Removal

1 .O Removal

1.1 Disconnect battery; machine should be fully lowered.

1.2 On trucks with a rider platform, secure the rider platform to the platform.

. _ remove two pivot mounting bolts that uarrier frame. Remove the rider

1.3 Remove shield from carrier frame around transmission.

1.4 Remove control handle.

Note: The transmission can be removed with the attached. Disconnect the wiring harness and go to stop 1.6. control handle from the oontrol panel

1.4.1 Remove brake rod linkage between control actuating lever. handle and brake

1.4.2 Pull handle to full down position and secure handle return spring in collapsed position with two (2) part, 20393-00. spring holders, Prime-Mover

1.4.3 Remove retaining ring and pin that the transmission ease. secures the return spring to

1.4.4 Disconnect control wiring harness wires from control panel. Label wires for reassembly.

1.4.5 Remove motor cover from side of transmission and remove wiring harness clamp from cover.

1.4.6 Disconnect wires from brake interlock switch.

1.4.7 Drive out roll pin that secures the handle pivot shaft and remove the handle pivot shaft. The handle is now free to come off the machine.

1.4.8 Guide the wiring harness down through the transmission pivot tube and remove handle and harness together.

1.5 Disconnect power cables from drive motor. Hark cables for reassembly. Pull cables up through transmission pivot tubes.

1.6 Loosen the steering guide rollers.

1.7 Raise and block the truck carrier frame so the drive tire is off the ground.

1.8 Support the transmission Prom overhead. A chain or lifting eye through the pivot tube is a good place to lift the transmission.

1.9 Remove the three cap screws that secure the transmission mount to the uarrier frame.

2.0 Dissassembly and Repair; 14:l Transmission

2.1 Throughly clean the outside of transmission before disassembly.

2.2 Remove drive tire and wheel.

2.3 Remove six (6) cap screws that Remove the guide ring.

2.4 Remove four (4) motor mounting cover side of the transmission hold on the steering gulda ring.

hollow hex key cap screws from the and remove the drive motor.

2.5 Lay transmission on work surface with cover side up.

2.6 Remove cover bolts, and 1” locknut from side cover.

2.7 Use four threaded holes in cover with cover bolts to push cover off of dowels. Apply pressure equally with all four pusher bolts.

2.8 Remove baffle from bottom of gear case.

2.9 Remove intermediate gear from case.

2.10 Remove brake lever and adjusting rod from over top of brake discs.

2.11 Remove brake discs , plates and retaining shafts.

2.12 Remove axle locknut and hub from axle. Remove axle from case.

2.13 Remove bearing races and snap rings from case.

2.14 Remove motor pinion bearing and cover and intermediate gear bearing and cover from side cover.

2.15

2.16

2.17

Remove intermediate gear bearing and cover from case.

Remove all old gasket material from cover, oase and drive motor.

Clean all parts in safety solvent and dry with compressed air.

!CAUTION! Use only a compressed air blower that meets OSHA and other safety standards.

2.18

2.19

Inspect all gear3 for damage and near.

Discard all o-rings and bearings. New parts should be used during reassembly.

2.20 Install two (2) internal snap rings in the drive axle bore of the gear case.

2.21 Press the drive axle bearing races into the gear case. Races should be installed with the smallest inside diameters back-to-back and tight against the snap rings.

2.22 Press one bearing cone on the drive axle with the large diameter against the gear.

2.23

Pl&ce the drive axle into the case.

Turn the gear case over with the gear from underneath.

2.24

2.25

2.26

2.27

2.28

gear aide down. Support the drive

Install second'bearing cone over drive axle.

Install lip seal in transmission case.

Install wheel hub on drive axle.

Put a solid bead of Loctite 515 ngasket eliminator" around the seam between the axle and the hub.

2.29 Use Loctite thread lock on axle locknut and install axle locknut on axle. Torque to 250 ft. lbs. while rotating the axle.

2.30 Press the intermediate gear bearing into the gear case. Install the bearing cone and one .OlO" shim. Use Loctite 515 as sealant and use

Loctite threadlock on the cover screws. Do not install the inter- mediate gear at this time.

2.31 Install a new gasket on the drive motor. Use a small amount of

Loctite 515 as sealant.

TORQUE NUT TO

250 FTJLBS. WHILE TURNING HUB.

2.32 Install the bushings and o-ring for the brake actuating rod into the gear case.

2.33

2.34 Install the drive motor in the gear case.

Install the brake actuating rod through the drive motor into the Sear case. This is done to help keep the drive motor properly aligned in the Sear case during assembly.

