Usage:
Start By:
a. remove drive chains
| NOTICE |
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Empty all ballast from the machine before starting the following procedure. |
1. Block all five front wheels on both sides to prevent the machine from moving.
2. Raise the rear of the machine off the ground. Weight of the machine at the rear wheels is approximately 2400 kg (5000 lbs.).
3. Place two blocks under the frame, as shown, to support the machine. Blocks must be under the sides of the frame. Do not block under the center of the machine.
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Make sure the machine is securely blocked and supported before working on or around the machine. |
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4. Remove the rear wheel and tire assemblies from the machine. Weight of each wheel and tire assembly is approximately 36 kg (80 lbs.).
5. Disconnect the brake lines from all four service brakes, located on the lower drive assemblies. Use caution to avoid damaging the fittings or twisting the brake lines.
6. Plug the brake lines and the ports on the brake assemblies to prevent contaminants from entering.
7. Remove two bolts and lock washers (1) securing two pivot pins (2) to one of the lower drive assemblies.
8. Set a floor jack under the lower drive assembly to be removed. Raise or lower the jack as needed to remove load from pivot pins (2).
9. Clean out two threaded puller holes in both pivot pins in the lower drive assembly to be removed. Install 3/8-16 bolts into the puller holes and tighten equally to remove the pivot pins.
10. Carefully lower the jack to separate the lower drive assembly from the frame. Make sure the lower drive assembly follows the jack down. Assist with a bar, if necessary. Weight of the lower drive assembly is approximately 104 kg (230 lbs.).
11. Collect shims (3) and save for reassembly.
12. Remove pad (4) and discard. This should be replaced with a new part during assembly.
13. Repeat steps 7 through 12 to remove the second lower drive assembly from the machine.
14. Inspect pivot pins (2) and shims (3) for damage or excessive wear. Bent, cracked, or badly worn components must be replaced with new parts.
15. Inspect two bushings (5) in each lower drive assembly. If the bushings are excessively worn or appear damaged, they must be removed and replaced with new parts.
16. Check mounting holes in the machine frame. Look for cracks, enlarged holes, or other structural damage. Repair or replace any damaged items before assembly.
Install Lower Drive Assemblies
1. Block the rear of the machine high enough to allow installation of the lower drive assemblies.
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Make sure the machine is securely blocked and supported before working on or around the machine. |
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2. Set the lower drive assembly on a floor jack, as shown. Weight of the lower drive assembly is approximately 104 kg (230 lbs.).
3. Set a new pad (4) in place on the lower drive assembly.
4. Orient the lower drive assembly so that, when installed, long lug bolts (6) will be towards the outside of the machine, and short lug bolts (7) will be towards the inside of the machine. Also, grease fittings (8) must face towards the rear of the machine.
5. Move the lower drive assembly into place under the machine. Install the drive chain around the sprocket inside the lower drive assembly.
6. Tie wire cables to each end of the drive chain. Feed the cables up into the frame, as shown. This will help install the drive chain in the following step.
7. Raise the floor jack to lift the lower drive assembly into place. Pull the wire cables from above to lift the drive chain while raising the jack.
NOTE: Make sure the drive chain remains installed on the teeth of the sprocket inside the lower drive assembly.
8. Do steps 4 through 6 of Install Drive Chains, located in this module. This will secure the drive chain around the top drive sprocket with a master link.
9. Adjust the jack position so that mounting holes in the lower drive assembly align with mounting holes in the frame.
10. Insert one thick and one thin shim (3) in each end of the lower drive assembly.
11. Tap two pivot pins (2) into the lower drive assembly. The lower drive assembly may have to be jacked up or down slightly to insert the pivot pins. Make sure each pivot pin goes through shims (3).
12. Secure each pivot pin (2) with a bolt and lock washer (1).
13. Repeat steps 2 through 12 to install the remaining lower drive assembly.
14. Do steps 8 through 12 of Install Drive Chains, located in this module. This will provide the correct tension in the drive chains.
15. Install one brake line to each brake assembly on four rear wheels. Use caution to avoid damaging the fittings or twisting the brake lines.
16. Bleed the brake system thoroughly.
Reference: For information on bleeding the brake system, see Service Brake and Parking Brake Systems, Operation Testing and Adjusting, Form No. KENR2406.
17. Install the rear wheel and tire assemblies to the machine. Weight of each wheel and tire assembly is approximately 36 kg (80 lbs.).
