Usage:
Start By:
a. remove drum support, propel side (CS-433B & CP-433B)
| NOTICE |
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Bolts of size M10 and smaller, which have been locked with thread lock, must be heated before removal to prevent possible damage. |
1. Remove one of the drain plugs in the side of the gear reducer to drain the lubricant. Reinstall the drain plug.
2. Remove the six bolts that hold hydraulic propel motor (1) to gear reducer (2).
3. Put an alignment mark across hydraulic propel motor (1) and gear reducer (2) for assembly purposes. The hydraulic propel motor must be installed in its original position on the gear reducer.
4. Install two forged eyebolts of the appropriate size in the hydraulic propel motor. Fasten a hoist to the hydraulic propel motor, and remove it from the gear reducer.
5. Remove o-ring seal (3) from the groove on the outside of the hydraulic propel motor. Discard the seal, and use new parts for replacement.
6. Remove cup spring (4) from the inside of the gear reducer.
7. Remove retaining ring (5) from the inside of the gear reducer.
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Piston (6) must be removed from the housing of the gear reducer with shop air pressure. The piston can come out of the cylinder bore with force during the removal procedure. To prevent possible personal injury, install a retaining bar across the top of the cylinder bore as shown. The retainer bar will retain the piston in the cylinder bore when applying shop air pressure. |
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8. Install a suitable retainer bar across the top of the cylinder bore in the gear reducer housing as shown. Apply shop air pressure (free of water) of approximately 525 kPa (75 psi) to release port (W) as shown. The piston will move up and out of the cylinder bore in the gear reducer housing. Remove the retainer bar and piston (6).
9. Remove two gasket assemblies (7) and (8) from the inside of the cylinder bore. Discard the gasket assemblies, and use new parts for replacement.
10. Remove disc carrier (9).
11. Remove outer discs (10) and inner discs (11).
12. Remove shaft assembly (12).
13. Disassemble shaft assembly (12). Remove retaining ring (13), shim (14), bearing (15) and sun gear (16) from the shaft.
14. Turn the gear reducer over. Remove the bolts that hold cover (18) to the output housing. Remove the two setscrews from the cover. Install two forcing screws of the appropriate size in the setscrew holes. Tighten the forcing screws evenly to loosen the cover; then remove it.
15. Remove planet carrier (20).
16. Remove retaining rings (21) from the planet carrier.
17. Remove three shafts (22) from the planet carrier with a press. Remove three planet gears (23).
18. Remove thrust washers (24), washers (25), rollers (26) and washers (27) from the planet gears.
19. Remove retaining rings (30) and shims (29) that hold four planet gears (28) in output housing (17).
20. Use a suitable puller to remove planet gears (28) from the output housing.
21. Position the gear reducer so fixing plate (31) is facing upward. Remove the countersunk bolts that hold fixing plate (31) to the gear reducer.
22. Remove fixing plate (31) with two pry bars as shown.
23. Remove seal ring (32) from the output housing. Discard the seal ring, and use new parts for replacement.
24. Remove the bolts that hold centering ring (33) in position. Remove the centering ring.
25. Remove o-ring seal (34) from the centering ring. Discard the o-ring seal, and use new parts for replacement.
| NOTICE |
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When hub carrier (35) is removed, rollers are likely to fall out. Do not damage or lose any of the rollers during removal of the hub carrier. |
26. Install two forged eyebolts of the appropriate size in hub carrier (35) as shown. Fasten a hoist to the hub carrier, and remove it from output housing (17).
27. Remove two sets of rollers (36) and (37) from the hub carrier.
28. Remove o-ring seal (38) and ring (39) from the bore in hub carrier (35). Discard the o-ring seal, and use new parts for replacement.
29. Remove slotted pin (40) from the hub carrier.
NOTE: The following steps are for the assembly of the gear reducer.
30. Thoroughly clean all components of the gear reducer prior to assembly. Check the components for damage or excessive wear. Prior to assembly, put a thin coat of clean hydraulic oil on all parts of the gear reducer.
31. Put a thin coat of 9S3263 Thread Lock on slotted pin (40). Install the slotted pin in the hub carrier.
32. Install a new ring (39) and a new o-ring seal (38) in the bore of hub carrier (35).
33. Put a heavy coat of 5P0960 Multipurpose Grease on the roller running faces of hub carrier (35).
Install roller sets (36) and (37) on the carrier hub. The grease will hold the rollers in position.
34. Fasten a hoist to hub carrier (35), and put it in position in output housing (17). Be sure none of the rollers fall off of the hub carrier during installation.