2.35 ‘f&n the transmission case so that the gear case is facing up. The end of the motor will be on the work surface. Support the drive axle end of the case with a block.

2.36 Install the straight gear motor adaptor over the armature shaft without the pinion gear.

2.37 Install a brake separator pad in the gear case over the motor armature shaft. See illustration for proper orientation.

2.38 Place a brake disc on top of the separator plate. The hub of the disc must be towards the motor (down).

2.39 Install a second separator plate over the brake disc. Place the second brake disc over the second separator plate. Position this brake disc with the hub away from the drive motor. Orient the disc so that the rivets are spaced between the rivets of the first disc at a 45O angle. 2.41 Place the third separator plate over the second brake disc. -68-

2.40

2.42 Place the pinion gear on the armature shaft and strike it with a non- marking hammer to snap it into the motor adaptor.

2.43 Install new o-rings on the retaining shafts and install the retaining shafts through the separate plates acid into the gear case, small end first. Make-sure the shafts are fully seated and lower separator plate. do not pinch the

2.44 Install the intermediate gear into the bearing in the gear case.

2.45 Install the brake lever and adjusting rod into the gear case. The brake lever must be free to pivot on the adjusting rod and roll pin. A locknut adjusting nut secures the adjusting rod into place on the motor side of the gear case.

2.46 Adjusting the brake lever:

a) The brake lever has a slight n-Vn shape on the side closest to the brakes. The section of the brake lever directly under the three countersunk spring anchor holes should contact the outer brake separator plate.

b) Lift up on the adjusting rod to hold adjusting locknut tight against motor side of gear case.

c) Use a feeler gauge between brake lever and separator plate to determine contact area.

d) Tightening the nut will move the adjusting rod towards the drive motor and will move the contact area towards the brake lever pivot. Incorrect adjustment will cause the brakes to drag or loss of braking force.

2.47 Place three (3) springs with spring seats into the three (3) couuter- sunk spring seat holes in the brake lever.

2.48 Install the baffle in the bottom of the gear case.

2.49 Use a solid bead of Loctite 515 “gasket eliminatoP around the gear case oover flange. Circle all bolt holes and dowel pin holes.

2.50

Upstall dowel pins in gear case.

2.51 Carefully install gear case cover. Take oare to line brake springs and the brake separator plate retaining appropriate holes in the cover. The motor pinion and gear bearings have not yet been installed. up the three (3) shaft with the intermediate

2.52 Tighten down all the cover screws equally. Torque to 30 ft/ibs.

2.53 Put new o-rings on and install four (4) motor mounting bolts. Tighten bolts in an “XN pattern and torque to 35 ft./lbs.

2.54 Install the locknut on the brake adjusting rod end that comes through the side cover.

2.55 Install three (3 1 spring adjusting hollow hex key screws. Tighten the screws till they just touch the spring seats then f additional turn. Install locknuts on screws.

2.56 Install the bearing for the intermediate gear into the gear case cover.

2.58 Install bearing cover. Use Loctite 515 as a sealant and put Loctite threadlock on the cover mounting bolts.

2.59 Install the drive motor pinion bearing in the cover.

a) Make sure the motor shaft and gear are concentric with the bearing mounting hole in the gear case cover.

!WARNINGI Do not force the bearing into the mounting hole by bending the shaft. This will result in armature breakage.

b) To check for concentricity, use a telescoping meter to measure four (4) opposing locations. of bearing bore to the motor shaft. gauge and a micro- Measure from edge

Subtract the smallest number from the largest number.

The specifications for the total indicated runout (TIR) is .005" or less.

c) If the drive motor shaft and gear are not concentric, first remove the drive motor and check for burrs, pieces of old gasket materials, ects., that might cause these-parts to be misaligned.

If okay, shim between the drive motor mounting and gear case until proper alighment is achieved.

2.60 Install the bearing cover over the bearing with shims and Loctite 515.

The bearing cover must be shimmed so that it is .OlO" above the outer bearing race. Put shims around bearing so they are .OlO" higher than the bearing.

2.61 Fill transmission with about one (1) quart of ATF Dexron 11.

2.62 Install the steering guide ring with six (61 bolts and lockwashers.

Torque bolts to 50 ft./lbs.

