Link Belt Crane HTC-8660 II Service Manual by Heavy Equipment Manual

Brakes,Recondition (Dana /Spicer EB&ESModels)

Thisprocedurecoversthereconditionofthecarrier wheelbrakes.

Thefollowingpagesaretakendirectlyfromtheservice literatureproducedbytheaxlemanufacturer.Multiple brakemodelsarecoveredbythisinformation.Pay particularattentiontoSection1ofthisprocedureto correctlyidentifythespecificbrakemodelbeing serviced.Properidentificationofthebrakesiscrucial toobtainthecorrectinformationtofollowfromthe chartedspecificationsincludedinthisprocedure.

Basedonthespecificapplicationofthebrakesusedon theaxle,Link---Beltliteraturewillsupersedeany discrepanciesinoperation,lubrication,maintenance, orservice,impliedbythebrakemanufacturer.Any concernsregardingsuchinconsistenciesshouldbe reviewedwithaLink---Beltdistributor.

Ifpartsarehardtodisassembleandassemble,donot useahammerunlessithasasoftface,donotforce partstogether,theymustbefreetooperateandnot bind.

Itisagoodpracticewhendisassemblingcomplex componentstolaythepartsoutintheorderthatthey weredisassembled.Keepingthepartsinthisorder duringdisassembly,cleaning,andinspectionwillaidin theassemblyprocess.

WARNING

Solventsandcleaningsolutionscanbe hazardous.Seriouspersonalinjurymay resultfrommisuseoftheseproducts.Read andfollowallthemanufacturers recommendationsconcerningsolventsand cleaningsolutions.

Thoroughlycleantheexteriorsurfaceoftheaxle,with anapprovedsolvent,topreventcontaminationfrom enteringitbeforebeginningthedisassemblyprocess.

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ServiceManual 0509 SM01---003---010.00 2of56 TableofContents Section1:GeneralInformation Foreword 5 HowtoUsethisManual. 5 LiningMaterialWarning 6 ModelCoverage 7 PartsNomenclature 9 ModelES---165---7andEB---165---7Interchangeability13 EBRollerandESCamInterchangeability13 Section2:PeriodicService MaintenanceAndAdjustment 16 BrakeMaintenancePreliminarySteps 16 BrakeAdjustment---ManualSlackAdjuster16 .......................................................... BrakeAdjustment---AutomaticSlackAdjuster17 ........................................................ BrakeOperationCheck 19 Lubrication 19 PeriodicInspections 19 ServiceIntervals 19 ................................................................................. Section3:Removal/Disassembly DrumRemoval 21 ShoeRemoval 22 ................................................................................... SlackAdjusterRemoval 30 CamshaftRemoval 30 AirChamberBracketRemoval 30 SpiderRemoval 31 DustshieldRemoval 31 .............................................................................. CleaningBrakeParts 31 Section4:Inspection DrumInspection 33 DrumTurning/Reboring 33 ShoeandLiningInspection 34 CamshaftRadialPlayInspection 36 ................................................................... CamshaftInspection 36 .............................................................................. CamshaftBushingandSealInspection36 SpiderInspection 37 AirChamberBracketInspection 37 AirChamberInspection 38 ........................................................................... SlackAdjusterInspection 38 ......................................................................... Section5:Repair/Replacement CamshaftBushingAndGreaseSealReplacement39 BrakeLiningReplacement 39 Section6:Installation/Assembly SpiderInstallation 41 ................................................................................ DustshieldInstallation(TwoPiece) 41 DustshieldInstallation(OnePiece) 42 AirChamberBracketInstallation 43 CamshaftInstallation 44 ............................................................................. CamHeadWasherAndSlackAdjusterInstallation45 ShoeandLiningInstallation 46 SpecificationChart 54

