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Disc Brake Manual - BHEL

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336WCBD3 Water Cooled Tensioner - Installation, Operation and

Maintenance Manual
DISCLAIMER
This manual contains information on the operation and maintenance of the BHEL supplied
equipment. The copyright in all the documents, drawings etc. in relation to the BHEL supplied
equipment vests in and is the property of BHEL. The contents hereof should not be used or
shared by the receiver with any third party without express written permission of BHEL.
The contents of this manual must be read as a whole before starting operation and
maintenance of the supplied equipment. If any of the content(s) of the manual seems unclear
or incomplete, please contact BHEL before starting operation and maintenance of the said
equipment.
It is an essential pre-requisite for the satisfactory operation and maintenance that the operating
and maintenance personnel are fully familiar with the design and that the said personnel have
received thorough training in operating and maintaining the machine/unit/equipment. It is
further essential for safe operation of the machine/unit/equipment that personnel have read,
understood and followed the safety instructions contained in the manual.
In case of any conflict between terms and conditions of this manual and the contract
specifications, drawings, instruction sheets or any other contract related documents, the
contract conditions/documents shall prevail. The contract specific conditions/documents shall
apply in priority.
BHEL offers no warranty, guarantee or representation regarding the completeness of any
information contained in this manual or any of the amendments made thereto. BHEL does not
extend warranty of any kind, including, without limitation, any warranty of design,
merchantability or fitness for a particular purpose.
BHEL does not assume responsibility of any errors or omissions in the information or
documents which are referenced by or linked to this manual. The entire risk as to the results
and performance obtained from using the information is assumed by the user.
BHEL in no event shall be liable to the user or any third party for any incidental, consequential,
indirect, special, or exemplary damages, including, without limitation, loss of business, loss of
profits, business interruption, loss of business information or any pecuniary loss, arising out
of, in connection with, or relating to the use of the information contained in or referenced by
this manual, even if BHEL has been advised of the possibility of such damages.
This manual and the information contained therein may include technical, other inaccuracies
or typographical errors. BHEL periodically changes the information herein which will be
incorporated into new additions/amendments to the manual. BHEL reserves the right to add,
delete, amend or modify the information contained in the manual from time to time in the form
of circulars, letters, notes etc. for better operation and safety of the machine/unit/equipment.
The said additions or amendments are meant for improvement /better operations of the
machine/unit/equipment and such amendments shall not give any right to claim any
compensation or damages under any circumstances.
BHEL shall in no way be responsible (i) in case the machine/unit/equipment mal-functions due
to any non-compliance of the instructions contained in this manual (ii) in case of operation of
the machine/unit/equipment beyond the rate limits (iii) in case of operation of the machine and
equipment in conditions different from the prescribed conditions of the manual.
Table of Contents
1.0 INTRODUCTION...................................................................................................................... 6
1.1 Description................................................................................................................................ 6
1.2 How It Works............................................................................................................................. 6
2.0 INSTALLATION....................................................................................................................... 7
2.1 Preparation and Alignment....................................................................................................... 7
2.2 Mounting................................................................................................................................... 8
2.3 Air System................................................................................................................................. 9
2.4 Coolant System......................................................................................................................... 9
3.0 OPERATION.......................................................................................................................... 13
3.1 Conditions of Operation.......................................................................................................... 13
3.2 Friction Lining Wear-In............................................................................................................ 13
3.3 Pressure and Speed Limits..................................................................................................... 13
3.4 Periodic Maintenance............................................................................................................. 14
4.0 MAINTENANCE..................................................................................................................... 15
4.1 Wear Limits............................................................................................................................. 15
4.2 Wear Adjustment.................................................................................................................... 15
4.3 Disassembly Procedures........................................................................................................ 19
4.4 Friction Material Replacement (Size 36WCBD3)..................................................................... 20
4.5 Wear Plate Replacement........................................................................................................ 20
4.6 Dual Cylinder Seal Replacement............................................................................................ 23
4.7 Bushing Replacement............................................................................................................. 25
4.8 Assembly Procedures............................................................................................................. 26
4.9 External Corrosion Protection................................................................................................. 28
5.0 ORDERING INFORMATION / TECHNICAL ASSISTANCE................................................... 28
5.1 Equipment Reference............................................................................................................. 28
6.0 PARTS ................................................................................................................................... 29
6.1 Basic Assemblies.................................................................................................................... 29
Index of Tables & Figures
Index of Tables
Table No. Table Title Page No.
1 Item Descriptions for Fig. 1......................................................................................................... 5
2 Alignment Requirements............................................................................................................. 7
3 'A' Dimensions on Fig 1............................................................................................................... 8
4 Fastener Description and Assembly Torque............................................................................... 9
5 Air Inlet Ports............................................................................................................................... 9
6 Coolant Supply Data ................................................................................................................ 10
7 Coolant Pressures..................................................................................................................... 11
8 No. of Cooling Water Hoses Required...................................................................................... 12
9 Percentage of Flow Required for Each Cooling Section Outlet................................................ 12
10 Maximum Outlet Coolant Temperatures................................................................................. 12
11 Maximum Disc Speeds........................................................................................................... 13
12 Wear Limits for WCBD3 Components.................................................................................... 15
13 Wear Measurements 'X', 'Y' and 'Z' Gaps............................................................................... 16
14 Wear Plate Fastener Torque................................................................................................... 23
15 Hydraulic Coolant (inlet & outlet Port Sizes)........................................................................... 23
16 Tensioner Weight.................................................................................................................... 24
17 Reaction Hole & Bushing Size NEW and Spring Free Height................................................. 25

Index of Figures
Figure No. Figure Title Page No.
1 WCBD3 Cross Section and Item Numbers................................................................................. 5
2 Proper vs Improper Alignment.................................................................................................... 7
3 Grease Requirement.................................................................................................................. 8
4 ORB (O-ring boss) Port Illustration........................................................................................... 10
5 Manifold Design for Hydraulic Supply Drain............................................................................. 11
6 Illustration of Dust Wear Grooves............................................................................................. 16
7 WCBD3 Single Disc ................................................................................................................. 17
8 WCBD3 Two Disc..................................................................................................................... 17
9 WCBD3 Triple Disc................................................................................................................... 17
10 WCBD3 Quad Disc................................................................................................................. 17
11 Removing Clamp Tube & Support Beam Wear Spacers ....................................................... 18
12 Location of Wear Spacers....................................................................................................... 19
13 Start Location of Gasket Tape................................................................................................ 22
14-A Paint Mask Limit-Do Not Paint............................................................................................ 22
14-B Placement of Gasket Tape.................................................................................................. 22
15 Overlap of Gasket Tape.......................................................................................................... 22
16 Wear Plate Bolt Tightening Sequence.................................................................................... 23
17 Lip Seal Installation - Dual Piston........................................................................................... 24
18 Bushing Replacement............................................................................................................. 26
19 Placement of Studs & Tubes................................................................................................... 27
336WCBD3 DISC BRAKE ASSY WITH GUARDS
WCBD3 Tensioners

Table 1
Item Description

Item Description

1 Mounting Flange
6 Stud
7 Friction Disc Assembly
12 Clamp Tube
13 Pressure Plate
17 Flat Washer
18 Self Locking Nut
19 Cylinder
21 Seal (inner)
23 Seal (outer)
28 Gear
29 Clamp Tube Wear Spacer
30 Reaction Plate
33 Dual Piston
34 Release Spring
105 Pipe Plug
114 Seal (Intermediate)
138 Support Beam
139 Support Beam Wear Spacer
140 Spring Spacer
WCBD3 Tensioners
1.0 INTRODUCTION

Throughout this manual there are a number of HAZARD Warnings that must be read and
adhered to in order to prevent possible personal injury and/ or damage to equipment. Three
signal words “Danger”, "Warning", and "Caution" are used to indicate the severity of a
hazard, and are preceded by the safety alert symbol

Danger
Denotes the most serious hazard, and is used when serious injury or death WILL result
from misuse or failure to follow specific instructions.

Warning
Used when serious injury or death MAY result from misuse or failure to follow specific
instructions..

Caution
Used when injury or product/ equipment damage may result from misuse or failure to follow
specific instructions.

It is the responsibility and duty of all personnel involved in the installation, operation, and
maintenance of the equipment on which this device is used to fully understand the Danger,
the Warning and the Caution procedures by which hazards are to be avoided.

1.1 Description

1.1.1 The 336WCBD3 water cooled tensioner is for E1400 draw works brake application, it can
be used in place of eddy current brake and it is not recommended to use this as parking
brake.

1.1.2 The WCBD3 water cooled tensioner is designed for constant tension applications and is
designed with a dual piston and cylinder that is also referred to as the “power head
assembly”. It is exceptionally well suited for high inertia stopping, rapid heat dissipation.
Corrosion resistant materials and coatings are used in all assemblies to provide durable
corrosion protection. The design of the WCBD3 tensioner permits mid-shaft or end-shaft
mounting and can handle high horsepower for higher RPM. The addition of the support
beam design adds strength and rigidity to the assembly and eliminates the need for
outboard support. The WCBD3 wear spacer design and location allow for easy wear
adjustment of models with multiple friction disc assemblies. The rugged construction
ensures long, trouble free service.

1.1.3 The 36WCBD3 tensioner is available in one basic size and can be supplied as single, dual,
triple or quadruple disc assemblies. The model number identifies the number of discs and
the nominal disc diameter. For example, 336WCBD3 indicates three 36” diameter discs.
1.1.4 When size, such as 36WCBD3, is referred to in this manual, it means that the information
given applies to all models using the 36” diameter water-cooled disc assembly; i.e.,
336WCBD3, 436WCBD3, etc.

1.1.5 Tensioners can be cooled with either closed loop or open loop cooling systems. Tensioners
can be cooled with closed loop systems that utilize a water/ ethylene glycol mix, up to a
50/50 ratio.

