SM306 MPF15-2A Service Manual 2004_April
Contents
1. Worn or damaged pinion bearings Replace pinion bearings clamp nut and shims Worn or damaged gear set axle shaft is in good condition Replace lip seal axle shaft bearing pinion bearings gear set and bearings shims and clamp nut Worn or damaged gear set axle shaft is worn or damaged Replace lip seal axle shaft bearing pinion bearings gear set and bearings clamp nut and axle shaft Worn or damaged helical gear and pinion Replace helical gear and pinion Komatsu Master Service Manual 2004 03 15 143 F code Section C code PT 2 0 2550 Transmission Version no T code Transmission Assembly 22 23 24 Master Service Manual 2004 03 15 144 F code Section C code MOMATS U de da eer n ld T code ss Description pau Description ani Description No No No 1 Transmission assembly 12 Cover 22 Kit seal 2 Case gear 13 Nut 23 Kit axle shaft 3 Gear 14 Plug drain 24 Kit drive gear 4 Nut 15 Cone bearing 25 Kit ring set 5 Gear 16 Shim 26 Ball 6 Cone bearing 17 Bearing 27 Ring pivot 7 Cone bearing 18 Seal 28 Plug bearing 8 Cup bearing 19 Axle 29 Pin spiral 9 Shim 20 Spacer 30 Fitting grease 10 Gear and pinion set 21 Gear pinion 31 Screw 11 Screw cap Komatsu Master Service Manual 2004 03 15 145 F code Section C code PT 2 0 2550 Transmission Version no T code 002. with a press or equivalent pressing device Komatsu Master Service Manual 2004 03 15 155 F code Section C code PT S2 0 2550 Transmission Version no T code 000 3 Use a brass drift punch and mallet to drive the spiral gear through the gear case The brass drift punch will reduce the risk of damaged threads on the end of the spiral shaft 4 Lift the helical gear 3 and spacer 20 from the gear case NOTE The bevel gear and spiral gear are a matched set Their alignment is critical Do not replace them separately 5 Inspect the helical gear and the spiral gear for damage or wear from the gear case Lift bearing from gear case 156 Master Service Manual 2004 03 15 F code Section C code MOMATS U i an ion Version no T code 000 4 1 6 Bearing Cup and Shim Removal NOTE Because the bearing cups and cones are usually damaged during removal replace as sets 1 Use a mallet and long punch to drive the spiral gear bearing cup 8 from the gear case Take care not to damage the shims Save the shims for reference in reassembly 2 Use the mallet and a punch to drive the helical gear bearing cup from the gear case Komatsu Master Service Manual 2004 03 15 157 F code PT Section S2 0 Transmission Version no 000 T code C code 2550 3 Remove the axle shaft bearing cup from the gear case using the punch and mal
3. edges of the radial rings could be very sharp 5 Use a screvvdriver to remove the radial rings 25 and thrust ring from the pivot ring 6 Remove the grease fittings using a punch and a mallet 7 Use a punch and mallet to remove the spiral pins 29 that are used to hold the radial rings in 150 Master Service Manual 2004 03 15 F code Section C code KO MAIS U PT 2 0 2550 Transmission Version no T code 000 position Inspect the spiral pins If they are worn replace with new spiral pins when reassembling the pivot ring 8 Clean the grease from the radial ring channel in the pivot ring Inspect the channels for wear If there is excessive wear replace the pivot ring Komatsu Master Service Manual 2004 03 15 151 F code Section C code PT S2 0 2550 Transmission Version no T code 000 4 1 2 Drive Unit Gear Case NOTEI Excessive gear case vvear in the channel pivot ring or hub areas are signs of a damaged gear case If this occurs replace the entire drive unit No further disassembly is necessary 4 1 3 Radial Ring Removal A CAUTION Due to normal or excessive wear the edges of the radial rings could be very sharp 1 Use a screwdriver to remove the radial rings 25 from the gear case 2 Clean grease from the radial ring channel in the gear case Inspect the channel for uneven wear If 152 Master Service Manual 2004 03 15
4. may be evident 3 Remove cover screws 11 using a 1 2 inch 13 mm socket Komatsu Master Service Manual 2004 03 15 147 F code Section C code PT S2 0 2550 Transmission Version no T code 000 4 Use a mallet to break the cover s seal to the gear case 4 1 1 Pivot Ring Removal 7 i 1 Remove the bearing filler plug screws 31 using a 1 2 inch 13 mm socket 2 Remove the bearing filler plug 28 with grease fitting 148 Master Service Manual 2004 03 15 F code Section C code MOMATS U di da m ion Version no T code 000 3 Remove the steel balls 26 through the bearing filler plug hole Work the steel balls forward by inserting a putty knife between the pivot ring and the gear case Use care not to damage radial rings Move the pivot ring slightly from side to side while working the putty knife toward the bearing filler plug hole NOTE If the pivot ring will not spin or turn it is an indication of damaged radial rings and or excessive wear to the channel in the gear case If this is the case replace the entire drive unit No further disassembly is necessary 4 After removing all the steel balls remove the pivot ring 27 by lifting it off toward the drive end of the gear case Komatsu Master Service Manual 2004 03 15 149 F code Section C code PT S2 0 2550 Transmission Version no T code 000 A CAUTION Due to normal or excessive vvear the
