Service Manual

Front Wheel Drive Axle

For
TLD
828, 929 & TXL-838
CARGO LOADERS

2/2011

D106495
 Table of Contents
Instructions and Specifications............................................... 3
Safety Procedures.................................................................. 4
Wheel Motor Application and Identification ........................... 5-10
Brake Functional Characteristics & Maintenance Inst ............ 11-15
Pallet Loader Preparation for Front Axle Maintenance........... 16
King Pin Bearing Replacement .............................................. 17-19
Assembling Wheel Motor Frame to Axle ................................ 20-24
Steering Ear Bushing Replacement ....................................... 25
Tie Rod End Replacement ..................................................... 26
Wheel Motor Replacement..................................................... 27-29

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Instructions and Specifications

INTRODUCTION
This manual provides instructions for maintaining the Tuthill Drive Systems on hydrostatic machines.
A complete pictorial breakdown of all the individual parts in the Tuthill Drive Systems can be found in the Parts
Catalog. Refer to this catalog for proper identification of parts required for service.
GENERAL
The terms right and left in these instructions are the same as the operators right and left hand when positioned in
the operator’s seat facing forward. IMPORTANT: Cleanliness is essential when installing or servicing hydraulic com-
ponents. When making hydraulic connections, areas surrounding the connection should be steam cleaned or
washed with solvent so that contamination will not enter the system. Always keep hoses and connectors and ports
suitably capped or covered to keep contamination out of the system. CAUTION: Make sure that system pressure is
relieved before disconnecting any lines or connections. Pressurized fluid escaping from the system can cause seri-
ous personal injury.

LUBRICATION Grease king pin bearings and tie rod ends every 50 hours of operation.

TORQUE SPECIFICATIONS RECOMMENDED FOR USE WITH TUTHILL FASTENERS

Recheck all bolt & nut torque after 1 hour’s use and again after first day of use. Periodically check tightness every
100 hours of use thereafter. Note: bolts that require Loctite should not be re-tightened once Loctite has had time to
cure. Note: When using original equipment fasteners, adhere to manufacturers’ recommended specifications.

Grade 8 (Class 10.9 Metric) Bolts & Grade C (Class 10

Hydraulic Fittings, Hose Ends & Tube Nuts
Metric) Locknuts
Bolt Torque [1] Locknut Torque Dash Size Thread Size
Size (S.A.E.) Torque [3] (ft.lbs.)
(ft.lbs.) [2] (ft.lbs.) (S.A.E.) (S.A.E.)
1/4-20 10-13 7-10 -4 7/16-20 9-12
5/16-18 18-25 15-18 -6 9/16-16 21-24
3/8-16 35-45 30-35 -8 3/4-16 35-40
7/16-14 55-70 45-55 -10 7/8-14 55-60
1/2-13 90-110 60-80 -12 1 1/16-12 77-82
9/16-12 120-150 90-110 -16 1 5/16-12 110-120
5/8-11 180-200 150-170
3/4-10 300-350 250-280
7/8-9 400-450 350-380
M10-1.5 35-45 30-35
M16-2.0 180-200 150-170
M20-2.5 400-450 350-380

(1) Torque to be applied to Grade 8 or (Class 10.9) bolts.

(2) Torque to be applied to Grade C or (Class 10) locknuts.

(3) Torque to be applied to S.A.E. straight thread O-Ring Boss (ORB) fittings/locknuts and 37
degree flared type (J.I.C.) fittings/hose ends and tube nuts.

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Safety Procedures

READ THESE PROCEDURES COMPLETELY. Make sure you fully understand all controls BE-
FORE operating the system.

The safety information given does not replace safety codes, insurance needs, or federal, state,
and local laws.

Standard safety procedures should be observed and practiced when operating or servicing the
Tuthill Drive System. CAUTION should be practiced at all times.

All components MUST be securely and correctly mounted and connected BEFORE operating
the system.

In the event of any malfunction in the system, the Tuthill Drive System should be shut “OFF”
immediately and not restarted until the machine is correctly serviced.

When raising the machine, make sure that a dependable left device is used to adequate capac-
ity. Use suitable jack stands to support machine. Apply “PARK” or “EMERGENCY BRAKE” and
block the rear wheels to prevent the machine from rolling.

DANGER – Escaping fluid under pressure can have sufficient force to penetrate the skin, caus-
ing serious personal injury. Fluid escaping from a small hole can be almost invisible. Use a
piece of cardboard or wood rather than your hands, to search for suspected leaks.

