5.Inspect drum band brake lining for oil, grease and glazing. If drum band brake lining is
6.Measure thickness of drum band brake lining. If drum brake band linings are less than 0.062 inch (2 mm) thick anywhere along edges replace brake bands (128) as a set.
7.Inspect cylinder bores. Minor scratches in bore lining may be repaired by lightly honing to remove. Refer to tolerances listed below for acceptable clearances. Replace liner if deep scratches or gouges are apparent. Measure inside diameter of liner. If measurement is greater than 4.764 inches (121 mm) replace liner. ‘Ring Gap’ may also be used to determine wear; place compression ring into liner, using a piston, push ring until approximately half way in liner and measure ‘Gap’
— 0.003 inch (0.076 mm) is normal; replace rings, or liner, if ‘Gap’ exceeds 0.020 inch (0.51 mm).
Repair
Actual repairs are limited to removal of small burrs and other minor surface imperfections from gears and shafts. Use a fine stone or emery cloth for this work.
1.Worn or damaged parts must be replaced. Refer to the applicable parts listing for specific replacement parts information.
2.Inspect all remaining parts for evidence of damage. Replace or repair any part which is in questionable condition. Cost of the part is often minor in comparison with cost of redoing job.
3.Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings.
4.Examine all gear teeth carefully, and remove nicks or burrs.
5.Polish edges of all shaft shoulders to remove small nicks which may have been caused during handling.
6.Remove all nicks and burrs caused by lockwashers.
Assembly
General instructions
•Use all new gaskets and seals.
•Replace worn parts.
•Assemble parts using match marks attached during disassembly. Compare replacement parts with originals to identify installation alignments.
•Lubricate all internal parts with rust and oxidation inhibiting lubricant, ISO VG 100 (SAE 30W).
K5C2 Control Valve Assembly
Refer to Dwg. MHP2036 on page 50.
Reverse Valve Assembly
1.Insert reverse valve (943) into bushing (944) with ball slot oriented UP, approximately
2.Insert bushing (944) and reverse valve (943) into valve housing (917) from exhaust flange side, ensuring that groove in bushing is aligned with pin (945).
3.Insert ball (916) onto reverse valve platform. With finger, push ball (916) in housing until ball hits end of reverse valve.
4.Holding ball (916) in position on reverse valve platform, rotate reverse valve from neutral position to approximately 45 degrees in either direction. Ball will ‘walk’ up side of reverse valve platform and move in ball hole in bushing.
NOTICE
•Do not rotate reverse valve past a 90 degree position, it may result in the ball (916) falling in motor.
5.Slowly push reverse valve, while still in the 45 degree position, the rest of the way in housing until flush with surface. From other side of valve rotate reverse valve back to neutral position, ball should be seated in ball slot at that time.
6.Lubricate ‘O’ ring (942) and place it in groove in exhaust flange (955).
7.Secure exhaust flange (955) to valve housing with capscrews
(901)and washers (902).
8.Insert ‘O’ ring (941) into seal bracket (939). Lubricate ‘O’ ring (942) and place into groove in seal bracket.
9.Place seal bracket over end of reverse valve. Using finger pressure, press until seal is seated on reverse valve and seal bracket is seated on valve housing. Secure with washers
(924)and capscrews (925) and (938).
Pilot Valve Assembly
NOTICE
•For easier installation it is recommended to use IR pilot valve tool (920). This must be purchased separately.
1.Install pilot valve assembly (910).
2.Apply thread sealant Loctite 567® to pilot valve assembly (910), place pilot valve assembly into valve housing. Use a large flat tipped screw driver to engage slots in pilot seat and tighten until pilot assembly is 1/8 in. (3.175 mm) from housing bore.
3.Insert plug (912) and tighten.
Piston Assembly
1.Lubricate and install ‘O’ rings (921) and (923) on piston (922).
2.Insert assembled piston into valve housing (917) from handle side.
3.Secure with gasket (918), piston cover (919), washers (902) and capscrews (901).
4.Place poppet seal (907) into poppet cap (906). Place this assembly into valve housing and seat on piston (922).
5.Place spring (905) over this assembly.
6.Secure with gasket (904), poppet cover (903), washers (902) and capscrews (901).
Handle Assembly
1.Place spring (937) over reverse valve handle end in seal bracket.
NOTICE
•Spring (937) will have to be ‘Cocked’ over stud in seal bracket. This will ensure handle returns to neutral.
32 | MHD56037 - Edition 5 |