ServiceManual 0509 SM01---003---010.00 3of56 ListofIllustrations Figure1BrakeModelIdentification 8 Figure2BrakePartNomenclature,General9 Figure3BrakeModelPartNomenclature10 Figure4BrakeModelPartNomenclature,Continued11 Figure5BrakeModelPartNomenclature,Continued12 .............................................. Figure6EBRollerandESCamContactPattern13 Figure7PartsIdentification 14 Figure8PartsIdentification,Continued15 Figure9CraneMaintenanceSupport16 Figure10BrakeChamberMeasurement,AtRest16 ................................................... Figure11BrakeChamberMeasurement,80psiApplied17 Figure12BrakeChamberMeasurement,ManuallyApplied.17 Figure13AutomaticSlackAdjuster 18 Figure14SlackAdjusterAdjustment21 Figure15RollerRetainerRemoval.. 23 Figure16UpperCamRollerandPinRemoval23 Figure17ES---165---7D,F,LShoeRemoval.24 Figure18ShoeRemoval 24 Figure19CastSpiderWithHorseCollar24 Figure20ShoeReturnSpringRemoval25 ........................................................... Figure21LowerShoeRemoval 25 Figure22RetainerLoopRemoval. 26 Figure23RollerandRetainerRemoval26 Figure24ReturnSpringRemoval 26 ................................................................. Figure25RetainingRingandWasherRemoval27 ..................................................... Figure26CapscrewRemoval 27 .................................................................... Figure27AnchorPinRemoval 27 Figure28AnchorPinBushingRemoval27 Figure29RetainingRingandWasherRemoval28 ..................................................... Figure30CapscrewRemoval 28 .................................................................... Figure31AnchorPinRemoval 28 ................................................................... Figure32ShoeRemoval 28 Figure33AnchorPinBushingRemoval29 Figure34GroovePinRemoval 29 Figure35SlackAdjusterRemoval 30 ................................................................ Figure36AutomaticSlackAdjuster 30 ............................................................... Figure37SpiderMountingHardwareRemoval31 Figure38DustshieldMountingHardwareRemoval31 Figure39DustshieldTorques---AllEB/ES---165---5/6/7/8LModels31 Figure40DrumInspection 33 ...................................................................... Figure41ShoeandLiningInspection34 ............................................................. Figure42BrakeandLiningBlocks 35 ................................................................ Figure43CamshaftRadialPlayInspection36 Figure44CamshaftInspection 36 Figure45SpiderInspection 37 Figure46AirChamberBracketInspection37 ......................................................... Figure47AirChamberInspection 38 ................................................................ Figure48SlackAdjusterInspection 38 Figure49AirChamberBracketBushingInstallation39 Figure50CamshaftGreaseSealInstallation40 Figure51InstallingSpiderMountingHardware41 ..................................................... Figure52DustshieldSpacing 41 .................................................................... Figure53DesignedInterferenceFit 41 ............................................................... Figure54DustshieldAttachingScrewLocations42

0509 SM01---003---010.00 4of56 Figure55DustshieldAttachingScrewLocations42 Figure56AirChamberBracketMountingHardware43 Figure57CamshaftInstallation. 44 Figure58CamHeadWasherInstallation44 Figure59CamInstallation---ES---165---5/6/7D,L44 Figure60ShimWasherandSnapRingInstallation45 Figure61SlackAdjusterEndPlayCheck45 Figure62SlackAdjusterLubricationandAdjustment45 ............................................... Figure63ShoeWebLubrication 47 Figure64ShoeRetainingSpringInstallation47 Figure65ShoeReturnSpringandRollerInstallation47 Figure66UpperandLowerShoePositioning48 Figure67ShoeReturnSpringInstallation48 ......................................................... Figure68UpperandLowerShoePositioning.49 Figure69ShoeReturnSpringInstallation49 Figure70RollerRetainerInstallation50 Figure71ShoeReturnSpringInstallation50 Figure72RetainerInstallation 50 .................................................................... Figure73AnchorPinBushingInstallation51 ......................................................... Figure74LowerShoeandAnchorPinInstallation.51 Figure75UpperShoeandAnchorPinInstallation51 Figure76CapscrewInstallation 51 Figure77ShoeReturnSpringInstallation52 Figure78RollerRetainerInstallation52 .............................................................. Figure79RollerandRetainerInstallation52 Figure80RetainerInstallation 52 Figure81GroovePinInstallation 53 Figure82SpiderAnchorPinBushingInstallation53 Figure83ShoeAnchorPinBushingInstallation53 .................................................... Figure84LowerShoePositioning 54 ................................................................ Figure85UpperShoePositioning 54 Figure86UpperShoeInstallation 54 Figure87LowerShoeandAnchorPinInstallation54 ListofTables Table1BrakeModelsandSpecifications7 Table2DistanceRange 16 ....................................................................... Table3StrokeValues 17 Table4LubricationIntervals 19 Table5ShoeRemovalProcedureIndex22 Table6BrakeShoeMaximumDiameters34 Table7ClevisPinHoleCenterline 38 .............................................................. Table8CamshaftBushingInstallationSpecifications39

