- bly into the cylinder bore. As the piston seal ap- proaches the snap ring groove of the cylinder housing (Fig. 7), wobble the piston until the seal works into the bore. Revised May, 1982 25 Series III "ST" BC, C&P Multi Disc Brake System Under Serist No 2001 Figure 8: Figure 9: 3. Hold the piston in the bore while installing the snap ring (Fig. 8). (Fig. 9) Install the rubber dust boot Figure 10: 4. Guide the pedal push rod through the dust boot and fasten the cylinder to the cab (Fig. 10). Recon- rect the pushrod and olevis at the brake pedal, if it was previously removed. Brake SystemsSeries III "ST" BC, C &P Multi Disc Brake System ‘Under Serial No 2001 2. Adjust the pushrod to allow some free play be- tween the pedal and piston, After zero clearance, one full tum of the pushrod into the yoke Is ap- propriate (Fig. 13). Slave Cylinder Removal and Disassembly Figure 11 1. Disconnect the fluid pressure line. Cap the line to prevent total loss of fluid. 5. Reconnect the brake line and brake switch wires (Fig. 11). 6. Fill the master cylinder fluid reservoir and bleed the brake system. Refill the reservoir after bleeding is completed Testing and Adjusting Figure 1: 2. Remove the two (2) through bolts fastening the slave cylinder to its mounting bracket (Fig. 1), and remove the unit by pulling the rubber boot from the pushrod/ clevis assembly. 3. Empty the fluid into a waste container while push- Figure 12: ing the piston inward. 1. Apply moderate pedal pressure for several minutes: to see if the piston seal will leak. If leakage is present, it can be observed when the rubber dust boot is loosened from the rear of the cylinder (Fig. 12). ‘Adjust Pedal Free Travel Figure 2: 4, Remove the rubber boot for access to the snap ring and piston (Fig. 2). Figure 13: 26 Brake SystemsSeries III "ST" BC, C &P Multi Disc Brake System Under Serial No 2001 Examine the bore of the cylinder (Fig. 5). If only light scratches or pitting are present, they may be removed with a small brake cylinder hone, I IMPORTANT: After honing operations, again thorough- ly clean and dry the siave cylinder. 3. If the scratches or pitting cannot be removed by light honing, replace the housing or entire assem- by. Figure 3: 5. Using a snap ring pliers or screwdriver (depending on the type of snap ring used), remove the snap Reassembly and Installation ring (Fig. 3) Figure 4: Figure 6: 6. The piston should be free to come out (Fig. 4). If it 1. Lubricate the housing bore and the piston/seal does not, light tapping on the cylinder body or assembly with clean brake fluid. (00 NOT USE OIL working the piston in and out should gradually free OR GREASE.) it, 2. Carefully install the piston/seal assembly into the Inspection and Repairs cylinder bore. As the piston seal approaches the snap ring groove of the cylinder housing (Fig. 6), 1. Thoroughly clean the cylinder housing and fill cap, wobble the piston until the seal works into the then blow dry with compressed air. bore. Inspect Bore Condition Figure 8: Revised May, 1982 7 Brake SystemsSeries Ill “ST” BC, C & P Multi Disc Brake System Under Serial No 2001 Figure 7: Figure 10: 8. Reconnect the brake line and return spring (Fig. 10). Fill the master cylinder fluid reservoir and bleed the brake system. Refill the reservoir after bleed- ing is completed. Testing and Adjusting Figure 8: 3. Insert the piston in the bore. Install the snap ring (Fig. 7) and the rubber dust boot (Fig. 8). Figure 11: 1. Apply moderate pedal pressure for several minutes to see If the piston seal will leak. If leakage is present, it can be observed when the rubber dust boot is loosened from the rear of the cylinder (Fig. 1). Figure 8: 2. For adjusting procedures refer to the Reassembly, Installation and Adjusting section of the Brake 4. Guide the pushrod through the dust boot and Group in this service manual fasten the cylinder to the mount bracket and torque the through bolts (Fig. 9) to 36 Ib. ft. (6.25 kg/M). Revised May, 1982 28 Brake Systems