18. Tighten the lug nuts on each wheel and tire assembly in a cross-pattern to 108 N·m (80 lb. ft.).
19. Lift the rear of the machine and remove the blocks. Weight of the machine at the rear wheels is approximately 2400 kg (5000 lbs.).
20. Lower the machine to the ground.
Cutaway From One Half of a Lower Drive Assembly
(1) Lug bolt. (2) Hub. (3) Brake drum. (4) Brake assembly. (5) Wheel cylinder bolt. (6) Bearing retainer. (7) Outside seal. (8) Spacer. (9) Inside seal. (10) Sprocket. (11) Cotter pin. (12) Slotted nut. (13) Axle shaft. (14) Key. (15) Shims. (16) Bearing cup. (17) Bearing cone. (18) Housing.
Disassemble Lower Drive Assemblies
Start By:
a. remove lower drive assemblies
1. Remove cotter pin (11) and slotted nut (12) from one end of axle shaft (13).
2. Pull hub (2) and brake drum (3) assembly off axle shaft (13).
3. Remove key (14) from axle shaft (13). Discard the key. This must be replaced with a new part during assembly.
4. Press lug bolts (1) out of hub (2) and brake drum (3) if any of these parts are damaged or need reworking. Separate hub (2) from brake drum (3).
NOTE: Check the locations of shoe retaining springs (19) and (20), and upper link (21) before removing. These parts must be installed in their original positions during assembly.
5. Remove shoe retaining springs (19) and (20) from brake assembly (4). Use a suitable brake spring tool.
NOTE: Shoe retaining springs (19) and (20) must be removed to remove wheel cylinder bolt (5) in the following step.
6. Remove wheel cylinder bolt (5) from brake assembly (4).
7. Remove bolts and lock washers securing brake assembly (4) to housing (18).
8. Remove the brake assembly. Collect shims (15) and save for assembly.
| NOTICE |
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Keep brake assembly (4), shims (15), and hub (2) and brake drum (3) assembly together. These parts must be installed on the same side of housing (18) as they were removed from. |
9. Pull bearing retainer (6) off axle shaft (13).
10. Remove outside seal (7) from bearing retainer (6). Discard the seal. This must be replaced with a new part during assembly.
11. Repeat steps 1 through 10 to remove components from the other side of the lower drive assembly.
12. Press one end of axle shaft (13) into housing (18), as shown. Bearing cup (16) and bearing cone (17) will be pushed out of the housing.
13. Remove bearing cup (16).
14. Use a bearing puller to remove bearing cone (17) from the axle shaft.
15. Slide spacer (8) off axle shaft (13).
16. Support sprocket (10) to prevent it from falling. Pull the axle shaft out of the housing, as shown.
17. Remove sprocket (10) from inside the housing.
18. Remove bearing cup (16), bearing cone (17), and spacer (8) from the axle shaft.
19. Remove two inside seals (9) from housing (18). Discard the seals. These must be replaced with new parts during assembly.
20. Clean axle shaft (13) and the inside of housing (18) thoroughly. Inspect these parts for damage, especially in the bearing and seal areas. Check axle shaft (13) for broken or damaged splines.
21. Examine sprocket (10) for broken or damaged teeth. Look for damage to the splines on the sprocket.
22. Check the two brake drums for hard spots, scoring, or an out of round condition. Check brake linings for excessive wear.
NOTE: If either brake assembly or brake drum needs to be serviced, see Disassemble Service Brake located in this module.
23. Wash bearing cups (16) and bearing cones (17) in solvent. Dry the bearings immediately after cleaning. Do not dry bearings by spinning with compressed air.
24. Inspect bearings carefully for damage or excessive wear. If necessary, replace bearing cups and cones in sets only.
25. Clean all other parts and inspect for damage or excessive wear. Repair or replace parts as necessary.
Assemble Lower Drive Assemblies
1. Apply a light coat of oil to two new inside seals (9). Install the seals into housing (18) with the lip side of each seal facing the inside of the housing.
2. Make sure each seal (9) seats squarely against the stops in housing (18).
3. Apply a light coat of oil to one spacer (8). Install the spacer onto axle shaft (13), against the axle shaft spline.
4. Press one bearing cone (17) onto the axle shaft. Make sure the bearing cone is seated squarely against spacer (8).
5. Set sprocket (10) inside housing (18). Insert the axle shaft assembly through the housing and sprocket. Work carefully to avoid damaging the two seals installed in the housing.
6. Make sure spline on sprocket (10) fully engages spline on the axle shaft. The sprocket should be centered inside housing (18).
