Manual+GDY106+Gta41+GEK91680A.pdf

GEK91680A

5GDY85/106 MOTORIZED WHEELSERVICE MANUAL

INCLUDING 5GEB16 AC MOTOR

Revisions are indicated by margin bars. Copyright 2002, 2004 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by Gener-al Electric Company customers (OEMs) and their customers, if such reproduction is used exclusively in connection with equipment used in thosecustomers internal operations.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the users purposes, the matter should be referred to the GeneralElectric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has noobligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or

contact your General Electric representative for assistance.Do not order from this publication.

GDY85/106 Motorized Wheel Service Manual, GEK91680A

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CONTENTSPage

1. GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. SCOPE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. GENERAL DESCRIPTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. BASIC OPERATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. MECHANICAL BRAKES 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5. 5GDY85 AND 5GDY106 AC MOTORIZED WHEEL MODEL DIFFERENCES 2. . . . . . . . . . . . . . . . . . . . . .

2. GDY85/106 MOTORIZED WHEEL MAINTENANCE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. DAILY 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. EVERY 250 OPERATING HOURS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. EVERY 500 OPERATING HOURS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4. EVERY 1500 OPERATING HOURS (wheels with removable retainer only) 6. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1. Tooling Required For Disassembly Of Retainer 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2. Disassembly Of Retainer For Thrust Washer Removal 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3. Installation Of Thrust Washer And Reassembly Of Retainer 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5. EVERY 3000 OPERATING HOURS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6. OIL ANALYSIS GUIDELINES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7. SUN PINION GEAR INSPECTION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1. Removal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.2. Inspection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3. Reinstallation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4. Modification of Lube Cap for 5GDY106 Wheels 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8. LUBRICATION SPECIFICATIONS FOR OHV EQUIPMENT 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. GDY85/106 MOTORIZED WHEEL LIFTING DEVICES AND SPECIAL TOOLS 19. . . . . . . . . . . . . . . . . . . . . . .

3.1. 40TON CAPACITY DUALHOIST CRANE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2. 25TON SHACKLES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3. HEAVYDUTY HYDRAULIC TORQUE WRENCHES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4. TRANSMISSION COUPLING BUSHING PULLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. C FRAME HYDRAULIC PRESS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6. HYDRAULIC PUMP 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7. TRANSMISSION END LIFTERS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8. HEAVYDUTY HOIST RINGS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9. FRAME LIFTERS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10. MOTOR ASSEMBLY HOIST PLATES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11. DUOCONE SEAL INSTALLATION TOOL 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12. SEAL COMPRESSOR 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13. WHEEL HUB AND OUTBOARD WHEEL HUB BEARING PULLER 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14. INBOARD WHEEL HUB BEARING PULLER 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15. COUPLING BUSHING INSTALLATION MATERIAL 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16. BRAKE OIL DRAIN FIXTURE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17. WHEEL STUD REMOVAL PRESS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18. SCOTTPURE WIPING CLOTHS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19. SHIMS FOR SETTING HUB BEARING END PLAY 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20. GEB16 AC MOTOR PULLER TOOLS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21. GEB16 AC TRACTION MOTOR ROTOR ASSEMBLY GUIDE 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22. GEB16 AC TRACTION MOTOR PARKING BRAKE END BEARING HEATER PLUG 31. . . . . . . . . . . . . . . 3.23. GEB16 AC TRACTION MOTOR BEARING CAP SEAL INSTALLATION PLUG 31. . . . . . . . . . . . . . . . . . . .

