Difficulty
Moderate
Steps
23
Time Required
1 - 2 hours
Sections
5
- Motor Cover
- 2 steps
- Motor Cage
- 2 steps
- Gearbox and Motor Assembly
- 4 steps
- Gear Oil
- 2 steps
- Drivetrain
- 13 steps
Flags
0
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Introduction
This repair requires two people to complete.
The gearbox will need to be refilled with 8oz of 75W90 gear oil (see operator’s manual).
Properly dispose of used gear oil at a certified collection center.
What you need
Step 1
Remove the motor cover bolts
- Before you begin, ensure the power cord is unplugged and the power switch is in the OFF position.
- Use a 13 mm socket to remove the two bolts securing the motor cover to the frame.
Before you begin, ensure the power cord is unplugged and the power switch is in the OFF position.
Use a 13 mm socket to remove the two bolts securing the motor cover to the frame.
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Step 2
Remove the motor cover
- Remove the motor cover.
Remove the motor cover.
Step 3
Remove the motor cage bolts
- Use a 13 mm socket to remove the four bolts securing the motor cage to the frame.
Use a 13 mm socket to remove the four bolts securing the motor cage to the frame.
Step 4
Remove the motor cage
- Remove the motor cage.
Remove the motor cage.
Step 5
Remove the drum
- Use a 19 mm socket to remove the the 70 mm-long bolt securing the drum to the output shaft.
Use a 19 mm socket to remove the the 70 mm-long bolt securing the drum to the output shaft.
Step 6
- Lift the drum straight off of the output shaft and set it aside.
- Two people may be required depending on the weight of the drum.
Lift the drum straight off of the output shaft and set it aside.
Two people may be required depending on the weight of the drum.
Step 7
Remove the gearbox and motor assembly
- Have a second person hold the gearbox and motor assembly while you remove the nuts to prevent it from dropping.
- Use a 10 mm socket to remove the four nuts securing the gearbox to the frame.
Have a second person hold the gearbox and motor assembly while you remove the nuts to prevent it from dropping.
Use a 10 mm socket to remove the four nuts securing the gearbox to the frame.
Step 8
- Remove the gearbox and motor assembly from the frame.
Remove the gearbox and motor assembly from the frame.
Step 9
Remove the drain plug
- Use a 5 mm hex key to remove the drain plug.
- Do not tilt the opening down until over a receptacle.
Use a 5 mm hex key to remove the drain plug.
Do not tilt the opening down until over a receptacle.
Step 10
Drain the gear oil
- Drain the gear oil into a receptacle.
- Refill with 8oz of 75W90 gear oil. See the operator’s manual.
Drain the gear oil into a receptacle.
Refill with 8oz of 75W90 gear oil. See the operator’s manual.
Step 11
Remove the fan cover
- Use a Phillips screwdriver to remove the four screws securing the fan cover to the motor.
Use a Phillips screwdriver to remove the four screws securing the fan cover to the motor.
Step 12
- Remove the fan cover.
Remove the fan cover.
Step 13
Separate the gearbox from the motor
- Use a 8 mm socket to remove the four 135 mm-long bolts securing the motor to the gearbox.
Use a 8 mm socket to remove the four 135 mm-long bolts securing the motor to the gearbox.
Step 14
- Pull the gearbox straight off of the motor.
Pull the gearbox straight off of the motor.
Step 15
- Remove the space washer and stop ring from the gearbox case.
Remove the space washer and stop ring from the gearbox case.
Step 16
Open the gearbox
- Use a 10 mm socket to remove the following nuts and bolts from the gearbox case:
- Five nuts
- One 40 mm-long bolt
Use a 10 mm socket to remove the following nuts and bolts from the gearbox case:
Five nuts
One 40 mm-long bolt
Step 17
- Separate the two halves of the gearbox case.
Separate the two halves of the gearbox case.
Step 18
- Remove the gearbox gasket.
- During reassembly, replace the gasket if it is damaged or worn.
Remove the gearbox gasket.
During reassembly, replace the gasket if it is damaged or worn.
Step 19
Disassemble the drivetrain
- Use a universal pulley to remove the bearing from the output shaft.
Use a universal pulley to remove the bearing from the output shaft.
Step 20
- Use a universal pulley to remove the bearing from the top of the pinion gear.
Use a universal pulley to remove the bearing from the top of the pinion gear.
Step 21
- Use a pair of pry bars to break the gear and output shaft loose from the gearbox.
- Once loose, remove the gear and output shaft by hand.
Use a pair of pry bars to break the gear and output shaft loose from the gearbox.
Once loose, remove the gear and output shaft by hand.
Step 22
- Use a pair of pry bars to break the second gear and pinion gear loose from the gearbox case.
- Once loose, remove the gear and pinion gear by hand.
- Before reassembly, wipe out as much of the old grease as possible and add plenty of new grease to each new component as you install them.
Use a pair of pry bars to break the second gear and pinion gear loose from the gearbox case.
Once loose, remove the gear and pinion gear by hand.
Before reassembly, wipe out as much of the old grease as possible and add plenty of new grease to each new component as you install them.
Step 23
Remove any remaining bearings
- There may be one or both bearings left in the gearbox case. Follow these steps to remove any remaining bearings:
- A torch is necessary. Wear protective eyewear and heat resistant gloves. Move to a well ventilated area away from anything flammable.
- Use a torch to heat the outside of the casing near the bearings.
- The bearings may fall out on their own as the casing expands.
- Tap the outside of the gearbox case with a hammer to knock the bearings out.
- If the bearings don’t fall out, reheat the casing and try again. If they remain stuck, flip over the gearbox case and use a flathead screwdriver to pry the bearings out.
There may be one or both bearings left in the gearbox case. Follow these steps to remove any remaining bearings:
A torch is necessary. Wear protective eyewear and heat resistant gloves. Move to a well ventilated area away from anything flammable.
Use a torch to heat the outside of the casing near the bearings.
The bearings may fall out on their own as the casing expands.
Tap the outside of the gearbox case with a hammer to knock the bearings out.
If the bearings don’t fall out, reheat the casing and try again. If they remain stuck, flip over the gearbox case and use a flathead screwdriver to pry the bearings out.
To reassemble your device, follow these instructions in reverse order.
Apply grease to the new gears and bearings as you install them.
Keep the [[Topic:Kushlan Cement Mixer 600DDS 2014#diagram/19504/hotspot/1657489|gearbox and motor assembly diagram]] accessible during reassembly.
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Sam Omiotek
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