SUBSECTION 7A INTRODUCTION GENERAL This section is divided into subsections that describe major assemblies and components of the propel system and in- cludes removal, disassembly. assembly and installation procedures. Rocommended inspection, adjustment. and rapair proce: ‘dures are included in the individual subsections, Whenever performing work in the propel sys- tem that requires the disconnection of the drive train of brake linkago, ensure thet the crawler tracks are blocked to prevent free roll- ing of the machine, (DESCRIPTION ‘The propel system machinery, shown in Figure 74-1, con: sists of two separate but identical sets of deive machinery, ‘ono for each crawler bet Each set of drive machinary consists of a reversible direct current motor, a W" bolt drive assembly, a triple reduction, transmission, # shear bar coupling and beake assembly, a final drive assembly and a crawier sida frame assembly ‘with an associated crawier belt. provide deiva powar for both forward and idcanbe independent controlled or right ‘ Iaft steering in both the forward and reverse directions, ‘When the machine is opersted in the digging made of oper ation the propel brakes hofd the input shaftof thefinaldrive assembly to prevent undesired movement of the excavator BELT DRIVE Propet ASSEMBLIES. MoToR IRIGHT) PROPEL, BRAKE CRAWLER, DRIVE ‘TUMBLER FINAL one ASSEMBLY VINTEGRAL WITH THE CRAWLER, CRAWLER DAIVE TUMBLER TRANSMISSION FRAME) Figure 7A-1. Propel Machinery TANSUBSECTION 7B PROPEL DRIVE SYSTEM GENERAL ‘This subsection describes the propel drive system and in cludes the removal, installation and adjustment proce- dures for the propel motors and the propel motor "V" belt drive coupling. DESCRIPTION ‘The propet drive systom, a8 shown in Figure 78-1, includes tho right and loft propel motors with their ventilation blow- ‘or assemblies, and the “V" belt drive assemblios. Tho two reversible, independently controlled motors are: mounted on their associated transmission and are coupled to the transmissions input shatts with a one 10 one reduc tion Power Band "V" belt drive. Whenthe operator operates. propel system. the output of the propel motorsis trans~ 184 through the matched sat drive belt assemblies, the triple reduction transmissions. through the shear bar cou- plings and released brake assemblies, to the final drive assemblies and crawier belts. This drive system provides: ‘the excavator with forward ar reverse propel motions with ferential and/or counter rotating type steering INSPECTION AND REPAIR a wont, shaft end play. dam- ged components, lovee connections, proper lubrication, ‘and proper belt tension. The propel motot ventilation sys- tom should be eheckad for proper nir flow. Repair of the propel drive aystem is limitedto the replacament of exces- sively worn or damaged components. AowusTING “Ve BELT DRIVE SCREWS. PROPEL MOTOR Figure 78-1. Propel Drive SystemSUBSECTION 78 After any propel motor service, chack the air flow through the motor. The propel motor should be sealed with solid covers, so that forced ventilation can flow through the motor land out the exhaust. Also check the blow: whee! for soundnass. PROPEL MOTOR REMOVAL Remove the peopel motor as follows: NOTE Each propel motor with its assaciated blower assam: bby. drive belt assembly, and propal vansmission can ‘be removed as a complete module if desired by ‘wically disconnecting the motor, disconnecting the propel brake,demating the shear bar coupling, and ‘than removing the propel transmission mounting bolts from the carbody and lifting the assembly from ‘the carbody. Tha propel motor and transmission assembly weighs approximately 20,000 Ibs BELT ORIVE MOTOR ASSEMBLY ADJUSTING (CASE REMOVED) ‘SCREWS bpive aeLT CASE ASSEMBLY GEAR CASE PROPEL TRANSMISSION PROPEL DRIVE SYSTEM ‘The propel system must be securad electrical- ly, using electrical safety tagout proceduresto Prevant possible parsonnel injury or equip- ment damage. 1. Remove the case cover sections from the drive belt as: sembly. 2. Tag and disconnect all slectrical laads to the peopel mo: tor. 3, Romove the motor blower assembly and cover plates from the propel motor housing, to gain access to the mator ‘mounting bolts, (see Figure 78:2), 4. Insure the motor and the propel geer case are match marked to aid in reassembly, 5. Loosen the four motor mounting botts. Loosen the two motor adjustment screws in equal amounts ta slacken the dive baits. PROPEL Motor BLOWER ASSEMBLY ADJUSTING ‘SCREWS, Figure 78.2. Propel Motor Mounting AssemblyPROPEL DRIVE SYSTEM The drive belts should be loos enough to ra- move tham without prying the belts off of the sheaves. This will pravent possible damage to the old belts if they are to be reinstalled and will aid in the installation of naw drive batts. 6, Remove the drive beits. The propal belt assemblies on ‘each propel drive ate matchedbelts and shouldbe replaced 'Sat for prapar operation. Do Not mixbalts from the right ‘side with those from the lett 7. if necessary, remove the sheave from the propel motor shaft. The sheave weighs approximately 380 ths. 8. Attach @ suitable liting device to the propel motor. The propel motor weighs approximately 6,000 Ibs. 8. Remove the motor mounting bolts, and litt the motor {from the mounting surface of the gear case. Note the posi- tion of the adjusting screws tor future reference during ‘motor installation. INSTALLATION, Install the propel motor as follows: 1, Insure the motor mounting surfaces are free from burrs ‘and the adjustment screws ate in the same position that wey were in at motor removal, Apply # coating of grease to -Bilding surtaces to ease the positioning ef the motors ‘during beit adjustment and ta prevent corr NOTE ‘The motor position should be such thatthe new drive bolts havo enough slack to be installed without pry- ‘ing the belts over the sheaves. 2. It necessary, install he belt drive sheave antothe motor shalt, Insurethe sheave retainingnutislecked in place with tha bent edge of a new retainer washer. Always use a now washer when reinstalling the sheave, 3. Lift the motor assembly onto the mounting brackets of ‘the goar case. The motor and sheave assembly weighs ap- proximately 6400 Ibs. '4_ Install the four motor mounting bolt assemblies as fol- awa (See Figure 78-2) A. Assomble the motor mounting belts with the top nutand lockwasher. 2B. Install the bolt essemblies {rom step 4A down through the motor base through the pear ease bracket, . Install the castte nuts with cattar pins on the bottom of the motor mounting bolts. . Tighten the mator mounting bolt assembles until snug tight, then loosen the top nute slightly to allow the mo- tor to slide during step 7 5, Insure the belt drive sheave on the motor shaft and the transmission Input shalt are aligned. Use a tong streight ‘edge #8 shown in Figure 7B-3, SUBSECTION 78 STRAIGHTEDGE moroR (A PROPEL TRANSMISSION | ( \ rransission INPUT (FIRST GEAR CASE REDUCTION) SHAFT Figura 78-3, Sheave Alignment Do not pry the drive belts over the sheaves or damage to the belts may reault. The drive belte must be replaced es 2 matched sat to provide proper operation. 6. Install the drive belts on the belt drive s! 7. Refer to Figure 78-2 and adjust the drive belts for proper tension as follows: A. I necessary, loosen the motor mounting belt nuts just fanough to allow tha motor ta slide on the mounting surface. 1B. Using the adjusting serews on tha mounting bracket, ro- tate the screws in equal amounts until the “" drive belts are tightened to the proper belt tension (see Drive Bolt Adjustment Topic). Insure the belt drive sheaves are aligned (see Figure 78-3), NOTE Always adjust the screw closest to the drive belt sheave first, to maintain propar loading and motor alignment 78-3SUBSECTION 7B Tighten the motor mount bolt assembly nuts in equal steps to the specified torque (20 Torque, Table 1-2). 8. Install the bolt drive assembly covers, 8. Install the propa motor cover plates and blower assem: by. 10. Connect altat the electrical connections thatwere dis- connected during motor tamoval, 11. Restore the propel system to the normal slectricatline- Lupand test the propel drive system for proper eperation. in- ‘sure the propel has proper air flow. Rendjust the drive belt assemblies if slippage occurs. NOTE After 100 hours af operation the propel drive belts should be readjusted to propar tension to compen- sate for strotch of the new belt assemblies. DRIVE BELT ADJUSTMENT There sre tivo propel drive belt adjustment procedures, one fornewbolts and onafor baits that hava beanin service ‘more than 100 hours of operation, ‘Toadjustnew propel drive beits for proper tension. proceed. 