Mechanical drive gear unit – 2550

Replacing wheel bolt

10.4 Replacing wheel bolt

The wheel bolts on the transmission are stud bolts. To replace the wheel bolts, proceed as follows:

•Pull out the battery's emergency disconnector.

•Remove the platform.

•Lift the machine using a jack and put it on blocks.

•Remove the drive wheel.

•Wheel bolts with damaged threads are removed using the stud bolt tool.

•Broken wheel bolts:

• Method 1: Drill a hole in the centre of the bolt and screw out the bolt using a screw extractor for M14 bolts.

• Method 2: If the bolt will not come loose with a screw extractor, the bolt must be drilled out.

-Drive a centre punch into the centre of the bolt. Be careful to centre the centre punch.

-Drill a pilot hole through the bolt using a 5 mm bit. Drill out the bolt using an 11.5 mm bit.

-Try to remove the remains of the bolt with pliers or the like. If that does not work, remove the remains by clearing the threads with a screw tap M14x1.5.

•Apply LOCTITE 270 on the threads of the wheel bolts. Mount the new wheel bolt with a stud bolt tool. Tightening torque 90 Nm

Assemble the drive wheel. Tighten the wheel nuts to xx Nm.

•Remove the blocks and lower the truck.

•Assemble the platform.

•Connect the battery disconnector.

11.1 Component parts

Electromagnetic brake – 3370

Dismantling

T-codeValid

Pos.DescriptionNotes

5 Shims for adjusting the air gap 1 = 0.5 mm 5 = 0.13 mm on each position

6 Friction disc, brake disc Nom. thickness: 9.7 mm Min thickness: 7.7 mm 7

11.2 Dismantling

•Loosen the screws (10).

•Lift off the brake from the motor axle.

•Place the brake on a clean surface.

•Unscrew the adjuster screws (2) gradually to reduce the spring tension equally.

11.2.1 Inspection

Check the parts for damage and/or wear:

•Check the brake disc (6) and the wear surfaces on the pressure plate (3) extra carefully.

•Check the springs (11) and the spacers (4, 5) with regard to damage.

•Check for signs of damage to the splines on the hub (8) and friction disc (6).

•Check for signs of swelling/deformation or damage to the magnet (1) and pressure plate (3).

11.3 Assembling

•Clean the parts carefully.

•Assemble the brake in the reverse order to dismantling.

•Bear in mind the following:

-That the hole in the pressure plate (3) aligns with the corresponding hole in the magnet housing.

-That the right number of springs have been fitted.

-That the play 0.25-0.38 mm has been set correctly. Should possibly be adjusted.

NOTE!

The friction surfaces must not come into to contact with oil or grease as this will seriously reduce the brake’s operation.

11.4 Manual release of the brake

The brake can be released manually, for example, if the brake is broken and the truck needs to be moved to the service area or in order to centre the brake disc easier during assembly. To release the brake unscrew the two screws (13) equally and gradually.

WARNING!

Lost braking function.

The braking function is lost when the brake is manually released. Drive the truck at reduced speed and pay extra attention. Do NOT forget to remove the screws.

11.5 Adjustment 11.5.1 Adjusting the play

•Measure the play in three places.

•Adjust the play by removing the shims (5).