R0015096 (c) Bench Assemble Transfer Drive Assembly

Instructions for bench assembly of transfer drives

Difficulté

Medium Moyen

Durée

2 hour(s) heure(s)

R0015096__c__Bench_Assemble_Transfer_Drive_Assembly_Screenshot_2024-06-05_080141.png

Introduction

Tools Required

External circlip pliers

Internal circlip pliers

Standard hex key set

Standard spanner set

C spanner

Parts Required

H0007576 x 2

B0000139 x 2

D0007577 x 2

D0015626 x 2

D0015561 x 2

D0015562 x 2

B0001167 x 2

D0015024 x 2

B0001100 x 6

B0001227 x 1

D0015610 x 4

Étape 1 - Unless otherwise stated

Use Loctite 243 on all fasteners

Use Loctite 572 on all pneumatic threaded connections

Pen mark all bolts to show finalised

Étape 2 - Assemble chain tensioner

2 off

1 Press bearing B0000139 into sprocket H0007576.

If fit is loose, use FE10 solvent to degrease parts and apply bearing fit to fix.

If fit is tight, inspect parts to Drawing to confirm correct sizes

2 Press D0007577 into sprocket and follow above for correct fitment .

3 Captivate with 20mm external circlip

Étape 3 - Attach to mounting plate

2 off

Attach sprocket assembly to D0015626 Using M8 x 35 Socket cap

Étape 4 - Attach Base

2 off

1 Attach D0015561 to D0015562 as shown using 3 off M10 x 30 socket caps

2 Mount assembled sprocket plate using M6 x 30 socket caps and heavy F0000247 M6 washers

Étape 5 - Check motor assembly configuration

Check motor has been supplied in the shown configuration.

Gearbox may need rotating on supplied motor assembly to match orientation shown.

Motor terminal box position is vital

Étape 6 - Fit Drive shaft

2 off

1 Insert 3 off B0001100 key into driveshaft

2 Insert driveshaft D0015024 as shown and captivate either side with external circlip

Étape 7 - Quality check

It is vital that the alignment bush from B0001227 clutch assembly can pass through the drive sprocket by hand

Polish sprocket to desired fit if required

Étape 8 - Please ensure the following amendment is recognised

The torque limiter has changed to a single spring washer style , and will be detailed in the step below .

This must be fitted to this assembly , and the correct tensioning process adhered to at the end of this procedure

Ignore any additional photos that show the 3 spring variant, photos are for reference only

Étape 9 - Check Configuration of clutch

Check B0001227 has been assembled in the correct order

1 C Spanner pressure nut

2 Locking washer

3 Spring washer

4 Spreader plate

5 Friction washer

6 Centralise boss

7 Drive sprocket

8 Main Flange

Étape 10 - Fit clutch to motor

2 off

Mount clutch assembly as shown and captivate with 25mm external circlip

ECR raised 12/06/23 to address problem of grubscrew lock off missing key fitted.

Until corrected , use M6 x 10 kcp grubscrew to lock on to shaft

Étape 11 - set torque convertor tension

To set initial tension on torque convertor , please ensure the following steps are taken

1 Tension adjustment nut by hand to achieve hand tension against friction plates

2 Use C spanner to apply additional 90 degrees of rotation to nut

Étape 12 - Mount motor to base

2 off

Attach motor to base as shown

Use M8 x 50 hex set bolts , A form washers and M8 nyloc nuts to secure 4 off mounting points

...Ensure fasteners are long enough to pass through nyloc section of nut

Étape 13 - Attach clamps

2 off per assembly

2 off assemblies

Use M12 x 100 hex set bolts (check size) and A form washers to attach 2 off clamp plates D0015610 to assembly as shown

Chain to be fitted on assembly to frame

...Do not apply adhesive to these as they will be removed for installation later on

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