28 follows: 1, Wonecessary, loosen the motor mounting Balt nuts. show in Figure 78-2, just enough to atiow the propel motor to stide on the mounting brackets 2. Ensure the belt drive shouves aro aligned, as shown in Figure 78-3. if necessary use the motor adjustmant screws to.aliga the sheaves NOTE Always adjust the scraw closest to the drive belt sheave first to maintain proper loading and motor lignment. 2. Using the motor adjusting serows on the mounting ‘bracket, rotate the screws in equal amounts until tha “V" drive belts are tightened to the proper belt tension as follows ‘A. Tighten the bolts until most of the sinek is removed and the boits are straight, as shown in Figure 78-4, 8, Apply aperpandiculss force ol 2201s, pressure, evenly actos the width of one Belt assembly and lock for & election of 11/'16 inch, as shown in Figure 78-4. the belt dofiection is more than 11/16 inch, adjust the motor adjustment screws in equal emourts until the ‘deflection is 11/16 inch andthe force it still 2201s. Do. ‘not exceed 220 Ibs, force to yet the 11/16 inch dettection. PROPEL DRIVE SYSTEM NOTE Rotate the belt drive shaft assemblies 19 reposition the drive belt and cheek the deflection of the belt in. least two more places on the belt to ensure the new belts were seated in the sheaves 4. Tighten the propel motor mounting bolt nuts 0 the speci fied torque (see Torque Table 1-2) 5; install the motor cover plates and blawer sssembly, 6. Check the propel system for proper operation. 7. Install the belt drive assombly covors NOTE After TOO hours of operation the now bolts should be readjusted to com; ing. Use a perpendicular force of 180 t0 200 Ibs, of force and adjust a8 necessary tor a detection of 11/16 inch. Oo not exceed @ force of 200 (bs. t0 get the 11/1 inch detlection, Refer to the chock and adjust- ment procedures for belts that have been in service, To check and adjust propel drive belts that have been yn sefvice for more than 100 hours, proceod a follows: Use tagoutprocedure in the operator's ccopto: provent operation of the propel machinery ‘while working on the propel belts orpersonnal Injury or death may result, 1. Gain access to the drive belts by removing the drive belt case cover sections 2 Check the alignment of the belt drive sheaves as shown ‘78-3. Adjust the motor if necessary to achieve proper sheave alignment, 3. Apply @ perpendicular force of 160 t0 200 ibs.. evenly ‘cross the width of one belt assembly and look for a do{lee- tion of 11/16 inch (soa Figure 78-4) 4. If the dettoction of tha bolt is more than 11/16 inch, laosnnthe motor mounting bolt nuts shown in Figure 78-2, _andadjust the motor adjustment serewsin equal steps unt hebolt defloctionis 11 /16inch anesthe force is still 1600 rxceed 200 Ibs. of forew fo gat the 11/16 Nore Rotate the beh drive shaft assemblies to repasition the belt andcheck the deflection of he belt in atleast Iwo more places on the belt to ensure the belts were ‘seated in the sheave, '5. Tighten the propel motor mounting bolt nuts tothe speci: fied torque (see Torque Table 1-2). ‘6. Install the motor cover plates and blower assembiy. 7. Check the propel aystoen for proper operation. 18. Install the belt drive assambly covers.PROPEL DRIVE SYSTEMS, ourer BELT SUBSECTION 7B INNER ™ Wve HEAVE ‘sraaiqyTeoGe ourer PERPENDICULAR BELT FORCE 11/16" DEFLECTION FROME STRAIGHT BELT NOTE: DEFLECTION IS EXAGERATED TO EMPHASIZE PROCEDURE Figure 78-4, Drive Belt Adjustment 785SUBSECTION 7¢ PROPEL TRANSMISSION GENERAL ‘This subsection describes the prepel transmission and in. cludes the inspection, rameval, disassembly, assembly and Installation procedures. Also included is the disassembly, inspection and assembly of the major shat assemblies of the propel transmission. NOTE Thote are two propel transmissions used on this ma- chine. One for the right propel system and one for the left propel system. This subsection describes and Illustrates therightpropel transmission, however, he procedures also apply to the iaft transmission. The ‘ight and left tranamission components are identical ‘except they are mounted in opposite positions in the ‘gear case. INSPECTION AND REPAIR Periodic inspections of the propel gear case and transmis: sion are recommended, The inspections should include a check for oll leaks, clear breather vents. bolt tightness and excessive wear or damage. The transmission components should be checked annually for cracks in teeth faces, un- usual wear. galling, scoring or spalling. The gears can be viewed by opening the inspection covers on tha propel transmission gear case cover. Repair of the propel transmission gear case and tranamis- sion is limited to the replacement of excessively worn or damaged parts found during periodic inspections or over- haul, TRANSMISSION (100J5482-1) DESCRIPTION The propel transmission, asshownin Figure 7C-1, isathrae ‘eduction, spur eut gear train that is enclosed in an oil tight ‘gear case. All gearing in thegear cases supportedonrolier bearings. The first reduction gear and second reduction bition are quill mounted on the output shaft. The propel ‘gear case Ig mounted on milled pads located an tha rear of the carbody. ‘The propel transmission transmits propel drive power from the prope! motor and belt drive assamibly to the driving member of the output coupling and tinal drive, ‘The propal transmission gesting and bearings areiboth and splash lubricated with geer oll contained in the transmis- sion gear case (s0@ Section X for lubrication specifice- tions. REMOVAL ‘The propel transmission assembly canbe removed from the ‘excavator for repair or overhaul. To remove the transmis- sion assembly, proceed as follows: Finst THRO ‘ourpur REDUCTION AEDUGTION SHAFT GEAR GEAR ASSEMBLY THIRO REDUCTION ‘SHAFT ASSEMBLY GEAR CASE Figure 76-1. Propel Transmission (100J5492-1) 74SUBSECTION 7G tracks with 1, Pesition the machine om leval ground with the upper at right angles to the earbody. 2. Itrnecessary, remove the propa! motor and batt crive as- sembly as described in Subsection 78, NOTE Either propel transmission, with its associated propel motor and Blower assembly, and the balt drive ai sembly can be ramaved from the carbedy as one module by disconnecting the motor efectrical cons nections and proceeding to step 3 without complat- ing motor removal 3. Partially remove the associated propel braka as follows. A, Release tha propel brake by pressurizing the brake roto- chamber. NoTE {tthe machine air pressure is available, manual over ride of the air solenoid valve will ralease the brake. B. With tha brake ralassad, refer to Figure 7C-2. and loosen the upper brake adjustmont nut (8) C. Vent the beaks rotochambar. This will partially relax the propel brake spring assembly Figure 7¢-2, Propel Brake (Loft) 10-2 PROPEL TRANSMISSION 1D. Attach a lifting device to the lower brake arm to support the lower atm. Remove the upper adjustment put (8) and the two auts on the bra ‘support Lower the and of the brake arm ta the ground. Remove. the slinger shield from the transmission side of the brake wheel 4. Astach a suitable ling device tothe lilting oyes 00 the propel transmission. Thapropel transmission andmetor a: ‘Sembly weighs approximately 30.000 Ibs.. the transmis sion atone weighs approximately 21,500 los. NOTE tis not necessary to drain gear oll from the gearcase ramoval. However, draining ie desired, neon. ‘that will Nold at least 80 gallons is required, 5, Remove the transmission mounting bolts and carefully lift the trangmission away from the earbody, Nore ‘AS tho transmission is removed, it shouldbe kept re Sonably square with the milled adgo of tha carbedy. ‘This.can be accomplishedby installing rwalifting ove= bolts in the place of two propel transmission flange Bolts on the reas of the transmission ease. Attach slings and puller hoist {come along} between the ‘ing eyes and hook of