1.1.6 This manual includes metric equivalents usually shown in brackets (#) following the U.S.
measurement system value. Be sure to use the correct value.

1.1.7 All WCBD3 tensioners are supplied with long wearing, non-asbestos friction material.

1.2 How It Works

1.2.1 Referring to Figure 1 and Table 1, the gear (28) is mounted on the shaft which is to be
stopped and the tensioner assembly is attached to the machine frame. The WCBD3 has a
dual chambered piston/cylinder power head assembly. In the WCBD3 tensioner, air
pressure is applied to either the inner, outer, or both sets of the ports in the dual cylinder
(19), causing the dual piston (33) and pressure plate assembly (13) to move towards the
mounting flange(1), compressing the release springs (34). As the applied pressure to either
or both pressure chambers increases, the friction disc assembly (7) is clamped between
the pressure plate and mounting flange, stopping or controlling the shaft that the discs are
mounted upon. Modulation of the air pressure then controls applied torque of the tensioner.
The inner cylinder/piston pressure chambers are chamber area of the power head is
referred to as the inner piston and the outer piston small cylinder/piston and the outer
cylinder/piston chamber area is referred to as the large cylinder/ piston. Multiple disc
tensioners utilize reaction plates (30) between the friction disc assemblies. The release
springs (34) assist the disengagement and retraction of the piston (33) pressure plate (13)
and reaction plates (30). High heat dissipation is accomplished by passing coolant through
a cavity behind the copper alloy wear plates (3).

Torque transfers through the tensioner from the shaft to be controlled; through the friction
disc assembly (7), through the pressure plate (13) and reaction plates (30), through the
clamp tubes (12) and studs (6) and to the mounting flange (1) (which is attached to a rigid
surface).
WCBD3 Tensioners
Caution
The tensioner is never to be operated without the coolant supply attached and coolant
running through the unit

1.3 WCBD3 Dual Piston Design Advantages


The WCBD3 dual piston/cylinder power head offers precise tensioning control by dividing
the piston/ cylinder into small inner and large outer section sections. See Figure 1. This
provides the ability to improve fine modulation of clamping pressure on the tensioner discs
and improved control over our standard single chamber design. For very light tensioning
loads, the outer piston can be used solely, with no pressure applied to the inner piston. For
the largest tensioning loads, both pistons can be used together. If it is desirable to operate
the tensioner at maximum tensioning load and not utilize the precise tensioning feature,
the tensioner can be ordered without the intermediate piston seal (114).

2.0 INSTALLATION

Danger
Prior to installation of the WCBD3 tensioner, make sure that the machinery will remain in
a secured position. Failure to do so could result in serious personal injury or possibly death.

Warning
Only qualified maintenance personnel should install, adjust or repair these units. Faulty
workmanship will result in unreasonable exposure to hazardous conditions or personal
injury.
Caution
Read these instructions thoroughly and review until you fully understand the installation
sequence before proceeding with the work described in this section. Failure follow these
instructions will result in unreasonable exposure to hazardous conditions or personal injury.

Caution
Do not paint the clamp tubes (12), the release springs (34), as this may hinder the
engagement or disengagement of the tensioner.

Preparation and Alignment


Note: For proper operation and service life, the WCBD3 tensioner/brake must be oriented
concentric and at right angles to the shaft within the limits shown in Table 2.
Table 2
Alignment Requirements
Concentricity Perpendicularly
(Parallel, TIR) (Angular, TIR) of
of Shaft and Mounting Flange to
Size Element (Inches (mm)) Shaft* (Inches (mm))

36WCBD3 0.010 (0, 25) 0.019 (0, 48)

*Perpendicularity measured near the O.D. of the mounting flange.

Caution
Proper alignment is necessary to assure that the friction disc assemblies (7) will track
properly. Improper alignment will result in excessive wear to the friction material and mating
surfaces plus the gear and splined bore of the friction disc assemblies block and gear (28).
See Figure 2.

Figure 2

2.1.2 To aid in obtaining accurate readings, a rigid bracket should be fabricated for mounting a
dial indicator when checking alignment.

2.1.3 Bearing or machinery manufacturers may require different alignment tolerances. Use the
tightest of those recommended.

2.1.4 Refer to the appropriate catalog information (available upon request) for appropriate
envelope dimensions, mounting register diameters, mounting bolt circles and positions for
each tensioner.
2.1.5 The tensioner reaction member (such as the machine frame) should have a machined
register to allow for mounting and alignment control of the tensioner. The mounting surface
should be designed to provide full support of the face of the mounting flange (1), preventing
deflection during operation. Refer to appropriate catalog dimensional info or contact your
Airflex representative for appropriate mounting configuration details.

2.1.6 Refer to Table 3 for the setup dimension between the tensioner mounting surface and the
end of the gear (28) (dimension “A” on Figure 1). Gears should be positioned to ensure
that - when the tensioner is mounted - the disc splines will not overhang the end of the gear
when components are in both new and worn conditions. The gear is typically bored and
keyed for a resulting class FN2S interference fit for inch shafting and ISO System S7h6 for
metric shafting. Contact Airflex Application Engineering for specific recommendations.
WCBD3 Tensioners
Table 3
"A" Dimension on Figure #1 inches (mm)

Size Triple Quad

36WCBD3 2.36 (59,9) 2.36 (59,9)

2.2 Mounting

2.2.1 The WCBD3 must be mounted to a clean, rigid surface with hardened, customer supplied,
flat washers and screws of the grade, quantity and size as listed in Table 4. Mounting to a
properly aligned, rigid surface that fully supports the face of the mounting flange (1)
minimizes any deflection during operation and helps to ensure that the friction discs disc
assemblies will track properly on the copper wear plates. Within the mounting flange (1),
reaction plate (30) and pressure plate (13) assemblies.

Note: To facilitate the mounting process, the friction disc assemblies should be aligned to
the gear and centered in the tensioner. With the tensioner positioned with the mounting
flange (1) facing down, lower the gear (28) slowly and carefully into the splined bore of the
friction disc assemblies (7). Adjust the discs so that they are centered in the tensioner and
fit in the gear. Apply and maintain an air pressure of 25 psi (1.7 Bar) to the cylinder. This
will engage and hold the friction discs in position during installation. Remove the gear.

Danger
Use only the proper number and grade fasteners shown in Table 4. Use of commercial
grade (Grade 2) fasteners where Grade 8 fasteners are specified may result in failure of
the fasteners and a sudden and drastic reduction in tensioner torque.

2.2.2 Ensure that the shaft is clean and free of nicks or burrs and that the key fits properly in the
shaft and gear.

2.2.3 Apply a light coat of anti-seizing compound or 30 weight oil to the shaft. Tap the key into
the shaft keyway.

2.2.4 Heat the gear (28) uniformly to 250°F (121°C) to expand the bore and ease assembly.
Press the gear onto the shaft, making sure the dimension between the gear and tensioner
mounting surface ("A") is held at 2.36" (59.9 mm) See Figure 1 and Table 3. Allow the gear
to cool to ambient temperature after it has been properly positioned on the shaft.

Caution
Do not allow the gear temperature to exceed 350°F (176°C). Overheating the gear will
adversely affect the hardness and wear life.
Do not allow the gear temperature to exceed 350º (176º). Overheating the gear will
adversely affect the hardness and wear life.
2.2.5 Pre-fill the grease channel in the friction disc splines (if applicable) with MOLUB-ALLOY
936SF Heavy grease or equivalent as shown in Figure 3. Try to maintain the grease level
at 1/8” (3 mm) below the top of the friction disc splines as shown in Figure 3. For reference,
the recommended grease is Eaton Part Number 000153X1182.

Caution
Excessive lubricant in the grease channel and on the gear teeth may contaminate friction
disc material, resulting in erratic response or loss of torque.

Caution
The use of anti-seize or bearing greases on the gear splines may result in premature
gear and disc spline wear.

Note: Orient the tensioner to position the drain plug (105) at the 6 o’clock position. This will
guarantee the coolant outlets are at the 12 o’clock and 6 o’clock position (provided that the
tensioner is been assembled correctly).

2.2.6 Attach the mounting flange (1) to the mounting surface using the appropriate fasteners. If
applied pressure was used to help position the discs during mounting, exhaust the air
pressure prior to tightening the fasteners. Tighten the fasteners to the specified torque
value. See Table 4.
WCBD3 Tensioners
Table 4
Fastener Description and Assembly Torque,
ft.-lb. (Nm)

Item No.
& Description Specification 36WCBD3

000153x0843 Screw (xx) Size 3/8-16 NC2


000153x0844 Lock Nut (xx) Quantity *
Torque (Dry) 40 (54)

18 Self Locking Nut Size 1-3/8 - 6NC-2 Gr. 8


Torque (Lubed) 750 (1015)

Mounting Screw Size 1-8NC-2 Gr. 8


(Customer Supplied) Quantity 12
Torque (Lubed) 660 (895)
* Reference subassembly drawing 515635.
Quan 108 screw & locknut for mounting flange sub assembly
Quan 108 screw & locknut for pressure plate sub assembly
Quan 108 screw & locknut for each reaction plate sub assembly

2.2.7 WCBD3 tensioners should be covered to protect the WCBD3 from dirt, rain, overspray and
other sources of external contamination. In extreme environments the use of a sealed
enclosure with internal strip heater is recommended to prevent moisture from collecting on
the unit.

Warning
Contamination from rain, overspray, coolant, dirt, oils and grease must be avoided. Failing
to provide adequate protection against contamination may result in loss of performance
and/or damage to the tensioner.

2.3 Air System


2.3.1 Maximum allowable pressure is 150 psig (10.3 Bar).
Warning
Maximum allowable air pressure in cylinder (19) is 150 psig (10.3 Bar). Application of
pressure exceeding maximum allowable pressure may result in damage to the tensioner.