DO NOT alter axles in ANY manner – alterations may reduce strength resulting in possible dam-
age or personal injury.

DO NOT alter any component of the Tuthill Drive System. Unauthorized modification may result
in possible damage or personal injury.

DANGER – Failure to follow proper procedures when mounting a tire on a wheel or rim can pro-
duce an explosion which may result in serious bodily injury. DO NOT attempt to mount a tire
unless you have the proper equipment and experience to perform the job safely.

WARNING – Decals MUST be obeyed completely to prevent possible damage or injury. If de-
cals are destroyed, lost damaged or cannot be read, replace immediately.

WARNING – Any damaged hi-pressure hose should be replaced with a comparable 4-wire
braid hose (DO NOT use a 2 or 3-wire braid hose).

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Wheel Motor Application andIdentification

LH MOTOR SERIAL TAG

POCLAIN PART No. A16500K
TUTHILL DRIVE SYSTEMS
708035-01

RH MOTOR SERIAL TAG

POCLAIN PART No. A16508T
TUTHILL DRIVE SYSTEMS
708035-02

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Functional Characteristics and Maintenance Instructions

Hydraulic—Servo—Brakes

1. Function of Hydraulic Servo Brake

The function of this brake is based on the fact that on operating the wheel cylinder, two
brake shoes are pressed against the drum, where at the primary brake shoe (1) is taken in
the direction of rotation of the brake drum, and the second brake shoe (2) aligned by the
lower floating support (3) is blocked against a fixed point at the top of the brake anchor
plate, or of the wheel cylinder (4).

By the supplementary force of the primary shoe, the so-called “self-energization” (servo
effect) of the brake is generated.

The braking efficiency is almost the same in both directions.

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2. Setting Device

The lower floating support (3) is in most cases designed as a setting device and either a
mechanical or an automatic type may be used.

CAUTION: For Maintenance or setting, it is necessary to pay attention to and

correspond with the special Knott instructions.

3. Wheel Cylinder (5)

The pressure produced by the brake operation is transferred to the brake shoes by
means of the wheel cylinder pistons.

3.1 Maintenance:

With every periodical brake check it is necessary to check the wheel cylinder and
connecting parts for leakages.

3.2 Repair Instructions:

After having dismantled the cylinder, all individual parts as well as the casing itself, must
be thoroughly visually controlled.

For the renewal of individual parts, repair sets can be provided, whereby we strongly
recommend that you exchange these parts completely and not partially.

Use only methylated spirits to clean the cylinder and its individual parts. Never use
mineral oil containing cleaning agents.

At reassembly, it is necessary to pay attention to the right sequence of the individual

parts and to use a suitable assembly paste or liquid.

When the visual control shows deficiencies in the casing such as rust scars, grooves, or
other damage, then the wheel cylinder must be exchanged completely. The same can
only be purchased from the manufacturer of the vehicle or the brake under specification
of the order number.

After having finished the work on the hydraulic installation, check the level of the brake
fluid in the reservoir. Refill if necessary and bleed the main and wheel cylinders
thoroughly according to the instructions of the manufacturer of the vehicle.

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4. Brake Shoes

4.1 Maintenance and Inspection

Properly speaking, the brake shoes need no maintenance. They should only be
checked for damaged parts and for the free movement of the parking brake
mechanism.

The thickness of the linings has to be checked by sight control through the wear
checking hole (6) at regular intervals depending n the use of the vehicle, but at
least twice per year. When the remaining lining thickness is small, these intervals
have to be shortened correspondingly in order to avoid greater damage to the
brake and drum.

Since, depending on the use of the brake, the linings are glued or riveted, it is
necessary to pay attention to the different thicknesses remaining.

Riveted Brake Linings: remaining thickness 1.0—1.5 mm over the rivet

head at the thinnest point of the lining.

Glued Brake Linings: remaining thickness min. 2.0 mm at the thinnest

point of the lining.

The brake lining has to be replaced according to the following instructions when
these thicknesses have been attained.

4.2 Repair and Exchange of the Brake Shoes

The brake linings and shoes have to be replaced of exchanged in the case of
soiling, unequal wear, insufficient braking power or after having attained the
minimum remaining thickness.

CAUTION: In order to avoid unequal braking behavior it is necessary in all

cases to replace all the brake shoes and linings of the axle.

Riveted linings may be riveted and un-riveted by suitably equipped workshops

according to the general regulations.