the preliminary lifting device. ‘The puller hoist can then be uted to tlt the transmis ‘sion. squaring it with the earbody's milled edge (soe Figure 7C-16), DISASSEMBLY The propel transmission is disassembled by removing the ‘major shatt assemblies from the propel gear case, as shawn in Figure 7C-3, Each major shalt assembly is further dises- semibted for overhaul and repair as described in the topic, Disassembly of Major Components. if an overhaul is not being performed, disassembly can be limited to the proce: dures required for a specific repalr, Disassemble the prope! transmission us follows: GEAR CASE COVER, Remove the transmission g cover as follows: iF case 1. I necessary, remove the propel motor and belt drive as sembly {fom the propel transmission gear case 35 de- scribed in Subsection 78, 2. Remove the top four eapseraws and loosen the bottom ‘capserews on the drive belt case mounting plate, the out- ut shaft Keeper plate and bearing carrier. and the third re duction shaft bearing retainer plat 3. Remove the cover nuts, bolts and lockwashors. NOTE ‘Two body fitted coupling bolts are instalied in the propel gear case (or alignment purposes. These body fitted bolts may need to be driven out during cover re- ‘moval. Replzice the coupling bolts with new coupling, bolts ifthe bolt threads or body are dsmogad (see Fig ure 7C-4 for coupling bolt location}PROPEL TRANSMISSION OUTPUT SHAFT. ASSEMBLY THIRD REDUCTION ASSEMBLY FIRST REDUCTION. ASSEMBLY SUBSECTION 7¢ Figure 7C:3, Proge| Transmission Disassembly/Assembly 4. Lift the cover from tha assembly. This assembly weighs approximately 4758 Ibs. OUTPUT SHAFT ASSEMBLY (910J353-3). Refer to Figure, TC-3 and 7C-5, Remove the output shalt assembly as fol- lowe: 1. Remove capscrews and lackwashers(06, G7, 26and27) from bearing carriers (08: and 23), 2. Lift the output shaft assembly from the gear case. This. assembly weighs approximately GOGO Ibs. Place the as sembly on a wooden base to prevent damage fo the gear ‘teeth. Place wooden wedges against the assembly tokeepit from rotting FIRST REDUCTION PINION ASSEMBLY (910545). Raterto, Figures 7C-3 and 7C-6. Remove the first reduction pinion assembly as follows: 1. H necessary. remove mut (01). lockwashar (02) and sheave (03) from shaft (25), 2. Remove the lower capserews (16), lockwashars(17), and ‘mounting plate (27) from the bearing capsula(19-and gear case bearing block. 3. While supparting the first raduetion shaft acsombly, pull the shaft assembly with the innr race of bearing (24) out ot bearing retainer (15), Carefully liftthe first reduction shaft assembly from the gear case. The first reduction shaft as sembly waighs approximately 380 Ibs. without the sheave, 690 lbs, with the sheave, 4, Remove snap ring (23) and the outer race and rollers of bearing (24) from the bearing housing of retainer (15) NOTE Bearing retainer (18) ie lockod in place with two socket head, self locking setscrews (14). if neces- sary, remove the setscrews and remove bearing re- taipar (15} from the gear ease bearing bleck THIRD REDUCTION SHAFT ASSEMBLY, Retorto Figure 7C- 3 and 7C-7. Remove the thied reduction pinion shalt as- ‘sembly from the goar ease 2s follows: 703SUBSECTION 7¢ couPLING: BOLT coUPLING ‘BOLT Figure 7C-#. Coupling Bolt Lubrication 1. Remave the capscrews and lockwashers from bearing retainer and bearing capsule (12 and 03), fnecessary, hold the retainer in place by installing two capserews with nuts ‘at the top of the bearing capsule. 2. Attach a lifting device to the third reduction pinion shatt ‘assembly and apply # stight tension to the assembly. 3. Remove the outer race and rollers of bearing (10) from, the inner bearing block of the gear case base, ndeare- ssembly out of the gear case, The third reduc ssambly weighs approximately 2300 Ibs 5, Place the third reducti blocks to protect the gear t trom rolling free 74 PROPEL TRANSMISSION DISASSEMBLY OF MAJOR COMPONENTS Alter ramaval from the propel tranémission gear case, the ‘major shatt assomblies may require further disassembly for Fepnir or overhaul. Refer to the appropriate procedure and «disassemble the component as required. OUTPUT SHAFT (910353:3}, Rater 10 Figuea 7C-S anddis- assemble the output shaft as follows: 1. Remove the shaft retainar plates (03) and shim pack (04) from the coupling end of shatt (19), Sava shim pack (04) for shaft reassembly, 2. Ramova bearing earrier (08) and shims (09), Trecupand fone cone af bearing (10) wil be removed with carrier (08), Pull the cup and cone of bearing (10) from carrier (08), Remove the remaining cone ofbearing (10) rom shaft(19), 3. Place jacks between the first andthird reduction gear (13 land 20) and jack gear (13) to the left to remove the cone of bearing (11). Remove shim pack (33} from shaft 18) and re- ‘ain shims tor reassembly, 4, Thread rods into the two threaded holes of the first re- ‘duction gear hub (13}. Pull geae (13) and quill pinion (14) ‘rom shaft (19) and spacer (16). 5. Remove bearing cups (11 and 17) fromquill pinion (14), 6. Press goar (13) off quill pinian (14) NOTE Gear (13) is keyed to pinion assembly, 7, Remove tockwire (2), capacrows(31), and retainer plate 490) from the elutch end af shaft (22) 8. Remove coupling member (28) from shaft (19), ‘8. Remove bearing cartier (23} with seal {27} from the our put shaft assembly, Remove sea|(27) from carrier (23), Re. move the cup and cones of bearing (21) from shaft (18) 10. Remove spacer (16) from shaft (19), and if necessary press gear (20) from shatt (19). 11. Pull bearing cone (21) from shaft (19). 12. (Clean and inspect the output shaft componsnis, Refer to Cleaning and Inspection topic. FIRST REDUCTION SHAFT ASSEMBLY (810NS45-1} Tho first reduction shaft assambly. thown in Figure 7C-6, ie partially disassembled during the propel transmission gear case disassembly. The following components may be 1o- ‘mowed from the shaftat the gear ease disassembly: nut{O1}, lockwashar [02), sheave (03), snap ring (23), the outer race and rollers of bearing (24), and mounting plate (26), ‘Tho snap ring (23) andl the outer race andl rollers of Bearing {24) remain in the bore of retainer (15) upon removal of the first reduction shatt from the gear case. Te complate the disassembly of the first reduction shatt as sembly proceed as follows: 1. Remove seat housing (12) with seal ring (07). seals (08 and 08) and shim pack (14), from bearing capsule (19) Flemove seal ring (07) and seals (08 and 09) from housing (12). Save shim (14) for reinstallation.PROPEL TRANSMISSION SUBSECTION 7¢ 13. GEAR (FIRST REDUCTION) 08. Shims 14 QUILL PINON 05. BEARING RETAINER 15 KEY 6. SPACER 17. BEARING CUP 23. BEARING GARRIER 18. BEARING CONE 24. SPACER 29. SHINS 18, OUTPUT sHarT 25. LOCKWASHER 30. KEEPER PLATE 20, GEAR (THIRD REDUCTION) 26. CAPSCREW 31. CAPSCREWS: 21. BEARING (DOUBLE ROW) 77. Olt SEAL 32, LOCKWIRE 22. shims 28. FEMALE COUPLING 33. SHIMS Figure 7C-5, Output Shaft Assembly (910J353-9) 70-8SUBSECTION 7¢ 14. SHIM: 16. CAPSCREW 47, LOCKWASHER (A iS i , SHIM. 48. BEARING RETAINER i RAGGA 04 0B 09 18 yb gg 22 Figure 76-6. First Reduction Shaft Assembly (810545) 108 PROPEL TRANSMISSION 18. BEARING 19. CAPSULEPROPEL TRANSMISSION SUBSECTION 7¢ 01, capscrEWs: 02. LOCKWASHER 03, BEARING CAPSULE 04, GASKETS 0.03" 05, BEARING 06. PINION SHAFT 07. KEY 98. GEAR 09. SPACER 10 BEARING 11. RETAINER PLATE 12. BEARING RETAINER 13, caPSCREW 14. SOCKET HEAD seTscneW 15. BEARING RETAINER 18. LOCKWIRE 17. GASKET 08 i 01 " 16 13 15: Figure 7C-7. Third Reduction Shatt Assembly (910N537-2) TerSUBSECTION 7¢ 2. Pull bearing capsule (19) with shim-pock (22) and O-ing (20) along with tha cup and outer eonw of bearing (18) and spacer (08), trom the end of shaft (25). 3. Remove shim pack (22}, O-ring (20) and the cup of boar- ing (18) trom bearing eapsuie (19), Savethe shim pack (22) {or rainstattaion 4. Remove the inner race of bearing (24), and the inner cone of bearing (18) with spacer (21) from shaft (26). 