4. CLEAN, DRAIN OIL, AND REMOVE MOTOR 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1. PRIOR TO DISASSEMBLY 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. RECOMMENDED CRANE CAPACITY AND LIFTING PRACTICES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3. CLEANING GUIDELINES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4. REMOVE THE GEB16 AC TRACTION MOTOR 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5. DRAIN TRANSMISSION OIL 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6. DRAIN BRAKE OIL 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEK91680A, GDY85/106 Motorized Wheel Service Manual

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4.7. CLEANING PROCEDURES 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1. Steam Cleaning 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.2. Vapor Degreaser 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.3. Solvents 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. GDY85/106 MOTORIZED WHEEL TRANSMISSION DISASSEMBLY 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. POSITION THE UNIT FOR DISASSEMBLY 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. REMOVE THE SUN PINION GEAR ACCESS COVER 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3. REMOVE THE SUN PINION GEAR 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. REMOVE THE LOWSPEED CARRIER ASSEMBLY 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. REMOVE THE TORQUE TUBE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6. REMOVE THE RING GEAR, GDY85C AND E MODELS ONLY 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7. REMOVE THE HIGHSPEED CARRIER AND DRIVE SHAFT 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. CHECK WHEEL HUB BEARING END PLAY 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9. REMOVE THE COUPLING PLATE OR COUPLING PLATE/RING GEAR ASSEMBLY 40. . . . . . . . . . . . . . . . 5.10. REMOVE THE OUTBOARD HUB BEARING AND WHEEL HUB 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11. REMOVE THE INBOARD HUB BEARING, GDY85B AND C MODELS 43. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12. REMOVE THE INBOARD HUB BEARING, GDY85D, E, J, AND GDY106 MODELS 43. . . . . . . . . . . . . . 5.13. REMOVE THE DISC BRAKE ASSEMBLY AND SEAL CARRIER 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14. REMOVE THE O RING AND DUOCONE SEAL 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15. CLEAN COMPONENTS AND BEARINGS 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. GDY85/106 MOTORIZED WHEEL TRANSMISSION DISASSEMBLY OF SUBASSEMBLIES 47. . . . . . . . . . . 6.1. DISASSEMBLE LOWSPEED GEAR CARRIER ASSEMBLY 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. DISASSEMBLE HIGHSPEED GEAR CARRIER ASSEMBLY 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3. DISASSEMBLE SPHERICAL ROLLER BEARINGS IF REQUIRED 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4. DISASSEMBLE COUPLING PLATE/RING GEAR ASSEMBLY 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5. REMOVE PLUG FROM DRIVE SHAFT IF REQUIRED 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. GEB16 MOTOR DISASSEMBLY, INSPECTION, AND REASSEMBLY 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1. MOTOR DISASSEMBLY 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1. Remove Parking Brake Gear 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2. Remove Parking Brake End Bearing Cap And Install Ball Bearing Puller 53. . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3. Rotate Motor And Remove Drive End Framehead Assembly 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.4. Remove The Rotor 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.5. Rotate Motor And Remove Parking Brake End Framehead Assembly 55. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.6. Disassemble Drive End Framehead/Bearing Housing Assembly 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.7. Remove Parking Brake End Ball Bearing From Framehead 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.8. Remove Remaining Components From Rotor Shaft And Rotor 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2. INSPECT, AND TEST MOTOR COMPONENTS 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.1. Check End Ring Notch Depth 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.2. Clean And Test The Stator And Rotor 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.3. Inspect Individual Components 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.4. Inspect Rotor Shaft 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3. RECONDITIONING PROCESSES FOR STATOR AND ROTOR 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1. Stator VPI Treatment And Rotor Powder Coating 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2. Rotor Shield and Stator Insulation Protection (GEB16A3 and Prior Only) 59. . . . . . . . . . . . . . . . . . . . . . . 