Usage:
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is stopped and when the fill plug is cool enough to touch with your bare hands. |
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NOTE: Identify all hydraulic lines as they are removed for reinstallation purposes. Cap and plug all lines and fittings to prevent any contaminants from entering the hydraulic system.
1. Connect a hose to valve (1). Drain hydraulic tank (2). The capacity of the hydraulic tank is 117.5 liters (31 gallons).
2. Disconnect hose assembly (4). Cap or plug immediately.
3. Disconnect hose assembly (10). Cap or plug immediately.
4. Disconnect hose assembly (9). Cap or plug immediately.
5. Remove four bolts (3). Disconnect hose assembly (8). Cap or plug immediately.
6. Remove four bolts (11). Disconnect hose assembly (6). Cap or plug immediately.
7. Loosen four bolts (7) mounting axle propel motor (5).
Typical Example
8. Install floor jack or suitable lifting device under the axle propel motor. Remove four bolts (7) and axle propel motor (5). The weight of the propel motor is 36 kg (80 lb).
NOTE: For installation of the axle propel motor, reverse the removal steps.
9. Fill the hydraulic tank to the correct level. Refer to the Operation & Maintenance Guide KEBU6665 for correct level.
Disassemble Axle Propel Motor
Start By:
a. remove axle propel motor
1. Remove eight bolts (1) and end cap (2).
2. Remove four bolts (3) and control housing (4).
| NOTICE |
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Do not tamper with adjustable screw (A). This controls the pressure for minimum to maximum displacement. |
NOTE: Refer to module KENR1894 Systems Operation and Testing & Adjusting for adjustment procedure.
3. Remove rod (5), spring (6), piston (7), retainer (8), spring (9) and spring (10).
4. Remove retaining ring (13), control piston (11) and sleeve (12).
5. Remove four bolts (14), cover (15) and control lens (16).
6. Remove screw (17) and control pin (18).
7. Remove piston (20) and rings (19).
NOTE: When removing, note orientation of rings to install, refer to "Assemble Axle Propel Motor" C35390P2 for more information.
8. Remove screw (22) from hole (21).
NOTE: Count the numbers of turns for later installation into original position.
9. Remove retaining ring (23).
| NOTICE |
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Use only a puller arrangement as shown in puller (A). Do not use a slidehammer type puller or damage to the motor may result. |
10. Use puller (A) to remove the rotary group. Make sure the cylinder block does not bind as it is pulled from the motor housing.
11. Remove puller (A) from the rotating group.
12. Pull cylinder block (24) from the drive shaft and piston assembly.
13. Remove four Belleville washers (25) and spring collar (26) from the center pin bore of cylinder block (24).
14. Position the drive shaft and piston assembly as shown.
15. Position each piston (27) perpendicular to retaining plate (28) and remove them by pulling straight out. Do this for seven pistons. The center pin cannot be removed at this time.
16. Check seven pistons (27) at area (X) for scratches and pitting. Make replacements, if necessary.
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Piston rings (29) may break apart during removal from the pistons. If the rings are to be removed, wear eye protection to prevent possible personal injury from flying parts. |
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17. Use a screwdriver to remove piston rings (29) from the piston.
18. Remove seven screws (30) that hold the retainer plate to the drive shaft assembly. The screws were installed with Thread Lock, so they will be difficult to remove. Impact the screw heads first to break the seal, and remove by using additional leverage on the screwdriver as shown.
19. Remove the retainer plate, center pin (31) and the ring that holds the center pin in position.
20. Check center pin (31) for scratches and pitting at areas (Y). Replace the center pin, if necessary.
Assemble Axle Propel Motor
1. Measure the drive shaft and bearing assembly to determine the thickness of the shim that will be used under the shaft seal cover. Refer to the Testing & Adjusting Manual for the proper measuring procedure.
2. Measure the center pin, spring collar, control block and control plate to determine the proper size spring collar that should be used for assembly. Refer to the Testing & Adjusting Manual for the proper measuring procedure.
3. Position the drive shaft and bearing assembly as shown. Put center pin (31), retainer washer (32) and retainer plate (33) in position on the drive shaft and bearing assembly.
4. Put 6V1541 Quick Cure Primer on seven screws (30) and let it dry. Put 9S3263 Thread Lock on the seven screws and install them loosely to hold retainer plate (33) to the drive shaft and bearing assembly. Put three pistons (27) in position to align retainer plate (33). Tighten seven screws (30) to a torque of 6 N·m (53 lb ft). Remove the three pistons from the assembly.
| NOTICE |
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All piston rings must be installed with the marks toward the flat end of the piston or the motor will not operate. |
5. Piston rings (29) are spherical and must be installed with the marks toward the flat end of the piston. Use Tool (A) to install the upper piston ring.
6. Use Tool (A) to install the lower piston ring with the marks toward the flat end of the piston. Repeat Steps 5 & 6 for all seven pistons.