5. Clean and inspect the first reduction shaft assembly components os described in this subsection, refer to the Clwaning and inspection topic. THIRD REDUCTION SHAFT ASSEMBLY (910NE37-2). The third reduction shaft assembly, shown in Figure 7C-7, is partially disassembled during the propel transmission gear ‘case disassembly. The outer race and rollers.of bearing (10) are removed from the gear end of shaft (6) prior to the: ‘moval of the third raduetion shaft assembly from the gear case. To complete the disassembly of the third reduction shaft proceed as follows: 1. Remove beuring retainer {12} and gesket(17}1rom bear ing capsule (03). 2. Cur tockwire (16) and remove capscrews (13) and re- {ainer (11) from the end of shaft (06), 3. Remove the bearing capsule assembly (03) with the ‘outer cone of bearing (06) from the and of pinion shatt (06). 4, Pull the cup of beating (05) from capsule (03), 5. Pull the inner cone of bearing {06) from shatt (08) 8, Pull the innor race of bearing (10) and spacer {09} from pinion shatt (08). 7, Press gear (08) from the pinion shaft, NOTE ‘Second reduction gear (08) is keyed 10 pinion shaft (06). necessary, remave key (07) from shat (06) 8. Clean and inspect the third reduction shaft assembly (re- for 10 the Cleaning and inspection topic) CLEANING AND INSPECTION CLEANING. Clean all parts of the disassembled major com: ponents with a suitable commercial solvent and dry thor- ‘oughly. Never use a hot alkaline solution on finished paris, or bearings. INSPECTION. All parts of disessambled major components should be inspected for wear or damage. Particular atten tio should be paid to the following items: 1. Inspect all gears for wear and surface condition, 2. Inspeet all spaeurs for wear, seoring oF galling 3. Inspect all enti-triction bearings Yor excessive play, dis- torted races, and ball or roller wear or damage. 4, Inspect all surfaces on which seat lips seat, These sur- faces myst be very smooth to prevent wearing away the ‘2a lips, which will eause oll leaks, ica PROPEL TRANSMISSION 5, lngpect all other parts far any evidence of damage. All parts that are questionable should be replaced. 6, Check dimensions of the major components as shawnin Figures 70-18 and 7C-18, REPAIRS ‘Repairs are limited to replacing excessively worn or broken, parts. The inspection is intanded to. determine if the parts, are within allowable tolerances. ‘When the transmission is disassembled for overhaul. the roller bearings must be renewed at assambly. When any major assembly is disassembled, replace the olls seats and gasket ASSEMBLY GENERAL. Assembly of the propel transmission gear case requires te build-up of the major shalt assemblies ofthe ttansmissionbolore ineshet assemblies can be instaledin ‘the gear case. The propel transmission assembly proce- dures are written on the basis tat a complete disessamBiy ff tho propo! transmission has boon done and that all ax- -cessively worn of broken parts have been raplaced. During the eszembly of the propel ranemiesion and the major shaft assembles, the folowing suggestions should be achered to 1. When the torque values are spocitiod be suro to uses torque wrench and tighten ae directed 2 Always prelubricate anti-friction bearings with @ suit able lubricant before final assembly. Novarhant th bearing above 300°F (148°C) or damage to the bearing may result. 3. It betring is to be hested for assembly purposes, the ‘entire bearing should be immorsad in an ol bath, or heated in an oven, for sufficient time to ensure that it is heated throughout. When heating a bearing in an oilbath, place a rack at the bottom of the container to set the bearing on. ‘This will prevent the bearing from touching the hot bottom, ‘4, Smooth out all nicks, burrs or galled spots on shaft, bores of bushings. 6. If the old bearing is to be used, the spacers must be re= ‘assambled in the bearings from which they were removed, Now bearings re recommonded, Double row tapered roller bearings on this ma- ‘chine are matched bearings. Parts of a match- ed bearing should not be interchanged with parts of identical bearings. The bearing conos and beating cups of amatchod Bearing mustbe installed on a shaft in the same order thet the new bearing comes packaged. ‘To assemble tho propel transmission, perform all of the tole lowing procedures in sequence, with the exception of thePROPEL TRANSMISSION assembly of he output shaftassembly procedure which can be dane at any time. THIRD REDUCTION SHAFT ASSEMBLY AND INSTALLA- TION, Rafer to Figures 7C-3 and 7C-7 and proceed as fol- lows: 1. Using » suitable press, press third reduction pinion shalt (06) with kay (07) into second reduction year (08). of bearing (08) and the inner race of the inner baaring cone of bearing (05) in place on the shstt end, taper away from the pinion. Tap the bearing slightly with a mild steet bar to properly seat the beneing NOTE Bearing (05) (s a matched, double row, roller bearing. Matched bearings are usually etched with letters on the sides of the cups and canes. it does not matter 1088.07 the shaft first. The important thing ‘is that the lettered parts match when stalled, as shown in Figure 7C-8. The” ide of cup, the 3. Install the.cup of besting (05) inbeating capsule (03). In- sure the side of the cup of bearing will match the installed cone of bearing (05), ile CONE ce cur Figure 7-8, Double Row Searing 4 Install the preheated spacer of bearing (05) onto shatt (06) and seat the spacer firmly against the inner bearing race, Apply a coat of bearing grease to the inner and outer cup of bearing (05), ‘SUBSECTION 7¢ 5. Install the assembled bearing capsule (03) with gasket (04) over the installed cone of bearing (05) andend of shaft, {06}. Insure the bearing components match (see Figure 7¢- 8) 6. Install the preheated outer cons of bearing (05) on shaft (06), Seat the bearing cone firmly against the spacer. 7. Install the end retaining plate (11) onto shaft (06) Tighten the capscrews (13) in equal steps to the specified torque and lockwire the capscrews securely (see Torque Table 1-2). 8. install retainer (12) with gasket(1 Tinto bearing capsule (03), Align the nolesin capsuite (03). gaskets (O4and 17)and retainer (12). Fasten the capsule assembly together temporarily with two capserews.and nuts 98. Preheat and install spacer (09) on the gear end of shaft (08), The flange side of the spacer goes against the hub of, ‘gear (08) (see Figure 7C-7), 10. Coat the bearing surface end ot shaft (26) with Loctite ‘No, 601 (P&H 212772-D9 of 010) andthen install the pre- hheated innor race of bearing(1Olaver the Loctite Insure the: bearing race is seatad against spacer (08), 11. Using a suitable sling and lifting device, position the third reduetion shatt assembly inthe gear case. Slightly the shaft assembly while guiding the gear end of shatt (06) Into the gear case bearing block. The third reduction as- ‘sombly weighs approximately 2300 lbs. 112, Lower the third reduction shaft assembly untiitis level ‘and the ond of shaft (06) is centered in the inner bearing block. 13. Install the outer rece and roller assembly of bearing (10) into the inner gear case beating block over the inner race and shatt (see Figure 70-8), 14 Align the capscrew holes in bearing capsule (03), gaskets (04), retainer (12) and the gear case bearina block. Slack the lifting tension an the shatt assembly, and install the lower eapserews (01) with lockwashersinte the aligned. holes. Tighten capscraws (01) finger tight NOTE ‘The bearing retainer (15), shown in Figure 7C-7, can be installed at this time. Apply 8 coat of bearing srease to the rollors of bearing (10), Install the bear- ing retainer (15). Lock retainer in place with two Socket head, self-locking, sotscrows (14). FIRST REDUCTION SHAFT ASSEMBLY AND INSTALLA- TION, Refer to Figures 7€-3 and 7C-6. Assemble and in: Stall the first reduction pinion assembly as follows: 1. Install the outer race and rollers of bearing (24) into the bore of retainer (15), Install snap ring (23) intoretainer (15) 70-9SUBSECTION 7¢ Naver heat bearings above 300°F (148: damage to the bearings may resutt, 2. Preheat the fallewing components ptlor to installing the items on the pinion shaft The inner race of bearing (24), ‘spacers (@4.and21). and thecones and spacer of double row bearing (18). 3, Install the haatad inner race of bearing(24) onthe short fend of pinion shaft (24) Insure the race is firmly seated ‘agoinst the shoulder of the pinion (see Figure 70-8). 