IMPORTANT– Original Knott replacement linings must be used in all cases for this
purpose. In the case of glued linings, the renewal can only be
done by exchanging the brake shoes.

NOTE: For replacement, an original Knott spare part will be delivered ready
for mounting! The same will be delivered under specification of the
order number of the manufacturer of the vehicle or the brake.

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IMPORTANT! There is no guarantee on the brake when using other parts or glueing new
linings to the shoes.

After the installation of ne brake shoes of after a repair, the brake has to be correctly set
according to Knott instructions.

5. Brake Drum

The brake drum can be machined out according to the instructions of the manufacturer
when checking reveals deeper grooves in the running surface of the drum. Should there
be no instructions, then refer to the following table, taking the wall thickness into
consideration.

Max. admissible machining out measurements for brake drums.

Brake Size Drum Ø (mm) when Max. machining out Ø
new (mm)
180 x 40 180.0 181.0
200 x 40 200.0 201.5
203 x 40 & 60 203.0 204.5
230 x 50 230.0 231.5
245 x 60 245.0 246.5
250 x 40 & 60 250.0 252.0
270 x 60 270.0 272.0
315 x 80 315.0 317.0
325 x 80 325.0 327.5
Attention is to be paid to the fact that both brake drums of an axle must always be machined out
to the same measurement.

CAUTION: For machined out brake drums it is necessary to use over-thick linings.

6. General Information

It is a matter of course that ascertained deficiencies of damage of parts not mentioned

here have to be repaired or replaced by original Knott spare parts. Missing specifications
or more detailed instructions are to be demanded from manufacturer of the vehicle or of
the brake.

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Pallet Loader Preparation for Front Axle Maintenance

Main Hydraulic Shutoff

Park cargo loader in a secure area on a flat solid surface. Secure cargo loader for axle mainte-
nance by applying “Park” or “Emergency Brake” and block rear wheels to keep loader form rolling.
Use dependable lift device to raise front of loader and place blocks under frame. If required locate
and close main hydraulic valve so as not to drain hydraulic system.

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King Pin Bearing Replacement

Disconnect tie rod end and steering cylinder from

tie rod ear and steering ear of wheel motor frame.
Move the steering cylinder and tie rod so that the
wheel end can be turned.

If applicable to this cargo loader, insure that main

hydraulic shutoff valve is closed so as not to drain
hydraulic system (See Page 16). Place drain pan
under wheel end, disconnect and plug all hydraulic
lines to wheel motor and brake. Remove forward,
reverse and two speed fittings and plug ports.

Remove these three

fittings and plug ports

CAUTION: Wheel motor is very heavy, use suit-

able lifting device to support wheel motor and re-
move it from wheel motor frame.

Remove and discard mounting bolts and washers,

carefully remove wheel motor from wheel motor

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King Pin Bearing Replacement

Remove jam nuts from top and bottom king pins

and drive king pins out of top and bottom c-frame
ears.

CAUTION: Wheel motor frame is very heavy use

suitable lifting device to remove it from axle.

Clean bores and top and bottom

surfaces of both c-frame ears
Drive top and bottom spherical bearings out of c-
frame ears. Clean the bores and top and bottom
surfaces of both c-frame ears. Inspect bores and
c-frame ears for burrs or other damage, repair as
needed.

Grease Passage

Apply grease to both top and bottom c-frame ear

bores and all surfaces of new king pin bearings.

Install bearings in top and bottom ear such that

grease fitting in c-frame ear and grease passage in
bearing align.

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King Pin Bearing Replacement

Using hammer or press, carefully drive or press

bearing into upper c-frame ear. The outer sleeve
of the bearing in the upper c-frame ear should ex-
tend past the lower face of the upper ear enough to
locate the steel washer. See picture below.

Steel Washer

Lower bearing installed in

bottom c-frame ear

Install bottom bearing the same as the top bearing

only the inner bearing sleeve will be flush with or
slightly below the top face of the lower c-frame ear.
As shown at the left.

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Assembling Wheel Motor Frame to Axle

Apply liberal coating of grease to both sides of the

steel flat washer and the bronze thrust washer.
Install the steel flat washer to the bottom surface of
the top c-frame ear as shown at left. Then install
the bronze thrust washer with the grooves facing
the steel flat washer to the steel washer.

IMPORTANT: Insure that both washers are cen-

tered on the bearing and not resting on the outer
sleeve of the bearing. One or both of the washers
resting on the bearing will prevent proper assembly
of the wheel motor frame to the axle.

