SEGHIONAIO DRMCO 9150 POWER SHIFT TRANSMISSION9150_ TRANSMISSION DISASSEMBLY AND ASSEMBLY. INSTRUCTIONS REMOVAL FROM GRADER. For instructions to renove the Transmission Unit from the grader see Transmission Removal GENERAL. The Transmission should be suitably supported during all stages of disassenbly and subsequent assenbly operations. Before Commencing work on the transmission, renove ait dirt and foreign matter fron the outside casing, clean using @ suitable cleaning agent MANUAL RANGE SHIFT RAIL ‘OUTPUT CAP] Fig 1. TRASMISSION ~ LID SIDE In order to eliminate prenature overhaul, it i5 important. that all ofl seals, snap ings and gaskets should be replaced on assenbly. Bearings are supplied as matched Sets, danaged or worn bearing conposents Should be discarded and replaced with a new natched bearing assenbly. Reference should be made to the spare parts manual for replacement of danaged parts, The Transmission is disassembled and reassenbled without the use of special tools, however care should be taken when renoving or installing. conponents having machined and close tolerance surfaces. Refer to Fig 1,2,3 for identification and Jocation of components, before work commences. FcouNTER SHAFT CaP floc | Inspection} cover mre rousiNe a) ent ‘OUTPUT YOKE] uance | Fig 2. TRASHISSION ~ CASE SIDE Page 1F-N°R CLUTCH PACK 1ST, GEAR HALF PACK 20's 3RD, CLUTCH PACK COUNTER SHAFT REVERSE IDLER SHAFT OUTPUT SHAFT TRANSMISSION CASE Ta (ON LID HALF PACK COVER UT CAP ISSUE NO. 1 9150 TRANSHISSION REF] PART NO REF] PART NO Nolan! PART NAME REQ fio [ENO PART NAME REQ ‘SHAP RING $100 - 300 7 46 2ND_& 3RD CLUT 1 (OUTPUT SEAL 1 "7 NIDSHAFT BEART 1 CLUTCH HUB - LONG 2 48 HALF PACK CLUT 1 CLUTCH SLEEVE 1 9 2ND COUNTER SHAFT CAP i SPACER 2 50 OUTPUT CAP ~ CASE SIDE A COUNTERSHAFT CAP 1 51 BOWER ROLLER BEARING SHIFT FORK 1 52 SHIFT SPOOL SEAL DETENT RETAINER 1 53 NAWWAL RANGE ~ OETENT HOUSING 1 GASKET AS Re 5a MANUAL RANGE ~ SHIFT RAIL. 1 GASKET AS RE 55 IDLER SHAFT CAP ~ CASE SIDE 1 AS RE 56 LER SHAFT CAP - LID SIDE 1 SRE 57 TTT, GEAR RETAINER 1 1 58 GASKET FOR INPUT SHAFT LID SIDE as REQ LOCKING PLATE 1 59 GASKET FOR INPUT & 1ST COUNTERSHAFT AS REQ INPUT SEAL 1 60 GASKET FOR 7.00 BOLT CENTRE aS REO 1 61 GASKET FOR QUTPUT LID SIDE JAS REQ 1 62 GASKET FOR LID 2 63 GASKET FOR HALF PACK COVER i 6a GASKET FOR HALF PACK COVER CAP 4 65 GASKET FOR TRANS. DETENT HOUSING BOER ROLLER BEARING el 67 INPUT YOKE ~ ROCKFORD SHAP RING 5100 ~ 268, 4 68 car TOLLER BEAR 74975) 2 6 X 11/4" LG, HEX. HO, capscReN | 1 70 5000 - 413 VEN GEAR 1 n 5100 - 243 REVERSE CTR SHAFT GEAR 1 2 ING = ROCKFORD (4310914) REVERSE CTR SHAFT GEAR 1 B ‘QuTPUT CAP LID SIDE 567, GEAR 1 a "LG. HEX. HO. CAPSCREW 8 227, LOW RANGE DRIVE GEAR 1 75 8 64T, GEAR 1 76 3 TIT, AST & ATH DRIVEN GEAR 1 7 * LG. HEX. CAPSCREW 7 587, GEAR 1 8 FLX 1" LG. HEX. HO. CAPSCREW 3 707, GEAR 1 3 X 13/4" LG. HEX. HD. CAPSCREN | 6 i 1 1 1 1 1 1 1 } 1 F-N-R CLUTCH CAP age 2.e les Fig 3. 9150 TRANSMISSION Ts al { & Page 3.DISASSEMBLY wi posi 2. Page 4 the Transmission Unit in an upright tion: Remove the nuts and Tockwashers attaching the upper and lower inspection plates, care being taken not to damage the studs when releasing the plates from the sides of the casing and renove the gaskets (Fig 4-5). Locate the Manual Range Detent Housing (Fig 6) on the case side of the Transmission, un.crew the Detent Retainer and renove the Detent Spring Remove the 3 capscrews and Tock- washers attaching the Manual Detent Housing to the casing. Rotate the housing to allow the Detent Ball to drop out into the hand Figure 6. . Withdraw the Manual Range detent Housing and remove gasket (Fig 7). Extract the Shift Spool Seal from the Manual Range Detent Housing and discard. Locate the Shift Fork through the Lower Inspection Hole remove the Tocking wire and loosen the Locking Screw in the boss of the Shift Fork (Fig 8). Rotate the Manual Shift Range Rail to unthread the fork from the rail. Slide the rail forward to clear the fork from the rail end and withdraw the fork from the Transmission case through the Lower Inspect- ion hole The Manual Shift Range Rail is now reroved from the Transmiss~ fon Unit, passing it through the bore forthe Manual Range Detent Housing (Fig 9) . Withdraw the Front Drive Yoke from the Output Shaft End (Fig 10). 