35. Install a new o-ring seal (34) in the groove in centering ring (33).
36. Install centering ring (33) on the gear reducer. Install the bolts that hold the centering ring, but do not tighten them at this time.
37. Clean a new seal ring (32) with a 50/50 mixture of alcohol and water. Orient the seal ring so that it will be installed as shown in Illustration C31060P1.
38. Lubricate two sealing points (X) with clean hydraulic oil. Sealing points (Y) must be completely free of oil when the seal ring is installed.
39. Install seal ring (32) in centering ring (33).
| NOTICE |
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Do not damage seal ring (32) when fixing plate (31) is installed. It may be necessary to repress the seal ring when the bolts, which hold the fixing plate, are being tightened. |
40. Put fixing plate (31) in position on top of seal ring (32). Put a thin coat of 7M7456 Bearing Mount on the threads of the countersunk bolts that hold the fixing plate in position. Install the bolts, and tighten them in an alternating order to a torque of 15 N·m (11 lb ft).
41. Finish tightening the bolts that hold centering ring (33). Tighten the bolts to a torque of 120 N·m (90 lb ft).
42. Turn the gear reducer over as shown.
43. Heat the four planet gears (28) to a maximum temperature of 95°C (203°F). Install the planet gears on the shafts in the gear reducer. Be sure the gears are completely installed on the shafts.
44. Install shims (29) and retaining rings (30) that hold the planet gears.
45. Turn the gear reducer over as shown. Install disc carrier (9).
46. Install five outer discs (10) and four inner discs (11) in the gear reducer. Install the discs in an alternating order. Start with an outer disc and end with an inner disc.
47. Put clean hydraulic oil on new gasket assemblies (7) and (8). Install the gasket assemblies in hub carrier (35) as shown.
48. Put clean hydraulic oil on piston (6), and install it in the cylinder bore of the gear reducer.
49. Install retaining ring (5) that holds piston (6) in the gear reducer.
50. Install cup spring (4) in the gear reducer with the convex side facing up as shown.
51. Install a new o-ring seal (3) in the groove on the outside of the hydraulic propel motor.
52. Fasten a hoist to the hydraulic propel motor, and put it in its original position on the gear reducer. Install the six bolts that hold it, but do not tighten the bolts at this time.
53. Turn the gear reducer over as shown. Align the splines on disc carrier (9) with the splines on the shaft of the hydraulic propel motor. Finish tightening the six bolts that hold the hydraulic propel motor to the gear reducer to a torque of 50 N·m (37 lb ft).
54. Assemble shaft assembly (12). Install sun gear (16), bearing (15), shim (14) and retaining ring (13).
55. Install shaft assembly (12) in the output end of the gear reducer.
56. Assemble planet carrier (20). Put a thin coat of 5P0960 Multipurpose Grease on all parts of planet carrier (20). The grease will hold the parts together. Install two washers (27), two sets of rollers (26) and two washers (25) in each planet gear (23).
57. Put a thin coat of 5P0960 Multipurpose Grease on thrust washers (24). Install the washers in planet carrier (20). Install three planetary gear assemblies (23) in the planet carrier, between the thrust washers.
58. Lower the temperature of three shafts (22). Install the shafts into the planet carrier and through the planetary gear assemblies. Be sure the shoulder on each shaft is seated against the planet carrier.
59. Install retaining rings (21) that hold the planetary gear assemblies and shafts.
| NOTICE |
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Check the three planet gears (23). If they have a center punch mark (41), these marks must be aligned with shaft assembly (12), as shown, before installing planet carrier (20) in the gear reducer. If the planet gears do not have center punch marks, no special alignment procedure is required. |
60. Install planet carrier (20) in the gear reducer.
61. Measure the distance from the flange facing of cover (18) to the planet carrier stop in the cover. Record this as dimension (A).
62. Measure the distance from the flange facing of output housing (17) to the stop in planet carrier (20). Record this as dimension (B).
63. Subtract dimension (B) from dimension (A). The difference must be .8 to .12 mm (.03 to .05 in).
64. If the difference found in Step 63 is not within specification, shaft assembly (12) will have to be removed and disassembled. If the difference is not correct, remove shim (14) and replace it with a shim of a different thickness to achieve the correct measurement.
65. Install a new o-ring seal (42) in the groove on cover (18).
66. Install cover (18) and the bolts that hold it. Tighten the bolts to a torque of 50 N·m (37 lb ft).
67. Fill the gear reducer to the correct level with lubricant prior to installing it. See the Operation & Maintenance Manual for the correct filling procedure.
End By:
a. install drum support, propel side (CS-433B & CP-433B)