7.3.3. Rotor Swaging Process 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4. MOTOR REASSEMBLY 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1. Parking Brake End Framehead 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.2. Assemble Rotor 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.3. Assemble Drive End Bearing Housing/Framehead 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.4. Install Rotor In Stator 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.5. Install Drive End Framehead 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.6. Install Speed Sensor, Motor Connection Straps, Block, and Clamp 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.7. Permanently Install Parking Brake End Framehead Bearing Cap 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.8. Install Parking Brake Gear 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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8. GDY85/106 AC MOTORIZED WHEEL COMPONENT INSPECTION AND REUSE CRITERIA 77. . . . . . . . . . 8.1. MACHINED COMPONENTS 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2. WHEEL HUB BEARING FITS 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3. TRANSMISSION GEARS 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1. Inspections 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.2. Repair Procedures 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4. WHEEL HUB BEARINGS AND SPHERICAL ROLLER BEARINGS 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5. WHEEL HUB STUDS 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6. DISC BRAKE ASSEMBLY 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. GDY85/106 MOTORIZED WHEEL TRANSMISSION REASSEMBLY OF SUBASSEMBLIES 89. . . . . . . . . . . 9.1. REASSEMBLE LOWSPEED GEAR CARRIER ASSEMBLY 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2. REASSEMBLE HIGHSPEED GEAR CARRIER ASSEMBLY 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3. REASSEMBLE COUPLING PLATE TO ONEPIECE OR HIGHSPEED RING GEAR 95. . . . . . . . . . . . . . . . 9.4. REASSEMBLE LOWSPEED RING GEAR TO HIGHSPEED RING GEAR 95. . . . . . . . . . . . . . . . . . . . . . . . 9.5. INSTALL WHEEL HUB BEARING CUPS IF NECESSARY 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6. INSTALL WHEEL HUB WHEEL STUDS IF NECESSARY 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. GDY85/106 MOTORIZED WHEEL REASSEMBLY 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1. PRIOR TO REASSEMBLY 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2. ASSEMBLE MOTOR TO FRAME, TURNOVER STAND/CRADLE AVAILABLE 101. . . . . . . . . . . . . . . . . . . . 10.3. ASSEMBLE MOTOR TO FRAME, NO TURNOVER STAND/CRADLE AVAILABLE 102. . . . . . . . . . . . . . . . . 10.4. POSITION WHEEL FRAME FOR TRANSMISSION END COMPONENT ASSEMBLY 103. . . . . . . . . . . . . . 10.5. ASSEMBLE DUOCONE SEAL HALF AND DISC BRAKE ASSEMBLY TO FRAME 103. . . . . . . . . . . . . . . . . 10.6. PREPARE SEAL CARRIER FOR INSTALLATION 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7. INSTALL SEAL CARRIER ASSEMBLY 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8. INSTALL INBOARD WHEEL HUB BEARING 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9. INSTALL WHEEL HUB/BRAKE ASSEMBLY O RING AND PREPARE TO INSTALL WHEEL HUB 109. . 10.10. INSTALL WHEEL HUB ASSEMBLY 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11. INSTALL OUTBOARD WHEEL HUB BEARING 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12. SET THE WHEEL HUB BEARING END PLAY 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13. POSITION COUPLING PLATE OR COUPLING PLATE/RING GEAR ASSEMBLY 111. . . . . . . . . . . . . . . . 10.14. INSTALL COUPLING PLATE OR COUPLING PLATE/RING GEAR ASSEMBLY BUSHINGS 112. . . . . . . 10.15. INSTALL PLUG AND WASHER IN DRIVE SHAFT 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16. INSTALL DRIVE SHAFT 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17. INSTALL HIGHSPEED GEAR CARRIER ASSEMBLY 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18. INSTALL RING GEAR, GDY85C AND E MODELS ONLY 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19. PREPARE TORQUE TUBE FOR INSTALLATION 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20. INSTALL TORQUE TUBE 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21. INSTALL SUN PINION GEAR 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22. PREPARE LOWSPEED GEAR CARRIER ASSEMBLY FOR INSTALLATION 115. . . . . . . . . . . . . . . . . . . 10.23. INSTALL LOWSPEED GEAR CARRIER ASSEMBLY 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24. CALCULATE AND SET THE SUN PINION GEAR END PLAY (wheel in vertical position) 117. . . . . . . . . . 10.25. CALCULATE AND SET SUN PINION GEAR END PLAY (wheel in horizontal position) 117. . . . . . . . . . . . 10.26. INSTALL SUN PINION GEAR COVER 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