7. Unscrew 3 capscrews, remove Locking Plate and Retainer, attaching Input Yoke to the end of the Forward-Neutral-Reverse Shaft (Fig 11 and 12). ott Figure 11. Reposition the Transmission Horizontally. with the case lid uppermost: 1. Unseat the cover on the Output Shaft Cap by gently tapping around sides and remove. Unscrew the 5 capscrews and remove lockwashers attaching the Output Shaft Cap to the Transmission Case Lid and remove the Output Shaft Cap and gaskets (Fig 13). 2. Unserew the 7 capscrews and remove Tockwashers. Lift away Ist and 4th gear Cover Plate and gasket from the Halt "ack Housing (Fig 14). Page 5.Page 6. Figure 12. Figure 13. . Unscrew and remove 4 capscrews (3/8" x 1" NC) with lockwashers, inseat the Ist gear Half Pack Clutch Cap, and withdraw with gasket/s from the st Gear Half Pack Clutch Housing (Fig 15). Unscrew and remove capscrews with lockwashers attaching the Ist. gear Half Pack Housing to the Transmis~ sion Case Lid (Fig 16). Tap gently around mating face of the housing to loosen. Manoeuvre the housing to clear the Ist and 4th Driven Gear (77t) and Tift up from the Transmission Case Lid. Remove gask~ et (Fig 17). Figure 15. Unscrew 3 capscrews and Remove Retaining Plate, for the Ist and 4th Driven Gear, from the end of the Countershaft (Fig 18) . Gently withdraw the Ist gear Half Pack Clutch Assembly from the 2nd and 3rd Clutch Pack Shaft (Fig 19) - Withdraw the Ist and 4th Driven Gear (77t) from the Countershaft. . Unscrew and remove 6 capscrews with Tockwashers and remove the Countershaft Cap and gasket from the lid face (Fig 20)Page Unscrew and remove 4 capscrens with Tockwashers and remove the Reverse Idler Shaft Cap and gaskets from the Transmission Lid (Fig 21) Unse the 6 capscrews retaining the Forward-Neutral-Reverse Cap to the Transmission Lid, Using a mallet, gently tap around the flange of the cap to loosen from its sea g and withdraw from Transmission Lid. Remove gaskets (Fig 22). Figure 23. 1B. + Remove all bolts;Jockwashers and nuts attaching the Transmission Lid to the Transmission Case. Insert 2 eye bolts into threaded holés in the lid (Fig 23) and suitably sling to an overhead hoist. Using the hoist lift away the Lid from the Transmission Case. Remove the gasket from the Transmission Case flange (Fig 24.) NOTE Tn removing the 1id from the Transmission Case, difficulty may be experienced in releas~ ‘ng the mating surfaces. On no account should sharp objects such as screwdrivers or drifts be forced between the lid and the transmission case flanges This practice will damage the machined surfaces, resulting in poor sealing on assenbly ‘and consequent loss of oi! from the Transmission Unit. With the Transmission Lid removed, exa- mination of the roller bearing outer races housed in the lid, will determine the necessity of their removal from the Transmission Lid. If a roller bearing outer race is found to be damaged for worn it should be discarded, note being taken to discard its mating inner race on its respective shaft. . To remove Roller Bearing Outer Races from the Transmission Lid, gently tap around the periphery of the bearing with a mallet, driving the bearing from the Transmission Lid. Remove and discard the Shift Spool Oi ‘Seal from its seating in the Transmission lid.14. Remove the 6 capscrews and lockwashers attaching the Mid-Shaft Bearing Mount to the inside of the Transmission Lid. NOTE: ‘The Mid Shaft Bearing Mount houses the roller bearing outer races for Yst Gear Half Pack Shaft and 2nd and 3rd Gear Pack Shaft. These should be inspected for wear and danage, and if found defective should be removed and discarded. Note should be taken to replace ‘the mating inner races on their respective shafts. 