2.3.2 Use only clean, filtered air (a 40 micron filter or better is recommended) which is free of
excess moisture. Long air line runs or dips in the line that allow moisture to collect should
have drip legs with blow-down capability. Excess moisture due to temperature changes
can be removed by using an in line ambient dryer.

2.3.3 The air inlet size is shown in Table 5. Air inlets are located on the face of the cylinder (19).
Each size of 36WCBD3 tensioner has three (3) air inlet ports for the inner (smaller) piston
and three (3) air inlet ports for the outer (larger) piston. Additionally, each size 36WCBD3
has one drain hole that is to be used to purge moisture from the cylinder. See Figure 1 and
reference the drain plug (105). The outboard port next to the drain plug shall be located at
the 6 o’clock position to facilitate purging of moisture that may accumulate in the air system
or cylinder.
Table 5
Air Inlet Size
Port Thread Size

Air inlet (inboard) 3/8"-18 NPT


Air inlet (outboard) 3/4"-14 NPT
Drain Plug 3/8"-18 NPT

Note: Purging of moisture from the air lines and cylinder should be performed daily until a
frequency is determined for purging the cylinder. This is dependent upon the amount of
moisture in the air line and the ambient temperature. A petcock or other appropriate drain
valve may be installed on this port to facilitate purging. Once per day (or at appropriate
interval) each morning before operation and after extended periods of shutdown or down
time.

2.3.4 Use full size piping consistent with the control valve size. All pipes should be free of metal
chips, cutting compound and any other foreign matter. Pipe ends should be reamed after
cutting to eliminate possible restrictions or air-line contamination. For optimum air system
response, a minimum number of bends and elbows should be used. Good engineering
practices should be followed, such as, blow-down of all air piping after installation and
before connecting and operating valves and the tensioner.

2.3.5 The WCBD3 tensioner does not require lubricated air; however associated control valves
may. Consult the valve manufacturer for appropriate recommendations.

Caution
The use of lubricated air in the air supply system (if required) will require the addition of a
‘point of use’ lubricator. Lubricated air is not required for the WCBD3 Eaton Tensioner but
once lubrication is used, lubrication will always be required in the air system. If the
lubricator is allowed to run dry then pneumatic valves and cylinders will dry out and stick
thus creating erratic operation and down-time. Good engineering design practices shall be
followed when using lubrication thus avoiding the overuse of lubrication, long airline runs
and elevation changes.

2.4 Coolant System


2.4.1 The 36WCBD3 is designed with four (4) coolant ports on in each pressure plate (13),
mounting flange (1) and reaction plate (30). Each plate has two opposing inlet ports and
two opposing outlet ports. In order to mount the 36WCBD3 with the coolant inlet and outlet
ports in the proper orientation, first locate the three pair of air supply ports on the cylinder.
One of the pairs of air supply ports has a third port which is a drain port (See Figure 1,
drain plug 105) outboard the inlet. This third port is a drain for purging water from the piston
and the system air-line Reference Figure 1, plug (105) for the drain port. Position the
36WCBD3 so that the drain port is located at the 6 o’clock position. Thus, the water coolant
outlets will be located at the 12 o’clock & 6 o’clock positions while the water coolant inlets
will be located at the 3 o’clock & 9 o’clock positions.
2.4.2 The coolant porting is designed for SAE O-ring Boss (ORB) fittings. The ORB fittings
conform to the J514 & J1926/3 specification for torque values. The O-ring Boss ports are
used for the hydraulic cooling media. Follow the fitting manufacturer’s recommendation for
the proper method of installation and tightening. The WCBD3 water cooled brake is
designed with SAE O-ring Boss (ORB) ports for the coolant inlets and outlets. These ports
utilize a straight thread and an O-ring for sealing versus the NPT tapered thread used
previously. ORB ports provide superior sealing properties and reduce the risk of damage
to the brake during fitting installation. An ORB port can be identified by the machined spot
face and a chamfer (for sealing of the O-ring). See Figure 4. Follow the fitting
manufacturer’s recommendation for the proper method of installation and tightening. The
36WCBD3 uses the SAE-20 for the ORB port size.

ORB PORT
Figure 4

2.4.3 Each inlet and outlet coolant port in each mounting flange (1), reaction plate (30) and
pressure plate (13) is designed with a ‘fixed’ orifice. The fixed orifice is designed to
proportion the flow to what is required by each component. Thus, a reaction plate that
requires a total of 100 GPM has the ports designed to pass 50 GPM per port. Alternately,
a pressure plate that requires 50 GPM has the ports designed to pass 25 GPM per port.
(The pressure plate and the mounting flange are designed for 50% of the flow of the
reaction plate). It is recommended, however, that the flow rate from each section be verified
with some type of flow metering device. It is recommended, however, that the flow rate
from each section be verified with some type of flow metering device.

2.4.4 After measuring the flow from each coolant section pressure plate (13), reaction plate (30)
and mounting flange (1) outlet port, an adjustment may be required. Thus, it is
recommended that each drain side (or return side) outlet port should be equipped with an
adjustable flow controls on each outlet hose . The flow for each size tensioner should be
balanced as shown Table 9.

2.4.5 Maximum allowable coolant pressure within the water cavity is 40 psig for size 36WCBD3
units. See Table 7 for coolant pressure limitations as measured at the inlets and outlets of
water jackets. Note that inlet Inlet pressures exceeding the maximum allowable static
pressures are only permissible under dynamic flow conditions, provided that the average
pressure between the inlet and outlet does not exceed the maximum allowable pressure
stated above. The use of an accumulator or pressure relief valve may be desirable to
reduce the effect of pressure spikes in the coolant system during operation.
Caution
High outlet pressures or surges exceeding the maximum allowable, in Table 7, may result
in damage to the tensioner.

Caution
Inlet pressures exceeding the maximum allowable average pressure are only permissible
when the outlet pressures are at or below the limits listed in Table 7.

2.4.6 The coolant supply and discharge hose, pipe and fitting sizes, along with minimum flow
rates for the tensioner rated horsepower, are listed in Table 6.

Table 6
Coolant Supply Data

Water Inlet Min Flow Min Flow Rate


and outlet Rate GPM GPM (dm3/min)
No Disc Pipe Size (dm3/min) 50% Water, 50%
of Size Thermal (Minimum 100% Ethylene Glycol
Discs inches Rating piping I.D.) Water by Vol
3 36 3000 (2237) SAE-20 J1926 ORB 300 (1134) 447 (1692)
4 36 4000 (2983) SAE-20 J1926 ORB 400 (1512) 596 (2256)

Table 7
Coolant Pressure, psi (bar)
Size Maximum Static Maximum Inlet*

36WCBD3 40 (2, 7) 40 (2, 7)

* Under Dynamic flow Conditions

Note: Above ratings for tensioning/winding type applications. For high cyclic application, consult
the factory.

2.4.7 Coolant supply connections to the tensioner should provide a parallel flow through each
coolant section of the tensioner. Series flow is not recommended as it can lead to
overheating of the tensioner.

2.4.8 Inlet and outlet coolant manifolds must be provided. Manifolds should be constructed to
allow for even flow through all ports. Individual hoses should be routed from the manifolds
to each port in the pressure plate (13), reaction plates (30) and mounting flange (1).

Caution
Do not plug any ports or plumb the cooling passages in series. Parallel arrangement of
hoses similar to that shown in Figure 5 are required for proper coolant flow.
Figure 5

WCBD3 Tensioners
2.4.9 Inlet and outlet coolant manifolds and hoses must be sized to handle the maximum flow
for each size tensioner per Table 6.

2.4.10 The number of flexible hoses required for both the inlet and outlet ports of each size
tensioner is given listed in Table 8.

Table 8
Quantity of Cooling Water Hoses Required

Tensioner
Size 136 236 336 436

No. of Inlet Hoses* 4 6 8 10

No. of Outlet Hoses* 4 6 8 10

* Hose ID shall be equal to or greater than supply & drain orifice ID.
2.4.11 Using flexible connecting hose to each tensioner coolant section will allow axial travel of
the pressure plate (13), and reaction plate (30) and mounting flange (1) during tensioner
operation without restricting the movement of the components. When determining hose
lengths, consideration should be given to movement and location of the pressure plate and
reaction plate as friction material wears. Hose lengths running between the manifolds and
the inlet or outlet ports should be equal in length, if possible. Reductions in the
recommended line diameter should be avoided to prevent excessive line pressures.

Caution
Short or excessively rigid hoses may restrict proper movement of the pressure plate (13)
and reaction plates (30).

2.4.12 Avoid the use of sharp bends and elbows that will restrict water flow. Loops and bends in
the lines may create air pockets, which substantially reduce the flow of coolant and can
contribute to overheating.

2.4.13 Coolant and coolant supply lines should be free of foreign material (a 500 micron water
filter is recommended). In the event that contaminated water is used as a coolant (not
generally recommended), use of a multi-stage filter/strainer may be desirable to avoid the
need for frequent cleaning of fine mesh filters.

2.4.14 Figure 5 illustrates a typical closed loop liquid to liquid coolant system. The heat exchanger
and temperature control would be replaced with a radiator, fan and motor in a liquid to air
system.

Note: The schematic (Figure 5) illustrates a dual disc tensioner (236WCBD3). Three
coolant ‘supply’ lines feed the ports at the 3 o’clock and 9 o’clock position. Three coolant
‘return’ lines ‘drain’ or ‘recirculate’ coolant from the ports at the 12 o’clock and 6 o’clock
position. Reference to Table 8 for the quantity of hoses required for all sizes of 36WCBD3.
Reference Refer to Table 16 9 for the percentage flow required at the outlet for all sizes of
36WCBD3. Figure 5 illustrates the supply lines & hoses and the return lines & hoses are
equal in length and flow controls are located on the return lines to balance flow.