2.63 Install the drive wheel assembly to the hub with five (5) bolts. Torque to 100 ft./lbs.

The procedure for disassembly requires no oedure. Only basic mechanical skills are ASSEMBLY special tools and no special pro- required to disassemble. Transmission reassembly &es not require any special tooling other than a torque wrench capable of at least 900 ft./lbs. of olejadurement. The assembly prooess is a straight forward mechanical procedure but care must be taken to assure proper axle bearings and brake mechanism assembly. Before reassembly, thoroughly clean gear case and all parts. Keep parts clean. All part numbers refer to illustration. 2.1 2.2 Install spacer ring into drive axle bore in transmission case.

This spacer is part of the drive axle bearing assembly (20) which is a matched set and should be replaced only as a set. The Timken SS set consists of two bearing cones, two bearing races, one large spacer ring, and one small spacer ring.

Install bearing races (20) into transmission case with the smaller diameters against the spacer ring.

2.3 Install one bearing cone (20) in axle bore with large end of bearing out board.

2.4 Install oil seal spaoer ring (19) against bearing race.

2.5 Install oil seal (18) into transmission case.

2.6 Test fit drive gear (29) onto drive axle (17) outside of transmisison case to remove burrs and assure proper fit. Remove gear from axle and set aside.

2.7 Install small spacer ring (20) between bearing cones.

2.8 Place remaining bearing cone (20) in bearing race on inside of transmission.

2.9 Completely coat inside splines of drive gear (29) with Loctite #609 retaining compound.

2.10 Place drive gear (29) into transmission case in order to install axle (17).

2.11 Install axle into transmission case through bearings and gear. The axle will have to be pressed into the bearing and gear.

2.12 Put Loctite Threadlock onto drive axle threads and install nut (30). Torque nut to 250 ft./lbs. while rotating axle.

2.13 Stake the flanged skirt of the nut into the key way slot on the axle.

Do not stake too hard so the flange skirt is torn. --

2.14 Install inner needle bearing race (31) onto end of axle.

2.16 Install brake arm (48) and eyebolt pivot (49) in case. Brake arm attaches to pivot bolt with a pin (47).

2.17 Install eccentric dowel pin (13) with ring (14) into case. The high side of the cam offset on the bolt should be towards the center of the gear case.

2.18 Install drive motor into transmission with o-rings (9 and 10) between motor mounting plate and gear case. Secure with three bolts and one nut but do not tighten mounting bolts.

2.19 Install brake plate locating dowels (47 and 57) in transmission case.

2.20 Install first separator plate (54) with the side without pads against the inside of the transmission.

2.21 Install one brake disc (53) over pinion gear. The disc should be iustalled with the hub first and the rivet heads facing out.

2.22 Install the plate spacer washers (50 and 51) as shown in the inset diagram of illustration. Note the direction that the washers (51) face.

2.23 Install a second separator plate (54) over guide pins.

.2.24 Install second brake disc with hub facing outwards and oriented so that the rivet heads do not line up with the first disk.

2.25 Install another set of spring washers (50 and 51) and the outer spacer plate (54)‘over the locating dowels. The outer plate (54) should be installed with bare side to the outside.

2.26 Install clinch rings (46) over locator dowels to keep separator plates from rattling. Do not compress expansion washers (50 and 51).

2.27 Check and adJust contact point of brake lever.(48). Contact point of lever on plates should be directly under the spring locating holes. The.eyebolt that the lever mounts to can be screwed in or out to adjust contact area.

2.28 Install idler gear bearing cups (31) and axle bearing cup (31) into transmission case and cover. Install so that inside of races are flush with inside surfaces of case and cover.

2.29 Place two shims (32) on idler gear shaft (33) and install gear into transmission case. Install a third shim (34) on outside shaft of gear.

2.30 Put brake springs (43) and seats (44) in place on brake lever (48 1.

2.31 Coat mating surface of tranmission case with Loctite 515 and care- fully install cover (35) onto transmission. Line up dowel pins (28) and spring seats (44) as cover is put into place.

2.32 Bolt cover in place with cap screws. Be sure that four (4) round head hex screws are used at four (4) holes closest to steering ring.

2.33 Install brake adjusting bolts (38) and locknuts (39) into cover; do not tighten at this time.

2.34 Install brake actuating rod (6) and adjusting cam (3 and 4) In transmission ease* The complete brake adjusting procedure must he followed after the transmission is_ installed In truck.

2.35 Install steering guide ring (26) and drive tire (21).

2.36 Install new pivot bearing and washer on top of transmission case.

2.37 Fill transmission with ATF Dexron II transmission fluid.