ServiceManual

Section1:GeneralInformation

Foreword

Thispublicationisintendedtoactasasourceof maintenanceinformationtothoseinvolvedinservicing brakes.

HowtoUsethisManual

1.Arrangement.Thismanualisarrangedinseven sections:GeneralInformation,PeriodicService, Removal/Disassembly,Inspection,Repair/Replacement,Installation/Assembly,andSpecifications.Generalpagelayout,includingsectionand paragraphheadings,indentionlevels,andFigure andTabledesignatorinformation,isshownon Pages2thru4.

2.TableofContents.TheTableofContentslistsall sectionheadingsandprimaryparagraphheadingsinthispublication.

3.IllustrationsandTables.Illustrationsandtablesare includedtohelpmakethetextofthispublication clear.SeetheListofIllustrationsandListofTables followingtheTableofContents.

4.SpecificationChart.Atabulationofallmeasurementspecificationsisprovidedatthebackofthis publication.

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DANGER AVOIDCREATINGDUST

POSSIBLECANCERANDLUNGDISEASEHAZARD

CAUTIONARYINFORMATION

Danger

BrakeLiningFiberWarning

Olderbrakeliningsmaycontainasbestos fibers,acancerandlungdiseasehazard. Brakeliningsmanufacturedtodaycontain non--asbestosfibers,whoselong--term effectstohealthareunknown.Usecaution whenhandlingeitherasbestosor non--asbestosmaterialsusedinbrake linings.RefertoOSHAregulationsforproper handlingofthesematerials.MaterialSafety DataSheets(MSDS)regardingbrakelining materialscanbeobtainedfromyourlocal distributor.

LiningMaterialWarning

Whilecurrentmanufacturersnolongerofferasbestos brakelinings,thelong---termeffectsofsomenon---asbestosfibershavenotbeendetermined.Current OSHARegulationscoverexposurelevelstosome componentsofnon---asbestoslinings,butnotall.The followingprecautionsmustbeusedwhenhandling thesematerials.

1.AVOIDCREATINGDUST.Compressedairordry brushingmustneverbeusedforcleaningbrake assembliesortheworkarea.

2.WORKERSDOINGBRAKEWORKMUSTTAKE STEPSTOMINIMIZEEXPOSURETOAIRBORNE BRAKELININGPARTICLES.Properproceduresto reduceexposureincludeworkinginawellventilatedarea,segregationofareaswherebrakework isdone,useoflocalfilteredventilationsystemsor useofenclosedcellswithfilteredvacuums.RespiratorsapprovedbytheMineSafetyandHealthAdministration(MSHA)orNationalInstituteforOccupationalSafetyandHealth(NIOSH)shouldbe wornatalltimesduringbrakeservicing.

3.Workersmustwashbeforeeating,drinkingor smoking;showerafterworking,andshouldnot wearworkclotheshome.Workclothesshouldbe vacuumedandlaunderedseparatelywithout shaking.

4.OSHARegulationsregardingtesting,disposalof wasteandmethodsofreducingexposureforasbestosaresetforthin29CodeofFederalRegulations§1910.001.TheseRegulationsprovidevaluableinformationwhichcanbeutilizedtoreduceexposuretoairborneparticles.

5.Materialsafetydatasheetsonthisproduct,asrequiredbyOSHA,areavailablefromyourdistributor.!

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ModelCoverage

Theserviceproceduresandspecificationsinthis publicationcoverthebrakemodelslistedinTable1. Thebasicinstructionscoverall15,16.5,and18inch braketypesandsizes,unlessspecifiedotherwise.A breakdownofbrakemodelidentificationisprovidedin Figure1.