2.4.15 The maximum coolant supply temperature at the inlet should be 100° F (38° C) or lower.
The coolant outlet temperature should not exceed the values given in Table 10. However,
in no event should there be more than a 50° F (28° C) temperature rise between inlet and
outlet. See Table 10 for maximum allowable outlet coolant temperature with various
water/ethylene glycol mixtures and other cooling media.

Caution
Temperature rise between inlet and outlet temperatures in excess of recommendation may
result in damage to the tensioner.
Table 9
Percentage of Flow Required for each Coolant
Section Outlet

Tensioner Size 336 436

Mounting Flange 12 o'clock 8% 6.25%

Mounting Flange 6 o'clock 8% 6.25%

Reaction Plate 12 o'clock 17% 12.50%

Reaction Plate 6 o'clock 17% 12.50%

Reaction Plate 12 o'clock 17% 12.50%

Reaction Plate 6 o'clock 17% 12.50%

Reaction Plate 12 o'clock 12.50%

Reaction Plate 6 o'clock 12.50%

Pressure Plate 12 o'clock 8% 6.25%

Pressure Plate 6 o'clock 8% 6.25%

Note: Each Coolant Section has two Outlets. The Outlets are located at the 12 o'clock and 6
o'clock position. Flow controls (if required) should be installed in each outlet and adjusted to
provide the percentage flow shown above.

Table 10
Maximum Outlet Coolant Temperature

Water Maximum Maximum


Ethylene Inlet Outlet Maximum Minimum
Glycol Coolant Coolant Ambient Ambient
Mixture % Temperature Temperature Temperature Temperature
Size by Volume °F (°C) °F (°C) °F (°C) °F (°C)

36WCBD3 100/0 100 (38) 150 (66) 110 (43) 0 (-18)


36WCBD3 50/50 100 (38) 170 (77) 110 (43) 0 (-18)
2.4.16 Open Loop Systems
2.4.16.1 For efficient operation of the WCBD3, an adequate supply of filtered fresh water
is required. Excessive water hardness promotes the formation of scale deposits, which in time,
will affect the service life of the WCBD3 unit. Water of high acidity or high in corrosive salts
may cause electrolytic corrosion between the dissimilar metals used in the water cavities.
Water treatment should be considered if the properties of the water exceed the following:
Equivalent calcium carbonate content hardness;
Maximum = 100 ppm.
pH value = 7.0 to 9.0

Caution
Open loop systems should be thoroughly flushed with clean fresh water after operation to
reduce the corrosive effects of contaminants on internal components.

2.4.17 Closed Loop Systems

2.4.17.1 For efficient operation of the WCBD3 in a closed loop system, ethylene glycol coolant
conforming to SAE Standard J1034 -1996 Revision should be used. For preparation of the
proper concentration of a water/ethylene glycol mixture, use make-up water which is low
in corrosive ions such as chlorides and sulfates. Recommended pH value of the water
ethylene glycol mixture is 7.5 to 10.5

3.0 OPERATION

3.1 Conditions of Operation


The following Hazard Warnings shall be followed for proper WCBD3 functioning.

Warning
Friction lining must be worn-in to achieve product torque rating. For new installations or
after repair, a minimum wear-in period for the fiction couple of four hours at 50% of the
rated horse power is recommended to achieve rated torque. Verify proper operation before
putting the product into service.

Warning
Protective means must be used to prevent oil, grease, dirt or coolant from coming into
contact with the surfaces of the friction discs (8) or the wear plates (3). Oil or grease on
these parts will significantly reduce the torque capacity of the unit. Dirt or coolant will
produce erratic torque. Do not risk personal injury of damage to the equipment.

Warning
Maximum free-wheeling speed must not exceed the speeds listed in Table 11. Exposure
to speeds in excess of these values may cause the friction discs (8) to burst and result in
extensive damage to the tensioner and/or cause personal injury.

Caution
For proper cooling of the WCBD3 tensioner, it is required that the coolant inlet and outlet
manifolds be located as close as possible to the tensioner. It is recommended that the inlet
hoses are of the same length and all outlet hoses are of the same length.
Caution
For operation in subfreezing temperatures, ethylene glycol antifreeze must be added to the
water. The antifreeze content of the mixture is critical and should not exceed 50% by
volume. Excessive amounts of antifreeze will reduce cooling capacity and can cause
cooling leakage due to overheating. Refer to Table 10 for the percentage of water/ethylene
glycol mix and the corresponding maximum outlet coolant temperature.

Caution
Maximum ambient temperature is 110°F (43°C). Minimum ambient temperature for closed
loop systems using ethylene glycol antifreeze is 0°F (-18°C). For open loop systems using
water as a coolant, the minimum ambient temperature is 45°F (7°C)

Caution
The tensioner is never to be operated without the coolant supply attached and coolant
running through the unit.

Table 11
Maximum Disc Speeds

Maximum Slip Maximum Free


Size Speeds (RPM) Wheeling Speeds (RPM)

36WCBD3 475 700

3.2 Friction Lining Wear-In

3.2.1 A minimum wear-in period for the friction couple of four hours at 50% of the rated
horsepower is recommended to achieve rated torque. Verify proper operation before
putting the product into operation.

3.3 Pressure and Speed Limits

3.3.1 Maximum applied air pressure is 150 psig (10.2 Bar).

3.3.2 Maximum coolant pressure allowable within the water cavities is 40 psig (2.75 Bar) for
36WCBD3 units. The use of an accumulator or pressure relief valve may be desirable to
reduce the effect of pressure spikes in the coolant system during operation.

Warning
Water piping elevations, restrictions in outlet piping or pressure surges may cause
pressures that exceed the maximum allowable, resulting in damage to the tensioner.

3.3.3 Maximum slip speeds and free-wheeling disc speeds are shown in Table 11.

Caution
Excessive slip speeds will result in rapid friction material wear. For good life of wear
components, the operating values in Table 11 should not be exceeded.
3.4 Periodic Maintenance

3.4.1 As the friction material wears, adjustment of the tensioner may be required to keep pistons
within the proper stroke range. See Section 4.0 for wear measurement, adjustment
procedures and component wear limits.

3.4.2 Periodically check for external air leakage in the area of the piston seals (21) (23). For
replacement, refer to procedures in Section 4.0, Maintenance.

3.4.3 Moisture that may accumulate in the cylinder can be purged. With air pressure exhausted
from the cylinder, remove the pipe plug (105) at the 6 o’clock position on the cylinder, and
apply low air pressure to assist in expelling any excess moisture. After draining the cylinder,
reinstall the pipe plug, applying a pipe thread sealant on the threads prior to installation.

Caution
Applied air pressure greater than 10 psig should not be used when draining the cylinder.
Use adequate shielding to avoid contact with direct spray from moisture being purged from
the cylinder.

3.4.4 Periodically observe the rotating discs while the tensioner is fully released. Dragging discs
may be caused by wear or contamination of the gear or disc splines, lack of spline
lubrication, disc imbalance, warped discs, or misalignment. Correct as required.

3.4.5 Pneumatic and electrical control interlocks should be periodically checked for proper
settings and operation.

3.4.6 If leakage or blockage of any water-cooled chambers suspected, a static or dynamic test
may be performed as follows:

3.4.6.1 Static Pressure Test

(a) Release the tensioner by exhausting the air pressure from the cylinder (19).

Warning
Ensure that the machinery will remain in a safe position prior to releasing the tensioner.

(b) Bleed all air from within the mounting flange (1), reaction plate (30) and pressure plate (13)
coolant cavities cavity. Air bleeding must be accomplished by running coolant through the
each cavity with the tensioner secured in its proper operating position.

Caution
Bleeding air from each coolant cavity will require isolation of the drain ports. When static
test is complete, all isolation shall be removed to maintain full flow through the system.

Warning
Removing any hoses for isolation of the supply or drain ports will require a compatible
fitting for the ORB porting. Failure to do so will damage the porting and cause leakage, a
loss of flow and possible damage to the tensioner.

Note: Avoid contaminating the friction material with coolant or water.


Warning
Contamination of the friction material could result in erratic or loss of torque.

(c) After the air has been bled from each coolant cavity, isolate the drain ports and apply
maximum allowable coolant pressure measured at the inlet to the water cavity. Maximum
allowable is 40 PSIG (2.7 bar) for size 36WCBD3. Maintain this pressure for 30 minutes.
Check for leakage at O.D. and I.D. wear plate seal areas.

3.4.6.2 Dynamic Flow Test

(a) Dynamic flow testing of the tensioner should be conducted at the required flow rate for the
rated HP dissipation and coolant quality, as given in Table 6. Inlet and outlet pressures for
the appropriate tensioner size as listed in Table 7 should not to be exceeded.

(b) There should be no restrictions on the outlet side of the tensioner to cause any back
pressure to the unit.

Table 12
Wear Limits for WCBD3 Components

Item Description Wear Limit Remarks

#3 Wear Plate Friction Wear Signature Maximum Wear for 36WCBD3 Wear will be in
is: 0.050" (1,27mm) form of even wear of
circular grooves in the
copper surface.

#8 Friction Disc Friction Material Fully Worn at Bottom of wear Brake has adjustment
groove. See Figure #5 provision See Section
Friction Material must also be replaced if 4.2
contaminated with oil or grease.

#7 Friction Disc Gear Backlash Maximum total backlash is 0.060" (1,5mm) If step is worn in gear,
Assembly (disc gear must be replaced.
Core) #28 Gear

#12 Clamp Tube Reaction Area Maximum wear is 0.015" (0,38mm) Wear will be in the form
of notch or step on the
side of tube

#13 Pressure Reaction Holes Maximum ID is 2.877" (73,07mm) Wear will be in the form
plate assembly of elongation of the
#30 Reaction original reaction hole
plate assembly diameter or enlarged
hole.

