Model 6210 Maintenance Manual

Section 7.Component Procedures

Drive and Brake Drive Unit

12.Secure the drive unit to prevent it from falling. Remove the ten bolts that secure the drive unit and bearing assembly to the frame.

Figure 7-38.Drive Unit Mounting Bolts

Mounting Bolts

2.Remove the screws [40] securing the speed sensor cover assembly [21] to the gear case cover. Move the speed sensor cover assembly to the side to prevent damage to the cable. Refer to Figure7-75 on page7-62

3.Remove the nine hex head cap screws [3] securing the gear case cover [2]. Pull the gear case cover away from the drive unit to disengage it from the roll pin [26] in the housing.

4.Remove the hex screw [19], washer [18], speed sensor pinion gear [17], and shaft seal [16] from the end of the armature. Refer to Figure7-75 on page7-62 .

5.Remove the pinion nut [20, Figure7-75 on page7-62] that secures the top (pinion) gear [4].

6.Remove the top (pinion) gear [4] attached to the traction motor armature shaft.

7.Remove the traction motor if required. See “Traction Motor” on page7-62.

8.Remove the traction motor bearing [10, Figure7-75 on page7-62], retaining ring [9], and seal [8] from the gear case if required.

9.Remove the 2nd stage gear set [5] from the gear case.

NOTE: Remove the ten Allen head bolts to remove only the transmission but not the steering bearing.

13.Remove the drive unit and steer bearing assembly by lowering them through the pivot-frame mount.

Drive Unit Disassembly

NOTE: The drive unit capacity is 0.4 qt. (0.4 liters). Make sure to have a correct size waste container for collecting the removed gear case lubricant.

1.Remove the drain plug [11]. Drain the gear case lubricant. After draining the gear case lubricant, thoroughly clean the outside with solvent or other non-corrosive cleaning fluid. Air dry all parts, and proceed with the disassembly of drive unit.

NOTE: The 2nd stage axle [25] has an M8 tapped hole in the end. It can be removed with the gear [5] in place.

10.Remove the retaining ring [27] from the drive axle [17] then remove the output gear [7].

11.Press the drive axle [17] through the inner and outer gear case bearings [13].

12.Remove the old bearings [13], spacer [19], and seal [16] from the gear case. Thoroughly clean the case.

Drive Unit Assembly

1.Install the new bearings [12 and 18] in the gear case [1] and cover [2] for the 2 nd stage gear set.

2.Install the new bearings [13], spacer [19], and seal [16] in the gear case for the drive axle.

Publication: 1146947, Revised: 12 Jan 2017 7-25

Section 7.Component Procedures

3.Place the case in a fabricated assembly base and carefully press the drive axle [17] in the gear case [1].

4.Position the drive unit on the work bench with the gear case side up. Install the output gear [7] in the case and secure with the retaining ring [27].

5.Install the 2 nd stage gear set [5].

6.Install the traction motor bearing [10, Figure7-75 on page7-62], retaining ring [9], and seal [8] in the gear case if removed previously.

NOTE: The seal must be installed correctly with its open side and seal ring positioned towards the bearing.

7.Carefully slide the traction motor armature shaft into the gear case if removed previously. See “Traction Motor” on page7-62.

Make sure that the motor end cap is installed before proceeding to the next step.

8.Install the pinion gear [4] and the pinion nut [20] on the armature shaft. Torque the pinion nut to 25.8 ft. lb. (35 Nm).

9.Install the shaft seal [16], speed sensor pinion gear [17], washer [18], and hex screw [19] to the end of the armature. Refer to Figure7-75 on page7-62,

10.Use gasket compound on the mating surface and install the gear case cover [2].

11.Torque the nine cover bolts [3] to 16.9ft.lb. (23Nm).

12.Install the two screws [40] to secure the speed sensor cover assembly [21] to the gear case cover. Torque the screws to 23.8 in. lb. (2.7 Nm).

NOTE: Make sure the speed sensor cable is correctly seated in the grommet to prevent damage from contact with the linkage when the drive unit turns.

Drive Unit Installation

Make sure the main ON/OFF switch is OFF and the battery connector is disconnected before you start.

1.Install the steer bearing assembly using ten Allen head bolts, if it was removed previously. Torque bolts to 48.6 ft. lb. (66Nm).

2.Install the drive unit assembly to the pivot frame. Feed the harness and cables through the drive unit housing to the locations where they were previously removed.

3.Secure the assembly with the ten Allen head bolts removed previously. Torque bolts to 336 to 384 in. lb. (38.0 to 43.4 Nm).

4.Feed the wire harness and power cables through the pivot tube.

5.Reconnect the cables/wire to the terminal block on the drive unit. See Figure7-39 for correct hardware order. Torque the brass nuts to 26.5in. lb. (3 Nm) to secure the phase cables.

Figure 7-39.Hardware Stack for Phase Cables

M6 BRASS NUT

M6 BRASS FLAT WASHER

DRIVE UNIT PHASE CABLE STUD

DRIVE UNIT MOTOR CABLE

M6 BRASS SPLIT RING LOCK WASHER

MAIN HARNESS PHASE CABLE

M6 BRASS FLAT WASHER

6.Reconnect the brake connector and the speed and temperature sensor connector on the drive unit housing.

7.Install the drive wheel. See “Drive Wheel” on page7-28.