4, install hested spacer (21) with the chamfered end to- ‘ward the pinion, Seat the spacer firmly against the pinion Id stoa! bar. ) oF Double row bearing (18) is # matched bearing ‘The parts of this bearing are not interchangs able with othor identical bearings. Each side of tho bearing parts has an etched letter. [tis not important if tho A side oF C sideis installed on tho shaft first. The important thing is that an A side of the bearing cone match the A side of the bearing cup. The same applies to the matched bearing cons and cup with the Istter C as shown on Figure 76-8. '5, Heat andinstall thse innar cone and spacer of bearing (18) ‘on the long end of pinion shaft (25). Seat the bearing cone firmty against spacer (21) 6, Assemble bearing capsule (19} as follows: ‘A. Press the cup of bearing (16) into bearing capsuto (19). Insure the "A side of the bearing cup will match the "A" side of eone BL Lubricate and install a new O-ring (20) inte the ma- chined groove on capsule (19). C. Install shim pack (22) that was removed during disas- ‘sembly, The shim pack should be approximately 0.125 inch thick 7. Install the assembled bearing capsule over the tubri= ‘cated cone of bearing (18). 8. Install the heated outer cone of bearing (18). Seat the ‘cone firmly egainst the bearing spacer. 9, Install the heated spacer (04) against the outer cone of Dearing (18). 10. Install seats (0 and 08) in te boreot retainer (92) The lipsal the seals should point intothe bore. Install gasket (| ‘on the inner lip of retainer (12) 11, Lubricate the surface of spacer (04}and the lipsof seals {08 and 09} 12, Carefully install the assembled retainer (12) with saas {08 and 09) over spacer (0) and shaft (25), Insure the seal lips are not inverted oF damaged. Install seal retainer (07) ‘with capscraws and lockwashers (05 and (6), Install grease piping (13) and fil seal cavity with mi {see Lubrication Section X}. 7-10 PROPEL TRANSMISSION 13. Install mounting plate (27} onto bearing capsule (19). Tompurarily fasten tha mounting plate to capsule (1 9} with two capscrews (16) and nuts. 14, Install keys (28) and press sheave (03) onto shaft (25), Install bent lockwashar (02) and retaining nut(O1). Tighton ‘nut (O1) securely and bend an edge of lockwashar (02) over 8 flat of mut (01), 15. Check the goar case base bearing blocks clean and free of burrs: Insure a slight charnfer is on the outer edge of the ‘outer bare which will allow the bearing capsule with O-ring {20} to be slid into place after gear case cover is installed, Apply a coating of graase to the chamfered edge of bore. 16. Using suitable liting equipment, lift the first reduction shalt assembly into position in the propel gear casa. Use care not to damage shim pack (22), The shaft assembly ‘weighs approximately 690 Ibs. with sheave installed, The first reduction shaft must bo level and aligned properly with the installed bearing race and rollars of bearing (24), to pravent possible bearing damag ‘17. Slide the first reduetion shatt assembly horizontally {nto the inner and outer bearing bleck, until the installed O- ring (20) on bearing capsule (19) is just outside of the gear case bearing block 18. Align bearing capsule (19), shim pack (22) and mount: {ng plate holes with the bores in the gear case bore. Install the bottom four capscrews (18) with lockwashers (17) Tighton capscraws (16) in equal steps until they are smug tight. Insure O-ring (20) slides over the chamfered edge of the gear case without damage to the O-ring ‘OUTPUT SHAFT ASSEMBLY AND INSTALLATION, Rater to Figures 7C-3 and 7C-5. Assemble and install the output, shaft sssernbly as follows: 4, Place third reduction gear (20) on a wood base. Block the gear so it will not roll of fall, 2. Lift shaft (19) and slide it in the bore of gear (20), Post- tion the shaft sa there is an equal overisp ofthe gear hub on ‘the shaft splines. (Double raw bearings (10 and 21) are matched bearings. The parts af matched bearings are not interchangeable with other identical bear- ings, Each side of the bearing parts has an ‘etched letter. itis not importantif thea side or C sido is installed on the shaft first. The important thing is that an Aside of the bearing cone match the A side of the bearing cup. The same applies to the matched bearing cone and ‘cup with the letter C us shown on Figure 7C-8. stall bearing (21) on shatt (19) as follows:PROPEL TRANSMISSION A, Slide a heated cone overt ‘against gear (20), Note which etched letter is against ‘gear (20), B. Slide the heated spacor for the bearing against the ‘installed cone. Place the bearing cup over the instaliod cone $0 the etched letters are matched as. shown on Figure 76-8. © Slide the remaining cone over the shstt into the bearing, cup, Insure that the etched letters on the cane and cup match 4 Sticte heated spacer (24) over shatt (19) against bearing, Take care not to damage the oll seal. Lubricate spacer (24) and seal lips with multipurpose grouse. 6, Install oll saal 2 7)into bearing carrier (23) Install » shiny ‘pack equa! t0.0.0625 inch on carrier(23)andslidethebear- ing carrier over shaft (19) onto bearing(21) and spacer (24), Ingure the lip of seal (27) s seated against the spacer prop: arly (see Figure 7C-5) 6. Install female coupling member (28) on shaft (19) ageinst spacer (24) 7. Make up shim pack (29) that will allow a clearance of 0.010 inch maximum between the and of shaft (19) and keeper plate (30) (see Figure 7€-9), ourput FEMALE ‘ailare cuuTcH LOCKWIRE (32) 10 INCH CLEARANCE NEEDED CAPSCREWS (31) sHiMS. (25) KEEPER PLATE (30) Figure 7¢-9. Keeper Plate Shimming SUBSECTION 7¢ 8. Install kowpar plata (20) over shim pack (29) with eap- ‘Screws (31). Tighten capscrews (31) with atorque ot 325 ft- bs. Secure capscrews (31) with lockwire (32) 9. Rafer to Figure 7C-5 and install thehested bearingcone (18) on shatt (19) against the ett side of third eduction goar (20), The taper of the céne should be away from gear (20). 10. If first reduction gear (13) was removed from quill pinion shaft (14), press the gear on pinion (14). Key (15), ‘mustbe installed in the pinion prior to installation of the re duction gear 11, Install bearing cups {12 and 17) into the first reduction ‘gear assembly, Care should be takon notte damage theands of the spacer when handling. 12, Slide spacer (16) on shaft (19), The spacer should be against bearing cone (18). 13. Lift the first reduction gear assembly intoplace on shaft {19}. Be sure the reduction assembly is tight against bear- fing (18) 14 Install shim pack (33) over shaft (19) against spacer (16), Shim pack (23) és the shim pack removed{ram the out- ut shaft during disassembly, NOTE I shim pack is not available or now components have ‘boon installed on the output shatt assembly, itwill be ‘necessary to measure and adjust the end play of the First reduction gear and pinion assambly, by lacing Shirns 4s necessary between bearing cone (11) and spacer (16). Fabricate the spacer too! shown in Fig. lure 70-14 ta aid in performing step 16. NOTE: THE LENGTH OF THIS, ‘TOOL WILL FIT THE OUTPUT SHAFT FOR MODELS 1900AL. 2100BL, 2300 AND 2800. TWE BOLT LENGTH WILL VARY DEPENDING ON EACH MODEL, bee F 14 ana no | yeavan cea: cn Figure 76-10. Spacer Too! Fabrication yeySUBSECTION 7 PROPEL TRANSMISSION 15. Install the heated bearing cone (11) on shatt (19), Al- FIRST lowe bearing cone to cool. Seat cone (11) into cup (12) nepucTion| against shim pack (38) using a mild sige! bar 16. Measure and adjust thi gear assembly as follows: nd play of the frst reduetion A. Place the spacer too! aver the shalt against the bearing The spacer toa should be held in place by the end plate and capscrews screvedto tha end of the shaft (soe Fig: ure 70-19) ‘output SHAFT ASSEMBLY Figure 7¢-11. Spacer Too! Installation B. Clamp 2 dial indicator tothe spacer too! with the indica- tor against first reduction gear (13) assembly, ©. Chuck the end play of the first reduction gear assembly by moving the gear assembly from side to side. To move the gear tothe right, place a bar botween the lugs.f the ‘spacer too! and gear (13) (soa Figure 70-12), Tomove the gear to the loft, place the bar betwaen the second reduction pinion (14) and the third reduction goar (26) (see Figure 7C-13), D. The-ond play of the first reduction gear assembly instep © must be 0.008 to 0.010 Inch (0.152 10 0.254 mm). If the end play is within the prescribed tolerance, proceed to step 18, if shims are to be added or ramoved 10 achieve proper end play continue with step E NH itt E. Remove spacer too! from the end of shaft (19). Place jacks between the first and third reduction gear assem- Dlies Jack the first reduction gear assembly to the lat just far enough 10 ramove bearing cone (11). INA F, Add or remove shims between spacer (16) and bearing sone (11) a5 required to obtain the proper end play. Re. e peat steps 13 and 14 umtil the «nd play Is within the FIRST REOUCTION ‘specified tolerance SEAR ASSEMBLY 17. Remove the spacer too! 18, Slide @ heated cone af bearing (10) over shaft (19) tight against bearing cone(11), Nate which side of bearing (1 O)is, Figure 7C-13. Gear End Play 70.12PROPEL TRANSMISSION against bearing cone (11) {refer to Caution in step 2 of this procedure}. 