Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 42 views

    Group 3 Disassembly and Assembly: 1. Brake Disassembly Procedure General Description

    Uploaded by

    André Targino
    The document provides instructions for disassembling and assembling various components of a truck reduction gear system. It describes in detail: 1. The brake disassembly procedure, including removing discs and housing. 2. Replacing the brake discs and disc pusher, inserting springs and discs in an alternating pattern. 3. Gearbox disassembly steps like draining oil, removing housing, ring gear, wheel hub, sun pinion, and helix pinion. Precautions are noted like using proper safety equipment and lifting devices due to heavy parts. Reassembly follows the reverse of the disassembly steps.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Group 3 Disassembly and Assembly: 1. Brake Disassembly Procedure General Description

    Uploaded by

    André Targino
    42 views8 pages
    The document provides instructions for disassembling and assembling various components of a truck reduction gear system. It describes in detail: 1. The brake disassembly procedure, including removing discs and housing. 2. Replacing the brake discs and disc pusher, inserting springs and discs in an alternating pattern. 3. Gearbox disassembly steps like draining oil, removing housing, ring gear, wheel hub, sun pinion, and helix pinion. Precautions are noted like using proper safety equipment and lifting devices due to heavy parts. Reassembly follows the reverse of the disassembly steps.

    Original Title

    3-3

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document provides instructions for disassembling and assembling various components of a truck reduction gear system. It describes in detail: 1. The brake disassembly procedure, including removing discs and housing. 2. Replacing the brake discs and disc pusher, inserting springs and discs in an alternating pattern. 3. Gearbox disassembly steps like draining oil, removing housing, ring gear, wheel hub, sun pinion, and helix pinion. Precautions are noted like using proper safety equipment and lifting devices due to heavy parts. Reassembly follows the reverse of the disassembly steps.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    42 views8 pages

    Group 3 Disassembly and Assembly: 1. Brake Disassembly Procedure General Description

    Uploaded by

    André Targino
    The document provides instructions for disassembling and assembling various components of a truck reduction gear system. It describes in detail: 1. The brake disassembly procedure, including removing discs and housing. 2. Replacing the brake discs and disc pusher, inserting springs and discs in an alternating pattern. 3. Gearbox disassembly steps like draining oil, removing housing, ring gear, wheel hub, sun pinion, and helix pinion. Precautions are noted like using proper safety equipment and lifting devices due to heavy parts. Reassembly follows the reverse of the disassembly steps.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 8

    GROUP 3 DISASSEMBLY AND ASSEMBLY

    ö During maintenance, assembly and disassembly activities use caution and proper safety equipment,
    in observance of the rules provided by safety laws.
    1. BRAKE DISASSEMBLY PROCEDURE
    1) GENERAL DESCRIPTION
    (1) Remove the two plugs (46) and drain the Truck connecting bolt holes
    oil off, at least partially; unscrew the 8
    screws (45).
    (2) Two of the holes where the screws are
    located have a M10 thread: drive two M8
    grubs in, in order to save the thread of the
    flange (34), then drive two M10 screws in 45
    until the brake housing (51) is extracted.
    51 45

    34

    46 35B7PT11

    2) REPLACE OF THE BRAKE DISCS

    (1) The brake discs unit is made of 7 steel


    discs (59) and 6 friction discs (58), ordered
    in an alternate way (the first one and the 59
    last one must be steel disc).
    (2) Between every couple of steel discs four 60
    elastic springs are inserted (64), one
    spring on each locking pin (63).

    (3) Remove the 13 discs of the brake units


    and the springs (64). Remove finally the 64
    Disc pusher
    support disc (60). 63 58

    (4) Wash down the housing thoroughly, then


    35B7PT12
    to assemble the parts again follow next
    steps:
    Η step1: Insert the support disc (60).
    Θ step2: Insert steel disc (59), 4 elastic
    springs (64) one spring on each
    locking pin (63), friction discs
    (58).
    Ι step3: Repeat step2 for other 5 times.
    Κ step4: Place last steel disc.