iv

LIST OF FIGURESFIG. PAGE1 MAGNETIC PLUG CONDITIONS EXAMPLE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COVER PLATE REMOVED AND MAGNETIC PLUG LOCATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 THRUST WASHER DIMENSION CHECK 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 THRUST WASHER GO/NO GO GAUGE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TOOLS REQUIRED FOR RETAINER DISASSEMBLY 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DISASSEMBLY OF RETAINER FOR THRUST WASHER REMOVAL 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SUN PINION GEAR ACCESS WITH SUN PINION GEAR COVER REMOVED 11. . . . . . . . . . . . . . . . . . . . . . . 8 THRUST WASHERS IN SUN PINION GEAR COVER RECESS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ABNORMAL THRUST WASHER CONDITIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ALIGNMENT OF CAP 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SUN PINION GEAR REMOVAL TOOL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 LOCATION OF 13/16 IN. HOLE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ALIGNMENT OF SOCKET HEAD SCREW 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SHACKLE PIN MODIFICATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SCREW PIN SHACKLE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 BUSHING PULLER TOOL 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 HYDRAULIC PUMP 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 HOIST RINGS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 GEB16 PULLER GROUPS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 GEB16 PARKING BRAKE GEAR PULLER 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 GEB16 ROTOR ASSEMBLY GUIDE 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 GEB16 AC TRACTION MOTOR 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 GEB16 AC TRACTION MOTOR MOUNTING BOLTS REMOVED 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ASSEMBLED TRANSMISSION 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 LOW SPEED CARRIER 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TORQUE TUBE 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 COUPLING PLATE / RING GEAR ASSEMBLY 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 HIGHSPEED CARRIER ASSEMBLY 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 BUSHING 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 JACKOUT BOLTS IN COUPLING PLATE RING GEAR ASSEMBLY 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 COUPLING PLATE 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DISC BRAKE ASSEMBLY LOCKING BOLTS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ADAPTOR PLATE 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 BACK PLATE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 HUB PULLER ASSEMBLY 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INBOARD HUB BEARING PULLER ASSEMBLY 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DISC BRAKE ASSEMBLY AND SEAL CARRIER 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 LOWSPEED GEAR CARRIER ASSEMBLY 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 HIGHSPEED GEAR CARRIER ASSEMBLY 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SPHERICAL ROLLER BEARINGS 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DISASSEMBLE RING GEAR 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 DRIVE SHAFT PLUG 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 INTERNAL SPLINED END OF DRIVE SHAFT 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 PARKING BRAKE END OF MOTOR WITH PARKING BRAKE GEAR 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 DRIVE END FRAMEHEAD AND ROTOR 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 APPLICATION OF THE ROTOR SHIELD 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 APPLICATION OF THE SILICON RUBBER 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