Table1BrakeModelsAndSpecifications

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Model Size Configuration Applications in. mm Shoe Spider Anchor EB---150---4L 15.0x4 381x102 Fabricated Fabricated SAP SteerAxles EB---165---5D 16.5x5 419x127 Fabricated Cast SAP SteerorDriveAxles EB---165---5L 16.5x5 419x127 Fabricated Fabricated SAP SteerorDriveAxles EB---165---6D 16.5x6 419x152 Fabricated Cast SAP SteerorDriveAxles EB---165---6L 16.5x6 419x152 Fabricated Fabricated SAP SteerorDriveAxles EB---165---7D 16.5x7 419x178 Fabricated Cast SAP SteerorDriveAxles EB---165---7F 16.5x7 419x178 Fabricated Forged SAP TrailerAxles EB---165---7L 16.5x7 419x178 Fabricated Fabricated SAP SteerorDriveAxles EB---165---8D 16.5x8.63 419x219 Fabricated Cast SAP DriveAxles EB---165---8L 16.5x8.63 419x219 Fabricated Fabricated SAP DriveAxles EB---180---7R 18.0x7 457x178 Cast HeavyCast SAP On/OffHwy.DriveAxles ES---150---4L 15.0x4 381x102 Fabricated Fabricated SAP SteerAxles ES---150---4D 15.0x4 381x102 Fabricated Cast SAP SteerAxles ES---150---6D 15.0x6 381x152 Fabricated Cast SAP SteerorDriveAxles ES---150---8D 15.0x8.63 381x219 Fabricated Cast SAP DriveAxles ES---150---8F 15.0x8.63 381x219 Fabricated Forged SAP TrailerAxles ES---165---5D 16.5x5 419x127 Fabricated Cast SAP SteerorDriveAxles ES---165---5L 16.5x5 419x127 Fabricated Fabricated SAP SteerorDriveAxles ES---165---6D 16.5x6 419x152 Fabricated Cast SAP SteerorDriveAxles ES---165---6L 16.5x6 419x152 Fabricated Fabricated SAP SteerorDriveAxles 165XLCast 16.5x6 419x152 Cast Cast DAP SteerAxleTransit ES---165---7D 16.5x7 419x178 Fabricated Cast SAP SteerorDriveAxles ES---165---7F 16.5x7 419x178 Fabricated Forged SAP TrailerAxles ES---165---7H 16.5x7 419x178 Cast HeavyCast DAP On/OffHwy.DriveAxles ES---165---7L 16.5x7 419x178 Fabricated Fabricated SAP SteerorDriveAxles ES---165---7M 16.5x7 419x178 Fabricated HeavyCast DAP On/OffHwy.DriveAxles ES---165---8L 16.5x8.63 419x219 Fabricated Fabricated SAP DriveAxles ES---165---8D 16.5x8.63 419x219 Fabricated Cast SAP DriveAxles ES---165---8F 16.5x8.63 419x219 Fabricated Forged SAP TrailerAxles ES---165---8L 16.5x8.63 419x219 Fabricated Forged SAP TrailerAxles 165XLCast 16.5x10 419x254 Cast Cast DAP DriveTransit

ES---150---8D

Service

B---StandardBrake

S---ExtendedServiceBrake

DrumDiameter

Example:150=15in(381mm)

BrakeOptions

DrumDiameter

150=15in(381mm)

165=16.5in(419mm)

180=18in(457mm)

ShoeSize

4=4in(102mm)

5=5in(127mm)

6=6in(152mm)

7=7in(178mm)

8=8.63in(219mm)

10=10in(254mm)

BrakeModelIdentification

Configuration

Example:L=FabricatedShoe FabricatedSpider SingleAnchorPin(SAP)

ShoeSize

Example:8=8.63in(219mm)

Configuration

L=FabricatedShoe/FabricatedSpider/SAP

D=FabricatedShoe/CastSpider/SAP

F=FabricatedShoe/ForgedSpider/SAP

M=FabricatedShoe/HeavyCastSpider/DAP

H=CastShoe/HeavyCastSpider/DAP

R=CastShoe/HeavyCastSpider/SAP

SAP=SingleAnchorPin

DAP=DoubleAnchorPin

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Figure1

PartsNomenclature

Generalpartsnomenclatureforbrakemodelsare identifiedinFigure2.Variationsinshoehold---down springsandguidesarealsoidentified.Specificparts

ES---150---4L

Camshaft Retainer SnapRing

Camshaft Shim Washer

SlackAdjuster InnerWasher

Camshaft Bushing Bracket Assembly

StabilizerNut

Slack Adjuster

nomenclatureforspecificbrakemodelsareprovidedin Figure3andFigure4.

