E. Place each thrust plate over needle bearings (3) so
that the pocket seal is toward end cover (19) or (24)
Tap the thrust plate into position with a soft hammer
until approximately 1/32 inch (0.8 mm) clearance is
left between the thrust plate and end cover. Check
pocket seal (1) to be sure that it is still in place in the
F. Insert a large pocket seal (2) into each of the four
slots in the thrust plates. Be sure to push the seals all
the way into the slots so that the hidden end is in
contact with the needle bearing races. Then tap the
thrust plates into position against the end covers.
Trim the exposed ends of the pocket seals with a
Figure 6B-5. Adjusting Brake Piston Clearance
the outside groove of the bushing. Lubricate O-rings
(9) and (11) with grease and install one O-ring (9) in
Be sure to trim the exposed ends of the pocket seals
the inside groove of the short bushing so that both
square and flush with the thrust plate.
backup washers are together at the thick wall side of
the groove. Install O-ring (11) in the outside groove
G. Install backup washer (29) in the outside groove of
of the short bushing so that it is at the same end of
shaft end cover (24). Lubricate O-ring (28) with,
the bushing as O-ring (9).
grease and install it next to the backup washer so that
it is in the groove nearest gear housing (21). Give the
Install one backup washer (12) and two backup wash-
O-ring and backup washer an additional coat of
ers (10) on long bushing (22). Lubricate O-rings (9)
and (11) and install them on the long bushing so that
the backup washers are together and both O-rings are
H. Install backup washer (26) in the inside groove in
toward the large end of the bushing. Give all O-rings
brake piston (27). Lubricate O-ring (25), and install it
an additional coat of grease.
next to the backup washer so that it is on the side of
the backup washer nearest the large bore of the brake
B. Place port end cover (19) and shaft end cover (24) on
piston. Give the O-ring and backup washer an addi-
a workbench with the bearing bores facing up. Install
tional coat of grease.
the short bushing in the center bore of port end cover
(19) so that the backup washers enter before the O-
I. Install pins (23) in brake piston (27). Assemble the
brake piston to the shaft end cover, taking care that
backup washers (26) and (29) do not extrude and get
Install the long bushing in the center bore of shaft
pinched between the mating surfaces of the brake
end cover (24) so that the small diameter end of the
piston and shaft end cover.
bushing enters first.
J. Install motor shaft (7) in the shaft end cover so that
Press each bushing in until it seats on the bottom of
the splined end of the shaft passes through the long
its bore. Be sure that all O-rings are installed toward
bushing first. Place the assembly on parallel bars so
the gear side of the end covers.
that it does not rest on the motor shaft.
C. Check that the bearing bores in the end covers are
K. Lubricate O-rings (18) and install one in the grooves
clean, and install needle bearings (3) in the bearing
on each side of gear housing (21). Give the O-rings an
bores. Press the bearings into the bores until the
additional coat of grease.
bearings are seated at the bottom of the bores.
L. Place the gear housing over the thrust plate on shaft
D. Place a small amount of heavy grease in the center
end cover (24) so that the housing and shaft end
slot of each thrust plate (17), and insert a small pock-
cover are concentric, and pins (23) enter the holes in
et seal (1) in the center slot.