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Assembling Wheel Motor Frame to Axle

Using suitable lifting device, move the wheel motor

frame into position on the axle as shown at left.

Align the keyway in the king pin with the keyway in

the wheel motor frame ear and install the top king
pin through the bearing, washers and wheel motor
frame.

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Assembling Wheel Motor Frame to Axle

Align the keyway in the king pin and the wheel mo-
tor frame ear and install the bottom king pin
through the bearing and wheel motor frame.

Install key into bottom ear/king pin.

Install key into top ear/king pin.

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Assembling Wheel Motor Frame to Axle

Jam Nut

To prevent bottom king pin from falling out, install

jam nut as shown at left. DO NOT TIGHTEN

Using suitable lifting device, apply upward pressure

Gap
to wheel motor frame. There will be a gap between
Wheel Motor Frame the lower ear of the wheel motor frame and the
lower ear of the c-frame. Drive the lower king pin
and lower bearing up to set the lower bearing flush
with the bottom face of the lower c-frame ear.

King Pin

Set top king pin and bearing, insure bearing is in-

side bronze thrust washer. NOTE: Wheel Motor
Frame will not turn if the bearing sets on the thrust
washer,

Install jam nut on top king pin, torque jam nuts on

top and bottom king pins to 500 to 550 ft.lbs.

NOTE: While tightening jam nuts swivel wheel mo-

tor frame to insure assembly is correct.

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Assembling Wheel Motor Frame to Axle

Jam Nuts, Top King Pin

Torque 500 - 550 ft.lbs.

Jam Nuts, Bottom King Pin

Torque 500 - 550 ft.lbs.

Right hand wheel motor frame completely assembled to axle

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Steering Ear Bushing Replacement

Bushing Driver Steering Ear Bushing

After removing old bushing drive in new bushing

with bushing driver or similar tool. Be careful not to
damage new bushing or bore in steering ear.

Steering Ear Bushing

Bushing Set in Steering Ear

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Tie Rod End Replacement

Notches in nut indicate

left hand threads

Install nut onto tie rod end as shown at left.

One end of the tie rod has left hand threads

(counterclockwise) and one end right hand threads
(clockwise). Install tie rod end into the appropriate
end of the tie rod.

Passage for cotter pin

Install ball stud of tie rod end into tie rod ear on
Tie Rod Jam Nut wheel motor frame. Install castle nut and torque to
100-125 ft.lbs. Align nut such that a cotter pin can
be inserted through ball stud and castle nut.

Torque Castle Nut 100-125 ft.lbs

Install cotter pin and bend over

After installing new tie rod ends and before setting

tie rod jam nut torque. Check wheel Toe In and
adjust as needed by turning tie rod to adjust wheel
Toe In. Set Toe In 5/32” +/- 3/32”

Torque Tie Rod Jam Nut

to 110-130 ft.lbs. After
Checking/Setting Toe In

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Wheel Motor Replacement

Loosen
Loosen
The following instructions apply to both left and
Loosen
right hand motors.

Loosen plastic plugs for the forward, reverse and

two speed ports. These plugs will be removed after
the motor is installed into the wheel motor frame.

Remove Plastic Plug

Remove side plug and drain plug

Remove Plastic Plug

-08 ORB/-08 JIC Long Adapter

Install –08 ORB Plug in side port and –08 ORB/-08

JIC Long Adapter into drain port. Install –08 JIC
Cap onto Long Adapter. Cap will be removed after
motor is installed into wheel motor frame.

Torque plug and adapter 37-60 ft.lbs.

-08 ORB Plug

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Wheel Motor Replacement

Remove plastic plug from brake wheel cylinder port

Install M14 x 04 JIC Adapter into brake wheel cylin-

der port.

Torque to 21-24 ft.lbs.

Clean mounting surface

Before installing service motor, clean wheel motor

frame mounting surface and threads. Apply
thread-locker to threads as shown at left or to
threads of supplied 5/8-11x 1 3/4” Hex Head Bolts.

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Wheel Motor Replacement

Long Adapter

CAUTION: Use suitable lifting device to move

wheel motor.

NOTE: Orientation of wheel motor and location of

long adapter.

Install wheel motor into wheel motor frame and se-

cure with (10) 5/8-11x1 3/4 Gr 9 Hex Head Bolts
and washers. Torque the bolts to 280-300 ft.lbs.

Long Adapter

Place drain pan or oil absorbent pad under the

wheel motor and remove the three plastic plugs.

Refer to installation drawing supplied with service

motor kit and proceed with installation

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