15. Remove the roller bearing outer races from the Mid Shaft Bearing Mount as fol1- ows: a. Place the Mid-Shaft Bearing with the outer face upwards, ina vice. b. Pass a suitable drift through the bore of the mount, to bear fon the face of the 2nd and 3rd Gear Clutch Pack shaft bearing. Using a hanmer tap the drift and drive the bearing from its seating in the mount. c. Reverse the Mid Shaft Bearing Mount in the vice and remove the 2nd and 3rd Gear Clutch Pack shaft bearing snap ring. 4. Remove Ist Gear Half Pack Shaft bearing in the manner described in note (b). Removal of Gearshaft and Clutch Packs from the Transmission Case. 16. The Gearshafts and Clutch Pack Assemblies are now withdraw~ complete fron the Tran- smission Case ‘n the following sequence. Fig 25). 1. Counter = ROLLER BEARING | | | TNNER RACE Figure 41 tl Figure 42.ti Figure 43. Figure 44. Note: The Caged Roller Bearings must be renewed on assembly. D0 NOT RE- Case USE CAGED ROLLER BEARINGS EVEN IF THEY APPEAR TO BE IN A SERVICEABLE 1 CONDITION. Lubricate the caged roller bearing with Tight of . Install the 72t Gear onto the shaft with plain face of the gear boss towards the spacer. Centralize the bore of the gear, on the caged Roller Bearing and tap the Gear to seat firmly against the spacer. (Fig 45). + Replace the Clutch Hub onto the shaft with the high shoulder seating into the splined bore of the 72t Gear. Reposition the Clutch Sleeve onto the Clutch Hub. Heat and install Caged Roller Bearing for the 55t Gear onto the shaft, locate on the face of the Clutch Hub. Lubricate the caged roller bearing with light oi1 (Fig 46) Instal] the 55t Gear onto the shaft with the shifter gear towards the Clutch Hub, centralize the bore on roller bearing and tap to seat firmly on the shoulder of the Clutch Hub and replace the spacer with the plain face locating against the 55t Gear (Fig 47) Heat and replace the roller bearing inner races to each end of the shaft. Assembly: Insert Output Shaft roller bearing outer race into the case side of the Qutput Shaft Cap. Lubricate the bearing with Tight of1 before tapping into position. Page 15.. % cap Figure 47. Re-Position the Transmission Case horizontally. with the case side uppermost 2. Replace 2 (.008in) (.2032mm) gaskets on the inner face of the Qutput Shaft Cap Flange and replace the cap into the Transmission Case side, secure with 6 (3/8" x 1.1/4" NF) capscrews and Tockwashers. Torque to 49ft-Ibs (6.77 kgm) (Fig 48.) 3. Position the roller bearing outer races in their respective bores in the Transmission Case side and lubricate with light oi1. Using a mallet, firmly drive the races into place (Fig 49). Figure 48. Page 16. ourpuT SHAFT (lbs + ) > counter Y ’ SHAFT B, a REVERSE 2nd & ard # cuurcH a INPUT SHAFT, Figure 49. Re-position the Transmission Case horizontal! to the Lid Sid The shaft assembles can now be installed eo i into the Transmission Case in the following order. F.N.R. Clutch Pack-Instal] with 52t Gear to case side (Fig 50). 