ShoeHold---DownSpringandGuideVariation

OldStyle

BarrelNutShoeHold---DownSpring

StandardNut

Shoe Spacer

NewStyle

ShoeGuideandShoe Hold---DownSpring

ShoeSpacerNotRequired (MustbeRemovedforNewStyleHold---Down

Camshaft Bushing Grease Seal Dustshield

Bolt

Grease Seal DustshieldScrew

CamRoller

ShoeAssembly

*ShoeHold---DownSpringandGuideVariation

ES---150---4D

ShoeRetainer Spring Color---Blue

ShoeAssembly

ShoeReturn Spring Color---Red

Camshaft

ShoeAssembly

Spider Assembly*

ShoeReturn Spring Color---Blue

Nut

Washer

CamRoller Bolt* Shoe* Hold---Down Spring

Camshaft Shim Washer

ShoeAssembly

Camshaft

Camshaft Retainer SnapRing

SlackAdjuster

SlackAdjusterInnerWasher

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Figure2 BrakePartNomenclature,General

ES---150---6D SteerBrake

Shoe

RetainerSprings

Color---Orange

ShoeAssembly

Retainer

ShoeReturn Spring

Spider (StampedSteel)

Roller

Camshaft Shim Washer

Slack Adjuster

Camshaft Bushing

Bracket Assembly

Camshaft Bushing

Camshaft Retainer SnapRing

SlackAdjuster InnerWasher

GreaseSeal GreaseFitting

Grease Seal

CamHeadWasher Roller

ES---150---8Dand

Camshaft

ES---150---8FDrive &TrailerBrake

Shoe RetainerSprings Color---Orange

Spider (StampedSteel)

CamHeadWasher

ShoeReturn Spring Color---Red

Retainer

ShoeAssembly

Camshaft Shim Washer

Camshaft Bushing

Bracket Assembly

Roller Grease Seal

Retainer

Camshaft Bushing

Grease Seal

Retainer

Camshaft Retainer SnapRing

SlackAdjuster

SlackAdjuster InnerWasher

GreaseFitting ForgedSpider

ShoeReturn Spring Color---White

Camshaft ShoeAssembly

Figure3

BrakeModelPartNomenclature

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Roller

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EB---165---5D

EB---165---5L

EB---165---6D

EB---165---6F

EB---165---7D

EB---165---7F

EB---165---7L

CamRollerandPinfor EB---165andEB---180Brakes Two---PieceRollerandPin

Inspection

ES---165---5D

ES---165---5L

ES---165---6D

ES---165---6F

ES---165---7D

ES---165---7F

ES---165---7L

ShoeAssembly Spider (StampedSteel)

HolePlug

Camshaft ShimWashers

Shoe RetainerSprings Color---Orange

Dustshield

Dustshield Screw

Grease

Fitting

GreaseSeal

BracketStud

CamRoller andPin

Camshaft ShoeAssembly

ShoeReturnSpring

CastSpider WithHorse Collar

Shoe RetainingSprings Color---Orange

CamHeadWasher

ShoeAssembly

Lockwasher Nut

Camshaft Bushing

Camshaft Retainer SnapRing

SlackAdjuster InnerWasher

GreaseSeal

CamshaftBushing

BracketAssembly

CastSpider

Note: Castspidersaretapped andrequire4boltsandlock--washerstoattachair chamberbracketassembly.

