76 PLANETARY DIGGER DRIVE SERVICE AND REPAIR
Contents
1. ESRRIDGE 76 PLANETARY DIGGER DRIVE SERVICE AND REPAIR MANUAL Example Part Number CJ EJ Ee Output Bail Motor Motor Shift Series Shaft Boss Supplier Number Cylinder THIS SERVICE MANUAL IS EFFECTIVE FROM S N 17050 AUG 1993 CURRENT SM76BA 76 SERIES SERVICE MANUAL TWO SPEED PLANETARY DIGGER DRIVES LUBRICATION amp MAINTENANCE Change the oil after the first 50 hours of operation Oil should be changed at 500 hour intervals thereafter All gearboxes require a GL 5 grade EP 80 90 gear oil for lubrication Manufacturer also recommends that unit be partially disassembled to inspect gears and bearings at 1000 hour intervals Model Qil Capacity Level Single Stage 6 5 pints 3 06 liters To horizontal centerline of primary cluster gears Recommended ambient and operating temperatures for conventional and synthetic gear lubricants 50 25 0 25 50 75 100 125 150 175 200 225 250 80W90 conventional 75W90 conventional 85W140 conventional Min Ambient operating Max Ambient temp Max Operating temp 75W90 synthetic 80W140 synthetic Note Ambient temperature is the air temperature measured in the immediate vicintiy of the digger A digger exposed to the direct rays of the sun or other radiant heat sources will operate at higher temperatures and therefore must be given special consideration The max operating Troubleshooting Rattling Grinding or Whining Noise2. DOWEL PIN 49 i 71 004 0513 2 1 2 HEX OUTPUT SHAFT 71 004 1383 2 5 8 HEX OUTPUT SHAFT 50 1 PER CUSTOMER SPEC HYDRAULIC MOTOR OPTIONS SEAL KIT P N 76 016 2011 INCLUDES ITEMS 43 44 46 AND O RING FOR SHIFTER SHAFT ASSEMBLY E C N 1803 X76 AB DATE 5 02 06 Unit Disassembly Procedure Refer to Exploded View Drawing on Page 3 1 Scribe from bail assembly 20 to the bearing carrier 2 across the outside of the digger drive to assure proper orien tation of oil fill and drain plugs motor mounting etc as the unit is reassembled 2 To drain oil position unit on its side and remove oil plug 41 located in the top case 1 To help ventilate oil while draining loosen hydraulic motor bolts 31 Maximum drainage occurs when oil is warm NOTE Particular care should be taken when placing the unit in a position for servicing Unit should be blocked up so that weight of the unit is resting on the bearing carrier 2 This fixture must be secure so that the auger drive will not tip over during disassembly and assembly procedures 3 Loosen upper shift cylinder note location and remove bolt part of Item 42 4 If shifter performance is in doubt leave lower bolt in place and follow cylinder adjustment procedure Step 19 in Unit Assembly Procedure to see if poor cylinder adjustment could be the cause of no shift or partial shift condition 5 Note location of lower washer Remo
3. GEAR PRI 15 1 71 004 0562 71 004 0572 SHIFTER GEAR 16 1 71 004 0772 SHIFTER COLLAR 17 6 71 004 0861 _ m WASHER PRI 18 6 71 004 0871 WASHER SEC 19 1 71 005 0302 SHIFTER SHAFT ASSY 20 1 PER CUSTOMER SPEC BAIL ASSY 21 1 01 102 0100 BRG UPPER SHAFT CONE 22 1 01 100 0040 keng BRG SHIFTER 23 6 01 105 0010 5 BRG PRI PLANET 24 3 01 105 0020 _ BRG SEC PLANET 25 1 01 102 0090 BRG LOWER SHAFT CONE 26 1 01 112 0030 THRUST RACE 27 1 01 127 0010 gl BUSHING 28 1 71 004 0151 keng BUSHING 29 12 01 150 0020 keng CAP SCR 3 8 16 30 1 01 103 0090 BRG UPPER SHAFT CUP 31 2 01 150 0110 CAP SCR 5 8 11 32 8 01 150 0520 CAP SCR S H 3 8 16 33 6 01 153 0020 ROLL PIN 3 16 34 12 01 158 0360 SS HEX FLANGE NUT 3 8 16 35 1 01 160 0100 SNAP RING 268 36 1 01 160 0030 SNAP RING EXT 255 37 1 01 160 0020 a 5 SNAP RING EXT NO 237 38 1 01 160 0040 SNAP RING EXT NO 250 39 1 01 160 0110 SNAP RING EXT NO 156 40 2 01 166 0040 _ LOCKWASHER 5 8 41 2 01 207 0010 PIPE PLUG 1 2 NPT SHIFT CYLINDER ASSEMBLIES 71 002 0601 SINGLE ACTING STD HYD 45 71 002 1351 SINGLE ACT HEAVY DUTY HYD 71 002 0692 a 5 DOUBLE ACTING HYD 71 002 0322 _ 5 AIR 71 002 1542 gl VACUUM 43 1 01 402 0010 gl O RING NO 250 44 2 01 402 0020 gl O RING NO 276 46 1 01 405 0540 OIL SEAL 47 2 01 152 0070
4. 1 replace with new bear ings 5 Check primary planet shafts 9 for any abnormal wear especially ones in which bearings needed to be replaced If any abnormal wear is found replace planet shaft 6 Using a punch drive roll pins 33 out of planet shafts 9 7 With a primary planet washer 17 on both sides of cluster gear 11 and with bearings 23 installed slide gear into car rier 7 and insert primary planet shaft 9 through carrier planet gear and washers 8 Planet shafts 9 should be installed with chamfered end of 1 8 inch hole toward outside diameter of the carrier 7 This will aid in alignment of holes while inserting roll pins 33 9 Drive three roll pins 33 through the carrier holes and into the planet shafts to retain the parts Secondary Planet Carrier Subassembly Items 6 8 10 18 21 24 33 amp 37 33 an 18 i Disassembly As with the primary planet carrier subassembly check for abnormal noise in the planet gear bearings 24 by rotating the planets while listening for any noise and feeling for any roughness If further inspection or replacement is required follow the same procedure as Steps 1 6 of the Primary Planet Carrier Subassembly Proce dure Substitute items as indicated secondary planet gears 10 secondary planet bearings 24 secondary planet shafts 8 secondary planet washers 18 and secondary planet carrier 6 The inner bearing cone 21 c