2nd and 3rd Gear Clutch Pack-Instal] with 60t Gear to case side (Fig 51) Output Shaft-Instal] with S5t Gear to case side (Fig 52) Counter Shaft-Instal] with 32t Gear to case side (Fig 53). Idler Shaft-Install with 30t Gear to case side (Fig 54) The Counter Shaft has to be raised slightly, to allow the 30t Gear on the Idler Shaft to clear the 32t Gear on the Counter Shaft. With the Idler Shaft installed the Counter Shaft is lowered back into position.Figure $4. Assembly of Lid to 1. Assenble the Mid Shaft Bearing Mount, to the inside face of the lid and attach with 6 capscrews (3/8" x 2" NF) and Tockwashers The capscrews being inserted from the outer face of the lid. Torque to 49 ft-1b (6.77 Kom) (Fig 55). - Replace a new Transmission Lid Gasket on the Transmission Case flange. Page 17.to seat firmly on the flange (Fig 56). Reference to Fig 57 will aid the pos joning of capscrews, nuts and lockwashers. Torque to 105 ft-1b (14.51 Kam). Figure 55. 3. Using an overhead hoist Tower the lid into position on the Transmission Case flange, care being taken not to damage the flange studs. Tap around the Lid Figure 56. 16 1/2" ¥ 2.1/2" NF. CAPSCREWS, 1” WASHERS & NUTS BOLTS INSERTED FROM LID SIDE | beens! nel 6 - 1/2" X 2" NF. CAPSCREWS, 1" WASHERS. BOLTS INSERTED FROM FLANGE SIDE 6 -1/2" X 2" NF. CAPSCREWS, WASHERS. BOLTS INSERTED FROM FLANGE SIDE {___} 6 - 1/2" X 2.1/4" STUDS, NASHERS & NUTS Fig 57 POSITION OF CAPSCRENS - ATTACHMENT OF LID. Pace 18.4 Install the roller bearing outer race into the Mid Shaft Bearing Mount locating it on the 2nd and 3rd Gear Clutch Pack Shaft (Fig 58). and secure with snap ring (Fig 59 Install in the Transmission Case Lid the roller bearing outer races for the Counter Shaft, Idler Shaft and Output Shaft. Lud- ricate with Tight oil before tapping firmly into position on the inner race shoulder (Fig 60) Figure 59. «Replace 2 (.008in) (.2032m) gaskets, and assenble the Idler Cap to the lid (Fig 61). attach with 4 (3/8" x 1.1/4"NF) capscrews and lockwashers. Torque to 49ft-1b (6.77 Kon) - Install] the F.N.R. Clutch Pack Shaft roller bearing outer race into the F.N.R. Cap. Replace 2 piston rings onto the F.N.R. shaft and assemble the F.N.R. Cap to the lid with 5(.008") (:2032nm) gaskets, attach with 6 (3/8" x 1.1/4" NF) capscrews and lockwashers. Torque to 49 ft Tb (6.77 Kgn) (Fig 61) Reposition Transmission to case side: 1 Assemble the Counter Shaft Cap to the case using 1 (.008") (.2032nm) gasket attaching with 6 (3/8" x1.1/4" NF) ‘capscrews and lockwashers. Torcue to 49 ft/1b (6.77 Kam)NOTE On assembly the gear shafts must have 2 floating clearance of 03" (.762 mn) nin. and .035" (.889 mn) max. between the outer bearing races. To attain this clearance, the bearing outer races must be adjusted after the end cap has been shinmed and attached to the case. Shinming the Caps: In order that the bearing outer races may be adjusted, the caps must be shinmed with gaskets to allow a clearance between the outer race face and the inside face of the cap to be established. To determine the anount of shim required:~ Bottom the shift assembly, and tap the bearing outer race firmly, seating it on the shoulder of the inner race. Using a depth micrometer check the dimens- jon between the bearing face and the Transmission Case or Lid (Fig 62). Using a depth micrometer, check the dimension between the cap flange and shoulder or counterbore of the cap (Fig 63) G Figure 63. Page 20. Adjustment of Bearing Outer Races: _ The difference between these two measurenents being the existing Clearance between the cap inner face and the bearing outer race. Thus the thickness of shin required 030" - existing clearance. The caps are installed to Transmission Case or Lid useing multiplier of .005" or .008" gaskets to the required shim thickness With the cap attached, position a dial indicator with its contact point resting on the shaft end. Set the indicator to zero and using suitable lever, force the gear shaft upwards to give 4 reading on the dial indicator of .030" Min = .035" max (Fig 64) By forcing the gear shaft upwards the bearing outer race is pushed out to seat on the face of the cap, thus creating the required floating clearance on the shaft Following the cap shinming and bearing outer race adjustment instructions for each shaft cap, assemble to the Transmission Case: « Idler Shaft Cap with gaskets, attach with 4 (3/8" x 1.1/4" NF) capscrews and lockwashers. - Input Shaft Cap with gaskets, attach with 6 (3/8" x 1.1/8" NF capscres and lockwashe- Figure 64,3. 