PAGE 14
240 REV.980615
SERVICE INSTRUCTIONS CONTINUED
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove the eight hex head capscrews, item 821, with lockwashers, item 823, from the motor adaptor, item
800. Since the brake springs, item 752, apply pressure against the inside of the motor adaptor, it is
recommended that the hex capscrews are unscrewed, one turn at a time, until the spring pressure has been
released. The complete motor assembly, including the motor adaptor, can now be removed from the brake
housing assembly.
2) Remove and discard three O-rings, item 801, and O-ring, item 707. (O-rings, item 801, seal the pressure transfer
hole for the automatic brake release and are situated on the flange of the brake housing.)
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
1) After the motor assembly has been removed, all parts of the brake assembly are accessible. Remove 10 brake
springs, item 752. Thoroughly examine springs for damage and measure overall length. Overall spring length
should be 2.27 inch. If any spring measures less than 2.21 inch, replace all springs as a set.
2) Pull the motor drive shaft, item 730, and complete brake hub assembly from the brake housing.
3) Disassemble brake hub assembly by removing circlip, item 719, from motor drive shaft. Remove motor drive
shaft from brake hub, item 720. Remove sprag clutch aligners, items 722 and 724, and sprag clutch, item 723,
from brake hub.
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE MOTOR
DRIVESHAFT, SPRAG CLUTCH AND BRAKE HUB AS A SET.
4) Thoroughly inspect motor drive shaft, item 730, and brake hub, item 720, particularly the surfaces where the
sprag clutch, item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag
clutch and motor drive shaft as a set.
5) Pull the brake piston, item 750, out of the brake housing using two 5/8-11NC bolts screwed into the two puller
holes in the piston and discard O-rings, item 751 and item 753.
6) Thoroughly examine the inner bores of the brake housing and the outer diameters of the brake piston for scoring
caused by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery
cloth.
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE THE
FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION
PLATES. PERFORM THOROUGH INSPECTION AND, IF NECESSARY,
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
7) Remove six friction plates, item 715, and seven divider plates, item 713, and inspect for damage or wear. Plates
should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates should
be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
DANGER
DANGER
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