#54 Pressure Reaction Hole Bushing ID Maximum wear is 0.031" (0,80mm) Wear will be in the form
plate & Reaction of elongation of the
plate Bushing. bushing ID

#19 Cylinder Seal Area Maximum wear is 0.005" (0,13mm) Wear will be in the form
of grooves where the
seals contact the
cylinder wall

#34 Spring Spring Free Height Maximum free height is 4.130" (104,90mm) Original free height is
4.250" (107,95mm)
Springs must be
replaced in complete
sets
Coolant inlet and outlet sizes are listed in Table 15. Full size hoses and piping should be
used. Check for low flow and/or leakage at the O.D. and I.D. wear plate seal areas.

Danger
Before performing any maintenance work on the WCBD3 tensioner, make sure that the
machinery will remain in a safe position. Failure to do so could result in serious injury or
possibly death.

Warning
Only qualified maintenance personnel should install, adjust or repair the WCBD3 units.
Faulty workmanship will could result in unreasonable exposure to hazardous conditions or
personal injury.

Caution
Read these instructions thoroughly and review until you fully understand the parts
replacement steps before proceeding with the work described in this section. Failure to
follow these instructions can could result in unreasonable exposure to hazardous
conditions or personal injury.

4.0 MAINTENANCE

4.1 Wear Limits

Warning
Periodically examine the tensioner for wear of friction linings and wear plates (3). Failure
to perform this examination periodically may result in excessive wear to components,
improper operation or a significant reduction in torque, and may result in personal injury
and/or damage
to the machinery.

4.1.1 Wear limits for the WCBD3 components are shown in Table 12. If any wear limit has been
reached or exceeded, that component must be repaired or replaced.

4.2 Wear Adjustment

Warning
If a wear adjustment is not made when required, the tensioner torque may deteriorate to
the point where the equipment will not stop properly.

Determining Wear
On single disc units, the friction material must be replaced when worn to the bottom of the
groove of the friction lining (as shown on Figure 6 or any "X" or "Y" dimension (see Figure
7) exceeds the limits shown on Table 13). On multi-disc units, a wear adjustment is
required when the "X" dimension has been reached and the friction discs or "Y" or "Z"
dimension(s) (see Figure 8, Figure 9 & Figure 10) are NOT worn to their limits.

4.2.1.1 Single Disc Units Single Disc Unit Wear Adjustment


Apply approximately 25 PSIG (1.7 bar) air pressure to the cylinder to engage the tensioner.
Measure the "X" gap between the cylinder (19) and the pressure plate (13) or the gap "Y"
between the pressure plate (13) and the mounting flange (1) as shown in Figure 7. If either
gap exceeds the limits shown in Table 13, the friction discs and/or wear plates must be
inspected to ensure that the wear limits listed in Table 12 have not been exceeded.
Note: The clamp tube (12) rests on the mounting flange (1) and fits in the ID of the spring
spacer (140). and the spacer is the same diameter as the clamp tube. When measuring
between the pressure plate (13) and the mounting flange (1) it is important to measure to
the surface of the mounting flange and not the top of the washer spring spacer.

Figure 6

Table 13
36WCBD3 Wear Measurements X, Y & Z Gaps - inches (mm)

Number X-Max
of Discs X-New* (Adjustment) Z-New Z-Min Z-New Z-Min Z-New Z-Min Z-New Z-Min Y-New Y-Min

1 1.64 2.06 n/a n/a n/a n/a n/a n/a n/a n/a 2.87 2.45
(41.7) (52.3) (72.9) (62.2)

2 1.78 2.20 2.67 2.25 2.67 2.25 n/a n/a n/a n/a 2.87 2.45
(45.2) (55.9) (67.8) (57.2) (67.8) (57.2) (72.9) (62.2)

3 1.92 2.34 2.67 2.25 2.67 2.25 2.67 2.25 n/a n/a 2.87 2.45
(48.8) (59.4) (67.8) (57.2) (67.8) (57.2) (67.8) (57.2) (72.9) (62.2)

4 2.06 2.48 2.67 2.25 2.67 2.25 2.67 2.25 2.67 2.25 2.87 2.45
(52.3) (63.0) (67.8) (57.2) (67.8) (57.2) (67.8) (57.2) (67.8) (57.2) (72.9) (62.2)

*Value shown is the GAP after wear adjustment.


New or rebuilt brakes may vary slightly from 'NEW' values shown due to tolerances.
WCBD3 Tensioners

Figure 7 Figure 8

Figure 9
Figure 10

4.2.1.2 Multi-disc Units Unit Wear Adjustment


Apply approximately 25 PSIG (1.7 bar) air pressure to the cylinder (19) to engage the
tensioner. Measure the gap "X" between the cylinder (19) and the pressure plate (13) to
determine if adjustment may be required.

Measure the "Z" gap between the pressure plate (13) and the reaction plate (30), the "Y"
gap between the reaction plate (30) and the mounting flange (1), and the "Z" gap between
the reaction plates (30) as shown in Figure 8, Figure 9 and Figure 10.

Note: The clamp tube (12) rests on the mounting flange (1) and fits in the ID of the spring
spacer (140). and the spacer is the same diameter as the clamp tube. When measuring
between the reaction plate (30) and the mounting flange (1) it is important to measure to
the surface of the mounting flange and not the top of the washer spring spacer.

If the "X worn" dimension has been reached or exceeded and the "Y" or "Z" dimensions
have not reached the limits shown in Table 13 AND none of the friction discs are worn to
the bottom of the wear groove, wear adjustment is required. It is also recommended that
wear plates (3) be inspected to ensure that the wear limits listed in Table 12 have not been
exceeded.

Warning
If wear adjustment is not made, the piston may extend out of the cylinder beyond an
acceptable operating range, resulting in loss of torque and/or seal (21, 23 and/or 114)
damage.

If the "Y" or "Z" dimensions have been reached or any of the friction discs are worn to the
bottom of the wear groove, the tensioner should be taken out of service and rebuilt with
new components as required.
4.2.2 Adjustment Procedure

Wear adjustment can be conducted without full disassembly of the WCBD3 tensioner.
Wear adjustment is accomplished by the removal of support beam shims (139) and wear
spacers (29). The wear adjustment spacers are slotted to allow for easy removal with a
chisel. The support beam shims are slotted to allow bending and removal of the shim with
the aid of a pair of pliers. Refer to section 4.2.2.4.

Warning
Before performing any maintenance work on the WCBD3 unit, make sure that the
machinery will remain in a safe position. Failure to do so could result is serious injury or
possibly death.

Note: Disconnect air and water supply lines to prevent damage to the hoses and binding
of components during the adjustment procedure.

4.2.2.1 Wear spacers (29) and support beam shims (139) should must be removed in complete
sets only (one wear spacer from each stud location and one shim from each support beam
stud). Mark the spacers and shims to be removed to avoid confusion during removal.

Warning
Removal of wear spacers (29) and support beam shims (139) in quantities other than
complete sets (layers) will result in severe damage to CBD3 components during re-
assembly, and could cause the tensioner to not function properly.

4.2.2.2 Loosen the locknuts (18) evenly (ONE TURN AT A TIME) and in an alternating (cross wise)
pattern to prevent binding of the cylinder on the studs. Continue to loosen the locknuts until
the force of the release springs (34) is relieved, allowing for access to the wear spacers
(29) and support beam shims (139). See Figure 12.

GRAB SHIM HERE TO BEND AND REMOVE


SHIM USING PLIERS
Figure 11

Figure 12

Note: Refer to Figure 12. The wear spacers (29) are located between the cylinder (19)
and the clamp tube (12). The support beam shims (139) are located between the cylinder
(19) and the support beam (138).

4.2.2.3 Wear spacers (29) are slotted to allow for in-place removal. Using a narrow chisel wedged
into the slot in the wear spacer, as shown in Figure 11, pry the wear spacer until it fractures
and is clear to be removed from the stud. Support beam shims (139) are designed with a
relief slot to allow for bending and removal by using a pair of pliers to bend the beam shim
and remove it from around the stud (6) (See Figure 11). Pry one shim from its position
around a stud (6) and between the cylinder (19) and support beam (138). Repeat for the
remaining spacers and shims in the set that is to be removed (one spacer from each stud
location and one shim from each support beam stud location).
Warning
Be sure to collect all wear spacers and shims when removed. Spacers lodging in between
tensioner components could prevent the tensioner from properly engaging or releasing.

4.2.2.4 Prior to tightening the locknuts, verify that the support beams and support beam shims are
located properly over the step on the cylinder to prevent damaging them during the
tightening process. While supporting the weight of the cylinder/ piston assembly , tighten
the locknuts (18) ONE TURN AT A TIME and in a crosswise pattern, alternating, until the
cylinder is seated firmly against the clamp tubes. Torque the locknuts to the appropriate
value. See Table 4.

Warning
Damage to the cylinder or support beam shims and support beams could occur if not
positioned properly, possibly causing the tensioner to malfunction.

Caution
The locknuts (18) must be tightened gradually and evenly to prevent damage to the
tensioner components.

4.2.2.5 Reinstall any piping or covers removed prior to operating the tensioner.

4.3 Disassembly Procedures

Warning
Ensure that the machinery is and will remain in a safe position prior to loosening
fasteners or removing the tensioner.

4.3.1 Disconnect the air supply lines and water coolant lines from the tensioner.

4.3.2 Using soft slings, and rig the tensioner and slide the WCBD3 off of the gear. Avoid placing
slings or straps directly on the release springs (34). 4.3.3 Transport the tensioner to a clean
working area and position the unit on a flat surface with the mounting flange (1) facing
down.

4.3.4 If the gear (28) requires replacement, remove it from the shaft with a portable jack, using
the threaded holes in the end of the gear for puller holes. Heating may be required to ease
removal. Replace the gear and install per Section 2.2.