5. R DRIVE IS NOW READY FOR USE Service Division Bulletin 013 Revision 1 supersedes bulletin dated 01 14 86 Date 06 01 87 Reference All Series 71 76 72 77 and 73 78 Digger Drives Subject Inspection of Secondary Carriers When repairing updating or inspecting an auger drive the second ary carrier should be inspected for possible wear around the spline where it contacts the shaft retaining ring Under heavy use and or in rocky regions continual impacting of the retaining ring against the carrier may cause wear in this area If it wears to a beveled shaped high loading in the pull out direction could cause the shaft retaining ring to dislodge from its groove allowing the hex shaft to pull out of the unit If the carrier is found to be worn to bevel shape when inspected it should be replaced with carrier part number 71 004 0073 Units with serial numbers prior to 4900 should also have the hex output shaft replaced with the current production revision part number 71 004 0513 Eskridge Series 76 and 77 Digger Drives Fill gear drive with EP 80 90 gear oil until it runs out of the fill plug while the digger drive is leaning approximately 312 from vertical about 7 A dry gear drive will hold about 6 pints of oil in this condition FLAT WITH SQUARE CORNERS CARRIER IS GOOD WORN WITH BEVELED AND ROUNDED CORNERS REPLACE CARRIER
6. annot be removed from the carrier 6 without destroying the bearing If the bearing needs replacement please consult Eskridge Proceed with Steps 7 9 of the Primary Planet Carrier Subassembly Procedure NOTE 1 See Service Bulletin on Page 10 concerning the wear of secondary planet carriers 6 NOTE 2 Retaining ring 37 must be inserted into carrier 6 before it is installed in unit as described in Step 2 of the Unit Assembly Procedure Shifter Gear Subassembly Items 15 16 22 35 amp 39 22 2226 Disassembly 39 and pull pieces apart Check for worn parts replace as necessary Reassembly Reassemble in reverse order To disassemble shifter gear assembly remove retaining ring Top Case Subassembly Items 1 5 13 19 26 27 28 32 38 41 amp 47 lt gt _ 9 e S Disassembly Inspect primary ring gear 5 for abnormal wear damaged teeth If replacement if required remove eight socket head capscrews 32 from ring gear Primary ring 5 is doweled into top case 1 use puller holes provided to thread two 3 8 16 bolts into ring gear 5 until part was completely separated from top case 1 2 If installing a new primary ring gear 5 always install new dowel pins 47 into ring gear before reassembling into top case 1 3 To remove sun gear 13 first remove retaining ring 38 shim 26 4 disassembly shift lever and fork remove
7. end down as shown onto the shaft until it seats against the shoulder Bearing cone 25 may be reused if it was removed only to replace the seal 46 2 Clean all foreign material from magnetic oil plug 41 Add small amount of pipe thread compound to pipe plug before installing back into bearing carrier 2 3 Place the bearing carrier 2 output side up opposite shown in diagram on the press table 4 Apply a layer of lithium or general purpose bearing grease to surface of outer bearing cup 3 Insert the shaft 49 into the bearing carrier 2 bearing cone down and use a soft hammer to install the shaft seal 46 into the bearing carrier CAUTION Output shaft is not retained at this point 5 Invert this assembly on the press table so it is standing on the shaft All subassembly service or repairs should complete at this point Continue to Unit Assembly Procedure to complete unit buildup Unit Reassembly Refer to Exploded Drawing on Page 3 A special tool should be made for the timing process An old timing gear cut off above the lower gear and welded to a 6 long bolt works well If an extra timing gear is not available the timing will be more difficult the timing tool keeps gears in time as they mesh with primary ring gear 5 mounted in top case 1 1 When all subassemblies at complete the unit is ready to be assembled Place lower assembly back on blocks which were used during the initial uni