2nd and 3rd Gear Clutch Pack Cap with gaskets attach with 6 (3/8" x 1.1/4"NF) Capscrews and lockwashers. Torque all capscrews to 49 ft 1b (6.77 Kon). Reposition the Transmission Case to Lid Sid Following the cap shinning and bearing outer race adjustment instructions for each shaft cap, assenble to the Transmission Case Lid:~ 1. Counter shaft Cap with gaskets, attach with 6 (3/8" x 1.1/4" NF) capscrews and washers. 2. Output Shaft Cap with gaskets, attach with 6 (3/8" x 1.1/4" NF) capscrews and washers. Torque all capscrews to 49ft Ib (6.77 Kam) Not The Output Shaft Cap must be removed after shimming and bearing adjustment and installed after the replacement of Ist and 4th Gear cover on Half Pack Housing 3. Insert the Half Pack Roller bearing outer race into the Mid Shaft Bearing Mount (Fig 65). Figure 65 2 8. Place Ist and 4th Driven Gear onto the Counter Shaft, position Retainer, and attach with 3'(3/8" x 1/4" NC) Capscrews. Torque to 31ft = Ib (4.28 Kan). Apply Loctite to capscrews before insertion. Locate the Ist Gear Half Pack shaft onto the 2nd and 3rd Gear Clutch Pack shaft. . Replace Half Pack Housing gasket (Fig 66). and locate Half Pack Housing on dowels. in Lid face and attach Half Pack Housing to Lid with capscrews and lockwashers, Refer to (Fig 67). Ui Figure 66. Instal1 roller bearing outer race into Half Pack Housing (Fig 68) Check shim requirements and assenble Half Pack Shaft Cap and gaskets to the Half Pack Housing using 4 (3/8" x 1°NC) capscrews and lockwashers. (Fig 69, and 70). Torque to 31 ft - Ib ( 4.28 kg.m) Carry out bearing outer race adjustment Replace gasket and Ist_and 4th driven Gear Cover on to Half Pack Housing (Fig 71). attach with 8 (5/16" x 1/2" Nc) capscrews. and Tockwashers. Torque to T7ft = 1b (2-38 Kq.m) Page 2114 = 3/8" X 1.1/4" NF CAPSCREWS & LOCKNASHERS TORQUE TO 49 Ft-1b. (6.77 Kg.m) 1 = 1/2" X 2.1/0" NF. CAPSCREW & LOCKWASHER: TORQUE TO 85 ft-lb, (11.74 kg.) DOWEL. ~ DOWEL 2 -(1/2" X 2.1/4") NC CAPSCREMS 8 LOCKWASHERS TORQUE TO 75 ft-Ib. (10.36 Kg.m) Figure 68. Figure 70. Page 22,rh Figure 71. 10. Reassenble Output Shaft Cap to Lid attach with 5 (3/8" x 1.1/4" NF) capscrews, replace cover on cap. Torque to'49 ft-1b (6.77 Kan) (Fig 72) Figure 72 Reposition Transmission Uni position: in_an_upright Replace of] seals in the Input Cap, Grive on Input Yoke Flange onto F.N.R. shaft, lock in position with retaining plate and 3 ( 5/16" x 3/4" NC) capscrews. Torque to 17 ft - Ib (2.30 Kon) Assembly of Manual Range Shift Rail Instal] Manual Range Shift Rail into Transmission Case, and thread onto Shift Fork. Locate Fork into the Clutch Sleeve (Fig 73) Figure 73. Install Detent Housing and gasket and attach with 3 ( 3/8" x 1.1/4"NF) capscrews and lockwashers. Torque to 49 ft-1b. (6.77 Kan). Position the rail to align the neutral or centre groove with the hole in the Detent Housing. Insert Detent Gall and Spring into the hole in the detent housing and screw jn Detent Retainer. (Fig 74) Figure 74. Page 23t AK Page 24 Turn the rail to centralize the Clutch Sleeve on the Clutch Hub, lock the fork to the rail with lockwashers, and wire- Tock the lockscrew to the rail. Replace gaskets and attach the upper and lower Inspection Plates using (5/16" NF) nuts and lockwashers. Replace the Manual Range Shift Rail oi] seals in the Detent Housing and into the Transmission Case Lid (Fig 75 and 76). Figure 75. Figure 76. Replace new gaskets and attached the Upper and Lower inspection place to the Transmission Case.