4.3.5 Match-mark the mounting flange (1), reaction plates (30), pressure plate (13), cylinder (19)
and support beams (138) to one another prior to disassembly to adequately show the
proper orientation of components and various ports to one another.

4.3.5 Match-mark the mounting flange (1), reaction plates (30), pressure plate (13), cylinder (19)
and support beams (138) to one another prior to disassembly to adequately show the
proper orientation of components and various ports to one another.

4.3.6 Loosen the locknuts (18) ONE TURN AT A TIME and in sequence until the release spring
(34) force is relieved.
4.3.7 Lift the cylinder and piston assembly off of the studs as an assembly. Set the assembly
aside on a clean, level area, making sure to avoid damaging the face of the piston.

4.3.8 Continue removing the remaining components if required.

4.3.9 Inspect all components using the wear limits in Table 13 12 as a reference.

4.3.10 For friction lining replacement refer to Section 4.4.

4.3.11 For wear plate replacement, refer to Section 4.5.

4.3.12 Refer to Section 4.6 to replace cylinder seals.

4.3.13 Assemble the tensioner per Section 4.8.

Caution
After replacement of friction material, a minimum wear-in period of four hours at 50% of
the rated horsepower is recommended for the friction couple to achieve rated torque.

4.4 Friction Material Replacement (Size 36WCBD3)

Note: When replacing friction material, it is recommended that the mating wear surface
be replaced to ensure good contact between the mating surfaces. See Table 12 for wear
limits. A light touch up of the wear surfaces may be performed to remove high spots or
burrs if desired but is typically not necessary.

4.4.1 Refer to Section 7.0 for the appropriate friction disc kit replacement part numbers.

Caution
Use only genuine Airflex friction material. Use of material not of Airflex origin may result in
unpredictable performance.

4.4.2 Disassemble the tensioner per Section 4.3.

4.4.3 Remove the old screws and discard. Remove the and discard the old friction material and
discard.

Note: Use of a pinpoint torch to heat the screws and soften the Loctite® will ease removal
of the screws.

4.4.4 Clean all burrs, corrosion etc. from the friction disc core or mounting surface. Chase
all tapped holes with a tap to clean threads and remove any residual Loctite.

4.4.5 Position the friction material to align the screw holes. Install several screws loosely at
several of the outermost screw hole locations to properly align the friction discs or blocks.

4.4.6 When installing screws in friction blocks, install and tighten the screws from the center most
position in the block, then progress towards the outer edges of the block.
4.4.7 Following the above pattern, install one screw at a time by applying Loctite® #262 to the
screw threads and tightening the screw to the proper torque value. Tighten screws to 15
ft-lb (20 Nm). Install and torque each remaining screw immediately after the application of
Loctite®, then proceed to the next screw.

Note: Be sure to remove, apply Loctite® and properly tighten the initial screws used for
alignment of the friction disc or block.

Warning
Loctite® may cure prior to properly tightening the screw if not tightened to the proper torque
value immediately after installation.

Caution
Use only Airflex-supplied screws.

Caution
Loctite® #262 must be shaken prior to application.

Caution
Loctite® #262 may irritate sensitive skin. Refer to the product label for proper safety
precautions.

4.4.8 After replacement of friction material, reassemble the tensioner per Section 4.8. During
start-up, observe wear-in and operation precautions per Section 3, Operation.

Caution
After replacement of friction material, a minimum wear-in period of four hours at 50% of
the rated horsepower is recommended for the friction couple to achieve rated torque.

4.5 Wear Plate Replacement

Note: When replacing wear surfaces plates (3), it is recommended that the mating friction
material be replaced to ensure good contact between the mating surfaces. See Table 12
for wear limits.

4.5.1 Disassemble the tensioner per Section 4.3.

4.5.2 Remove the screws and locknuts holding the wear plates (3) and remove the wear plates.
If the wear plates cannot be easily lifted off, gently tap the O.D. to break the gasket seal.

Do not attempt to break the gasket seal by prying between the wear plate and housing.
Damage to the sealing surfaces may occur.

4.5.3 Internal Corrosion Protection


Note: Water-cooled tensioners used in both the open and closed loop operating modes are
required to be painted with Flame Control TemperKote® 1000 PRIMER and top coated with
TemperKote 1000 TOPCOAT.

4.5.3.1 Lifting off the wear plates (3) in section 4.5.2 will expose the water passages. Inspect the
water passages and, if necessary, use a wire brush to clean them. For best results,
surfaces should be free from oil, grease, dirt, mill scale, rust, corrosion products, oxides,
and foreign matter. The water passages should be sand blasted prior to painting. Remove
all remaining abrasive from surface by air blasting. Coat the freshly blasted surface as soon
as possible. Do not allow surface to become wet. Do not wash freshly blasted surface with
solvents.
4.5.3.2 Sand blast the surfaces to be painted.

Note: Read the manufacturer’s instructions thoroughly for proper handling, preparation,
application and spray of paint system.

4.5.3.3 Primer: One coat of Flame control TemperKote 1000 Primer at approximately 5.0-7.5 mils
wet film thickness to yield a dry film thickness of 2.0-3.0 mils dry.

4.5.3.4 Topcoat: Apply coat of Flame Control TemperKote 1000 paint (Topcoat). to achieve the
total topcoat thickness of 6.0-8.0 mils dry . Measure the coating thickness on the machined
surfaces at 4 places. The Total dry coating thickness should not be less than 5 mils.

Note: Follow the manufacturer’s recommendation for applying layers (film thickness) of
paint and allow for sufficient drying time.

Caution
Care must be taken to deal with painting in the ‘water cavity area’ to ensure that there is
full coverage of paint with uniform thickness on the water cavity surface. Refer to Figure
14-A to mask the inner & outer lands that will receive the gasket tape for sealing.

Note: If nubs in the water cavity are severely corroded, wear plates (3) may not be properly
supported. Replace the pressure plate (13), reaction plate (30) or mounting flange (1), if
necessary.
Note: Measure the coating thickness on the machined surfaces at 4 places. The Total dry
coating thickness should not be less than 5 mils.

4.5.4 Assembly with Gasket Tape

Note: The Pressure Plate (13), Reaction Plate (30) and Mounting Flange (1) will be referred
to as IRON in the following paragraphs. Refer to Figure 1 for item number references
shown in the parenthesis (#).

4.5.4.1 Preparation and Cleaning of the Iron

Ensure that the IRON surface is smooth and free of scale, burrs and corrosion. Thoroughly
clean both the inner and outer lands which will receive the gasket. Use a solvent based
cleaner such as acetone, mineral spirits or a general-purpose waxs/oil/grease remover
turning the wipe until it is free of new dark debris. Finish the cleaning process bye blowing
off lint on the sealing surface. If a paint touch-up is required, reference Figure 14-A to mask
the inner & outer lands that will receive the gasket tape for sealing.

Caution
Follow manufacturer’s instructions and proper safety precautions for the use of solvent
based cleaners (acetone, mineral spirits, or general purpose was wax/oil/grease remover).

4.5.4.2 Preparation and Cleaning of Copper Wear Plate

Ensure that the wear plate surface is smooth and free of burrs and corrosion. Thoroughly
clean both the outer and inner areas which will be in contact with the gasket tape. Use a
solvent based cleaner such as acetone, numeral spirits or a general purpose was
wax/oil/grease remover. Finish the cleaning process by blowing off any lint from lint and
the sealing surface.
Caution
Follow the manufacturer’s instructions and proper safety precautions for the use of solvent
based cleaners (acetone, mineral spirits or general purpose) for oil/grease.

4.5.4.3 Preparation of the Gasket Tape Ends

Start with the leading end of the gasket tape and skive the end at 45 degrees per Figure
15. This initial step is required to insure a smooth transition of the tape when the tape is
overlapped per section 4.5.4.4 (b) below. Also skive the trailing end of the tape at 45
degrees after it is overlapped per section 4.5.4.4 (b) below.

Figure 13

Figure 14-A
Figure 14-B

Figure 15

4.5.4.4 Applying the Gasket Tape to the IRON

(a) Start with the sealing area nearest to the inner diameter on the IRON. Remove the
adhesive backing on the gasket tape a little at a time to prevent the adhesive from picking
up dirt during installation. Start by positioning one end of the tape at the centerline of a bolt
hole as shown in Figure 13, using the edge of the water cavity as a guide, as shown in
Figure 14-B. Proceed to apply the tape on the sealing surface following a smooth circular
path, being sure to press the tape in place.

(b) After the gasket tape has been placed around the entire inner circumference of the IRON,
overlap the starting end of the end of the tape by a minimum of 0.44” (11.2 mm). See Figure
15. Be sure to smooth the tape at the overlap transition in order to get a good seal. No air
gaps or bubbles should be present.

(c) Repeat steps ‘a’ and ‘b’ for the outer sealing area nearest to the outer diameter of the
IRON, again using the edge of the water cavity as a guide.
Caution
Before the gasket tape is covered with the wear plate, the sealing surface should be
protected to prevent contamination from dust, dirt or oils. No additional cleaning or liquid
should be applied to the surface of the IRON or gasket tape.

4.5.5 Inspect the new wear plates (3) and remove any scratches or raised edges with very fine
sandpaper or steel wool. Position the smoothest side of the wear plate on the sealing
surface, being careful to align the holes with those in the IRON.

4.5.6 Position the clamp rings over the holes in the wear plates (3) and install the new hex head
screws (4) and locknuts (5) provided, securing them finger tight.

Caution
To prevent excessive warping of the wear plate (3) and to endure ensure a good seal, the
following hardware tightening procedure must be followed.