8. it to rotate them until top case is properly installed While keeping the timing marks aligned position the top case 1 near the proper orientation to scribed line on outside of unit Work top case down until fully seated with gears in time CAUTION If unit is not properly timed the gear drive will be severely damaged Be sure gear drive turns smoothly and easily 12 Fill unit with EP 80 90 gear oil to proper level as specified on Page 2 13 14 15 16 17 18 19 Install shifter gear assembly 15 16 22 35 amp 39 by lifting shift lever part of Item 19 to allow clearance Install o ring 43 onto hydraulic motor 50 Using hand tools to avoid stripping the aluminum install hydraulic motor 50 on mounting pad on top case 1 with two capscrews 31 and lockwashers 40 torque to 130 ft lbs Bolt lower end of shift cylinder assembly 42 to shift lever 19 Line up scribe mark on bail assembly 20 with scribe mark on top case 1 and lower bail over hydraulic motor 50 until bail flange contacts the cover Check all o rings to make sure they are properly seated Install twelve capscrews 29 with hex flange nuts 34 and torque to 30 ft lbs Install and adjust shifter Shifter cylinder should be compressed to its shortest length Next with the shifter gear pushed all the way up bail side adjust the length of the shifter cylinder to allow installation torque to 70 ft lbs THE DIGGE
9. large retaining ring on inside then slide apart 5 Inspect o ring on shift shaft for damage Lubricate shaft with grease when reassembling 6 Reassemble top case before continuing to Unit Assembly Procedure Base Subassembly Items 2 3 25 30 41 46 amp 49 Disassembly CAUTION Output shaft is no longer retained care should be taken not to injure feet because output shaft can fall out Additional care should be taken not to damage output shaft when it is pressed through base 1 Output shaft removal Bearing carrier 2 should be set pinion side down as shown on a plate or table with output shaft 49 protruding through a hole in the table Press output shaft out bottom of base by applying a load to top end internal end of shaft until it pass es through inner shaft bearing cone 21 NOTE If reusing old bearing cone do not damage roller cage by pulling on it 2 If outer bearing cone 25 needs to be replaced a gear puller may be used to remove it from output shaft 49 3 Remove the shaft seal 46 for inspection or replacement Lubricate inner lip of new shaft seal 46 and slide the seal onto the shaft 49 until it fits snugly over shaft seal diameter with the open side toward the inside of the digger drive Reassembly NOTE Press bearing cone onto output shaft by pressing on inner race only Do not press on roller cage or it may damage bearing 1 Press outer bearing 25 large
10. n shifter and allow shift to occur Diagnosing the Upper Gear Drive Area The Series 76 digger drive cannot be shifted on the fly The digger drive must be at a complete stop with the load removed backed out of hole in ground before shifting Shifting on the fly is the primary cause of damage to the gears in the shifter assembly Damage caused by shifting on the fly will be seen as initial grinding of the gears at the gear faces a wear pattern developing on the top of the cluster gears and on the shift gear itself and a severe wear pattern developing on the points of the shifter gear Additionally the sun gear will show damage on the points a rounding or even severe burring of these parts is possible 2 76BA amp ITEM QTY 76BA 76BC DESCRIPTION 1 1 71 004 0014 TOP CASE 2 1 71 004 2144 gt BEARING CARRIER 3 1 01 103 0080 LOWER SHAFT CUP 4 1 71 004 0042 RING GEAR SEC 5 1 71 004 0142 RING GEAR PRI 6 1 71 004 0073 PLANET CARRIER SEC 7 1 71 004 0113 771 004 0433 PLANET CARRIER PRI 8 3 71 004 0081 PLANET PIN SEC 9 3 71 004 0121 _ PLANET PIN PRI 10 3 71 004 0092 PLANET GEAR SEC 11 3 71 004 0132 71 004 0412 CLUSTER GEAR PRI 12 1 71 004 0102 SUN GEAR SEC 13 1 71 004 0172 71 004 0402 SUN
11. rrier subassembly out of the unit in cludes Items 7 9 11 17 23 amp 33 12 If sun gear 12 has not been removed from digger drive do so now Sometimes the sun gear sticks to the primary carrier 7 13 Remove secondary ring gear 4 14 Remove retaining ring 37 from end of output shaft 49 CAUTION Output shaft is not retained at this point 15 Lift the secondary planet carrier subassembly out of the unit includes Items 6 8 10 18 24 amp 33 use a puller if need ed NOTE See Service Bulletin 013 concerning the wear of sec ondary planet carriers The unit is now disassembled into groups of parts and or subassemblies The area s requiring repair or service should be identified by thorough inspection of the parts after they have been washed in solvent Primary Planet Carrier Subassembly Items 7 9 11 17 23 amp 33 Disassembly Rotate cluster gears 11 to check for any abnormal noises or roughness in the primary planet bearings 23 or planet shafts 9 If replacement or further inspection is required proceed as follows 1 Drive the roll pins 30 completely into the planet shafts 9 2 Press planet shafts out of carrier 6 3 Remove cluster gears 11 and primary planet washers 17 from carrier 6 The cluster gears are a matched set and all three should be replaced if damaged 4 If any of the primary planet bearings 23 need replacing press them out of planet gears 1