19. Slide the heated spacer of bosring (10) against the in- stalled cone on shatt (18) 20. Install the cup of bearing (10) into bering carrier (08), Care should be taken #0 the etehed letters on the installed ‘cone and the bearing cup will match when the eartier i in stalled (see step 18), 21. Place shim pack (09) equal to 0.0626 inch on bearing ‘carrier (08). Instalibearing carrier (08)on shatt(19). Besure the carrier is properly seated on the installed cone of boating (10) 22, Slide the remaining heated cone of bearing (10) over, shaft (19) into the bearing carrier assembly, Etched letters ‘on the cone and cup in the carrier assembly must match {se Figure 70-8) 23, Tap the outer cone of bearing (10) with a mild stee! bar to assure-the bearing is properly seated. 24, Make up shim pack (04) that will allow a clearance of 0.010 inch maximum, between the end of shaft (19) and. keeper plate (03), as shown in Figure 7C-14 25. Install keeper plate (03) over shim pock (0) with cap: ‘screws (02). Tighten capscraws {02) in equal steps to a Jorque of 325 ft-lbs. Secure eapscrewrs (02) with lockwire (01), 26, Install retainer (05) with tw capecrews tohold bearing ‘enttier together during the handling of the output shaft as- sembly eae ol ast NEEDED ‘SUBSECTION 7C 27. Align the bottom holes of the bearing carriers (08 and. 23) to the bores in the gear case bearing blocks. Install the four bottom capscreys in each carrier 28, Check that the prape| transmission gear and pinion, Sshatts are froe to rotate. NOTE ‘The shimsonthe firstreduction shat bearing capsule (19)in Figure 76-6, ond the shims onthe ounpar sha bearing eapoule (08) in Figure 7C-5, may hove tobe adjusted to get proper gear mesh, if any major com- ponent replacement has been accomplished. GEAR CASE COVER INSTALLATION. To install the propel ‘900r £386 cover procood 8s follows: 1. Check the ftange and bearing blocks of the gear ease hace and cover. Insure they are clean and free of burrs. The first reduetion shaft bearing block should have a slight chamter on the outer edge tallow clearance'or the O-ring on the bearing capaul 2. W necessary, install a now 1/92 inch gaeket on tho gear case thange Nowe ‘Some models of propel teansmiasion gear cases do, ot use a gasket betwoen the gear case flanges. I a (gasket was not installed on gear case, use amodium universal jointing compound P&M21-587-O2berwean the Nanges. 3. Check that the propel gear case is clear of al tools, rags, ote. and eheck that the transmission gearing is free 10 rotate, ourpur SHAFT ASSEMBLY Figure 7C-14, Keeper Plate ShimmingSUBSECTION 7¢ “4. Hf necessary, joosen the bottom capscrews on the ‘reduction shaft bearing capsule. Slide the first reduction shatt assembly out enough to clear the O-ring. This is to Prevent damage to the O-ring during step 5. 5, Using 8 suitable liting devi, If the propel gear cave cover and place it on the gear ease bese, Use the tao .oupling bots to align the eover to the base (see Figure 7C> 15 for coupling bolt location), NOTE {11s recommended that light coat of lubrieantbe ap- pliedtothechamtered edge othe first reduction shaft Lbgoring block in the gear case cover prior 10 setting the cever on the gear case base, to help prevent possible damage to the O-ring on the first reduction ‘shatt bearing capsule 010/2— BUNCE HLHM.B. 9 12°86. & 1-1/2 — OUNC COUPLING BOLT x 12746. 0 1-3/4 — SUNCH.W.M.B. 16" LG. TUNE HHMB 0 8° AS Figure 7C-15, Gear Case Cover Bolt Locations 70-14 PROPEL TRANSMISSION 6. Alter the ptopel guar ease cover is aligned, slide thetiret eduction shaft assembly into place by equally tightening, the copscrews on the bearing capsule Tighten these lower ‘eapserewe snug tight. 7. Tighten the lower capscrews on tho output shaft bear. ing carriars and thd reduction shaft bearing capsule, snug tight Install the prope! gear case cover eapserows, shown in Figure 76-15, and tighten tho cover capscrews and coupling bolts in equal steps to the specified torque (see Torque Table 1-2). 2, Install the resto the shaft assembly carrier and capsule eapserews. and lockwashors and tighten all of the cop- screws in equal stops to the specified torques (aes Torque Table 1:2), INSTALLATION ‘To install mapropel transmissionto thacarbody, proceadas follows: 1, Cloan the milled faces of tho carbody and the propel transmission. 2. Attach & suitable litting device to the four iting eyes on ‘the propal transmission. 3, The transmission shauld be positioned so that itis Sonably square with the milled edgo of the carbody while it ‘being lite into place on the carbety. One method is to instail two lifting eyebolts in place of two flange bolts at the rear of the tranamission, Attach a sult able Gling and puller hoist (come along) between the lifting ‘eyes and hook of the primary liting device. The puller hoist ‘can thon be used ta itt ho the eartiody’s milled edge (see cARBOOY PROPEL TRANSMISSION Figure 76-16. Transmission installation Handling SlingPROPEL TRANSMISSION SUBSECTION 7G 4. Position the transmission in place on the carbody. install, the maunting bolts and tighten the bolts to the specified torques (see Torque Table 1-2) NOTE The propel transmission mounting bolts should bein. stalled so the nuts are ts the eutside wharever possible 5, Fill the propel transmission to the proper dipstick level (see Lubrication Specifications Section X) 6. Install the moter and drive belts and perform the drive belt adjustment procedures, as describedin Subsection 78. 7. Install the slinger shield on the transmission side of the brake wheel. 8. Using asuitabto lifting dvice, raise the lower brake arm Of the propel brake. Install the brake adjustment nut (8) and the two brake support nuts, shown in Figure 7C-17. 9. Adjust the propel brake as described in the Propel Brake ‘Adjustment topic in Subsection 70. 10. Install the drive beltcase assembly inthe reverse order (of removal 11. Engage the shear ber coupling membersand install the split collar, as described in Subsection 7E 12. Check the propel system for proper operation, Figure 7C-17, Propel Broke 7-418‘SUBSECTION 7C PROPEL TRANSMISSION RIGHT SIDE rer ‘CODE DIMENSION | BEARING BLOCK Ib a | NNER BLOCK ID | sorein > | BEARING BLOCK ID © | CHAMPHER F | BEARING BLOCK ID @ | SeAnNa BLOCK ID Figure 7-18, Gear Case Dimensions (914278) 70-16PROPEL TRANSMISSION OUTPUT SHAFT ASSEMBLY (9703353.3) 157 REDUGTION GEAR FIRST REDUCTION SHAFT ASSEMBLY (910J545.1) aves ano nepucrion| ‘ean SECOND [REDUCTION THIRD REDUCTION SHAFT ASSEMBLY (810N537-2) ‘SUBSECTION 76 ‘coaE ‘e00E AETTER| DIMENSION evren| Dimension | inch [OWA BEARING 0 low 15.2899 foams GEAR BORE 18.003, 7 [61a Bearing 1 ow 18007 Lees CARPHES.BORE CD PINION O.. 18.005 | © [ow Beane = anne 2 [roareoe. 499 TEETH & |omncanme — | e208 CARRIER 6.0. 