4.5.7 For each wear plate being replaced, the torque tightening instructions are as follows:

Follow the tightening sequence shown in Figure 15 for the first 16 screws. Note: The torque
of the screws & nuts (4) (5) that attach the wear plate (3) to the mounting flange (1), reaction
plate (30) & pressure plate (13) is a four step process.

(a) Step One: For the first 16 screws, bring the initial torque of each screw up to 33% of the
torque value shown in Table 14 using the tightening sequence shown in Figure 16. Install
and torque the remaining screws in any reasonable crosswise pattern to 33% of the torque
value shown in Table 14.

(b) Step Two: Repeat the sequence of torque tightening on the first 16 screws as shown in
Figure 16 and bring each screw up to 66% of the torque value shown in Table 14. Torque
the remaining screws in any reasonable crosswise pattern to 66% of the torque value
shown in Table 14.

(c) Step Three: Repeat the sequence of torque tightening on the first 16 screws as shown in
Figure 16 and bring each screw up to 100% of the torque value shown in Table 14. Torque
the remaining screws in any reasonable crosswise pattern to 100% of the torque value
shown in Table 14.

(d) Step Four: Finish torque tightening by selecting a starting position (usually at the 12 o’clock
position) and check the 100% torque of each screw going in a sequential clockwise or
counterclockwise rotation. Mark or highlight screw head or nut & shank after final torque
check as a visual indication that the screw/nut has been tightened to specification shown
in Table 14.

Table 14
Wear Plate Fastener* Torque: ft.lb. (Nm)

Model Size Torque

36WCBD3 3/8-16NC2 40 (54)

* Alloy Steel Grade 8


Figure 16

4.5.8 After completion of the assembly, each water cavity should be checked for leaks per static
test in 3.4.6.1.

4.5.8.1 Using lifting straps, suspend each assembly with the cooling water outlet port at the 12
o’clock and 6 o’clock position. Connect a water supply line to the cooling water inlet outlet
port at the 6 o’clock position. Next plug the cooling water inlet ports and leave the cooling
water outlet port at the 12 o’clock position open to purge air from the coolant cavity. See
Table 15 for cooling water port sizes.

Table 15
Inlet & Outlet Coolant Port Sizes

Model Size O-ring Boss (ORB)

36WCBD3 SAE-20 J1926

4.5.8.2 Slowly fill with water to purge all air from water cavities.

4.5.8.3 Install an ORB pipe plug(s) in the outlet 12 o’clock port(s) and apply appropriate water
pressure (40 psig (2.76 Bar) for the 36WCBD3. Pressure is measured at the inlet . Maintain
this pressure for a minimum of 30 minutes.

4.5.8.4 Check for leakage at the O.D. and I.D. seal areas. No leakage is allowed.

4.5.8.5 If the assembly leaks, check the torque on each screw and re-test. If leaks still occur, the
wear plate(s) or sealant groove may be damaged. Repeat procedure from 4.5.2

4.5.8.6 Follow steps in section 4.8 to reassemble the tensioner.

Caution
After replacement of wear plates (3), a minimum wear-in period of four hours at 50% of the
rated horsepower is recommended for the friction couple to achieve rated torque.

4.6 Dual Cylinder Seal Replacement


4.6.1 Disconnect the air connections and match mark the cylinder to a stud or other component
to ensure proper orientation during reassembly.
4.6.2 While supporting the cylinder (19), loosen the locknuts (18) ONE TURN AT A TIME and in
an alternating (crosswise) pattern until the spring force is completely relieved. Remove the
locknuts and washers (17). Deep well sockets are required for removal of the locknuts.

4.6.3 Using lifting equipment, carefully remove the cylinder (19) and piston (33) as an assembly.
Set aside in a clean area. See Table 16 for cylinder weights.

Table 16
Tensioner Weight lbs (kg)

Tensioner Size 136 236 336 436

Total weight 3000 (1361) 3750 (1701) 5100 (2313) 6700 (3039)

Cylinder/Piston 760 (345) 760 (345) 760 (345) 760 (345)


Assembly weight

4.6.4 Place the cylinder and piston assembly with the piston facing down on blocks
approximately 6" (150 mm) high. The blocks must only contact the cylinder (19) so that the
piston (33) will be free to move out of the cylinder bore.

4.6.5 If a regulated air line is available, the piston can be partially ejected from the cylinder by
applying no more than 15 PSIG (1.0 bar) to any of the pressure ports on the cylinder.

Caution
Application of a higher pressure may cause damage to the components.

4.6.6 To complete the removal of the piston from the cylinder, open all air inlets. Alternately insert
a 0.50" (12 mm) diameter by 6" (150 mm) long wood dowel or small brass drift into each
air inlet and gently tap the piston with a mallet so that it moves evenly out of the cylinder.
Be careful not to damage the sealing surfaces of the piston or cylinder by cocking the piston
in the cylinder.

4.6.7 Note how the lips of the Outer seal (23), the Intermediate seal (114) and Inner seal (21)
are oriented back-to-back. Refer to Figure 1 and Figure 17. Remove the cylinder seals (21,
23 and 114) and discard.

Note: Some WCBD3 tensioner assemblies do not include the intermediate seals (114).
Refer to the appropriate parts list to ensure proper seal configuration and assembly.

4.6.8. Inspect the cylinder sealing surface condition for nicks or scratches, corrosion, or any other
defect which may prevent the seals from being effective. The maximum amount of radial
wear on the seal surfaces is 0.005". The wear on the sealing surfaces will be in the form
of grooves where the seals contact the cylinder wall. Replace the cylinder, if necessary.
Figure 17

4.6.9 Thoroughly clean the seal grooves in the piston (33) and apply a thin coat of Molycote®55
O-ring lubricant to the piston seal grooves and chamfer on the piston, the sealing surfaces
in the cylinder (19), and the seals (21), (23) and (114).

4.6.10 Install the new seals in the grooves in the piston, noting the original orientation of the seal
lips. See Figures 1 & 17.

4.6.11 Position the cylinder on a flat level surface so that the pressure cavity faces upward.

4.6.12 Carefully place the piston (13) onto the cylinder (19) with the chamfered edge of the piston
facing downward, taking special care to avoid damaging the seal lips.

4.6.13 Gradually apply an evenly distributed force to press the piston (13) into the cylinder (19)
being sure not to cock the piston, which may damage the sealing surfaces. The use of ’C-
Clamps’ may assist with the assembly process.

4.6.14 Using a lifting strap, slide the cylinder/piston assembly onto the studs (6). Orient the drain
port plug (105) to be in-line with the coolant ports or align match marks if match marking
was previously performed.

4.6.15 Lubricate the threads on the end of the studs (6) with 30 wt. oil or anti-seizing compound
and install the washers (17) and locknuts (18).

Note: Failure to position the wear spacers (29), support beam shims (139) and support
beams (138) properly on the shoulder of the cylinder (19) before the locknuts (18)are
tightened may cause damage to those components.
WCBD3 Tensioners

4.6.16 While supporting the weight of the cylinder/piston assembly, tighten the locknuts (18, ) -
ONE TURN AT A TIME- and in an alternating (crosswise) pattern until the cylinder is seated
firmly against the clamp tubes. Torque the locknuts to the appropriate value. See Table 4.

Caution
The locknuts (18) must be tightened gradually to prevent damage to the tensioner
components.

4.6.17 Test for proper seal installation as follows

4.6.17.1 There are two sets of ports on the cylinder; the outermost positioned ports connect to the
outer pressure chamber. The innermost ports connect to the inner pressure chamber.
Remove all pipe plugs or fittings from the inner ports.

4.6.17.2 Install a pressure gauge in one of the outer cylinder ports. Apply 80 PSIG air through a
second outer cylinder port (after plugging the other outer NPT port) to engage the brake.

4.6.17.3 After the air pressure has stabilized, shut off the air supply. Monitor the pressure gauge
for a drop in pressure for a period of ten minutes. If the air pressure does not drop below
60 PSIG (4.1 Bar) within 10 minutes, the seals have been properly installed. If leakage is
excessive, try to note the location of the leakage. If the intermediate seal isleaking, air will
pass into the small (inner) chamber.

4.6.17.4 Exhaust all air pressure from the brake. Remove the plugs and gauges from the outer-
most ports and install them in the inner ports, leaving all of the outermost ports open.

4.6.17.5 Apply 80 PSIG (5.5 Bar) air pressure through one of the inner ports in the cylinder (after
plugging the other inner port) to engage the brake.

4.6.17.6 After the pressure has stabilized, shut off the air supply. Monitor the pressure gauge for
a drop in pressure for a period of ten minutes. If the air pressure does not drop below 60
PSIG (4.1 Bar) within 10 minutes, the seals have been properly installed. If leakage is
excessive, try to note the location of the leakage. If the intermediate seal is leaking, air will
pass into the large (outer) chamber.

4.6.17.7 If excessive leakage is found in testing of the large or small pressure chamber,
disassemble the brake and check the suspect seals and sealing surfaces for damage or
other causes of leakage. Repair or replace components as required.

4.7 Bushing Replacement

Note: Pressure plate (13) and reaction plates (30) have bushings (54) installed in the
reaction holes (Figure 18). The Pressure plate and Reaction plate bushings are different
lengths. Be sure to install the correct length bushing in the proper component. Refer to the
Reaction plate and Pressure plate sub-assemblies in the parts list for the selection of the
proper replacement bushing. Replacement of the bushings can be performed per the
following procedures.

4.7.1 Disassemble the tensioner per Section 4.3.

4.7.2 Refer to the wear limits in Table 17 to determine if the bushings (54), in Figure 18, require
replacement.
Table 17
Reaction Hole & Bushing size 'New'

Pressure Plate* Reaction Hole Diameter 2.876" (73,05mm)


Reaction Hole Bushing I.D. 2.565" (65,15mm)

Reaction Plate* Reaction Hole Diameter 2.876" (73,050mm)


Reaction Hole Bushing I.D. 2.565" (65,15mm)

* Refer to Figure 18

4.7.3 Heat up the area around each bushing (54) to soften the Loctite® and press out the old
bushings.

Caution
Loctite Locquic® Primer Grade "T" contains harmful vapors. Refer to the product label and
followproper safety precautions.

