GROVE Published 10-21-2010, Control# 198-04 9-17
5540F/YB5515 SERVICE MANUAL
5. Remove the bolts and nuts used to fasten the brake
mounting bracket to the crane. Remove the parking
brake assembly.
6. Separate the mounting bracket 31 from the brake
assembly.
7. Clamp the brake in a vice with soft jaws with the cover 3
in a vertical position.
NOTE: Clamping should be done on sides of the brake, not
on machined surfaces.
8. Using a sharp bladed tool, carefully remove two seals 28
from housing 26. Note the direction the seals were
installed.
9. Loosen but do not remove four capscrews 1. Loosen
screws evenly in the order of A, B, C and D Figure 9-29
until spring pre-load is released.
10. Remove capscrews 1 Figure 9-28, lockwashers 2, cover
3 and gasket 23. Using a thin blade, remove seal 4 from
cover 3.
11. Remove belleville springs 5 and if present, washer 6.
When removing the belleville springs take note of the
stacking sequence.
12. Remove piston 9 from housing 26 bore. Remove o-ring
11 and backup ring 10 from piston. Push rod 12 should
also come out with piston 9.
13. Remove piston 15 from housing 26 bore. Remove o-
rings 13 and 16 and backup rings 14 and 17 from piston
15.
14. Remove lining and piston assembly 22 from housing 26
bore. Remove o-rings 18 from the lining and piston
assembly.
15. Lubricate all rubber components in clean hydraulic oil.
Use the same type as used in th
e hydraulic system.
Keep The Linings Free
Of Oil, Grease And Solvents.
16. Clean all parts and housing bore thoroughly with a
suitable solvent and then coat them with clean hydraulic
oil of the same type used in the hydraulic system. Keep
all parts free of contaminants, dirt and debris.
NOTE: Coat the surfaces Figure 9-28 with a Lithium Base,
E.P. No. 2 bearing grease or equivalent.
17. Install new o-rings 18 on lining and piston assembly 22
and insert the assembly into housing 26 bore.
18. Carefully install two new seals 28 in housing 26. Be sure
to install the seals the same direction as they were
removed.
19. Install new o-rings 13 and 16 and new backup rings 14
and 17 on piston 15. Be sure they are installed in the
correct order.
20. Install piston 15 into housing 26 bore. Be sure piston is
installed in the correct direction. Be careful not to pinch
the o-ring on the inlet ports.
21. Install new backup ring 10 and new o-ring 11 on piston 9.
Be sure they are installed in the proper order. Install
push rod 12 in bore of piston 9. Install piston into
housing 26 bore.
22. Fully lubricate the threads of adjusting screw 7 and lock
nut 8 and install into cover 3.
NOTE: Completely lubricate belleville springs with a light
coat of Lithium Base, E.P. No. 2 bearing grease.
23. Install washer 6, if used, and belleville springs 5 over
end of piston 9. Follow the stacking sequence
Figure 9-30.
24. Install new seal 4 in cover of 3. Be sure inside of cover is
coated with grease.
25. Install new gasket 23, cover 3, lockwashers 2 and
capscrews
1. T
ighten the screws evenly in the order of
A, B, C and
D Figure 9-29. When installed, tighten each
screw to a torque of 22-27 lb-ft (29,8 - 36,6 Nm).
26. Assemble the brake assembly onto the mounting
bracket 31.
27. Install the parking brake assembly onto the frame of the
crane.
28. Attach the hydraulic hose.
29. Adjust the lining clearance as described on page 9-6.
30. Open the accumulator needle valve and then bleed air
from the system as described on page 9-5.
NOTE: The needle valve must be in the open position for
the brake system to operate properly. If it is not
open, the charging pump will cycle every time the
brake pedal is depressed and if the crane’s engine
stops there may not be enough pressure to stop
the crane.
WARNING
Cap (3) is under spring pressure. Use care when
removing the cap to prevent personal injury.
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