SAHR Brake Disassembly Assembly — 3-09.3-14 ery ‘Milas Copco Atlas Copco Wagner Inc. mime | PO £0 20307 + Potarc Oregon + 27220-0807 USA SAHR* Brake (Spring-Apply, Hydraulic Release) Disassembly/Assembly Manual 476805 4LAISGEThis book is intended to be used in conjunc- tion with the maintenance and service manual of the axle model on your vehicle. Unless oth- erwise stated, all instruction in the axle’s man- ual are to be followed during disassembly and assembly of the axle unit, differential and carri- er assembly, planet carrier assembly, and No- Spin differential assembly (if required). Only the axle manual’s brake section changes. This book will tell you which procedures to follow regarding the brake assembly. SAHR Brake Service Manual WARNING: The procedures described here must be followed exactly. Failure to do so may result in personal injury. High internal spring tensions are basic to the SAHR brake’s design. This makes improper disassembly of the brake unit very dangerous. Have all nec- essary tools available and be familiar with the procedures before starting the disassembly. DISASSEMBLY CAUTION! The front cover and backing plate must be “backed out” slowly to relieve inner spring tension. If these steps are not followed precisely, personal injury may result! NOTE: The pictures in this manual illustrate the disassembly/assembly procedures with the brake unit dismounted from the axle. If you are preforming these procedures with the brake assembly still mounted on the axle, make certain to exercise care in keeping all parts as clean as possible to avoid contamina- tion. STEP 4 NOTE: The front cover is under spring pres- sure for approximately the first inch of bolt travel unless pressure (1500 psi) is applied to release the brake. If pressure is applied to the brake (by using a portapower, for example), you can simply loosen and remove all the bolts. Otherwise: Back-out the bolts from the front cover plate by loosening each bolt 1/2 to 1 tum ata time ina criss-cross pattern until all bolts are re- moved. Then lift off the front cover plate. page 2SAHR Brake Service Manual STEP 2 Remove quad sealing ring from the hcusing. STEP 3 Remove disks from the brake housing page 3SAHR Brake Service Manual STEP 4 Flip the brake assembly over. CAUTION! This step will release the spring force, so pro- ceed with care. STEP 5 Begin by removing every other bolt. Then slowly release the backing plate by loosening the remaining bolts 1/2 to 1 turn ata time ina criss-cross pattern Make certain to criss-cross when loosening the bolts to minimize stress on the backing plate. ca ; 1 & Continue slowly loosening the bolts 1/2 to 1 turn at a time until all but three or four equally spaced bolts are removed. These bol's will hold the unit together when you flip it over. page 4SAHR Brake Service Manual STEPS Once you've flipped the unit over, remove the remaining bolts and lift the housing off the springs and backing plate. STEP 7 Remove springs from the brake housing page 5SAHR Brake Service Manual STEP 8 Remove the O-ring from the backing plate. STEP 9 Remove the port O-rings from the brake hous- ing, page 6‘SAHR Brake Service Manual STEP 10 Tap the piston from the housing with a rubber mallet. Separate the piston from the housing. STEP 11 Remove outer piston seal & expander ring from the piston. page 7SAHR Brake Service Manual STEP 12 Remove inner piston seal and expander ring from the housing, CLEANING AND INSPECTION CLEANING Clean all parts thoroughly using a solvent. Parts should be immersed in cleaning fluid and moved up and down slowly un- til all old lubricant and foreign matter is dissolved and parts are throughly cleaned INSPECTION Make a careful and thorough inspection of all parts. You can avoid costly failures at a later date by identifying and replacing all parts showing wear or fatique. Carefully inspect all piston seal surfaces, grooves, edges of grooves, as well as housing bore and outer diameter of piston Housing, Covers, etc. Make sure that all housings, covers, and bearing caps are thoroughly cleaned and that mating surfaces are free of nicks or burrs. Check for cracks or other conditioxs which could re- sult in oil leaks or failure. Piston and Hou: 19 Seals You should always use new Wagner replacement seals when rebuilding the SAHR brake. Handle all sealing members care- fully. Cutting, nicking, or overstretching can result in prema- ture failure. page 8SAHR Brake Service Manual ASSEMBLY STEP 1 Install expander ring and outer piston seal in the piston. Do not overstretch or cut the rings. STEP 2 Install expander ring and inner piston seal in the brake housing. Here's a diagram of how the back-up ring and expander should fit into the piston and housing grooves. page 9SAHR Brake Service Manual STEP 3 Insert the piston into the brake housing. Use a press of C-clamps to install the piston evenly and to prevent seal damage. The piston must enter the housing evenly. STEP 4 Clean all holes in the backing plate. Page 10SAHR Brake Service Manual STEPS Insert O-ring onto backing plate. STEP 6 Insert springs into the backing plate. There are two sizes of springs. Install so that the tops are even. page 11SAHR Brake Service Manual STEP 7 Lower housing & piston assembly onto back- ing plate. Be sure to index the housing to the backing plate so the ports and dowel holes all ine up. STEPS Insert and partial tighten three or four bolts through the backing plate into the housing, Evenly space these bolts to distribute the load as the brake unit is being turned over. page 12SAHR Brake Service Manual STEPS Turn the assembly over. STEP 10 Install O-rings into the port grooves. page 13SAHR Brake Service Manual STEP 11 Install all mounting bolts with loctite 262 CRITICAL! Slowly tighten the backing plate onto the housing by turning each bolt 1/2 to 1 turn in a criss-crossing pattern. Do not use an impact wrench. Just before the backing plate contacts the housing, install roll pin(s) thru backing plate into mating holes in the housing Continue tightening until the backing plate is snug against the brake housing, STEP 12 Torque the bolts to 300-330 ft./Ibs page 14SAHR Brake Service Manual STEP 13 Finish installing roll pins. Then flip the assembly over STEP 14 Install stationary and friction disks from the brake housing. CAUTION! Be certain that a stationary disk is placed against the piston first. A friction disk against the piston will damage the piston. page 15‘SAHR Brake Service Manual STEP 15 Insert quad sealing ring into the housing, STEP 16 NOTE: To properly secure the front plate to the housing, either pressurize the brake to release it and simply install all bolts, or tighten bolts in a criss-cross pattern 1/2 to 1 turn ata time. Set the front plate back on the housing, and in- sert and tighten the bolts. Torque the bolts to 300-330 ft.lbs. page 16SAHR Brake Service Manual BRAKE COMPONENTS IM 4. Roll Pin 2. Capscrew 3. Oring 4. Spacer Ring 5. Plug 8. Spring 7. Spring 8, Inner Seal Assy 9, Outer Seal Assy 40. Oving 11, Washer 12 Backing Plato 18. Piston 14. Housing Brake 45 Bleed Valve 16. Capscrew 17. KitBrake: 191 Friction Dise 20, Reaction Dise 21, Quad Sealing Ring DRAIN PoRT 22. Washer SAE #6 23. Cover Plate 24. Nut SECTION A-A BLEED PORT COOLING OUT PORT SAE #10 BRAKE RELEASE PORT ny SAE 46 BRAKE RELEASE PORT. SAE #6 NOTE 3: Lubricate threads of spindle hardware with loctite COOLING IN PORT 262 & torque to 600 ft-lbs. SAE #8 page 17