Model 5200 High-Level Orderpicker

Spiral Gear Disassembly

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Model 5200 High-Level Orderpicker

Drive Unit Drive and Brake

Assembly Procedures

Safety glasses are required. Prepare the housing for assembly by running a tap through all bolt and screw holes. Cleaning the threads make sure there is no damage. It also enables you to determine the correct tooling to use in th e assembly process.

Before beginning assembly of the drive unit, record the bearing seat data stamped on the housing. Record the setting distance information stamped on the bevel and spiral gears. This data is used in the formula to determine shim thickness later on.

Gear Set Assembly

1.Press the bearing cone on the bevel gear until it is seated. Place the matching bearing cup on the bearing cone for measuring purposes. See Figure7-62 .

2.Press the bearing cone on the spiral gear until it is seated. Place the matching bearing cup on the bearing cone for measuring purposes. See Figure7-63

Always watch for pinch points when using a press or pressing tools.

3.Use a bearing zero offset tool and the formulas on page 7-38 to determine the shim thickness. This dimension is required to assemble the gear set in the housing.

Calculate Shim Formulas

Spiral pinion gear shim calculation: •A = Dimension A (See Figure7-64 ) stamped on housing (4.438)

Publication Number: 1043922B, Revised: 2 Sept 2015

Model 5200 High-Level Orderpicker

Section 7.Component Procedures

Drive and Brake Drive Unit

•B = Number (See Figure7-65 ) etched on gear (S/D 2.378)

•C = Zero Offset (See Figure7-66 )

Use a dial indicator to determine the zero offset. Turn the spiral gear as if seating the bearings. Record the data from the dial indicator to use in the formula.

•D = Plug Height (2.025)

•E = B + C + D

•F = A - E

F = Shim thickness required

This calculation is used to determine the shim amount behind the bear ing cup in the main housing. The shim(s) sets the spiral gear for correct backlash.

Bevel gear shim calculation:

•G = Dimension B (See Figure7-67 ) stamped on housing (2.506)

•H = Number (See Figure7-68 ) etched on gear (S/D 0.541)

•J = Zero Offset (See Figure7-69)

Use a dial indicator to determine the zero offset. Turn the bevel gear as if seating the bearings. Record the data from the dial indicator to use in the formula.

•K = Plug height (1.875)

•L = H + J + K

•M = G - L

•M = Shim thickness required

This calculation is used to determine the shim amount behind the bear ing cup in the main housing. The shim(s) sets the bevel gear for correct backlash.

Publication Number: 1043922B, Revised: 2 Sept 2015

Section 7.Component Procedures

Model 5200 High-Level Orderpicker Drive Unit Drive and Brake

Housing Bearing Cup and Shim Assembly

1.Place the spiral gear shims in the housing, then place the bearing cup in the housing. See Figure7-70.

2.Install the bearing cup into the housing bore. See Figure7-71 .

3.Place the bevel gear shim in the housing, followed by the bearing cup. Use a press or mallet to press the bearing cup into the housing bore. See Figure7-72 .

NOTE: Make sure to wipe away any chips or excess metal pieces resulting from driving the race to seat it.

Publication Number: 1043922B, Revised: 2 Sept 2015