INSTALLATION & MAINTENANCE
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1 INSTALLATION & MAINTENANCE 1441 Wolf Creek Trail, P.O. Box 305 Sharon Center, OH PTT Table of Contents Safety... 2 Description... 3 Pre-Installation Check... 6 Maintenance Instructions... 9 Disassembly Instructions... 9 Reassembly Instructions M 1
2 Always follow the operating instructions in this publication. This ensures trouble-free operation and fulfillment of any rights to claim warranty. Read these instructions before starting any installation or maintenance. These instructions contain important information about servicing and maintaining your Hydraulic Service/Spring Applied Brake. Always keep them in a safe and clean location. The following notes appear throughout the publication. Please take a moment to review and understand them. Electrical hazard Possible consequences: Severe or fatal injuries Hazardous situation Possible consequences: Severe or fatal injuries Important information Possible consequences: Damage to components or voiding of warranty Safety Proper installation, maintenance and operation procedures must be followed due to the possible danger to person(s) or property from accidents that may result from the use of machinery. PT Tech will not be responsible for personal injury resulting from careless maintenance and working practices. Safety devices and guards that may be specified in safety codes should be provided. These devices are not provided nor are the responsibility of PT Tech. Rotating equipment is potentially dangerous and can cause serious injury or death. Care should be taken by machine manufacturers and operators to ensure adequate safety guards and devices are installed and all applicable safety codes are adhered to. Do not operate the equipment if these guards and/or devices have been removed or bypassed. To prevent accidental starting of the engine or electronic damage when performing maintenance, disconnect battery cables from battery and remove ignition key from switch. Proper lockout/tagout procedures should always be closely followed. PT Tech has made provisions for attaching lifting bolts. The holes provided are of adequate size and quantity to safely lift the product itself. These lifting points must not be used to lift anything other than the PT Tech product. Lifting excessive loads at these points could result in property damage or personal injury. Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing. Bolts should not be long enough to bottom out in lifting hole. Personal injury can result from fluid under pressure. Care must be taken to ensure fluids are contained during inspections, maintenance, adjusting or repair of the equipment. All pressurized hydraulic components should be properly guarded to prevent personal injury M 2
3 Description The A+ brake (PTT-381-0) is a hydraulically applied service and spring-applied parking brake. Cooling fluid is pumped thru the shaft for superior thermal capacity. Benefits of the A+ Brake: Item A+ Comments Disc Pack 5 Discs More discs=more torque More discs=longer life Friction Material Proprietary Greater thermal fade resistance More consistent coefficient of friction Cooling Thru Shaft Hydraulic fluid forced through discs to remove significantly more heat Housing Seal O-ring Greater elasticity-less chance of leakage Shaft Seal / Less chance of damaging the shaft surface Availability Stock Delivery when you need it PRODUCT SPECIFICATION Service Brake Torque Service Brake Pressure Max. Back Pressure Max. Nominal Parking Brake Torque (new) Nominal Parking Brake Torque (worn) Parking Brake Release Pressure Min. Parking Brake Release Pressure Max. Recommended Fluid Weight Weight Recommended Cooling Flow 1,000 lb-in per 100 psi 1,400 psi 15 psi 20,000 lb-in 15,000 lb-in 350 psi 2,200 psi 30 wt. 113 lbs 3-5 gpm M 3
4 Fluid recommendations for the cooling circuit: Conoco PowerTrans MobilFluid 424 CAT TDTO SAE 30 Shell Donax TD Castrol Agri Trans Plus Sinclair 303 TH Sinclair TO-4/C-4 Chevron Synthetic All-Weather THF In general: any universal tractor transmission fluid which has wet brake static friction suppressants that meets John Deere J20C & J20D, Allison C-4, or CAT TO-2/TO-4 specifications. The use of hydraulic fluid or any other non-recommended oil may result in abnormal brake functions such as, chatter, squeal, harsh stops, pulsating, and/or uneven braking. ATTENTION: DO NOT use Water Glycol based fluids in the brake for cooling or piston actuation as severe damage will result. ATTENTION: using any fluid other than the recommended oil may significantly affect the performance and function of the product M 4
5 STORAGE REQUIREMENTS The service and parking hydraulic circuit for all PTT brakes is actuated and tested for leaks during assembly. They are then drained and put into packaging. If the brake must be stored, the following is recommended: Store the brakes sealed tightly in their original bags, in a temperature controlled environment. If the brakes are to be stored for longer than 1 year, it is recommended that every year the brake be removed from packaging and the service / parking circuits be actuated. This procedure will ensure the parts stay lubricated and coated with oil M 5
6 Pre-Installation Check Upon removing the brake from the shipping crate, check the following Items. Check the splined shaft. It should be free of any marks that could affect the installation (figure 1). Figure 1 Check the wear indicator. The wear indicator should be protruding by 1/8 (figure 2). Figure M 6
7 INSTALLATION INSTRUCTIONS Insert the splined shaft (Figure 3) into the gearbox and align the mounting bolt holes. Make sure the service brake bleeder port and the parking brake bleeder port valves are facing up (Figure 4). Connect the keeper plate to the shaft taped holes. Figure 3 TAPPED HOLES Figure 4 Insert mounting bolts and tighten progressively and evenly to 110 lb-ft (Figure 5). Figure M 7