4.7.4 Clean the bores in the mating component, removing any residual Loctite®.

4.7.4.1 If the reaction hole is oblong or measures from the wear specification (Table 17) then
consult the factory. Inspect he ID of the reaction hole before installation of the new bushing
(54).

4.7.5 Apply Loctite® #RC601, 635 or 680 to the bushing O.D. and mating hole in the reaction
plate (30) and pressure plate (13) using a swab. Apply enough liquid to entirely fill the
space between the parts. Install the bushings (54) by twisting the bushing while pushing it
down , until it is flush with the casting surface. Inspect to see that a ring of liquid adhesive
is visible at the parting line. Reapply Loctite if required. Allow the Loctite to cure for 15
minutes before moving the subassembly.

Caution
The bushing (54) shall be held in place so it is centered in the reaction hole. Do not allow
the bushing to protrude beyond the surface of the reaction plate (30) or pressure plate
(13) during

Figure 18
installation. Allow the Loctite to cure for 15 minutes before moving the sub-assembly.

4.7.6 Assemble the tensioner per section 4.8 as required.

4.8 Assembly Procedures

Note: Friction discs and water jackets (mounting flange, pressure plate, and reaction plate)
should be assembled per the appropriate maintenance procedures prior to final assembly
of the tensioner.

4.8.1 Position the mounting flange (1) on a flat, level surface, mounting face down.

4.8.2 Install the studs (6) into the mounting flange (1). The stud end with the shorter length of
threads is to be assembled into the mounting flange. Clean the stud end to be assembled
by applying Loctite Locquic® Primer Grade "T" to the threads. After the threads have dried,
apply Loctite® #271 on the threads to be assembled and insert the stud completely into the
threaded hole in the mounting flange so that the installed end is flush or slightly recessed
inside the face of mounting flange. See Figure 1. Using a machinists square as a reference,
hold the stud in position so that it remains perpendicular to the machined surface of the
mounting flange until the Loctite® has cured. Repeat for the remaining studs.

Caution
Loctite Locquic® Primer Grade "T" contains harmful vapors. Refer to the product label and
follow proper safety precautions.

Caution
The end of the stud (6) must not extend past the mounting surface of the mounting flange
(1).

4.8.3 Noting the location of the water inlets/ outlets in the mounting flange (1), install the
appropriate number of clamp tubes (12) over the studs (6) that are located on either side
of each water inlet/outlet. Eight clamp tubes are required. See Figure 19.

4.8.4 Place a support beam (138) over each pair of studs that are located at 45 degrees to each
water inlet/ outlet. Four support beams are required.

4.8.5 Place a friction disc assembly (7) onto the mounting flange (1). Center the friction disc.

4.8.6 First, install a spring spacer (140) over every clamp tube the install a release spring (34)
over every clamp tube (12) and be sure the spring is resting on the spring spacer. For
single disc WCBD3 tensioners, proceed to Section 4.8.10.

4.8.7 Noting the location of the water inlets/outlets in the mounting flange (1), lift the reaction
plate (30) into position, align the water inlets/outlets with those in the mounting flange, and
slide the reaction plate over the studs (6) and clamp tubes (12).

4.8.8 Install a release spring (34) over every clamp tube (12). Refer to Parts list in Section 6 for
quantity of springs per tensioner model.

4.8.9 Place friction disc assembly onto the reaction plate (30).
4.8.10 Repeat the sequence of steps 4.8.7 through 4.8.9 until all friction discs (3), reaction plates
(30) and release springs (34) are assembled.

4.8.11 Noting the location of the water inlets/outlets in the mounting flange (1), lift the pressure
plate (13) into position and align the water inlets/outlets with those in the mounting flange.
Slide the pressure plate over the studs and clamp tubes.

4.8.12 Install Wear Spacers and Wear Shims.

4.8.12.1For single disc tensioners no wear spacers (29) or support beam shims (139) are required.
Go to section 4.8.13

4.8.12.2For multi disc tensioners, install the appropriate number of wear spacers (29) on each
clamp tube and an equal number of wear support beam shims (139) over the studs at each
support beam (138). Refer to Section 6.1 for quantities of wear spacers and wear shims
required for each tensioner size.

Figure 19
WCBD3 Tensioners
4.8.13 Thoroughly clean the seal grooves in the piston (33) and apply a thin, even coat of
Molycote® 55 O-ring lubricant to the piston seal grooves and chamfer on the piston, the
sealing surfaces in the cylinder (19), and the seals (21), (23) and (114).

4.8.14 Install the new seals in the grooves in the piston, noting the orientation of the seal lips.
(See Figure 17).

4.8.15 Position the cylinder on a flat level surface so that the pressure cavity faces upward.

4.8.16 Carefully place the piston onto the cylinder with the chamfered edge of the piston facing
downward, taking special care to avoid damaging the seal lips.

4.8.17 Gradually apply an evenly distributed force to press the piston into the cylinder being sure
not to cock the piston which may damage the sealing surfaces or seals. The use of ’C-
clamps’ may assist with the assembly process.

4.8.18 Lift the cylinder/piston assembly into position and slide it over the studs, noting the
orientation of the ports on the cylinder face. Orient the drain port plug (105) to be in-line
with the coolant ports or align match marks if this match marking was previously performed.

4.8.19 Lubricate the threads on the end of the studs with 30 wt. oil or anti-seizing compound and
assemble the washers (17) and locknuts (18).

4.8.20 Tighten the locknuts, ONE TURN AT A TIME and in an alternating (crosswise) pattern until
the cylinder is seated firmly against the clamp tubes. Torque the locknuts to the appropriate
value. (See Table 4).

Note: Make sure that wear spacers, support beam shims and support beams are in proper
positions on the shoulder of the cylinder as the locknuts are tightened, perhaps after this
paragraph. If not, they may be damaged.

Caution
The locknuts (18) must be tightened gradually to prevent damage to the tensioner
components.

4.8.21 Re-install the tensioner per Section 2.0.

4.9 External Corrosion Protection

4.9.1 Touch up needs to be done for the locations where the paint is damaged. Touch up can
be done for two main reasons.

4.9.1.1 Touch up done for repair purpose (to repair the scratches during transport and/or handling)
should be done at component level with PRIMER followed by TOPCOAT with spray gun.

4.9.1.2 Clean any contamination, scale, or loose paint from disturbed surfaces and touch up the
assembly. Repair. Touch up done after the assembly (to cover the damages done any
damage that may have occurred during assembly) by brush and with TOPCOAT ONLY.
4.9.2 Application of Primer & Topcoat

Caution
Do not paint the clamp tubes (12), the release springs (34), wear plate (3) and active friction
block surfaces as this may hinder the engagement or disengagement of the tensioner.

Note: The customer should refer to and follow the paint manufacturer’s recommendations for paint
application and safety precautions.

4.9.2.1 One coat of Flame control TemperKote 1000 Primer at approximately 5.0-7.5 mils wet film
thickness to yield a dry film thickness of 2.0-3.0 mils dry.

4.9.2.2 Apply coat of Flame Control TemerKote 1000 paint (topcoat) to achieve the total topcoat
thickness of 6.0-8.0 mils dry.

6.0 PARTS

6.1 Recommended Spares of Total Brake assembly (19662739183-00)


1. OE9751318262 BEARING SKF 23140 CC/W33 OR EQUI 1 No.
2. OE9710642006 HUB, COUPLING, FOR AUX BRAKE 1 No.
3. OE9751318254 PILLOW BLK BRG ASY 22230 WITH 1 No.
L.W. & NUT
4. OE9719713020 CLUTCH YOKE -AUXILIARY BRAKE 1 No.
5. OE9717284881 SHIM SET - DISC BRAKE MANIFOLD 1 Set
6. OE9717284890 SHIM SET - PLBK BRG 1 Set.
WCBD3 Tensioners
6.0 PARTS
Basic Assemblies of Disc Brake

336WCBD3 436WCBD3
(E1400) (E2000)
Item Description Part Number Qty Part Number Qty

1 Mounting Flange S/A OE9751417015 1 OE9751417015 1

6 Stud OE9751417023 16 OE9751417244 16

7 Friction Disc Assembly OE9751417031 3 OE9751417031 4

12 Clamp Tube OE9751417040 8 OE9751417252 8

13 Pressure Plate S/A OE9751417058 1 OE9751417058 1

17 Flat Washer OE9751417066 16 OE9751417066 16

18 Locking Nut OE9751417074 16 OE9751417074 16

19 Cylinder OE9751417082 1 OE9751417082 1

21 PolyPak Seal OE9751417090 2 OE9751417090 2

23 PolyPak Seal OE9751417104 2 OE9751417104 2

24 Warning Decal OE9751417112 1 OE9751417112 1

25 Name Plate OE9751417120 1 OE9751417120 1

26 Drive Screw OE9751417139 8 OE9751417139 8

28 Gear Hub 39662739939-00 1 39662719975-00 1

29 Clamp Tube Wear Spacer) OE9751417155 16 OE9751417155 24

30 Reaction Plate S/A OE9751417163 2 OE9751417163 3

32 Decal Plate OE9751417171 2 OE9751417171 2

33 Dual Piston OE9751417180 1 OE9751417180 1

34 Release Spring OE9751417198 24 OE9751417198 32

105 Brass Pipe Plug OE9751417201 1 OE9751417201 1

114 PolyPak Seal OE9751417210 2 OE9751417210 2

138 Support Beam OE9751417228 4 OE9751417260 4

139 SHIMS Support Beam OE9751417236 16 OE9751417236 24

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