7
Remove seal (item #37) from gear housing end bearing (item #9).
Loosen nut (item #20) and remove nylon setscrew (item #17).
Remove ring gear from gear housing end bearing, if necessary.
Remove bushing (item #12) from end bearing.
Press new bushing into end bearing. Install ring gear, then nylon
setscrew and nut. Ring gear must be fully seated in end bearing
and slot in ring gear MUST NOT be aligned with clutch shifter hole.
Install new seal in end bearing, with sharp edge of seal outward.
Generously apply grease (MOBILITH SHC 007) to teeth of ring gear
(item #26), teeth of planet gears in drum (item #1), and to bushing
(item #12) in gear housing end bearing. Apply a small amount of
grease to base of bushing (item #13) on motor end bearing. Apply
grease to teeth of output sun gear (item #7) and input shaft (item #10).
Place end of shaft with output sun gear on it into drum (item #2). Rotate shaft to engage planet gears with
output sun gear. Place Gear End Bearing on Drum and engage planet gears with ring gear.
Assemble motor end bearing (item #8) to drum assembly and use tie plates (items #11) and capscrews (items
#15) to hold both end bearings together. Tighten capscrews to 75 Nm (55 ft-lb).
If necessary, remove and replace the shifter assembly (manual, item #2, or air-cylinder, item #3), as follows:
MANUAL CLUTCH SHIFTER ASSEMBLY
Loosen setscrew (item #51) and jam nut, then unscrew shifter assembly (item #2). Be sure slot in ring gear is
not aligned with clutch shifter hole. Rotate drum, if necessary, to ensure hole and slot are not aligned.
Reinstall shifter assembly with plunger, jam nut, and handle positioned in gear housing as shown below.
Thread assembly (with handle engaged in cylinder slot) into the gear housing. Pull drum toward the gear end
bearing housing to remove play. Hold drum in position and continue threading the shifter assembly in until the
gap between the end of the handle and cylinder is
11,1 mm +0 - 1,6 mm(7/16
+0
-1/16 in) and handle is in the horizontal position (see below).
Note:
This gap
will vary with drum endplay. With the drum pulled against the motor end housing, the gap should be 9,5 mm
(3/8 in).
Lightly tighten jam nut. Rotate drum until handle snaps fully into the engaged position. Pull handle out
and rotate 90°. Verify that drum can be rotated freely (at least one full revolution) with clutch shifter at the
DISENGAGED position. Securely tighten
jam nut while holding the handle. Tighten
setscrew (item #19) securely. Re-check
clutch operation as described on page 5.
AIR CYLINDER SHIFTER ASSEMBLY
Loosen set screw (item #21) to remove
shifter assembly (item #3). To reinstall,
place 1 or 2 shims (items #41) over
plunger and thread shifter assembly into
gear end housing. Add or remove shims
to orient ports for pneumatic connections.
Ports should point down (below
horizontal). Tighten setscrew. Check for
clutch operation as described on page 5.
If the light assembly (item #2) or light
switch (item #45) needs to be replaced,
refer to the schematic on page 12 for
electrical connections and disassemble
and reassemble as shown.
37
26
12
17
20
9
AIR-CYLINDER
CLUTCH SHIFTER
MANUAL CLUTCH
SHIFTER
LIGHT SWITCH
LIGHT ASSEMBLY
11,1
+0
- 1,6
mm
(7/16
+0-1
16
in)
JAM NUT
PLUNGER
MANUAL CLUTCH ADJUSTMENT
HANDLE (HORIZONTAL)
CYLINDER
16
4
39
2
3
41
16
2
21
11
38
45
Summary of Contents for HD-P 42
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