DANA 53R-300 User manual

Allied Systems Form #80-790

FOREWORD
This manual has been prepared to provide the customer and the maintenance personnel with
information and instructions on the maintenance and repair of the Spicer Off Highway Products.
Extreme care has been exercised in the design and selection of materials and manufacturing of these
units. The slight outlay in personal attention and cost required to provide regular and proper
lubrication and inspection at stated intervals, and such adjustments as may be indicated will be
reimbursed many times in low cost operation and trouble free service.
In order to become familiar with the various parts of the product, it’s principle of operation,
troubleshooting, and adjustments. It is urged that the mechanics study the instructions in this
manual carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only Spicer Off Highway Products
approved parts as listed in the applicable parts manual should be used. Use of “will fit” or non-
approved parts may endanger proper operation and performance of the equipment. Spicer Off
Highway products does not warrant repair or replacement parts, nor failures resulting from the use
of parts which are not supplied or approved by Spicer Off Highway Products. Important: Always
furnish the distributor with the serial and model number when ordering parts.
CAUTION
To reduce the chance of personal injury and/or property damage, the following
instructions must be observed.
Proper service and repair are important to the safety of the service technician and the safe, reliable
operation of the machine. If replacement parts are required the part must be replaced with one of
the same part number or with an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended in this manual are effective methods of performing service and
repair. Some of these procedures require the use of tools specifically designed for the purpose.
Accordingly, anyone who intends to use a replacement parts service procedure or tool, which is not
recommended by SOHPD, must first determine that neither his safety nor the safe operation of the
machine will be jeopardized by the replacement part, service procedure or tool selected.
It is important to note that this manual contains various ‘Cautions’ and ‘Notices’ that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the unit or render it unsafe. It is also
important that these ‘Cautions’ and ‘Notices’ are not exhaustive, because it is impossible to warn of
all the possible hazardous consequences that might result from failure to following these instructions.
1

Table of Contents
1. Forward and Caution
2. Table of Contents
Chapter 1 - Wheel Hub
3. Hub Disassembly
6. Hub Reassembly
8. Hub Installation
10. Bearing Preload
11. Planetary Installation
Chapter 2 - 13150 & 16150 Posi-Stop Brake
14. Technical Description
15. Brake – Exploded View
16. Part Identification
17. Brake – Cross Section
18. Brake – Functional Description and Application
19. Brake Disassembly
21. Cleaning and Inspection
22. Brake Reassembly
24. Brake Lubrication, External Cooling, and Face Seal Break-in
25. Face Seal Rebuilding Instructions
26. Face Seal Installation Instructions
27. Piston Installation Diagram and Installation Tool Drawing
28. Brake Friction Disc Lining Wear Check Procedure
29. Brake Lifting Tool Drawing
30. Brake Pressure Check Procedure
Chapter 3 - 24100 & 26100 (LCB) Liquid Cooled Brake
31. Technical Description
32. Brake – Exploded View
33. Part Identification
34. Brake Cross Section and Slack Adjuster Setting Procedure
35. Brake Disassembly
37. Brake Cleaning and Inspection and Reassembly
40. Brake Lubrication, External Cooling, and Testing Procedure
41. Wheel Hub Seal Tool Drawing and Face Seal Break-in Period
42. Face Seal Rebuilding Instructions
43. Face Seal Installation Instructions
2

Chapter 4 - 24200 & 26200 (LCB) Liquid Cooled Brake
44. Recommended Actuation and Cooling Fluids
45. Brake Disassembly
50. Brake Reassembly
61. Hydraulic Pressure Test
Chapter 5 - 25150 Posi-Stop Brake
62. Disassembly and Reassembly
66. Cleaning and Inspection
67. Spring Compression Tool Drawing
68. Piston Removal and Installation Tool Drawings
Chapter 6 – Tech/Assembly Information
69. Wheel Bearing Preload
70. Recommended Lubricants
72.Spindle Capscrew Installation and Torque
2a

2
CHAPTER 1
HUB DISASSEMBLY
1
Remove drain/fill plug, drain fluid as required. Remove capscrews.
3 4
Insert hook or other secure lifting device into planet
flange.
Tighten pusher screws to separate flange from
housing.
5 6
Carefully remove planet assembly. Remove 0-ring from planet.
3