16202 [snare so2e2 | * (sare [ova @ |sraccnoo. | © |sracerio. ® |sHeave ro. a [anarroo. spacer on. = |GAPBULE NO. 17 [saat 0. w [carsue 00, V [eoRenD. ) Ww jsarroo. /RETAINER 0.0 ¥ [soREIO. = [sMaFrOO. |suarTo, ‘a | SHAFTOD. ‘oc |suarr an, ‘00 | BEARING CAPSULE 0.0. te /noneto. Figure 7C-19, Propel Transmission Component ‘Dimensions (10018499-1) wearSUBSECTION 7D PROPEL BRAKES GENERAL ‘This subsection describes the propel brakes ofthis machine apd includes removal, disassembly, assembly and installa tien procedures. Ass included are recommended inspec- tion, repair and adjustment procedures DESCRIPTION The propel brakes an this excavator are spring set and air 1824 toggle action type brakes with “V" shaped brake ‘shoes. The propel brakes perform the functions of holding, brakes when the machine is digging end as parking brakes. ‘when the machine is stopped or shutdown. ‘Two propel brake assemblies are used on this excavator, as shown in Figure 7D: 1, The brake essemblies are mounted ‘an the output side of the propel transmissions, The brake Wheolsare actually partof the erawier final drive assembly, This provides positive braking of the crawler fi assambly and traes the prope! transmission goa any chucking motion induced by rapid swing reversals of the upper and the digging reactions of the attachmam, INSPECTION AND REPAIR Proper propel brake adjustments and mainte- nance is mandatory to assure adequate brak- ing of the machine in normal and/or emer ney situations on steep. Periodic inspections of the propel brake assemblies are recommended to check for damage and proper operation. Ai leaks, oxcessive wear of linings and pin connections, and/or grease oF oil contaminated brake linings should be corrected as soon as possible, The brakes should be checked for proper adjustment every 1000 hours (se Adjusiment topic in this subsection} Figure 70-1. Propel Brakes D1SUBSECTION 7D SPRING FRAME ASSEMBLY BRAKE LINKAGE BRAKE SHOE ASSEMBLY PROPEL BRAKES SPRING ADJUSTING NUT SPRING FRAME RETAINING IN ECCENTRIC PLUGS with PINS: BRAKE ARM RETAINING PINS. RETAINING PINS. mouNTING: BRACKET eccenTnic PWwGS (TH PINS Figure 70-2. Propel Brake Assembly (7100/5342) BRAKE ARM LOWER ‘SUPPORT BRAKE ARM NoTE The brake linings must be replaced when any part of the brake linings are warn toa thickness of 3/16 inch oF less, The brake linings should be replaced if they are glazed oF if thay are ell oF grease contaminated. PROPEL BRAKE ASSEMBLY (10045341) DESCRIPTION. The propel brake assembly consists of the components shown in Figure 70-2. ‘The propel brake assembly operates as follaws: Air pres: ‘Sure from the machine air system pressurizes the air cylin: der and the sir cylinder push rod pushes the brake tension, ‘ad against brake spring pressure, Thetensionrod.acwuates the toggle linkage which releases the lower brake arm. Furthar movemant causas nuts(C and D in Figure 7D-2}t0, contact the top of a bracket mounted on the crawler frame thereby limiting the lowering of the lower brake arm and forcing the top brake arm to raise, ‘When the aif is vented from the sir cylinder through the quick relense exhaust valve, spring pressure actuates the ‘toggle linkage, tightening the brake shoes into tha brake ‘wheel to set the brake. ‘Service procedures for this brake assambly consists of adjustment of the brake for brake lining wear, overhaul af 2 the ake shoe linings. REMOVAL ANO DISASSEMBLY. Complete removal of the propal brake acsembly is usually unnecessary. Major com- onents, such as the spring frame assembly with air cylin= dor or the brake arm assemblies can be removed without dotaching the complete brake assembly with mounting bracket from the cerbody, Further disassembly of major componants for replacement of parts or overhaul of air cylinders ean be done by using applicable parts of the fol- lowing procedure, Remove and disassemble the propel brake assembly as follows: Block the crawler tracks during brake disas- sembly to prevent free ralling of the machine. components, and replacomont of the 1. Loosen the airline connactions st thebrake air eylindor. ‘Do Not disconect the air lines at this time. Tap the fitting gently to break the seal, This will allow any pressure ‘rappad in the system to escape, 2. Disconnect the air line and remove tho spring frame suard.PROPEL BRAKES 3. Loosen thejam nutandback eff the spring adjusting nut toremove the spring tension on the cylinder rod (see Figur 70-2), The sieeve nut should be bottomed on the end of the pring frame assembly 4. Attach a lifting device to the spring frame assembly and remove the catter pink and retaining pins from the rod and mounting bracket. Support the brake linkage before unpinning the toggle tension red. When the linkage is un- pinned swing the linkage down out of tha way. 5, Lilt the gpring frame essembly from the machine. The spring assembly weighs approximately 81.6 Ibs. NOTE Disossembly of the spring frame assembly is neces- sary only ifthe spring needs to be replaced or the air cylinder requires servicing 6, oi Figuee A jssemble the spring rod assambly as follows (seo 70-3) Release spring pressure completely by loosening the Jam nut and spring adjusting nut BL Remove the welded flat from the top of the slueve nut land the end of the toggle tension rod. Then back the sleeve nut tovrerds the toggle end of the tension rod, Unscrew the tunsion rod from the air evlinder push rod, Flamave the jam nut, spring adjusting nut end spring ‘seat from the tension rod, E Remove the tension red with the sieeve nut from the spring frame by sliding it out af the spring guide and spring, t DIMENSION. man 37.00" SPRING LENGTH ‘SUBSECTION 7D F. Romove the breather assembly from the air cyling G, Remove the mounting bolts from the air cylinder, Refer to Section Vill for service of the air cylinder 7, The brake linkage and the upper and lower brake arms can be removed using @ hoist and unpinning the brake arm support from the lower arm and unpinning the brake arms, from the frame. Each brake arm assembly weighs approxi- mately 877 Ibs. NOTE ‘See the following repair topic for brake arm disas- sembly and brake shoe lining replacement. REPAIR, Repair of this brake assembly consists of the ra- placement of worn of damaged parts. Overhaul of the brake Air components:can be accomplished by removing and dis- assembling the spring frame assembly, as described in this subsection and then referring to Section Vil Brake shoe linings should bs replaced when worn toathick- ‘hess of 3/16 inch, or ifthe linings are glazed or it they are. contaminated with oil or grease. To replace brake shoe linings proceed as follows: 1. Remove tha brake arm assemblies from the excavate previously deseribad in this subsection, Tho maximum allowable temperature. when applying heat to the linings for removal ix 500°F. Do not excaed this limit, 2, Unpin the brake shoe from the brake arm and ther re- move the brass mounting screws from the finings. Apply haat to the linings to melt the bonding and remove the:lin- ings. | SPRING ‘SEAT CYLINDER, ROD aa TOGGLE SLEEVE SPRING SPRING reveiw "Nur ue serine too ain CYLINDER. aosusting | | © ‘NUT Joo" BREATHER Figure 70-4. Spring Frame Assembly (81817) 70-3SUBSECTION 7D 3. The surface of the lining and shoes must be free from paint, rust, al, grease, or wax, Sand the surfaces and wipe ‘with @ suitable solvent (P&H Part Number 212679), 4. Mix equal parts of Scoteh-wold brand structural odhe- sive [P&H Pert Number 212675}, Mix thoroughly, equal aris, by volume or weight of B (bese) and A (accelerator). NoTE Bonding of 2 linings to shoes requires approximately 1/6 quart of A.und 1/6 quart of B. Mixed color should tba a uniform gray. 5. Apply adhesive evenly on the bonding surfaces of bath the shoe and linings. Use only enough adhesive tocoatboth surfaces. Excessive adhesivethickness willreduco the final ‘bond strength, 6. Join the adhesive coated surtaces. Install the serows 0 ‘hold tham in pines. Allew them to cure at 6O°F (16°C) or ‘above untit completely firm. Heating the newly installed \inings up to 350°F (178°) will speed curing, When using heat, cure only until irm. Prossure is not necessary. 7, Pasition the brake arme on the sides of the brake shos ‘assembly and install the brake shoe retaining pins, eccen- tric plugs and cotter pins (see Figure 70-2), ASSEMBLY AND INSTALLATION. This assembly and in- stallation procedure is written on the basis that acomplete brake disassembly has been completed. Refer to Figure 70- 2 and assemble and install each propel brake assembly a8 follows: Install the serviced upper and lower brake arm assemn~ by liking them in place with a suitable lifting device 88nd pinning them to the mounting bracket. Each brake arm assembly weighs approximately 877 Ibs. 2. While helding the lower brake in 3 horizontal position, install the brake arm support red with nuts"C"" and "D". Pin, the suppert rod in ploce on the lower brake arm assembly. 8. Assemble the spring frame assamblyas follows (se Fig- lure 70-3): ‘A. Aniach the ale cylinder to the spring frame with cap: ‘scraws, washers and nuts: Install the breather into the ‘side of the cylinder B. install the tension rad sleeve nut onto the tension rod with the flat toward the toggle link pin ond. Back the. tension rod adjusting nut toward the pin and as far as. the threads permit, C. Place the spring guide and spring into the spring frame. Funthe tension rod through the spring, spring quide and Spring seat. Turn the spring adjusting nut and jam nut ‘onto the tantion red . Clean ait oi, grease, wax, paint end rust inhibitors from the internal thenad at the end of the tension rod and the thread on the end of the cylinder red E. Apply locking compound (P&H #212772) to the threads ‘of the tension rod and cylinder roc, 7D-4 PROPEL BRAKES F. Scrow the tonsion red onto the cylinder rad until the tension rod is uptothe end of the threads on the cylinder rod. The tension red should be on the cylinder rod about 2.00 inches. G. Turmthe steeve nut until ittouches the face of thespring frame. Measure dimensions “B' and “A, shown in Figure 70-3. Dimension “8” should equal 7.00 inches and dimension "A" should equal 78.625 inches, +H. Continue to turn the sleeve nut two more revolutions Monsure dimensions “8” and “A”, Dimension “8” should now equal 7.260 inches and dimension A’ shauld equal 75.875 inches. 4. Wold a 1/4%x1-1/2x8.00inch flat intopiace, as shown in Figure 70-4, to lock the sleeve nut in position on the tension rod. NoTE Stops G, Hand J ensure that the brake cylinder push fodis pulled outO 25 inches so that the brake cylinder will havo clearance whan the brake ig satand will not bottom out, K_ Adjust the spring length to 37.00 inches with the ad: justing nut, Lock the adjusting nut in place with the jam ut 4, Refer 1o Figure 70-2and install the bre and spring frame onto the machine, rms, linkage 5, Gonnect the air fines 10 the propel brake air cylinder, Nore ‘Check ail of the retaining pins tobe sureall cotter pins: have been installod, ‘SPRING FRAME SLEEVE NUT Figure 70-4, Tension Rod Fat Installation ‘6. Porform all ofthe propa beat ‘Adjustment topic in this subsection, 7. Operate the propel beakes through a few cycles, and recheck mezsurements (seo Figure 7D-5) ADJUSTMENT, When the propel brakes are set. they should becapablect stalling the propel motor andthe brakePROPEL BRAKES adjustment measurements should be as shown in Figure, 7D.5. The overall length should be 76.875 inches, the Spring length should be 36.00 inches and the dimension between sleeve nutand spring frame should be about 1.25 inches. To adjust the brakes atter removal and installation, proceed follows (see Figure 70-5) 1. Set tha propal Brake by releasing the ait from the brake cylinder. The brake shoes of the upper and lower brake arms should make contact (seat) in the brake wheel 2. Measurathe length of the installed spring frame assem- bly between the cantars of the brake pins, shown.as Diman- sion “A” in Figure 7D-3. This dimension should be 76.875, inches. I this dimension is not correct go to step 3. M the, dimension is 76.875 inches go to step 4 3. To adjust the propel brake length 10 76.875 inches pro- coed 28 follows: A. Apply sir pressure to the bral B. Remove the keeper pl ‘shown in Figure 7D-5. ©. Mf dimension “A” is greater than 76.875 inches, r ruts "A" and “"B", If dimension is less than 76.875 inches, lower nuts "A" and" eylindor to release the ‘on the adjusting linkag D, Repeat Stops 1, 2 and 3A through 3C until the proper dimension "A" is achieved, E, Whan tha correct dimension “A” is achieved, tighten ut “A” againstthe brake link such that the keeper plate con be reinstalled. Tighten nut "B" against the link, BRAKE ARM ‘SUPPORT SUBSECTION 70 Note ‘The dimension between the sivave nut face and the Spring frame shouldbe approximately 1.25inches, as shown in Figure 70-6 4. With the brake set, adjust the Brake arm support hex nuts (Cand D}s0 there js 0.25 inch minimum t0.0.50 inch maximum clearance between the bottom face of hex nut ‘Cand the washer (see Figure 70-5) 5, Release the brake by pressurizing the sir eylinder. Check ‘thatthe lower brake shoe just clears the brake wheel. If not ‘set the brake and adjust nuts (C and D) to enlarge the cctearance gap deseribad in stop 4. too much clearance ‘exists botwean tha lower shoe and the brake wheel reduce ‘the clearance gap, NoTE A minimal elearance batweon the lower brake shoes and the brake wheel will assure a quicker release of the top shoe assembly, and at a lower air pressure, NOTE {now Brake arm assemblies are installed, adjust the ‘eccentric plugs 85 follows: A. With the propel brake set, turn the eccentric plugs until ins "E” bottom on the brake shoe on bath sides of the brake arm, Then tum the eccentric plugs until there is (0.12 inch gop between pins “E” and the brake shoes. B. Ropoat step A on other arm assembly, © Weld squares against the flats of the eccentric plugs to provent rotation. Do Not weld the plugs. BRACKET ECCENTRIC PLUG. Figure 70-5, Propel Brake Adjustment (100J5341) 70-5SUBSECTION 7E FINAL DRIVE SYSTEM GENERAL Tho final drive system of this machine consists.aftwofinal This subsection describes the final drive assembly and assemblies as shown in Figure 7E-1. There is final drive covers recommended inspection, disassembly, repair and assembly for the right crawler and one for the aft crawler, assembly proceduras. CRAWLER SIDE FRAME MALE couPLING MEMBER. DRIVE TUMBLER "BRAKE WHEEL FINAL DRIVE GEAR CASE Figure 7E-1. Final Drive System‘SUBSECTION 7E DESCRIPTION Each final drive assembly, as shown in Figure 7E-2, con- sists of a pinion shaft assembly. a drive gear and shaft anda ‘drive tumbler, Each final drive assembly is mounted in a sealed gear case and yoke assembly at the rear of its asso- elated crawler side {rame. The final drive gear casa and yoke are integrally welded into the side frame structure, ‘The final drive assembly shafts are supported by bushings thot are mounted in machinad bores of each finalgear case and yoke: Drive power from the propeltransmissionsis coupledto the final drive assemblies through the engaged components of shear bar couplings, shown in Figure 7E-2.1n thefinal drive PROPEL BRAKE & COUPLING FINAL DRIVE PINION SHAFT FINAL DRIVE GEAR FINAL DRIVE SYSTEM ‘assemblies the final drive pinions drive thefinal drive gears which ate mounted on common drive shatts with the drive tumblers. The drive tumblers then drive the associated cerawlar belts, Lubrication of the fina! drive assembly is accomplished by bath and splash method in the final gear case and by the automatic lubrication system which greases the shaft bushings. See Section X er lubrication specifications. INSPECTION AND REPAIR Poriodic Inspections of the finat drive assembly compo: ents are recommended to check linkages, bushings and shafts for proper lubrication, excessive wear of broken CRAWLER, SIDE FRAME FINAL DRIVE ‘SHAFT ASSEMBLY DRIVE TUMBLER ‘CRAWLER BELT Figure 7E-2. Final Drive SystamFINAL ORIVE SYSTEM SUBSECTION 7E 01. DEFLECTOR 02 SCREW ‘92, Lockwasnen ‘Ot, BRAKE WHEEL Sue ‘SURFACE | (REF ausMINa. FLANGE 0.0. BUSHING FLANGE TWICKNESS (REF) usin 108i = @ | MUSHNG.LENOTA 87 View an F |00. 12.007 ae (ner Susu 52.08 | pusina To 0 Poon CUEARANCE ner Figure 765. Fea ve Pilon Shut Asserbly CSR} 75‘01, LOcKWInE 02. CAPECREW (03. KEEPER PLATE COVER 08, BUSHING 05. THAUST WASHER, (08. DRIVE GEAR 7. THRUST WASHER, 98, BUSHING (03. THRUST WASHER 4, TUMBLER 11. TanusT asin 42, sUSHING 13, DAVE SHAFT 14. COVER PLATE. 45. cAPScREW ‘18, LOCKWASHER 49, GREASE FITTING 18, PRUG/GREASE FITTING 19 O-RING 220, KEEPER PLATE 21. SPRING WASWERS C2) 122. SPRING WASHERS 2} 23 SeaCER. 124, HARDENED THRUST WASHER. ‘SUBSECTION 7E Kio. BUSHING 1 [00 sar w /oistance aerween SPACERS (REF) N/T WASHER jnar)_ —__4 0 |curanance oar (REF, * joo 7 fausnina ei 0 [sume 13.333 PD Remove he devies which 6 holding the crowir bet crawler shoes and Install the two link pins. Install the link pin retaining capscrews. spacers and nuts onboth —G._Adjust the crawler belt as described inthis subsection. 3° DIA. Figure 7F-19. Idler Roller Build-Up (13.950)