5. 0 4 Repair and Rebuild Visually inspect outside of gear case for damage wear or cracks Excessive damage wear or cracks in the gear case indicate that the transmission needs to be replaced rather than repaired or rebuilt 4 1 Transmission Disassembly Removal 1 Park truck on a level surface 2 Turn key switch OFF and depress Emergency Power OFF EPO switch Disconnect battery connector from truck 3 Jack the rear of truck so the drive wheel is approximately 1 inch 25 mm off the floor Block truck in this position Drain transmission fluid Remove drive tire see page 192 Remove steer motor see page 207 Remove drive motor see page 129 o N 0o Remove transmission mounting bolts 3 see page 141 A WARNING Use a suitable hoist for lifting the transmission 9 Attach an overhead hoist to transmission Pull transmission assembly out from the top 146 Master Service Manual 2004 03 15 F code Section C code MOMATS U El da on Version no T code 000 Disassembly de UE Safety glasses are required NOTE Call outs in the following procedures refer to illustration on page 144 1 Clean the outside of the drive unit thoroughly and drain any remaining oil from the drive unit by removing the drain plug 14 2 Visually inspect the outside of the gear case 2 for damage wear or cracks Pay particular attention to the area where hub wear
6. F code Section C code MOMATS U di a ME E n Version no T code 000 Transmission Transmission Mounting Item No Description 1 Transmission assembly Drive wheel assembly Screw Nut Gear Key Plug dipstick Dipstick O 0 NJ OD a BJ OJIN O ring Y o Drive motor Plug fill Romatsu Master Service Manual 2004 03 15 141 F code Section C code 1 Theory of Operation This transmission is of the double reduction gear type The gears are a combination of helical and bevel gears for strength and lovv noise The final drive gear is mounted on opposing tapered roller bearings Gears and bearings are enclosed in an oil filled case The drive motor is mounted externally with the drive motor pinion gear mounted on the armature shaft The electric brake is on the drive motor 2 Maintenance See Planned Maintenance Schedule on page 69 2 1 Fluid Changing 1 Remove drain plug 14 see page 144 from drive unit and drain all the fluid 2 Reinstall drain plug 3 Remove fill plug 11 see page 141 A CAUTION Incorrect selection of fluid for a particular application may cause damage 4 Refill using the proper grade fluid see page 82 The capacity of the drive unit is 1 1 2 gallons 6 liters 3 Troubleshooting Because of the uncomplicated nature of the transmission troubleshooting is limited t
7. F code Section C code MOMATS U di an Meer Version no T code 000 there is excessive wear no further disassembly is necessary The pivot ring must be replaced 4 1 4 Axle Shaft and Bevel Gear Removal SST NS dj i SSS 1 Loosen the setscrew locking the clamp nut 13 using an Allen socket or wrench and a breaker bar An Allen wrench may be needed if the access is limited by the location 2 Use a screwdriver in the clamp nut slot to turn the clamp nut off Komatsu Master Service Manual 2004 03 15 153 F code Section PT S2 0 Transmission Version no T code 000 C code 2550 rere _ a s 3 Use a brass drift punch and mallet to drive the axle from the gear case The brass drift punch will reduce the risk of damaged threads on the end of the axle Lift the bevel gear from the gear case In cases where severe chipping is present a mallet may be needed to knock the bevel gear loose 154 Master Service Manual 2004 03 15 F code Section C code MOMATS U m ag m PE Version no T code 000 4 1 5 Spiral Gear and Helical Gear Removal 1 Turn the drive unit gear case over to remove the clamp nut 4 from the spiral gear 3 Loosen the setscrew locking the clamp nut 4 using an Allen socket or wrench 2 Use a screwdriver in the clamp nut 4 slot to turn the clamp nut off Inspect the clamp nut for damage NOTE The spiral pinion may need to be removed
8. let 4 Use the mallet and a punch to drive the bevel gear bearing cup from the gear case Take care not to damage the shims Save the shims for reference in reassembly 5 Visually inspect the gear case bores and sealing surfaces for damage or wear 158 Master Service Manual 2004 03 15 F code Section C code MOMATS U di ion ion Version no T code 000 4 1 7 Spur Gear Removal Check the spur gear for damage or wear If the spur gear is damaged use a drift punch and mallet to remove it from the gear case Komatsu Master Service Manual 2004 03 15 159
9. o identifying problems if they are mechanical or electrical in nature Fluid leaks are obviously mechanical in nature and can be found by visual inspection Unusual noise and or slow running could be mechanical or electrical in nature Generally speaking if the problem is caused internally in the transmission then metal contamination will be evident in the oil If there is a mechanical problem outside of the transmission then it will become evident by inspecting the drive motor and brakes PT 2 0 2550 Transmission Version no T code 000 142 Master Service Manual 2004 03 15 KOMATSU F code Section C code PT 2 0 2550 Transmission Version no T code 000 Transmission Troubleshooting Symptom Probable Cause Required Action Oil Leaks Damaged lip seal Replace lip seal axle shaft bearing and clamp nut Worn or damaged axle shaft Replace lip seal axle shaft bearing axle shaft and clamp nut Gear case main cover joint Reseal Worn or damaged gear case Replace drive unit Drive wheel wobbles Worn or damaged axle shaft bearings Replace lip seal axle shaft bearing and clamp nut Worn or damaged axle shaft Replace lip seal axle shaft bearing axle shaft and clamp nut Loose wheel mounting hardware Inspect gear case for damage retorque mounting hardware Noise Worn or damaged axle shaft bearings Replace lip seal axle shaft bearing and clamp nut
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