8 Connect the hydraulic coolant line from the pump to the brake s inlet (Figure 6). Connect the other hydraulic coolant line to the exit port (Figure 6). Figure 6 Connect the Parking Brake hydraulic actuation line to the PARKING BRAKE INLET port (Figure 7). Connect the Service Brake hydraulic actuation line to the SERVICE BRAKE INLET (Figure 7). Figure M 8
9 Maintenance Instructions Spare Parts Kits Part No. Item Spare Parts Kits Qty PTT Spring Kit 1 PTT Wear Indicator Kit 1 PTT Compression Plate Kit 1 PTT Hardware Kit 1 PTT Disc Pack FP & SP Kit 1 PTT Bearing & Seal Repair Kit 1 PTT Shaft 1 The A+ brake (PTT-381-0) wear indicator should be checked weekly to verify it is protruding. If the brake is worn out (wear indicator is flush), refer to disassembly and re-assembly instructions of this manual. Disassembly Instructions The following service instructions should be followed to ensure proper performance of the brake. a. When the wear indicator is flush the brake s friction disc pack needs to be replaced (figure 8). Figure 8 Wear Indicator M 9
10 Instructions for Dis-assembly b. Inspect the pilot diameter for any problems. It should be 5.999/5.998 (figure 9) Figure 9 Pilot dia. c. Remove the four bolts that connect the spring and the piston housings (figure 10). Figure 10 d. Remove the piston housing. The shaft and disc pack will come out with it (figure 11). Figure M 10
11 e.use a rubber mallet to remove the shaft and disc pack (figure12). Figure 12 f. Remove the remaining friction end plate, dowel pins, and springs (figure13). Figure 13 g. Progressively and evenly, remove the bolts that retain the compression plate (figure 14). Remove the compression plate and springs. Compression plate has spring force behind it M 11
12 Figure 14 h. Press bearing off of the shaft (figure15). Figure M 12
13 Reassembly Instructions Service Brake Piston a. Install Polypak seal with its internal rubber O-ring facing (up) towards the three Tetraseals. Do this on each of the four Service Brake Pistons (Figure 16 &17). Figure 16 Figure 17 O-ring facing (up) towards Tetraseals M 13
14 Parking Brake Piston (see Figure 22) Sub-title: Piston OD Seal b. Install backup ring into outer groove with the curved side of the backup ring facing away from the piston fingers (figure 18). Figure 18 Piston fingers Sub-title: Piston ID Seal c. Install backup ring into inner groove with the curved side of the backup ring facing away from the piston fingers (figure 19). Figure M 14
15 d. Install O-rings into the outside and the inside diameter grooves of the piston (Figure 20 & 21). The O-rings should be next to the curved side of backup ring. Figure 20 Figure M 15
16 Figure 22 e. Press bearing off of the shaft (figure23). Figure 23 f. Install the four Service Brake pistons, tetraseals facing down (figure 17). g. Install the twelve red springs into the spring housing (figure 24). Figure M 16
17 h. There are four dowel pins with flats and two dowel pins without flats (figure 25). Figure 25 Flats Rounded ends i. Install the two dowel pins (without flats) into the positions as shown in figure 26. Note the rounded ends of the dowel pins should be facing up. Figure M 17
18 j. Install the four dowel pins with flats into spring housing. Be sure flats face each other (figure 27). Note the rounded ends of the dowel pins should be facing up. Figure 27 Rounded ends Flats k. Install the compression plate and four bolts with Never-Seez applied to them. Tighten in an even and progressive manner to a torque of 45 lb-ft (figure 28). Figure 28 4 dowels with flats M 18
19 l. Install first friction end plate with notched tabs going around single dowel pins. Friction material should be facing up (figure 29). Figure 29 m. Install 2 blue springs around the same two single dowel pins (figure 30) Figure M 19
20 n.insert shaft with new bearing (figure 31). Be careful, shaft should be lightly pressed into position and seated properly. Figure 31 o.install disc pack starting with a separator plate (figure 32), then a friction plate (figure 33). Repeat until all separator plates and friction plates are used. The friction plates have tabs that go between the dowel pins with flat surfaces. Figure M 20
21 Figure 33 p.install the top friction end plate with notched tabs going around the single dowel pins. The friction material must be face down (figure 34). The friction plate has tabs that go between the dowel pins with flat surfaces. Figure M 21
22 q. New shaft seal should be pressed into place from the inner surface of the piston housing. The seal s lip must be facing up (figure 35). Figure 35 r.lightly oil the O-rings and piston-housing cavity (figure 36). Figure M 22
23 s. Install piston housing with the deepest notches (between piston fingers) aligned with the double dowel pin holes that are drilled into the piston housing (figure 37), and align the smallest notched finger with the brake port (figure 38). Figure 37 Figure M 23
24 t.stake the large o ring with grease. Install o ring into groove in piston housing (figure 39). Figure 39 u.lube seal and shaft with oil. Install piston housing over shaft. v.align holes in the piston housing with dowel pins in the spring housing. Squeeze the two housings together. You should feel the compression of the springs (figure 40 & 41). Figure M 24
25 Figure 41 w.partially install bearing onto shaft and into housing making sure to align shaft center before clamping housings together (figure 42). Figure M 25
26 x.insert bolts and tighten progressively and evenly to 110 lb-ft (figure 43). Figure 43 y.finish installing the bearing and retain with the snap ring (figure 44). Figure M 26
27 z.install the wear indicator pin (figure 45). Figure 45 Testing: Air test main cavity to 25 PSI and hold for 5 minutes. Pressure test service side at 2,000 PSI and hold for 5 minutes. Pressure test parking release at 2,000 PSI and hold for 5 minutes, and ensure the shaft is able to easily rotate by hand. No leakage allowed M 27
28 M 28
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