7. Apply a light coat of oil to remaining spacer (8). Install the spacer onto axle shaft (13) inside housing (18). Work carefully to avoid damaging the seal installed in the housing.
8. Brace one end of axle shaft (13) to prevent it from moving. Press the remaining bearing cone (17) onto the other end of the axle shaft, inside housing (18).
9. Make sure bearing cone (17) is seated squarely against spacer (8) inside the housing.
10. Install two bearing cups (16) over bearing cones (17), inside housing (18).
11. Apply a light film of oil to two new outside seals (7). Orient each seal so the closed side faces a bearing retainer (6), as shown. Press one seal into each bearing retainer.
12. Make sure both seals are seated squarely in bearing retainers (6).
13. Install two bearing retainers (6) with seals into housing (18). Use care to prevent damaging the seal lips on the keyways of the axle shaft.
14. Shims (15) come in three sizes: The thin shims are .13 mm (.005 in.) and .18 mm (.007 in.) thick. The thick shims are .51 mm (.020 in.) thick. Use these shims to place a preload on the bearings, as follows.
15. Orient housing (18) so that grease fittings (22) are positioned as shown.
16. Install two thick shims (15) on the left side of housing (18). Align the shim holes with the threaded holes in the housing.
17. Install left-hand brake assembly (4) to housing (18) over shims (15). Install wheel cylinder bolt (5) to fasten the brake assembly to the housing.
NOTE: If the right-hand brake is installed on the left side of housing (18) by mistake, bolt holes will not line up in the following step.
18. Secure the brake assembly with bolts and lock washers. Tighten all bolts to 102 N·m (75 lb. ft.).
19. Install a combination of thick and thin shims (15) to the other side of housing (18). The total thickness of these shims should be roughly equal to the height of bearing retainer shoulder (6).
20. Install right-hand brake assembly (23) to housing (18) over shims (15). Secure the brake assembly with just three bolts and lock washers. Stagger the three bolts in alternate holes.
NOTE: If the left-hand brake is installed on the right side of housing (18) by mistake, bolt holes will not line up correctly.
21. Tighten the three bolts to 102 N·m (75 lb. ft.).
22. Hook one end of a spring scale on a tooth of sprocket (10), as shown. Slowly pull the spring scale to rotate the sprocket. Record the force needed to just start the sprocket rotating.
23. The spring scale reading in step 22 should be 11 ± 2 kg (25 ± 5 lbs.).
24. If the spring scale reading is not correct, remove right-hand brake (23). Adjust the shims as follows:
a. If the spring-scale reading is too low, remove some shims from the assembly. This will increase the bearing preload.
b. If the spring scale reading is too high, add some shims to the assembly. This will decrease the bearing preload.
c. Repeat steps 20 through 24 until the bearing preload is correct.
NOTE: It is all right for the shim thickness to be different on the two sides of the assembly.
25. When the spring scale reading is correct, install the remaining bolts and lock washers to secure the brake assembly. Install wheel cylinder bolt (5). Tighten all bolts to 102 N·m (75 lb. ft.).
26. Install shoe retaining spring (20), upper link (21), and shoe retaining spring (19) onto the two brake assemblies, in the order listed. Use a suitable brake spring tool.
27. Look inside housing (18). Make sure sprocket (10) fully engages the spline on the axle shaft. Sprocket (10) must be centered in the housing.
28. Install two new keys (14) into the keyways on the ends of axle shaft (13).
29. Using a center punch, stake each key at two points where the key meets the keyway.
30. Secure one hub (2) and brake drum (3) assembly with long lug bolts (1), if these parts have been separated. Secure the remaining hub and brake drum assembly with short lug bolts.
31. Observe the following when installing the hub and brake drum assemblies in the following step: When installed on the machine, long lug bolts (1) must be towards the outside of the machine, and short lug bolts (23) must be towards the inside of the machine. Also, grease fittings (22) must face towards the rear of the machine.
32. Install hub (2) and brake drum (3) assemblies onto axle shaft (13). Tap into place so that keys (14) hold the assemblies securely.
33. Install slotted nuts (12) on the ends of axle shaft (13). Tighten the nuts to 163 N·m (120 lb. ft.). After tightening, slots on nuts must be positioned to allow installation of cotter pins (11).
34. Install cotter pins (11) through slots in nut (12) on each end of axle shaft (13).
35. Pump no. 2 grease through two grease fittings (22) at the rear of the lower drive assembly. Stop when grease enters the inside of the housing.
End By:
a. Install lower drive assemblies