7. Rotate the piston rings so that the end gaps of the upper and lower piston rings are 180° apart.
8. The spring collar that was selected in Step 2 should be used at this time. Put spring collar (26) and four Belleville washers (25) into the center pin bore of cylinder block (24).
9. Put SAE 10W oil on seven pistons (27) and in the piston bores of the cylinder block. Install seven pistons (27) into the cylinder block as shown.
10. Put SAE 10W oil on the center pin and in the center pin bore of the cylinder block. Position the drive shaft and bearing assembly with the drive shaft horizontal. Position the cylinder block with the pistons horizontal. Make sure the Belleville washers stay in the proper position when the cylinder block is put in the horizontal position.
11. Align center pin (31) with its bore in the cylinder block and assemble the unit.
12. Hold cylinder block assembly (24) and the drive shaft assembly together and put them in the vertical position. Push each piston into a drive shaft socket through the retainer plate. An audible click is made when each piston is seated properly.
| NOTICE |
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When all seven pistons are seated properly in the retainer plate sockets, the cylinder block will easily angle to one side as shown in the next step. Do not force the cylinder block to angle or damage to the pistons may result. |
13. Angle cylinder block (24) to one side.
14. Put the entire rotating group in a vise. Allow clearance between the drive shaft bearing and the top of the vise for the housing when it is installed over the rotating group.
| NOTICE |
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Do not force the motor housing onto the rotating group or damage to the motor may result. The assembly should be done in one smooth, easy movement. If the housing does not fit over the rotating group easily, the problem should be found and corrected before continuing assembly. |
15. Heat the motor housing evenly to a temperature of 80°C (176°F). Put the motor housing into position over the rotating group. Move the motor housing down over the rotating group and tilt it to clear the rotating group as it is assembled. Continue until the rotating group bottoms out in the motor housing. A small amount of tapping on the outside of the motor housing may be needed, but do not force the assembly together. Allow the motor housing to cool before continuing assembly.
16. Install the seal in cover (24) with the lip toward the inside of the motor. Install the O-ring seal on the cover. Apply 5P960 Multipurpose Grease to the O-ring seal. Put SAE 10W oil on the lip type seal.
17. Put Tool (C) over the drive shaft. Install the proper shim that was determined in Step 1 and the cover in the motor housing.
18. Use Tool (D) to install retaining ring (23). Use Tool (B) to pull the rotating group up against retaining ring (23). This will position the rotating group in the correct location in the motor housing. Remove Tool (B).
19. Install screw (22) in hole (21).
| NOTICE |
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Do not tamper with adjustable screw (22). This controls the minimum to maximum displacement. Refer to the Systems Operation Manual KENR1894 for the adjustment procedure. |
20. Install two back-up rings and seal ring (19). Install piston (20) and install pin control (18) into the piston with the detent toward the set screw.
NOTE: Install first backup ring (B) with chamfer towards piston. Install lip seal (C) with lip towards piston. Install last backup ring (D) with chamfer away from the piston ring.
21. Install set screw (17) to lock down pin control (18).
22. Install lense control (16). Install cover (15) with four bolts (14).
23. Install pin (11) and piston (12). Install retaining ring (13).
24. Install springs (9) & (10). Install retainer (8) and cap (7). Install spring (6) and rod (5).
25. Install O-rings (40).
26. Install control (4) with four bolts (3).
27. Install cap (2) with eight bolts (1). Tighten eight bolts (1) to a torque of 49 N·m (36 lb ft).
End By:
a. install axle propel motor
Remove & Install Axle Gearbox
Start By:
a. remove axle propel motor
Typical Example
1. Position a floor jack or similar lifting device under the gearbox.
2. Remove six bolts (1).
3. Remove axle gearbox (2). The weight of the axle gearbox is 25 kg (55 lb).
NOTE: For installation of the axle gearbox, reverse the removal steps.
End By:
a. install axle propel motor
Disassemble & Assemble Axle Gearbox
Start By:
a. remove axle gearbox
1. Remove twelve bolts (1).
2. Remove cover (2), carrier (3) and ring gear (4) from housing (5).
3. Remove spacer (6), gear (7), spacer (8) and coupling (9) from carrier (3).
4. Use a hammer and punch to push roll pin (11) into shaft (12). Remove shaft (12) and gear (10). Remove the roll pin from the shaft. Repeat this for the other two gears.
NOTE: The following steps are for the assembly of the gearbox.
5. Position gear (10) and install shaft (12). Install the roll pin in the shaft. Repeat for the other two gears.
6. Install gear (7), spacer (8) and coupling (9) into carrier (3).
7. Position the housing down on the flange.
8. Install carrier (3) in the housing. Install O-ring (13) in the housing.
9. Install ring gear (4). Install washer (6).
10. Install O-ring (14) in the cap.
11. Position cap (2) and fasten with twelve bolts (1).
End By:
a. install axle gearbox