Description: Detailed procedure on removing old bushing and installing new Brake Bushing Replacement Kit 10447

Transcription

1 Procedure: BRAKE BUSHING REPLACEMENT PROCEDURE Product: Document #: Rev: Page: MODEL 7000, 7000A, & 8000 GYRO of 14 Description: Detailed procedure on removing old bushing and installing new Brake Bushing Replacement Kit PURPOSE: This service bulletin describes how to remove old brake bushing and install new bushing. The replacement bushing is the same in all gyros noted, but the procedure to get accessibility to bushings is different between gyro types. TOOLS REQUIRED Hydraulic Brake Service Kit Brake Bushing Service tool Kit M7, M7A, M8 Brake Bushing Replacement Kit M7, M7A, M8 Brake Pin and Rod End Replacement Kit Internal Retainer Ring Pliers S.K. pin extractor tool Brake Bushing Insert Tool Hammer/mallet 13/16 wrench Wrenches for upper Gimble Bearing Housing 3/4 bolts, Socket Size 1-1/8, torque to 200 ft-lbs 1/8 Allen wrench, (for gimble angle sensor cover) Wire ties Self-amalgamating tap Grease ADDITIONAL DOCUMENTS REQUIRED Brake Bleeding Gimbal Angle Sensor Replacement and Calibration PARTS REQUIRED M7, M7A, M8 Brake Pin and Rod End Replacement Kit Item Part No. Description Qty Comments Brake Bushing - 1" long 2 Installed in rod end Brake Bushing - 5/8" long 4 Installed in gimbal shaft Flat Washer, 0.860" OD x 0.260" ID,.050"-0.060" Thick 2 Installed in gimbal shaft Retaining Ring,.875, Stainless Steel 2 Installed in gimbal shaft Flat Washer, 3/4 Delrin 4 Between rod ends and gimbal shaft Cover, Brake Pin 2 Used on gimbal shaft Grease 1 Used in gimbal shaft Superglue 1 Used to hold delrin washers. (if needed)

2 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 2 of 14 Additional Parts If Needed: M7, M7A, M8 Brake Pin and Rod End Replacement Kit Item Part No. Description Qty Comments Rod End 2 Installed on cylinder Brake Crank Pin 2 Installed in gimbal shaft Thread Locker, Loctite #243, 0.34 oz. (blue) 1 Apply to male and female threads on cyl rod and rod end CAUTION: Hydraulic brake circuit must be depressurized following Service Bulletin before starting this procedure. Step 1, DEPRESSURIZE BRAKE SYSTEM: 1. Must have 24 Volts (DC) on to the control box 2. Go to the Service page on the display by hitting "Menu" 3. When on the Service page, Press the "Down" button" till the "Brake" is high lighted 4. Press "Menu" to get into the Brake page, the press "Up" or "Down" to open the brake. 5. When this is done, depressurize the brake system following Service Bulletin using hydraulic brake service kit After system is depressurized, close brake manifold needle value and remove supply hose assembly. STEP 2, REMOVE GIMBAL BEARING HOUSING 1. Remove gimbal angle sensor by removing three button head screws using a 1/8 allen wrench. Remove screws 2. Cut the safety wire on the Gimbal Bearing Housing Bolts

3 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 3 of Then remove the 3/4 dia. bolts with the 1-1/8 socket, (Caution: bolts are torqued to 200 ft./lb.) 4. Remove gimbal bearing housing from foundation. Start by prying with a small tip screwdriver on both corners between frame and gimbal bearing housing as shown. Then use a bigger screwdriver to pry evenly on both sides to remove gimbal housing. Step 3, Removing the Cylinder Rods from the Rod Ends: 1. With brake still open, push the gyro back so the top brake cylinder rod is fully retracted. 2. Remove the outside brake solenoid plug by loosening the screw in the center of plug and lifting off pins, see photo below (this will lock the upper brake cylinder) Upper brake cylinder 3. Using the 13/16 wrench, loosen and remove the upper cylinder rod from the rod end. 4. Then pull the gyro to the front, until the lower brake cylinder is fully retracted.

4 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 4 of Unplug the inside brake solenoid on the front of the brake manifold (this will lock the lower brake cylinder) Lower brake cylinder 6. Using the 13/16 wrench, to loosen and remove the cylinder rod from the rod end. Step 4, Removing the Rod Ends from the Gimbal Shaft: 1. Remove upper and lower plastic covers, retaining rings and washers from in front of brake crank pin. ( Use the Internal Retainer Ring Pliers) 2. Using the S.K. pin extractor tool, pull the upper Brake Crank Pin out from gimbal shaft.