7 8
Remove sun gear.
Pull axle shaft out until sun gear extends past
housing.
9 10
Remove lock plate bolts. Remove lock plate.Remove axle shaft.
11 12
Support wheel end with adjustable stand. Carefully
slide internal gear out of hub as shown.
Remove spindle nut.
4

13 14
Carefully insert hook into one of the internal gear
hub holes as shown. Insure hook is secure in
hub.
Inspect the internal hub bearings. Replace as
required. See bearing heating and freezing
p
a
g
e for installation ti
p
s.
15 16
Install a secure lifting device on the wheel.
Remove wheel assembly using hoist and lifting
device or safe e
q
uivalent.
17 18
Remove face seal from hub. Remove hub seal.
5

19 20
Remove face seal from brake housing.
Remove hub seal and bearing. Inspect bearing
cone and cup. Replace as required.
21 22 Hub Reaasembl
y
Lubricate hub bearing and cup. Install
bearing.
See sub-assembly section for
plantary disassembly and
reassembly.
Clean, inspect and replace
components as required.
23 24
Apply sealer to seal bore.
Apply sealer to seal case, spread evenly around
case o.d.
6

25 26
Install face seal on installation tool.
Install hub seal using proper driver.
27 28
Carefully install install face seal.
Position seal for installation. Lubricate seal and seal
bore with denatured alcohol or soapy water before
installation. DO NOT USE OIL!!
29 30
NOTE!
It will be necessary to release
the brake apply springs before
installing the wheel assembly or
setting bearing preload.
See figure 31
Repeat process for hub.
7

31 32
Ali
g
n brake plate teeth.
Apply 1500 psi [103 bar] hydraulic pressure
using equipment with the proper pressure rating
for the task.
33 34
Remove any dirt or contaminants from seal
faces.
Lubricate the seal faces with clean oil.
NOTE: Excessive amounts of oil may give the
impression of a seal leak after unit is put into
service.
36 Hub Installation
35
Using hoist, install hub assembly on spindle.
Lubricate the hub seal.
8

37 38
4039
Carefully work hub splines into brake plate teeth.
Work hub fully onto spindle and through brake
plates. See arrow for reference.
NOTE: Support hub with stand while installing
internal
g
ear hub.
Install internal gear hub in wheel assembly.
Lubricate internal hub bearing with oil and rotate
several times. Lubricate hub and spindle splines.
41 42
Slide internal hub onto spindle.
Carefully align internal hub splines on spindle. Align
oil holes as shown, see arrows. Use adjustable
stand to hel
p
with hub ali
g
nment.
9

43 44
Lubricate spindle threads with anti-seize. Apply anti-seize to the spindle nut contact
face and install.
45 Bearin
g
Preload
46
Note: It is imperative that the
hubs be rotated during the
bearing tightening and pre-loading
process to insure the bearings are
not damaged and accurate
readings are obtained.
Hook a strap onto a wheel stud as shown and
wrap around hub.
47 48
Using a hoist connected to strap rotate the hub
while while running spindle nut down with impact
gun. Do not exceed 1200 lbf/ft [1627 Nm].
Torque, rotate and shock the hub assembly
as described on the Bearing Preload page
69.
10

.
49 50
Shock hub as described in preload procedure.
Rolling torque can be measured
using a strap and scale as shown or
by using a torque wrench and
adapter bar which spans the
diameter of the hub, attaching to
the planetary bolt holes.
51 52
Install lock plate and align holes as described.
Attach scale and measure rolling torque as
described in preload procedure.
54 Planetary Installation 53
Apply Loctite 262 or equivelant to lock plate
screws. Tighten to 25-28 lbf/ft [34-38 Nm].
Install axle shaft and sun gear.
11

55 56
58
6059
57
Slide assembly into differential splines.
Lubricate o-ring with grease, install in planet
housing o-ring groove
Install planetary assembly on sun gear. Do not
allow axle shaft to support weight of planetary
assembly.
Align scallops in planetary assembly and hub
as shown by arrows, mate the two
components.
Tighten capscrews to 300-330 lbf/ft
[407-447 Nm]
Apply Loctite 262 or equivelant to planetary
capscrews. Be sure to install pusher screws
before installing capscrews and washers.
12

61
Install fill/drain plug. Tighten to
30
-
35 lbf/ft [41
-
47 Nm]
13