12. s Hydraulic motor failure and or difficulties are commonly confused with gear drive problems as they can share similar symptoms reports of rattling grinding or whining noises in the digger assembly Carefully check the hydraulic motor for problems before removing the digger drive from the boom If the digger drive is removed a motor problem can only be determined by testing the motor on a hydraulic test stand or by eliminating the gear drive as the noise source after a total teardown of the unit If you determine that the hydraulic motor is the source of the problem please contact the original equipment manufacturer of the digger drive assembly Shifting Difficulties Jumping Out of Gear This symptom commonly attributed to gear drive failure can be due to air in the hydraulic lines leading to the drive not the drive itself Excessive back pressure in the system may also cause this problem Inability to Shift into High Gear This symptom can be due to a poorly adjusted shift cylinder While the cylinder is carefully set at the factory the process of disassembly may turn or move the cylinder in such a way that it contacts the case contact between the cylinder body and the gear drive prevents the rod from making its full one inch travel Difficult Rough or Impossible Shifting Hand testing a shifter may indicate a no shift condition even when the shifter is okay If metal to metal contact is made a short turn of the output shaft may alig
13. t disassembly procedures for remaining unit build up CAUTION Output shaft is not retained 2 Install a new o ring 44 on the bearing carrier 2 Referring to scribe marks for proper orientation install the secondary ring gear 4 3 Push retaining ring 37 into center of secondary planet carrier 6 4 Install the secondary planet carrier 6 assembly by rotating it until carrier spline lines up with shaft spline Begin pressing carrier onto shaft 5 Before secondary carrier is fully seated install retaining ring 37 onto end of output shaft 6 Continue pressing secondary carrier until fully seated Check retaining ring 37 to be sure it is in the ring groove 7 Install a new o ring 44 on the bearing carrier 2 8 Check to be sure retaining ring 36 is installed on sun gear 12 Slide the sun gear into the secondary planet carrier 9 Install the primary carrier 7 by rotating until spline lines up with sun gear assembly should drop into place 10 Install a new o ring 44 on top case 1 use grease to help hold it in place 11 Timing Procedure There are machinist s marks on each of the three cluster gears 11 These marks should be aligned so that each points toward the center of the primary planet carrier See Timing Procedure Diagram Use the of the timing tools mentioned above will make top case installation easier Leave the timing tool in the center of the cluster gears and use
14. ve lower shift cylinder 42 bolt nut and washer bolt and nut are accessible through the bail 6 Remove twelve hex head capscrews 29 and hex flange nuts 34 from bail assembly 20 lift bail from unit NOTE There are no bolts retaining the major components together proceed with caution when moving the unit 7 Remove two capscrews 31 and lock washers 40 from hydraulic motor 50 Notice that the motor is larger on one side it must be replaced the same position as removed Remove motor from unit Check o ring 43 for damage 8 Observe location of shift fork part of Item 19 shifter gear assembly Items 15 16 22 35 amp 39 and top case 1 Check for binding or loose shift connections 9 Press down on shift lever part of Item 19 Remove shift er gear assembly Items 15 16 22 35 amp 39 If shifter is jammed in sun gear 13 and cannot be removed dismantle shifter assembly in the case by removing snap rings 35 amp 38 and pulling bearing 22 and collar 16 out of fork Shifter gear 15 should be free of nicks burrs or gouges 10 Use a screwdriver wood chisel or similar flat strong tool ground flat for insertion between the aluminum top case 1 and the ring gear 4 Tap lightly on tool do not drive into case heavy prying will damage the o ring contact surfaces in the case Remove the top case assembly includes Items 1 5 13 19 26 27 28 32 38 41 amp 47 11 Lift the primary planet ca
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