5 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 5 of To remove the lower pin you must pull the gyro forward so the pin is accessible. Note: Depending on what model you are working on you will have to move the control box and / or drive box so they don t interfere with the top of gyro. M7000 model does not need extra clearance, because both boxes are remote mounted. M7000A you will have to remove three of the four ¼ inch bolts and loosen the fourth that supports the control box, so the top of the gyro clears the box. M8000 you will have to move both control box and drive box enough the clear the top of the gyro. Note: Remove 3 bolts and loosen the bolt closest to saddle, so you can pivot the box away from gyro.

6 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 6 of 14 Step 5, Removing the old Bushings in the Gimbal Shaft: 1. To remove the outside bushing, use the Brake Bushing Insertion Tool to drive it thru to the center cut out. 2. To remove the inner bushing, use the old rod end pin and add grease on the end of the pin or fill the bushing half way with grease. 3. Drive the pin into the bushing with a punch to drive out the bushing. (grease should push out bushing) 4. If the bushing is worn and the grease dose not push the bushing out, you can use a small screwdriver to break old bushing apart. ( Be very careful not to scar the inside bore) 5. Remove all the grease from the inner bore before installing new bushings.

7 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 7 of 14 Step 6, Installing New bushings in Upper and Lower Bores of Gimbal Shaft and Rod Ends: 1. Install the gimbal shaft bushing (P/N: /8 long) starting with the inside bushing first, use the brake bushing insertion tool to drive the bushing flush with the outside face. FLUSH 2. Use the bushing tool to drive the outside bushing into place, make sure the bushing is flush on the inside of the slot. FLUSH 3. Drive in the rod end bushing flush into rod end (P/N: long).

8 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 8 of 14 Step 7. Install Rod Ends Into Gimbal Shaft 1. Install brake crank pin (P/N: 10306) into front bore so it sticks out enough to slide the first Delrin flat washer (P/N: 60156) on pin. (Threaded hole in pin must be facing out) 2. Slide the crank pin through rod end far enough to slide the second Delrin washer on to the pin.

9 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 9 of Drive crank pin into the gimbal shaft until it is flush with outer brake bushing. 4..Apply a small amount of grease to the end of the pin and install flat washer and retaining ring. 5. Remove any excess adhesive from old cover on the gimbal shaft with alcohol wipe and install cover. 6. Pivot both rod ends to assure they move freely.

10 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 10 of 14 Step 8. Thread the Brake Cylinders into Rod End 1. Use alcohol wipe to clean threads on both rod end and brake cylinder. 2. Apply four drops of Loctite 243 on both internal and external threads when installing brake cylinder rod into rod end. Caution: Failure to apply Loctite to both threads may allow rod end to loosen and cause damage to gyro. 3. Install lower brake cylinder first. (Take special care when aligning threads) The male and female threads must be perfectly in line before threading the brake cylinder rod into rod end. Note: The Brake cylinder rod and rod end thread is ¾-16 NF. a. You can use a rag under the lower brake cylinder to help support it during alignment. b. Use a 13/16 inch wrench to turn cylinder rod. c. Take care when starting threads, if the threads get tight STOP AND BACK OFF THREADS AND CHECK ALIGNMENT before starting again.

11 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 11 of After the cylinder rod is threaded all the way into the rod end, tap 13/16 wrench with rubber mallet to make sure it is tight. Lower brake cylinder 5. Make sure brake is still open, then reinstall inside solenoid plug and tighten center screw with small Phillips screwdriver. (plug closest to gyro) 6. Pull gyro back to engage upper brake cylinder into rod end. 7. Repeat procedure 1 thru 4 to engage upper brake cylinder to rod end. 8. Reinstall outside solenoid plug and tighten center screw with small Phillips screwdriver.

12 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 12 of 14 Upper brake cylinder Step 9 Install Gimbal Bearing Housing. 1. When installing gimbal bearing housing apply silicone around each bolt hole before installing the gimbal bearing housing. Then seal the entire mating joints as shown. 2. Apply anti-seize to the threads of all the ¾ bolts and silicone to the washer before inserting into housing.

13 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 13 of Then torque the bolts to 200 ft. /lb. (Apply caulk around seam of housing. 1. Wire- tie all bolts so they can t loosen. 2. Remount gimbal angle sensor with three button screws and check calibration following. Service Bulletin Gimbal angle sensor replacement and calibration 3. Reposition both drive box and control box with ¼ inch bolts. Step 10 Recharge Brake System Pressurize the brake system following Service Bulletin 90025Brake Bleeding using hydraulic brake service kit ECN No. REVISION DESCRIPTION OF CHANGES DATE APPROVED 1 INITIAL RELEASE

14 BRAKE BUSHING REPLACEMENT PROCEDURE 078 REV 14 of 14 REVISION HISTORY SEAKEEPER, INC PECAN COURT, SUITE 151, CALIFORNIA, MARYLAND, 20619, U.S.A PHONE: FAX: