MAINTENANCE

D R I V E UNIT R E P A I R / R E B U I L D

The drive unit used on your Crown Lift Truck, is a double reduction gearbox incorporated spiral bevel gears for strength,
quietness and smooth operation. The unit is totally enclosed and oil is pumped throughout to give maximum lubrication to
both bearings and gears.

DRIVE UNIT COMPONENT OVER VIEW

Shown in the illustrations below is a parts breakdown and two cross sectional views of the drive unit components. The views
shown may vary slightly between the RR, RS, RD, SP 3000, TS and TSP trucks.

Crown 1994 PF10344-1 Printed in U S A .

01 REV. 6/95
M3.0-1430-050 M3.0-1430-050
 MAINTENANCE

FIELD INSPECTIONS AND REPAIRS

This drive unit location facilitates the inspection of the drive unit as well as the replacement of the drive axle seal. To inspect
the drive unit, the bottom side cover can be removed. This will allow access to the drive unit lower half which consists of
the axle nut and spiral bevel gear.

REMOVING AXLE SEAL

To remove the drive axle seal, drill two holes 180 degrees
apart into the seals steel lip. Attach a small sheet metal screw
to the end of a slide hammer. Insert the screw into each of the
holes and gently remove seal.

2876P

INSTALLING NEW AXLE SEAL

When installing the new seal apply a thin coat of sealant (part
# 065005-001) to the outer diameter of the seal. Next push
seal into place. To seat the seal, place a wood block over the
seal and use a rubber mallet to drive in as shown. This will
prevent damage to the seal.

2875P

NOTE

RR truck shown. Access to axle on SP 3000, TS and TSP trucks may vary. Refer to appropriate truck service
manual, section M3.0.

Crown 1994 PF10344-2 Printed in U.S.A.

M3.0-1430-051 M3.0-1430-051
 CAOUJh MAINTENANCE

DRIVE UNIT DISASSEMBLY

Once the drive unit is removed it is ready to be taken to the bench for disassembly.

1. REMOVING RETAINING RING FROM MO-

TOR PINION GEAR

To begin drive unit disassembly, remove

the retaining ring from the motor pinion gear
area.

2. SLIDEPULLERONMOTORPINIONGEAR

The pinion gear is drilled and tapped to

facilitate use of a slide hammer for removal
as shown. If the pinon gear and associated
components are to be reused, record the
position and number of shims removed.

3. REMOVING PINION AREAO-RING FROM

CASTING

Remove the O-Ring from the pinion area of

the housing.

3050P

Crown 1994 PF10344-3 Printed in U.S.A.

M3.0-1430-052 M3.0-1430-052
 MAINTENANCE

4. REMOVING UPPER PINION GEAR

Remove the locknut securing the upper reduction gear to

the pinion gear. Remove the pinion mounted reduction
gear as shown.

5. REMOVING IDLER GEAR SHAFT

Insert a 5/16" course thread screw into the idler gear shaft
and remove it with a pry bar.

6. REMOVING 6 BOLTS FROM PINION BEARING RE-

TAINER

Remove the 6 bolts from the pinion bearing retainer.

3053P

Crown 1994 PF10344-4 Printed in U.S.A.

M3.0-1430-053 M3.0-1430-053
 CAQlUh MAINTENANCE

7. PULLING PINION GEAR

The pinion gear can now be pulled as an assembly with

bearings and spacer. If the pinion gear and bearings are
reused record and retain the shim pack. Once the pinion
assembly is removed the idler gear and spacers can now
be removed. Inspect the bearings and gear for excessive
wear. The gearand bearings can be replaced separately.

8. REMOVING MOTOR PINION GEAR, BEARING AND

RETAINER

Remove the motor pinion gear bearing and bearing re-

tainer from the drive housing. The bearing cup can be
driven cut from the bottom. Now remove the O-ring from
the housing bore that seals the bearing and retainer just
removed.

9. STUD BEARING REMOVAL

When the motor pinion gear and lower bearing are re-
moved the stud bearing can be driven out from the top. If
the drive unit is not to be rebuilt, but the stud bearing
requires replacement it can be removed separately. To
remove the stud bearing, split the bearing shell with a
chisel. Use pliers to bend the retainer over and remove the
stud bearing.

3056P

Crown 1994 PF10344-5 Printed in U.S.A.

M3.0-1430-054 M3.0-1430-054
 CRQUJh MAINTENANCE

10. OIL PUMP REMOVAL

Remove the oil pump from the housing. This will facilitate
removal of the drive axle. Inspect the oil pump forcontami-
nates or damage. Rebuilding or replacement of the oil
pump is recommended before drive unit reassembly.

11. REMOVING LOCKNUT FROM AXLE

Remove axle locknut. Due to the thread locking adhesive

the locknut may need to be heated during removal.

Cut the wirelocks and remove the 8 bolts that secure the
ring gear to the hub.

12. REMOVING GEAR AND SHIMS

The spiral bevel gear can be removed with a slide hammer

using a 3/8" course threaded bit.

3059P

Crown 1994 PF10344-6 Printed in U.S.A.

M3.0-1430-055 M3.0-1430-055
 CROUJh MAINTENANCE

13. SPIRAL BEVEL GEAR REMOVED

Behind the spiral bevel gear is the shim pack used to

control backlash between the spiral bevel gear and the
pinion. These shims can be reused provided the axle, hub
or related components are not removed or replaced.

14. REMOVING HUB WITH PULLER

The hub is heat press fitted to the axle. Depending on

wear pulling may require the use of a puller and heat. If
the hub can be removed without a puller, the hub and axle
assembly should be replace;

The axle can be removed. Do not use the seal flange for
support if pressing is required to remove the axle, use the
housing. Replace the seal.

15. PRESSING OR DRIVING OUT BEARING RACE

If the bearings are to be replaced, remove the two cups

from the housing as shown.

3062 P

Crown 1994 PF10344-7 Printed in U.S.A.

M3.0-1430-056 M3.0-1430-056
 MAINTENANCE

ASSEMBLING DRIVE UNIT

1. DRIVE UNIT COMPONENTS

Shown are all the components that make up the drive unit.
Before reassembly be sure to inspect all components for
wear or damage. Install the housing components which
include the bearing cups and oil pump tubing.

2. PINION COMPONENTS

The pinion assembly can be completely disassembled

when bearing removal is required. Inspect and replace
any components showing signs of wear.

3064P

Crown 1994 PF10344-8 Printed in U S A

01 REV. 6/95
M3.0-1430-057 M3.0-1430-057
 cram MAINTENANCE

4. PINION HEIGHT ADJUSTMENTTOOL PART NUMBER

116207

The tool shown is required to accurately determine the

correct pinion gear height or pinion gear to spiral gear
relation. After the bearing cups are installed insert the tool
with the nut side toward the axle seal retainer. Tighten the
nut until it is snug.

3065P

5. TOOL INSTALLED

The face of the tool shown has a radius of exactly 1 in.

(25mm) from the center of the axle bore.

3066P

6. SLIDING PARALLEL

Place the sliding parallel supplied in the kit between the

tool and the pinion gear. Squeeze the sliding parallel
firmly together and tighten down the screws.

Crown 1994 PF10344-9 Printed in U.S.A.

M3.0-143CMD58 M3.0-1430-058
 MAINTENANCE

7. MEASURING THE SLIDING PARALLEL

Remove the sliding parallel. With a micrometer measure

the dimension of the sliding parallel and record. In this
example the measured dimension is 1.378 in. (35mm).

8. ETCHED PINION GEAR DIMENSION

Located on the bottom of the pinion gear is a etched

dimension that represents the distance from the bottom of
the pinion gear to the center of the axle bore. In this
example the etched dimension is 2.378 in. (60mm).

3069P

9. AXLE CENTER TOTAL

The dimension stamped on the bottom of the pinion gear,

in the previous step, is used to identify the proper depth of
the pinion gear to the axle center line. The pinion height
tool measures exactly 1 in. (25mm) from the center to any
side (radius). In this example the sliding parallel mea-
sured exactly 1.378 in. (35mm). These two numbers
added together equal 2.378 in. (60mm) which exactly
matches the dimension on the bottom of the pinion
assembly. The measured dimension and the pinions
etched measurement should not be more than + .003 in.
(.08mm) difference. If the measured dimension did not
check within the maximum tolerance the shims under the
pinion gear will require adjustment. The shims are avail-
able in .008, .010 and .013 in. (.2, .25 and .3mm) thick-
3045P
ness.

Crown 1994 PF10344-10 Printed in U S A

M3.0-1430-059 M3.0-1430-059
 CAOUIh MAINTENANCE

10. AXLE INSPECTION

Inspect the axle before installation to insure there are no

nicks or scratches.

Before installing bearings on the axle heat each bearing

:
and the pump cam to 250 F (120°C) for approximately 25
minutes. To insure proper heating only use a temperature
controlled oven or oil bath. Heating the bearings by any
:
other method or exceeding the 2 5 0 F (120°C) will cause
bearing damage.

: :
The hub should be heated to 4 5 0 F (232 C) for approxi-
mately 35 minutes. Heating the hub will ease installation
and insure proper seating.

11. AXLE ASSEMBLED

After the axle is assembled install it.

=
'I - ESSING THE HUB

Press the hub onto the axle.

3072P

C ^ « n 1994 PF10344-11 Printed in U.S.A.

M3.0-1430-060 M3.0-1430-060
 MAINTENANCE

13. UPPER HOUSING ASSEMBLY

The axle and hub are assembled into the drive unit, begin
— assembly of the upper half. Install the drive motor pinions
lower bearing and cup. Pre-lubricate the bearing by filling
it 1/4 of the way with drive unit oil.

14. IDLER GEAR

Temporarily remove the main pinion assembly. Install the

idler gear and spacer. To ease installation grease each
spacer and place it on the bearing of the idler gear.

15. TIMING MARK ON PINION AND SPIRAL BEVEL GEAR

The pinion gear and spiral bevel gear are matched sets
and should never be replaced individually. Each of the
gears are marked with X's. To time the gears correctly, the
pinion gears X should be placed between the two X's on
the spiral bevel gear. Before installation of either gear,
mark the tooth of the pinion gear and outside surface of
3075P
the spiral bevel gear with a black marker.

Crown 1994 PF10344-12 Printed in U.S.A.

M3.0-1430-061 M3.0-1430-061
 MAINTENANCE

16. PINION GEAR INSTALLATION

Install the pinion gear and proper shim pack. Install the
bolts for the pinion gear and tighten. Install the woodruff
key on the pinion gear shaft and install the gear.

3076P

17. TIGHTENING NUT

Tighten the nut with Crown tool part number 100253-001.

Once the nut is tight bend the tab over on the locking
washer.

3077P

18. IDLER GEAR SHAFT INSTALLATION

Position the idler gear and align the spacers. Install a

5/16" course thread screw into the idler shaft. Carefully
tap the shaft until it is fully seated.

Crown 19S4 PF10344-13 Printed in U.S.A.

M3.0-1430-062 M3.0-1430-062
 MAINTENANCE

19. DRIVE MOTOR PINION INSTALLATION

Install the drive motor pinion and bearing.

3079P

Crown 1994 PF10344-14 Printed in U.S.A.

M3.0-1430-063 M3.0-1430-063
 CRQUJh MAINTENANCE

22. SHIMS AND SPACER

The size of the shim pack must be determined. Shim sizes

include .008, .010 and .013 in. (.2, .25 and .3mm).

23. BEARING DEPTH

To determine the proper shim pack size, measure the

dimension from the top of the pinion bearing to the top of
the drive unit housing and record. In this example it is
1.125 in. (30mm). Install the snap ring, measure its depth
and record. Example .275 in. (7mm).

24. SPACER DIMENSION

Measure the spacer thickness and record. Example .720

in. (18mm).

3084 P

Crown 1994 PF10344-15 Printed in U.S.A.

M3.0-1430-064 M3.0-1430-064
CRQUJh MAINTENANCE

25. SNAP RING THICKNESS

Measure the snap ring thickness. Example .095 in.

(2.4mm).

26. MEASUREMENT ILLUSTRATION

With the previously recorded dimensions calculate the

shim pack required. Take the total depth dimension 1.125
in. (30mm), subtract the dimensions of the snap ring,
spacer, and snap ring depth.
SWAPPING GROOVE
O-aiHG GROOVE ' .275 in. (7 mm) Snap ring depth
.095 in. (2.4mm) Snap ring thickness
• .275
.720 in. (18.3mm) Spacer thickness
1.090 in. (27.6mm) Total measured dimensions
1.125 BEARING RETAINER DEPTH
- .370 SNAP RING • DEPTH 1.125 in. (30mm) Top of bearing to top of drive unit housing
.755 TOTAL
- .720 SPACER THICKNESS 1.090 in. (27.6mm) Total measured dimension
.035 SHIM PACK SUBTOTAL
T .030 ADDED DIMENSION .035 in. (.9mm)
.065 TOTAL SHIM PACK
.030 in. (.8mm) Added Dimension
.065 in. (1.7mm) Total

The snap ring groove inherently adds an additional .030

in. (.8mm) that was not measured during the previous
procedure. For this reason add .030 in. (.8mm) to your
total measurement. In this example the total shim pack
measures .065 in. (1.7mm). The dimension tolerance is
+.003 in. (,08mm), therefore a shim pack of four .010 in.
(.25mm) shims and two .013 in. (.3mm) shims will provide
a total of .066 in. (1.7mm) meeting our dimension.

SPACER AND SHIM INSTALLATION

Install the shims and spacer with the 2 3/8 pipe as shown.
After the spacer is seated install the snap ring.

Crown 1994 PF10344-16 Printed in U.S.A.

01 REV. 6/95
M3.0-1430-065 M3.0-1430-065
 CAOUJh MAINTENANCE

28. COVER INSTALLATION

Install the cover and fasten the screws.

29. SPIRAL BEVEL GEAR INSTALLATION

The shims between the spiral bevel gear and hub are
used to set the backlash between the spiral bevel and
:e = -s. The shim sizes available are .005, .007 and
.020 in. (.13, .18 and .5mm). Begin with three .020 in.
(.5mm) shims and install the gear. Install at least two of
r
•~e s: a bevel gear bolts and tighten.

30. NUT INSTALLATION

Install the axle nut and torque to a 100 ft. lbs. (135Nm).

308SP

Crown 1994 PF10344-17 Printed in U.S.A.

M3.0-1430-066 M3.0-1430-066
 CRQWW MAINTENANCE

3 1 . CHECK BACKLASH

With the use of a dial micrometer, measure the backlash

of the gear at the axle nut. This dimensions should be
between .003 to .006 in. (.08 to .15mm) total. Be sure to
place the micrometer feeler arm tip, or ball, on the very
edge of the nut cutout as shown. The addition of shims will
increase backlash while the removal of shims will de-
crease the backlash. A change of .006 in. (.15mm) shim
will change this dimension by .002 in. (.05mm), or a 3-1
ratio.

32. SPIRAL BEVEL INSTALLATION

Install the remaining gear bolts and tighten. Next install

the lock retainer wire around each of the bolts.

3091P

T O R Q U E REQUIRED
14 FT./LBS. (1.9 MKG)

100 FT./LBS. (13.8 MKG) 90-110 FT./LBS. (12.4-15.2 MKG)

Crown 1994 PF10344-1 Printed in U.S.A.

M3.0-1430-067 M3.0-1430-067
 CRQUJh MAINTENANCE

33. AXLE NUT INSTALLATION

Remove the axle nut and apply red thread lock adhesive
to the axle threads.

34. NUT INSTALLED

Install and torque tre axle nut to a 100 ft. lbs. (135Nm).

35. OIL PUMP INSTALLATION

Install the oil pump. Install the lower cover and gasket.

3094P

Crown 1994 PF10344-19 Printed in U.S.A.

M3.0-1430-068 M3.0-1430-068
 CRQUIh MAINTENANCE

36. CHECKING PUMP OPERATION

Fill the drive unit with oil. Use an old motor coupling
connected to a 1/2 drill to operate the drive unit. Remove
the pipe plug at the top of the drive unit and look for oil flow
as the drive unit turns. Oil should start to flow out of the
pipe plug hole. If oil does not appear the oil pump or pump
lines are malfunctioning and disassembly will be required.

3095P

Crown 1994 PF10344-20 Printed in U.S.A.

M3.0-1430-069 M3.0-1430-069
 CRQUJh DRIVE UNIT

Your Crown Turret Sideloader truck has dual drive units
located at the corners of the power unit. Each drive unit is a
double reduction gearbox incorporating spiral bevel gears
for strength, quietness and smooth operation. Each unit is
totally enclosed and oil is pumped throughout to give maxi-
mum lubrication to bearings and gears. The drive motors,
located on the sides of the power unit, directly above the
drive units, are equipped with a hydraulically released,
spring applied, brake system.
DRIVE TIRE R E P L A C E M E N T
1. Press the drive tire off hub and press replacement tire
on. The outside of the hub must be pressed flush with
outside edge of the tire.
2. Inspect hub and remove any paint that may be present
on tapered lug seats or on inner hub face that contacts
truck axle. See Illustration 2.
3. Finger tighten lug bolts, then tighten to 135/150 Nm
(100/110 ft.lbs.) making sure that they are tightened in
the sequence shown in Illustration 2.

If Present, Remove Paint on Tapered

/f\CAUTION Lug Seats and on Inner Hub Face that
Contacts Truck Axle
Chock the load wheels and raise the power unit
end of the truck until the drive tire is clear of the
floor. Block the power unit securely in this posi-
tion.

Remove the side cover plate. Refer to Illustration 1 for bolt

number and location.

060023-014

ILLUSTRATION 1 Tighten Lug Nuts in Sequence Shown

Open power unit door and remove from power unit. When ILLUSTRATION 2
replacing drive tire, make sure the composition and size are
such that maneuverability and braking requirements are
maintained. Remove the eight lug bolts and remove drive tire
and hub. The drive tire is a "press-on" type.

7371 - EO12027

Crown 1984 PF5829-1 Rev. 2/04 Printed in U S A

01 R E V . 2/04
M3.0-18.0-001 M3.0-18.0-001
 CRQUlh DRIVE UNIT

AXLE SEAL REPLACEMENT
1. Raise rear of the truck so that the drive wheel does not
make contact with the floor. Place necessary hard-
wood blocks under truck in this position to prevent any
injury if hoist or jack should fail.)
2. Remove drive tire from axle.
Clean the seal seating thoroughly. Apply a light coat of
gasket sealer (065005-001) to the O.D. of the seal.
Before installation wipe the sealing element, or lip, with
the lubricant being retained.
Slip the new seal gently on to the axle and squarely up
against the seal retainer making sure the lip of the seal
faces the fluid to be sealed.

3. Drill two (2) .125 in. holes 180° apart through the outer Seat the seal into the seal retainer. Use a hardwood
wall only, of the seal to be replaced. Use a "slide puller", block and a rawhide or rubber mallet to seat the seal
similar to the one shown in Illustration 3, and remove squarely into the retainer. Do not hammer directly on
the old seal. Screw the puller into the face of the seal. the seal and avoid cocking the seal when seating.
After the threads are sufficiently secured into the seal, Check and make sure the new seal outer surface is
operate the puller gently, but firmly, until one side of the flush with the seal retainer.
seal is removed. Move to the other side, if necessary,
and repeat. Do not scratch or nick the seating area of
the seal or the sealing surface on the axle. Seal (In Proper
Surfaces To Position)
Slide Puller Be Inspected
Seal Retainer

Axle
ILLUSTRATION 4

ILLUSTRATION 3

Inspect the O.D. of the axle for any possible groove or

other marks that could cause any leakage after the new
seal is installed. If a slight groove is present, due to seal
wear, the seal can be installed a little deeper into the
seal retainer. Any severe wear, nicks, or scratches
present on the sealing surface of the axle will necessi-
tate its replacement.

Crown 1984 PF5829-2 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-002 M3.0-18.0-002
 CJldUJh DRIVE UNIT

DRIVE UNIT REMOVAL

/f\CAUTION
Be sure battery is disconnected before preform-
ing any maintenance operation.

1. Disconnect and remove battery from truck. Remove

power unit door.

2. Remove side cover plate from power unit skirt area.

Refer to Illustration 1 for related removal information.

NOTE

Chock load wheels and raise power unit end of

truck until drive unit is clear of floor. Block power
unit securely in position.

3. Remove drain plug in bottom of drive unit housing with

a .25 in. hex key wrench and drain gear oil.

4. Remove eight lug nuts and hub tire assembly from

drive unit.

"248 ILLUSTRATION 5

5. Refer to Illustration 5. Remove fan (2), drum (5), and

brake assembly (7) from top of drive motor. Remove
brake cylinder (11) from mounting bracket (15). Stabi-
lize the brake cylinder so that unnecessary movement
of cylinder and brake lines is avoided. The remaining
brake components can remain intact on the brake
bracket. Take care and remove bracket from motor and
secure in a position that will allow the drive motor (9) to
be lifted up. Avoid moving bracket to the point of
straining any electrical connections.

Crown 1984 PF5829-3 Hev. 2/04 Printed in U.S.A.

01 REV. 2/04
M3.0-18.0-003 M3.0-18.0-003
 DRIVE UNIT

ILLUSTRATION 6

Crown 1984 PF5829-4 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-004 M3.0-18.0-004
 CRQUJh
6. Remove drive motor cables from drive motor. Note the
routing and location of all cables for reference at
assembly. Also, note position of the drive motor and
remove the four fasteners at the motor base. Install a
1/2-20 eye bolt in the top of the motor shaft. Attach
hoist, or other suitable lifting equipment, to eye bolt and
move motor aside taking care to lift-motor straight up
until it is clear of seal area of drive unit.
7. Install a 3/8-16 eye bolt in the pinion shaft of the drive
unit. Attach a hoist, or other suitable lifting equipment,
to eye bolt and lift just enough to remove slack from
lifting equipment.
8. Refer to Illustration 6 and remove six bolts attaching
the steering bracket to the sides of the drive unit
housing. Remove the four hex socket head bolts (68)
and drive the two dowel pins (69) on through the
mounting bracket until the clamp stud (67) is free. As
these fasteners are removed the weight of the drive
unit will be transferred to the hoist. Lower the drive unit
to the floor and remove lifting equipment from drive
unit. Remove two dowel pins from the clamp stud
assembly. Dowel pins will be used again when install-
ing drive unit.
9. Move drive unit to a clean work area if further disas-
sembly is required.
DRIVE UNIT INSTALLATION
1. Position drive unit under mounting bracket of power
unit. Install a 3/8-16 eye bolt in pinion shaft at top of
drive unit. Attach a hoist, orother suitable lifting device,
to eye bolt. The hook up must come down through the
mounting bracket.
2. Raise the drive unit. Mesh the steering gears properly.
Refer to Illustration 6. Position the clamp stud assem-
bly with felt seal (66 & 67) into drive unit. Align the drive
unit assembly with the steering bracket.
Crown 1984 PF5829-5 Rev. 2/04
01 R E V . 2/04
M3.0-18.0-005
DRIVE UNIT
3. Apply thread locking adhesive to four bolts and secure
clamp stud assembly to the power unit frame. Do not
torque these bolts at this particular time. Install the two
dowel pins to maintain proper drive unit alignment.
Torque the four bolts securing the clamp stud assem-
bly to power unit frame 340 to 375 Nm (250 to 275
ft.lbs.).
4. Apply thread locking adhesive and install the six bolts
securing the steering bracket to the drive unit housing.
Torque these fasteners to 34 Nm (25 ft.lbs.). Remove
lifting device from drive unit pinion shaft.
5. Install drive motor to power unit mounting bracket.
Utilize hoist, or suitable lifting device, to lift motor by
1/2-20 eye bolt in top of drive motor armature shaft.
Position drive motor and carefully lower motor onto
top of drive unit pinion shaft. Secure drive motor to
mounting bracket with four appropriate screws and
lockwashers. Remove eye bolt and all other lifting
equipment from top of drive motor.
6. Route and connect drive motor cables to drive motor.
Carefully mount the drive motor brake bracket to the
drive motor. Check components of brake bracket for
satisfactory condition and operation. Place the brake
assembly on top of brake bracket and install four
fasteners securing brake assembly and bracket to the
top of the drive motor. Torque four bolts to 35 Nm (25
ft.lbs.).
7. Orient and attach brake cylinder to the brake bracket.
Attach brake assembly actuator arm to brake linkage,
nstall brake drum, lockwasher, nut, and fan to top of
drive motor. Be sure to lock nut, before installing fan.
Check for proper brake linkage operation.
8. Inspect drive tire hub assembly, remove any paint
present on lug bolt seats or inner face of hub that
contacts truck axle, then install and torque lug bolts as
specified in the "Drive Tire Replacement" on the first
page of this section.
Printed in U.S.A.
M3.0-18.0-005
 cjiaiun DRIVE UNIT

Drive Motor (62)

Screw (63) Oil Seal (55)

Retaining Ring (56)

Undercarriage
"O" Ring (54)
Assembly
Spacer (54)

Bearing (59) Shim Pack (53)

Bearing Retainer (52)

Steering Gear (57)
Ball Bearing (51)

Drive Unit Casting (1 Pinion Shaft (Motor) (50)

Idler Gear (45)

Ball Bearing (70)

"O" Ring (48)

Stud Assembly (67)
Bearing Retainer (49)
Dowel Pin (69)
Needle Bearing (64)
Bolt (68)
Needle Bearing Sleeve (65)

Felt Seal (66)

11250 ILLUSTRATION 7

DRIVE UNIT REPAIR

Motor Pinion Disassembly

1. Refer to Illustration 6 & 7. Remove retaining ring (56).
2. Attach a slide hammer puller to the pinion shaft and pull
the pinion shaft from drive unit.
3. Remove bearing (51) from pinion shaft. Record num-
ber and position of shims (53) for reference during
assembly.
4. Remove upper O-ring (48) from drive unit housing.
5. Remove ring gear (57) and idler gear shaft (46).
Remove cover (40), nut (38) and lockwasher (37). Lift
reduction gear (35) from top of pinion shaft (19). The
woodruff key (36) should remain in top of pinion shaft
(19).
6. Slide idler gear (45) aside and remove the cupped
retainer (49), with bearing (44), from drive unit housing
(1) and inspect lower O-ring (48).

Crown 1984 PF5829-6 Rev. 2/04 Prinled in U.S.A.

01 REV. 2/04
M3.0-18.0-006 M3.0-18.0-006
 <2J\rjUJn
Motor Pinion Assembly
1. Refer to Illustration 6 & 7. Inspect and/or replace lower
O-ring (48), if needed. Lubricate O-ring with clean
hydraulic oil to prevent possible damage when install-
ing cupped retainer (49) and bearing (44).
2. Fill retainer (49) one third to one half full with gear oil
that is of the same type in drive unit. Press bearing (70),
with seal up, into cupped retainer (49) and install into
drive unit housing. DO NOT OVER FILL RETAINER,
too much oil will cause the bearing seal to be damaged
when the idler shaft is pressed in.
3. Slide idler gear (45) into position and install idler shaft
(46). Install woodruff key (36), reduction gear (35),
lockwasher (37), and nut (38) to top of pinion shaft (14).
Secure cover (40) and install ring gear (57).
4. Press bearing (51) onto pinion shaft (50). Place re-
tainer (52) on top of bearing (51) and put into drive unit
housing.
5. Measure the distance from top of retainer (52) to the
bottom of the snap ring groove, record the distance.
Idler Shaft (46)
"O" Ring (47)
Ball Bearing (44)
Retaining Ring (43)
Idler Gear (45)
Drive Unit Housing (1)
ILLUSTRATION 8
Reduction Gear Replacement
Crown 1984 PF5829-7 Rev. 2/04
01 R E V . 2/04
M3.0-18.0-007
DRIVE UNIT
6. Measure width of spacer (54); add shims (53) until the
distance is within .127 mm (.005 in.) of the distance
obtained in step 5.
NOTE
Measure width of snap ring groove and width of
snap ring. Add shims to take up any additional
play at this point. Shims are available in the
following thickness: .203 mm (.008 in.), .254 mm
(.010 in.), and .330 mm (.013 in.).
7. Install upper O-ring (48) into housing, lubricate O-ring
with clean hydraulic oil to prevent possible damage
when installing spacer (54).
8. Press seal (55) into spacer (54), then install in housing
on top of shims (53).
9. Install retaining ring (56) and check for end play.
Steering Gear (57)
Pinion Shaft (50)
1. Refer to Illustration 6, 7 & 8. Remove ring gear (57)
from drive unit.
2. Remove cover (40), located above spiral bevel pinion
and reduction gear.
3. Remove spanner nut (38), lockwasher (37), and reduc-
tion gear (35).
Printed in U.S.A.
M3.0-18.0-007
 DRIVE UNIT

Idler Gear Replacement Spiral Bevel Gear & Pinion Replacement

1. Refer to Illustration 6, 7 & 8. Remove ring gear (57) 1. Refer to Illustration 6 & 9. Remove cover (4) and gasket
from drive unit. (61) from side of drive unit.

2. Remove cover (40), located above spiral bevel pinion
and reduction gear.
3. Remove spanner nut (38), lockwasher (37) and reduc-
tion gear (35).
4. Remove cover (23) and gasket (22) from side of drive
unit.
2. Remove lock wire (25) from bolts securing spiral gear
(21) to hub (19). Remove bolts (23) securing gear to
hub. Remove defective gear from hub.
3. Clean any dirt or grease from drive unit. Check bear-
ings for binding or gritty effects, looseness or wobble.
SPIRAL BEVEL GEARS ARE INSTALLED AS SETS,
DO NOT MISMATCH.

5. Remove six screws (31) that secure the spiral bevel
pinion in the drive unit. Remove pinion from drive unit.
6. Remove idler shaft (46) with O-ring (47) from drive unit.
7. Remove idler gear (45) and spacers (42).
8. Remove bearings (44) from idler gear. Inspect and
replace bearings if required, install into new idler gear.
9. Reverse steps 1 through 7 to assemble.
Drive Unit Housing (1)
4. Spiral bevel pinion (21) must be replaced if necessary
or when replacing spiral bevel gear. Follow steps listed
to remove spiral bevel pinion from drive unit.
A. Remove cover (40) and gasket (39) from drive unit.
Remove spanner nut (38), lockwasher (37) from top
of pinion. Remove gear (35) from pinion shaft.
B. Remove bolts (31) securing pinion shaft assembly
to the drive unit housing. Lift pinion shaft out of drive
unit. The shim pack (29) must also be removed.

Spacer (28)
Drive Tire (5)
Bearing Cup (27)

Bearing Cone (26)

Seal Retainer (12)

Spiral Bevel
Pinion (21)

Cam (16)
Lug Bolt (6)
Hub (19)

Locknut (22)
Axle (8)

Bearing Cone (14) Bearing Cone (18)

Bearing Cup (15)

Shim Pack (20)

Spiral Bevel
Gear (21)

Cover (4)

Bearing Cup (17)

ILLUSTRATION 9
Crown 1984 PF5829-8 Rev. 2/04 Printed in U S A

01 REV. 2/04
M3.0-18.0-008 M3.0-18.0-008
 (2R0UJh DRIVE UNIT

Lockwasher(33)
Locknut(34)
Bearing Cone (26)
Washer Special (32)

Bearing Cup (27) Bearing Retainer (30)

Spacer(28)

Spiral Bevel Pinion (19)

Bearing Cup (27)

Bearing Cone (26)

ILLUSTRATION 10

C. Remove parts from spiral bevel pinion. Refer to
Illustration 10.
5. Assemble parts removed from defective pinion to re-
placement pinion. Clean and inspect parts before
;;;embly. Replace any part that shows any sign of
excessive wear, looseness, chips, cracks, etc. Install
parts to pinion per the following steps.
A. Place bearing cone (26) onto pinion followed by
bearing cup (27), place spacer (28) on top of bearing
cup.
B. Press bearing cup (27) into bearing retainer (30) and
place on top of spacer (28).
C. Place bearing cone (26), special washer (32),
lockwasher (33) and locknut (34) on pinion shaft.

I\ CAUTION D. Tighten locknut (34) to eliminate end play.

Never "Spin Dry" a bearing using air pressure,
after removing from cleaning solvent, as this
could cause the bearing to explode.

Cronn 1984 PF5829-9 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-009 M3.0-18.0-009
 DRIVE UNIT

Position pinion shaft assembly into drive unit housing

per the following:

A. Measure pinion gear assembly from end of gear to

bottom of bearing retainer. Refer to Illustration 11.

230 ± .4 mm
9.062 ± .016 in.

Bearing
Cup
Diameter

Gear
And Axle
Centerline

ILLUSTRATION 12

F. Make up shim pack to equal figure in step "E". Place

pinion gear assembly and shim pack into power unit
ILLUSTRATION 11
housing and tighten six bolts (31) to 35 Nm (26
ft.lbs.), refer to Illustration 6.
B. Measure distance from centerline of axle to shim
stock surface. See Illustration 12, dimension 230 ±
NOTE
.4 mm (9.062 ±.016 in.).
Take measurementforverification purposes from
C. Subtract the pinion gear assembly measurement
the end of the pinion gear to the centerline of the
from the shim stock surface length.
axle. If measurement is incorrect, add or remove
shims as required.
D. Read measurement etched on bottom of pinion
gear.

E. Subtract figure obtained in step "C" from figure

obtained in step "D".

Crown 1984 PF5829-10 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M3.0-18.0-010 M3.0-18.0-010
 CAQUJh DRIVE UNIT

A. Put together a shim pack (20). An initial pack made
up of two .508 mm (.020 in.), two .178 mm (.007 in.)
and one .127 mm (.005 in.) shims, which equals a
shim pack thickness of 1.499 mm (.059 in.), is a
recommended starting point. A shim pack as de-
scribed, or similar, should yield a backlash of .127
mm (.005 in.) to .178 mm (.007 in.). Backlash in this
instance is checked by feel only.
Blue all teeth on spiral bevel gear. Locate the "X"
etched on the bottom of the spiral bevel pinion, and
position mark so that it will be towards the open side
of the drive unit housing and will mesh between the
pair of "X"s etched on the spiral bevel, as shown in
Illustration 14.

B. Refer to Illustration 13. Take a total indicator reading

with a dial indicator, with the arm positioned as
shown, on the hub. If a T.I.R. reading of more than
.076 mm (.003 in.) is obtained, the hub must be
removed, rotated approximately 90° and reinstalled
until a reading of .076 mm (.003 in.) or less is
obtained.

C. Apply a light coat of grease to the hub diameter

where the spiral bevel gear will be seated. Place the
shim pack, with a thickness range of 1.397 mm
(.055 in.) to 1.499 mm (.059 in.), onto hub backface.
1257 ILLUSTRATION 14
Crown 1984 PF5829-11 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-011 M3.0-18.0-011
 CRQUJh DRIVE UNIT

E. Check backlash, it should be from .127 mm (.005 in.)

Spiral Bevel Gears - Typical Preferred Tooth Contact
(Pinion Member Left Hand in All Cases Shown)
Correct
to .178 mm (.007 in.). An axial movement of .076 mm
(.003 in.) will change backlash .051 mm (.002 in.).
Remove spiral bevel gear and add or remove shims
to obtain desired amount of backlash. Replace gear
and check backlash.

F. Check foot print in the following manner:

lliills^ • Apply enough force to either the pinion or ring gear
to create drag.
• Rotate either gear a minimum of two full turns in
Bottom Side
either direction.
Central Toe
Bottom Side Contact • Compare the resulting footprint with patterns
Central Toe shown in Illustration 15.
Contact
Incor NOTE
-
Profile Error: To Core-: e r _ i On Pinion Cone
The spiral bevel pinion must be installed in the
Error ->
drive unit in such a manner that the "X" on the
bottom of the pinion mates with the "X"s located
on the O.D. of the gear.

NOTE

Disregard any shaft angle or cross contact error.

Bottom Side If a profile error exists, correct by repeating steps
S~ — y
High Heel A through F of step 6, "Position Pinion Shaft
Bottom Side Contact
Low Heel Assembly into Drive Unit Housing".
Contact
G. After desired backlash has been obtained and com-
Incorrect
ponents of axle assembly have been assembled,
Profile Error: To Correct - Move j n On Pinion Cone lockwire the bolts securing the spiral bevel gear to
the hub. The lockwire used is especially designed
Error - t
for this purpose.

Torque Required
13.5 Nm (10 ft.lbs

Bottom Side
Low Toe
Bottom Side 'Top S c£ Contact
High Toe High Hee
Contact Conta::

ILLUSTRATION 15

D. Place the spiral bevel gear onto the hub backface.

Use only a soft face or rubber mallet to help seat
gear. Apply thread locking adhesive to the eight
bolts securing the ring gear to the hub. Torque bolts
to 80-95 Nm (60-70 ft.lbs.).
Torque Required Torque Required
80-95 Nm (60-70 ft.lbs.) 68 Nm (50 ft.lbs.)

ILLUSTRATION 16
Crown 1984 PF5829-12 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-012 M3.0-18.0-012
 CROUJh
The following guidelines should be used when securing
fasteners with safety wire.
• In an application where several fasteners are to be
secured with one piece of safety wire, the wire holes in
the bolt head should be in approximately the same
relationship to each other.
DO NOT OVER TORQUE OR UNDER TORQUE
BOLTS TO OBTAIN PROPER RELATIONSHIP.
• The direction of wrap and twist of the wire should be
made in such a manner that the loop around the bolt
comes under the strand protruding from the hole to
keep the loop down.
• Route wire so that the wire tension will keep the bolt
from coming loose.
NOTE
Do Not overstress safety wire. Extreme care
must be taken when twisting wires to insure they
are tight but not overstressed to the degree that
breakage will occur under a light load or vibration.
After wiring the last fastener, twist wire ends to form a
pigtail of 6 to 8 twists, cut off excess wire. Bend pigtail
in such a manner to prevent it from being snagged.
Check the completed wiring and make sure the safety
wire is not cracked or peeled as a result of kinking,
nicking, or over twisting. Refer to Illustration 16.
ILLUSTRATION 17
Crown 1984 PF5829-13 Rev. 2/04
01 REV. 2/04
M3.0-18.0-013
DRIVE UNIT
Drive Axle Replacement
1. Refer to Illustration 17. Remove safety wire (25) from
the screws locking the gear (21) to the hub. This safety
wire can be cut off and thrown away, it must not be used
again.
2. Remove screws (23 & 24) and locknut (22).
3. Remove the spiral bevel gear (21) by inserting a brass
rod thru the inspection window and tapping with a
rubber mallet, the spiral bevel gear can be driven from
the hub. Rotate the axle at the same time until gear is
off. If tapped holes, 3/8-24 UNF, are available in the
gear then a puller can be used.
NOTE
Check the quantity and thickness of shim pack
(20) for future reference.
Remove the hub (19). A gear puller will be required to
remove the hub from axle (8).
Use an arbor or hydraulic hand press and remove the
axle from the drive unit housing. The outer bearing (18)
will be forced off the axle at this time.
Printed in U S A.
M3.0-18.0-013
 DRIVE UNIT

NOTE HUB POSITIONING GAUGE

Make sure all blocks are positioned under the

drive unit housing and not in contact with the seal 53.924/53.950 mm
retainer. (2.123/2.124 in.)
C" Dimenson
6. To remove the cam (16), inner bearing (14) and cup
(15) an appropriate puller should be used. 20 mm
7 5 mm 3 0 in
(.81 in.) ^i^W^iiJIl (' -
Thoroughly clean the drive unit housing and all components i
with solvent to remove all grit and sludge build ups. A close
35 mm(1.38 in.)
inspection of the gears and pinion should be made to check
1-12 x 2 in. Set Screw
for chips, cracks, or irregular wear patterns on gear teeth.
Also check bearings by turning them with your fingers. Feel Brass Sleeve 53.924/53.950 mm(2.123/2.124 in.) O.D.
for binding or gritty effects, excessive looseness or wobb'e. x 48 mm(1.88 in.) I.D. x 35 mm(1.38 in.) Long

z 250-20 x.75 in. Nylock Tip Set Screw

/t\ CAUTION
ILLUSTRATION 18
Never spin dry a bearing using air pressure, after
removing from cleaning solvent, as these condi-
10. Use an arbor or hydraulic hand press to press bearing
tions could cause the bearing to explode.
cone (14) onto axle, and cam (16) onto axle. Apply a
light coat of grease to the seating area of the bearing
SPIRAL BEVEL GEARS ARE INSTALLED AS SETS,
and cam before pressing into position. Install axle into
DO NOT MISMATCH. drive unit housing and press bearing (18) into position
on axle.
7. Clean the axle thoroughly. If the axle needs replacing,
the splined hub must also be replaced. The axle and
11. Measure the distance from the cone back face of
hub are sized into matched sets at the factory and must
bearing (18), record this as dimension "A". Measure
be replaced as a set. Likewise, if the splined hub needs
thickness of the hub (19), add .025-.050 mm (.001 -.002
replacement, the axle must also be replaced.
in.) for clearance. Subtract "B" dimension from "A"
dimension to get "C" dimension. Set the Hub Position-
8. Inspect and clean the two bearing cups, (15 & 17), in ing Gauge to the "C" dimension.
the drive unit housing.
12. Apply a coating of anti-seize compound, 065005-003,
9. The bearing cones (14 & 18), cam (16), and hub (19) to the splined area of the axle. Press hub (19) into
must be preheated for proper assembly. The hub must position on the axle using the Hub Positioning Gauge.
be preheated to 176° C (350° F) to 204= C (400= F). Turn or rotate the axle shaft assembly by hand to check
=
The bearing cones and cam must be heated to 120 C for proper pre-load of bearing setup.
(250° F).

CAUTION

Do Not heat the bearings beyond this tempera-

ture. Damage to bearings will occur if tempera-
ture is allowed to go beyond 120° C (250° F).

The hub should reach its required temperature in 25 to

30 minutes. The bearings and cam should reach their
required temperature in approximately 15 minutes.
Use an electric oven or electrically heated oil bath that
are thermostatically controlled to preheat components.

Crown 1984 PF5829-14 Rev. 2/04 Printed in U.S.A.

01 REV. 2/04
M3.0-18.0-014 M3.0-18.0-014
 OTUJh DRIVE UNIT

DRIVE UNIT LUBRICATION S Y S T E M Oil Pump Assembly

Disassembly of Oil Pump NOTE

1. Refer to Illustration 19 & 20. Remove drain plug (23) Inspect all component parts and drive unit hous-
and drain oil from drive unit. ing for dirt and burrs before assembly.

2. Remove oil pump housing (1) from drive unit. 1. Place ball (4) and spring (5) into oil pump housing (1).

3. Take oil pump assembly to clean work area fcr c sas- 2. Place ball (7), Spring (8) and special pipe plug into
sembly. piston (9). Lubricate piston with oil and install into pump
housing.

3. Visually check the alignment of the cam on axle to be

sure of proper contact with oil pump piston when
Bearing Cone installed in drive unit housing.

1
9 20 21
Drive Bearing Cup
Unit Piston (9) Tubing is
Housing Spring (8) Installed
Ball (7) Through
O-Ring (2) Cored
Plug,
Oil Pump Hole in
Special (6) Casting
Housing
Spring (5)
Ball (4)

262 ILLUSTRATION 19

4. Check O-rings (2) and (3) for damage.

11
5. Remove piston (9), spring (8), and ball (7) from oil
pump housing.

6. Remove special pipe plug (6), spring (5) and ca 4

from oil pump housing.

7. Thoroughly clean housing and all parts.

ILLUSTRATION 20

Crown 1984 PF5829-15 Rev. 2/04

01 REV. 2/04
M3.0-18.0-015
 CRQUJh DRIVE UNIT

4. Install O-rings (2) and (3) onto pump body.

5. Thoroughly lubricate pump body and port with gear oil,

then screw pump assembly into housing until seated.

6. Install drain plug and fill drive unit with .71 liter (1
1/2 pints) of gear oil.

7. To check oil pump output remove pipe plug (15) and

observe oil flow from port.

DRIVE UNIT A S S E M B L Y C H E C K LIST

| | Thoroughly clean drive unit housing and all parts.
| | Keep matched gears or lapped gears in their original pairs.
I | Always replace both members of a spiral bevel gear set.
| | Properly mesh the teeth marked with "X" on spiral bevel gear set.
|~| Set spiral bevel pinion to correct mounting distance to obtain desirable "foot print".
• Check gear set for recommended "backlas"
L | Be sure all locknuts, bolts, plugs, etc., are in place and tightened to their recommended torque value.
I | Check gear oil for proper level in unit before operating under a loaded condition.
10825

Crown 1984 PF5829-16 Rev. 2/04 Printed in U.S.A.

01 R E V . 2/04
M3.0-18.0-016 M3.0-18.0-016