    3-5
    3) REPLACING DISCS PUSHER

    (1) The disc pusher device (57) is seated on


    the brake housing (51). 57

    (2) Unscrew first the 3 screws (62) with their


    springs (61), then remove the discs pusher
    device (57).

    51
    61
    62
    35B7PT13

    (3) Place the spacer-seal (52) on the flange


    (34) contact surface. Insert the brake
    housing (51), center on its 2 pins (39) and
    on the 4 brake locking pins (63) and, using
    a rubber hammer, fine-tune the cartridge 34

    position until it is completely inserted.


    51,52
    39

    63

    35B7PT14

    (4) Now, insert the 8 screws (45) in their own


    holes and set them with the following
    torque wrenches:
    ÂScrew M8 ; 4.08kgfÂm(29.5lbfÂft)

    45
    Brake 45
    housing

    Flange

    35B7PT11-1

    3-6
    2. GEARBOX DISASSEMBLY
    ö The gearbox is made with heavy parts, secure the parts and use proper lifting equipment.
    1) GENERAL DESCRIPTION

    (1) It's possible to open the gearbox without


    disassembling it from the truck.
    (2) You have to drain the oil from both
    chambers, the reduction gearbox and the
    brake, removing the plugs from the bottom
    side and removing the brake oil plugs too.

    Brake oil Gearbox oil


    drain plug drain plug
    35B7PT15

    2) HOUSING REMOVAL

    (1) Secure the gearbox housing (12) and


    9 (M8, 3EA)
    unscrew the screws (11), the screws (10)
    and the screws (9) which connect the
    casing to the cover (34). 34

    (2) Remove the casing pulling it along the


    wheel axis. 10
    (M10, 2EA)
    ö Pay attention: the casing is heavy!

    11
    (M20, 7EA)

    12
    35B7PT16

    3) DISASSEMBLY OF THE RING GEAR AND OF THE WHEEL HUB

    (1) In order to pull out the planet gears (26)


    and their bearings (27), remove the
    retaining ring (28) and use a special
    extractor.

    26,27
    28
    35B7PT17

    3-7
    (2) To unscrew the lock nut (29) a special tool
    2 24
    is required. To remove the wheel hub (2)
    place a special tool on the center of the
    M60 thread of the hub, and carefully press
    it out. At this point slip off the planet carrier
    (24) too.

    29

    * SPECIAL TOOL
    A 10 33

    18
    12.8

    70 +0.5

    62
    84
    12.8
    A A-A
    35B7PT18

    (3) Unscrew the 6 nuts (23), remove the


    22,23
    washers (22) and pull out the ring gear
    (20).

    20

    35B7PT19

    3-8
    4) DISASSEMBLY OF THE SUN PINION

    (1) To disassembly the sun pinion and the


    input shaft you have to remove the flange
    and the connected motor from the truck.
    Secure the motor, then unscrew the frame
    connecting screws(M24, 8EA). Place the
    flange and the motor on a surface.
    Unscrew the motor connecting
    screws(M14, 8EA) and separate it from
    the flange.
    ö Prior to this operation you have to drain
    the brake oil and to remove the cartridge
    and the brake disc unit.

    (2) Remove the retaining ring (30). To remove


    the helix gear (31) put a disc (͚i =96mm,
    30
    ͚e = 130mm) on the cover (looking from
    the brake side) and carefully press on a
    31
    pipe (͚i = 24mm, ͚e = 45mm) placed on
    the sun pinion (40) (looking from the
    gearbox side).

