Form 04581377-Edition 3 3
3. Grasp the shaft of the Output Gear (57) and pull it, along with
the two Thrust Washers (55 and 56), out of the Gear Housing.
4. Grasp the shaft of the Intermediate Gear (58) and pull it, along
with the two Thrust Washers (55), out of the Gear Housing.
5. Grasp the shaft of the Drive Gear (59) and pull it, along with
the two Thrust Washers (55 and 56), out of the Gear Housing.
6. Using pick or screwdriver end, remove the Seal (62).
7. Press the three Needle Bearings (60 and 63) out of the Gear
Housing Cover.
8. Press the three Needle Bearings (60 and 63) and the Inner
Ring (61) out of the Gear Housing.
9. Pull the two Dowel Pins (50) out of the Gear Housing.
Gear Case - Disassembly
1. Tilt the Gear Case (18) and carefully slide out the Gear Head
Assembly (25) and Spacer (24).
2. Use a pick to pry out the metal Spacer (23).
3. Tilt the gear case and slide out the Spindle Assembly (22).
4. If necessary use an allen wrench to unscrew the Plug (19) and
remove the Washer (20).
Disassembly of Electronics Pod
1. Use an allen wrench to remove M6 Screws (35) from Flange (34).
2. Remove the M3 Screw (30) and slide the Cover (38) off.
3. Remove the two O-Rings (37) and remove the Memory Chip
Assembly (31).
4. Unscrew the Nut (36) and remove the Flange (34).
5. Use a small flathead screwdriver to carefully peel the dried sealant
out of the ground slot.
6. Remove the M3 Screw (30) to free the ground wire.
7. Loosen the nut constraining the grommet in the strain relief and
unscrew the strain relief from the Housing (29).
8. Pry out the Clip (33) and slide out the Communication Board (32).
9. Disconnect the motor temperature sensor connector, motor
communication connector, and the torque transducer connector from
the Communication Board (32).
10. Disengage female socket on the communication board from the male
connector on the motor cable.
11. Slide the Housing (29) off of the transducer and motor cables.
Tool Mounting Methods
It should be noted that assembly of the tool into the modules will differ
slightly depending on the method used for mounting. If the tool will be
mounted with the plate spacer in place, the tool can be assembled by
following the first set of instructions (A). The reason for the plate spacer
is to allow the tool to be mounted fully assembled.
The tool can also be mounted with a bracket or mounting plate that takes
the place of the spacer. If this is the desired mounting method, the
mounting plate used must be the same thickness as the plate spacer
provided or the tool will not fit together properly. In this case the second
set of instructions (B) should be followed.
Assembly
General Instructions
1. To protect the part's surfaces and to prevent distortion of Housings
and threaded joints, use care when grasping the tool.
2. Always press on the inner ring of a ball-type bearing when installing
the bearing onto a shaft.
3. Always press on the outer ring of a ball-type bearing when pressing
the bearing into a bearing recess.
4. Refer to the "Lubrication" section of this manual for instructions on
how to properly grease this tool.
Assembly of Modules
(A)
1. Apply serviceable thread locker to all screws that connect the
assemblies together.
2. Insert the two M4 Screws (5) into the Housing (3), through the plate
spacer, and engage the threads in the Transducer Assembly (16).
3. Insert the M8 Screws (17) through holes in the Transducer Assembly
(16) and engage the M8 threads in the Gear Case (18).
4. Insert the M6 Screws (21) through the holes in the Gear Case (18)
and engage the M6 threads in the Motor Assembly (27).
5. Insert the tool into the mounting plate.
6. Use an allen wrench to Insert four M8 Screws (4) through the holes in
the mounting plate, through the holes in the Housing (3), through the
Plate Spacer (15), and engage the threads in the Transducer
Assembly (16).
For Offset Tools:
Replace Step 3. with:
3a. Insert the M8 Screws (17) through holes in the Offset
Gearbox Assembly and engage the M8 threads in the Gear
Case (18).
3b. Insert the M6 Screws (52) through holes in the Transducer
Assembly (16) and engage the M6 threads in the Offset
Gearbox Assembly.
3c. Insert the M8 screws (51) through holes in the Transducer
Assembly (16) and engage the threads in Offset Gear Box
Assembly.
Replace Step 6. with:
6. Use an allen wrench to Insert three M8 Screws (4) through the
holes in the mounting plate, through the holes in the Housing
(3), through the Plate Spacer (15), and engage the threads in
the Transducer Assembly (16).
(B)
1. Apply serviceable thread locker to all screws that connect the
assemblies together.
2. Insert the M8 Screws (17) through holes in the Transducer Assembly
(16) and engage the M8 threads in the Gear Case (18).
3. Insert the M6 Screws (21) through the holes in the Gear Case (18)
and engage the M6 threads in the Motor Assembly (27).
4. Position the connected transducer, gear case and motor assemblies
flush with the backside of the mounting plate and the spindle
assembly flush with the front side of the mounting plate.
5. Line up the screw holes and use an allen wrench to insert the four
M8 Screws (4) through the holes in the Housing (3), through the
holes in the mounting plate and engage the threads in the
Transducer Assembly (16).
For Offset Tools:
Replace Step 2. with:
2a. Insert the M8 Screws (17) through holes in the Offset
Gearbox Assembly and engage the M8 threads in the Gear
Case (18).
2b. Insert the M6 Screws (52) through holes in the Transducer
Assembly (16) and engage the M6 threads in the Offset
Gearbox Assembly.
2c. Insert the M8 screws (51) through holes in the Transducer
Assembly (16) and engage the threads in Offset Gear Box
Assembly.
Replace Step 4. with:
4. Position the connected transducer, gear case, offset gearbox,
and motor assemblies flush with the backside of the mounting
plate and the spindle assembly flush with the front side of the
mounting plate.
Replace Step 5. with:
5. Line up the screw holes and use an allen wrench to insert the
three M8 Screws (4) through the holes in the Housing (3),
through the holes in the mounting plate and engage the
threads in the Transducer Assembly (16).
WARNING
• This procedure is to be done by an authorized, trained repair
person to ensure proper functioning of the tool.
Spindle Assembly
1. Press Needle Bearing (2) into the top of the Housing (3) below top
face to leave room for Seal (1).
2. Press Seal (1) into the top of the Housing (3) below the top face.
3. Turn the housing over and press the second Needle Bearing (2) into
the housing below inside shoulder.
4. Locked Spindle: Fully Retracted (If spindle will not be locked go to
step # 5). Slide spindle lock onto spindle so that it seats flush against
the splined face.
5. Position Spring (9) inside large hole of spindle.
6. Locked Spindle: Fully Extended (If spindle will not be locked go to
step # 7). Insert spindle lock into the housing so that it rests on the
rear face of the splined drive.
7. Slide Washer (6) onto Spindle (7) and insert spindle into the
Housing (3).
8. Work 2.5 cc of Ingersoll-Rand grease 222 into the inner diameter of
the Coupler (8).
9. Align the Coupler (8) to slide over the spline of the spindle and slide
to the Housing (3).
10. Insert Tas Spindle (13) into the Driver (11) with the holes aligned.
Push the Roll Pin (12) through the holes to fasten the parts together.
11. Insert the large circular end of Pin (10) into the square hole of the
Driver (11)
12. Insert other end of Pin (10) into the Spring (9).
13. Align the driver and tas spindle with the spline of the coupler and
insert driver and tas spindle into the Housing (3).
