DANA 53R-300 Service Manual Download Page 1

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Allied Systems Form #80-790

Summary of Contents for 53R-300

Page 1: ...Allied Systems Form 80 790 ...

Page 2: ...y 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 re...

Page 3: ...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 A...

Page 4: ...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 ...

Page 5: ...rain 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 ...

Page 6: ...e 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 ...

Page 7: ...ure in hub Inspect the internal hub bearings Replace as required See bearing heating and freezing page for installation tips 15 16 Install a secure lifting device on the wheel Remove wheel assembly using hoist and lifting device or safe equivalent 17 18 Remove face seal from hub Remove hub seal 5 ...

Page 8: ... cup Replace as required 21 22 Hub Reaasembly 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 ...

Page 9: ...l 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 ...

Page 10: ...sure 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 ...

Page 11: ...ith stand while installing internal gear 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 help with hub alignment 9 ...

Page 12: ... 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 ...

Page 13: ... 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 ...

Page 14: ...ssembly 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 ...

Page 15: ...61 Install fill drain plug Tighten to 30 35 lbf ft 41 47 Nm 13 ...

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Page 64: ...d portion with the bolts over the spindle Back the bolts out far enough they do not contact the cylinder face 5 Install spindle nut and tighten securely against compression tool 6 Tighten the four 4 compression tool bolts against the compression tool cylinder This will hold the springs in position while removing the brake cover and brake discs WARNING Outer brake housing cover is under 72 000 lbs ...

Page 65: ... sealing ring See Cleaning and Inspection 14 Position a new brake housing to spindle O ring on brake housing Install brake housing on axle spindle studs with brake bleeder hole located at the top Use caution as not to damage O ring Position washers on studs and install nuts Tighten nuts to specified torque See Torque Chart 15 Remove wire from one compound spring set inner and outer at a time and i...

Page 66: ...nd outer seals D To facilitate installing the piston in the brake cover a simple installation tool can be made A drawing of the tool is on page Three 3 of these tools are needed E The three 3 steel blocks with a hole in them are used with three 3 brake cover bolts washers and three 3 5 8 11 NC nuts The bolts come through the cover approximately 120 apart The piston is positioned in the piston groo...

Page 67: ...ue See torque chart 32 When all cover bolts are tightened to specified torque install the two 2 warning tags and capscrews Tighten capscrews to specified torque See torque chart 33 Carefully and evenly loosen bolts in compression tool When bolts are away from compression cylinder remove spindle nut Remove compression tool and cylinder from spindle and brake Install and adjust wheel end assembly No...

Page 68: ...roughly cleaned and mating surfaces are free from nicks burrs and other damage Check all parts carefully for evidence of cracks or conditions which could cause leaks or failures Piston and Housing Seals Replacing seals is more economical if done when unit is disassembled rather than performing a premature overhaul to replace these parts at a later date Further loss of lubricant through a worn seal...

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Page 71: ... is rotated Record the maximum rolling torque figure observed while the hub is being rotated This figure will be the No Load rolling torque 6 The acceptable value for axles using LCB liquid cooled brakes is up to 200 lbf ft 27 Nm other brake types 25 100 34 136 Nm NOTE The specifications given are for axles using new parts For service on axles with used parts the procedure is the same except the m...

Page 72: ...pressure specified for the particular brake being used or inaccurate rolling torque readings can result Adjustment Chart Brake Type Bearing Preload LCB Posi Stop 30 80 lbf ft 41 108 Nm Over No Load None Drum Dry Disc 20 40 lbf ft 27 54 Nm Over No Load ...

Page 73: ...ssure lubricant applications Normal Oil Change Intervals Oil change intervals for mineral based lubricants in normal environmental and duty cycle conditions is 1000 hours in all off highway applications and 10 000 miles in on highway applications Severe or sustained high operating temperature or very dusty atmospheric conditions will result in accelerated deterioration or contamination Judgement m...

Page 74: ...als IMPORTANT NEW BOLTS ARE HIGHLY RECOMMENDED FOR EACH REPAIR REBUILD DO NOT LUBRICATE THREADS DO NOT USE LOCTITE DO NOT CLEAN CHASE THREADS WITH A TAP Use only solvent and compressed air T TE EC CH HN NI IC CA AL L S SE ER RV VI IC CE E B BU UL LL LE ET TI IN N OFF HIGHWAY PRODUCTS NO TSB 340 Mo Yr 08 08 241394 240594 241103 SPINDLE BOLTS Tighten new bolts in a circular pattern to 2508 2712 Nm 1...

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DANA 53R-300, Service Manual

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