    40
    35B7PT20

    5) DISASSEMBLY OF THE HELIX PINION

    (1) Remove first the retaining ring (38) and


    38
    helping yourself with a rubber hammer
    take out the helix pinion (35) beating it
    from the gears side.
    35

    35B7PT21

    3-9
    3. ASSEMBLY OF THE REDUCTION GEAR
    ö After the worn out parts have been replaced, to assemble the unit again follow the disassembling
    process steps in reverse order.
    1) ASSEMBLY OF THE SUN PINION

    (1) Key the bearing (33) in its own slot on the


    flange (34), locking it with the retaining ring
    (32), insert the sun pinion (40) using a 33 31
    press and pushing on the inner ring of the
    bearing (33); place the feather key (41)
    into its own slot and insert the helix gear
    (31) on the sun pinion (40). To easy keying 32
    operations, you may heat the helix gear
    (31) to maximum 100~120ÁC. Insert the
    retaining ring (30).
    41

    40

    35B7PT22

    2) ASSEMBLING THE RING GEAR AND THE WHEEL HUB

    (1) Insert the cup (outer ring) of the tapered 2


    bearings (6, 17) in their front and rear
    4
    housings on the housing (12). 5
    6
    (2) Insert the seal ring (5) onto the wheel hub 7
    1
    (2).
    (3) Insert the cone (inner ring) of bearing (6)
    onto the hub (2) possibly heating it up to
    100~120ÁC. Insert the needle cage (4) in
    its own slot in the hub (2).
    (4) Introduce the pre-assembled hub into the
    casing.
    (5) Insert the set-right spacer (7) and the
    spacers (1) into the shaft and then place
    the cone of the bearing (17), pressure-
    12 17
    keying it in.
    35B7PT23

    3-10
    (6) Insert the ring gear carrier disc (19) into
    the ring gear (20) and fix it introducing the
    retaining ring (18) in its housing.
    20

    19

    18
    35B7PT24

    (7) Place the disc in the housing (12)


    centering it on the six studs (21). If the
    studs (21) need to be replaced, insert the 21,22,23
    new ones into the housing (12) with high-
    strength thread locker. Place the washers Ring gear(20)
    (22), spread locking compound (strong) on
    the nuts (23, 6EA) and tighten them with a
    10.2kgfÂm(73.8lbfÂft) torque wrench
    setting. 12
    35B7PT25

    (8) Heat the planet carrier (24) up to 120ÁC,


    2 24
    then place it onto the wheel hub spline (2)
    and press it down until the group is pack-
    closed; Tighten the ring nut (29) with an
    dynamometric key set at 51kgfÂm(369lbfÂ
    ft) torque wrench, then lay the outer edge
    low.

    29

    35B7PT26

    (9) Insert the planet gears pre-mounted with


    their bearings (25+26+27+25) on the 3
    axes of the planet carrier (24), then lock
    them with the retaining rings (28), one for
    each planet gear.

    24 25 26 27 25

    28
    35B7PT27

    3-11
    3) ASSEMBLING THE HELIX PINION

    (1) Key the bearing (36) onto the helix pinion


    (35) and lock it with the retaining ring (37),
    then insert it into the housing in the flange 37
    and lock all with the retaining ring (38).
    35

    36
    38

    35B7PT28

    4) ASSEMBLY OF THE COVER

    (1) Lay a coat of sealant on the housing (12) 15


    contact surface and key the pre-mounted
    cover (34) onto the housing centering it on
    the 2 pins (15) and, using a rubber
    hammer, seal it all.
    (2) Insert the screws into their own seats and
    tighten them at:
    ÂScrew(11), M20Ý80 : 40.8kgfÂm(295lbfÂft)
    ÂScrew(10), M10Ý60 : 4.59kgfÂm(33.2lbfÂft) 9 (M8, 3EA)

    ÂScrew(9), M 8Ý30 : 4.08kgfÂm(29.5lbfÂft)


    torque wrench setting. 34

    (3) Now is possible to assemble the brake


    disc unit paying attention to respect the 10
    (M10, 2EA)
    steps on page 3-5.

    11
    (M20, 7EA)

    12
    35B7PT29

    (4) Place the seal (52) on the cover (34)


    contact surface. Insert the brake housing
    (51), centering it on the 2 pins (39) and,
    using a rubber hammer, fine-tune the 34
    housing position until it is completely
    inserted. 51
    39
    (5) Now, insert the screws (53, 8EA) in their
    own holes and set them with the following
    torque wrench:
    Â Screw(M8): 4.08kgfÂm(29.5lbfÂft) 53
    35B7PT30

    3-12

    You might also like