Camshaft Shim Washer

Bracket Assembly Grease Seal Inspection HolePlug

Lockwasher Nut

Shoe

ReturnSpring Color---Red

Spider (StampedSteel)

CamHeadWasher

Camshaft

ShoeReturn Spring Color---Gray

BrakeModelPartNomenclature,Continued

Roller

Retainer

Camshaft Retainer SnapRing

SlackAdjuster

SlackAdjuster InnerWasher Camshaft Bushing

GreaseFitting

CamshaftBushing GreaseSeal

Bracket Stud Dustshield

Retainer Roller

ShoeAssembly

Forged Spider

Cast Spider

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Figure4

ModelES---165andEB---165 Interchangeability

BrakepartsfortheExtendedServiceBrake(Model ES---165)areuniqueandmustnotbeintermixedwith StandardBrakeparts(ModelEB---165)unlessotherwiseinstructed.Thesepartsconsistofthecamshaft, camshaftwasher,returnspring,camroller,andshoe/ liningassembly.Anyattempttooperatethebrakewith otherthanitsintendedpartsmayresultinunsatisfactoryperformance.

On--RoadRepair: IfacraneshouldneedOn--RoadrepairandESBrakehardwareisnotavailable,it ispossibletoretrofitthebrakewithStandardBrake partsinordertoreturnthecranetoservice.These partsconsistoftheStandardshoe/liningassembly, camroller,pin,andreturnspring.Theretainingsprings andcamshaftwithcamwasherwillworkinthissituationanddonotneedtobereplaced.

EBRollerandESCAMInterchangeability

EBRollerandESCamInterchangeability.TheEBRollerandtheESCamarecompatibleandcanbeusedtogether.Figure6illustratestheproperfitofanEBRoller toanESCam.Asshown,thecontactpatternisattwo pointsandthetwopartswillfunctionsatisfactorilywith thisfit.

Note:TheESRollerandEBCamarenotcompatible andshouldnotbeusedtogether.

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EBRollerESCam Normal Contact Pattern

Figure6 EBRollerAndESCamContactPattern

Brakemodelpartsidentificationforshoes,return springs,spiders,andcamshaftsareidentifiedin Figure7.

AllEB--165Models

Shoe withTab Shoe withoutTab

Note: Shoewithtabcannotbe usedonlightweightbrakes

DoubleAnchorPin

DoubleAnchorPin WithCamRoller andAnchorPin Bushings

ShoewithSpring AttachingLugs

Shoewithout SpringAttaching Lugs

AllEB--165Models

SingleAnchorPin

Color--CodedByApplication

BlueES---150---4L/EB---150---4L

WhiteES---150---8D,8F

RedUsewithHigh---Mount Shoes(AllEB---165)

BlackUsewithLow---Mount Shoes(AllEB---165)

GreyES---165---5D,5L,6D,6L 7D,7L,7F,8D,8L,8F

YellowES---165---7M

OrangeES---165---7H

GreenEB---180---7R

RedES---150---6D ES---165---5D,5L,6D,6L,7D,7L

PartsIdentification

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Figure7 ES--165--7D,L,F ES--150--D,FES/EB--150--4LES--165--D,L,F

OldNew

ES--165--7M ES--165--7H EB--180--7R

HighAndLowMountShoesShoeReturnSpring

31/2inch (88.9mm) 4inch (101.6mm) High---Mount Shoe Low---Mount Shoe

BrakeSpiders

LightweightStampedSpider

SingleAnchorPin

SpiderPartNo. Location

AirChamber

AirChamber BracketFlange

Shapefor StampedSpider

CastSpider

DoubleAnchorPin

AirChamber

BracketFlange

Shapefor CastSpider

SpiderPartNo. Location

CastSpider

SingleAnchorPin

BracketFlange

Shapefor CastSpider

SpiderPartNo. Location

ReducedEnvelopeSteerBrake CastSpider

SingleAnchorPin

SpiderPartNo. Location

AirChamber

BracketFlange

Shapefor CastSpider

StampedSpiderES/EB--150--4L

SpiderPartNo. Location

Camshafts

CamHeadforEB---165and EB---180Brakes

AirChamber BracketFlange

Shapefor ES/EB---150---4L

ReducedEnvelopeDriveBrake CastSpider

SingleAnchorPin

AirChamber

BracketFlange

Shapefor CastSpider SpiderPartNo. Location

CamHeadforES---165and ES---150ReducedEnvelopeBrakes

CamshaftPartNo. Location

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1---3/8in (35mm)

PartsIdentification,Continued 1---1/8in (29mm)

Figure8