v

LIST OF FIGURES (Contd)FIG. PAGE48 SWAGING TOOL 41D797671 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 SWAGING TOOL INSTALLED 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 SWAGE POSITION AND DIMENSIONS 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 MEASURING SWAGE DEPTH WITH GAGE 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 DEPTH GAGE 41B586938 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 SET OF THREE SWAGED BARS (THREE LOCATIONS) 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 PARKING BRAKE END BALL BEARING ASSEMBLY 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 DRIVE END ROLLER BEARING ASSEMBLY 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 DRIVE END BEARING CAP MACHINING 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 PARKING BRAKE END FRAMEHEAD 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 GEB16 AC MOTOR LONGITUDINAL SECTION 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 NONREUSABLE GEAR TEETH CONDITIONS 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 REPAIRABLE / REUSABLE GEAR TEETH CONDITIONS 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SEVERE CRACK IN SUN PINION GEAR 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SPALLED SPHERICAL ROLLER EXAMPLE 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 INBOARD WHEEL HUB STUDS 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 WHEEL FRAME BUSHING HOLES 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 BUSHING REPAIR DIAGRAM AND PROCEDURE 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TYPICAL DISC BRAKE ASSEMBLY 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 TYPICAL LOWSPEED GEAR CARRIER ASSEMBLY 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 NORDLOCK TWOPIECE WASHERS 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 ALIGNMENT SLEEVE 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 TYPICAL PLANET GEAR SHAFT 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 TYPICAL HIGHSPEED GEAR CARRIER ASSEMBLY 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 TYPICAL ONEPIECE RING GEAR 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 TYPICAL TWOPIECE RING GEAR 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 WHEEL HUB INBOARD BEARING BORE 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 WHEEL HUB OUTBOARD BEARING BORE 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 DUOCONE SEAL (TWO SEAL HALVES) 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 ONE DUOCONE SEAL HALF 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 FRAME DISC BRAKE MOUNTING SURFACE 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 DISC BRAKE MOUNTING BOLTS 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 GDY85A, B, C, & F SEAL CARRIER DIMENSIONS 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 GDY85D, E, J, & GDY106 SEAL CARRIER DIMENSIONS 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 SEAL CARRIER MOUNTING SEAT GROOVE ON FRAME 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 INBOARD SIDE OF SEAL CARRIER WITH SEAL HALF AND DOWEL PIN INSTALLED 108. . . . . . . . . . . . . 84 INBOARD WHEEL HUB BEARING INSTALLED 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 WHEEL HUB MOUNTING BOLTS. 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 COUPLING PLATE RING GEAR ASSEMBLY 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 TYPICAL DRIVE SHAFT PLUG 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 TYPICAL SUN PINION GEAR 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 THRUST WASHER SET 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 SUN PINION GEAR ENDPLAY 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 LONGITUDINAL SECTION GDY85A, B 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 LONGITUDINAL SECTION GDY85C 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 LONGITUDINAL SECTION GDY85D, F, J 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 LONGITUDINAL SECTION GDY85E 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 LONGITUDINAL SECTION GDY106A 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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1. GENERAL INFORMATION1.1. SCOPE

This publication provides information for the inspection, maintenance, and basic overhaul of GDY85 andGDY106 AC motorized wheels, including the GEB16 AC traction motor. The information applies to all models listedin the chart at the end of this section.

Where there are significant differences in the procedures for various models or special features, those differenceswill be fully described.

1.2. GENERAL DESCRIPTIONThe GDY85 and GDY106 motorized wheel is bolted onto the vehicle axle box and serves as the truck axle, trans-

mission and AC traction motor to drive the offhighway vehicle. The AC traction motor portion of the motorized wheelextends into the axle box and is force ventilated by an alternator driven fan.

Each motorized wheel consists of a GEB16 AC traction motor mounted to the flange end (inboard) of a GA80(GDY85) or GA83 (GDY106) transmission assembly.

The GEB16 AC traction motor consists of a stator frame with a framehead and rotor bearing housing on each end(inboard, parking brake end; outboard, drive end). The rotor has a shaft with external splines on both ends. The park-ing brake gear for the vehicle is mounted on the inboard end spline (located inside the axle box). The drive shaft en-gages the external spline on the outboard end of the rotor to connect the motor to the transmission assembly.

The GA80/GA83 transmission assembly consists of the frame structure, drive shaft, sun pinion gear, highspeed and lowspeed gear carriers, coupling plate with ring gear, torque tube, disc brake assembly, Duocone seal,inboard and outboard wheel hub bearings, and wheel hub.

The disc brake assembly bolts to a mounting surface of the frame structure. The Duocone seal carrier is Oringsealed and mounts on an outside diameter (OD) of the frame just above the disc brake assembly. The Duocone sealprovides sealing between the disc brake assembly and the Duocone seal carrier. The inboard hub bearing is an inter-ference fit on an OD of the frame above the Duocone seal carrier and, along with the outboard hub bearing, supportsthe external rotating components of the motorized wheel. The wheel hub bolts to the rotating portion of the disc brakeassembly and is supported by the inboard and outboard hub bearings. The coupling plate/ring gear assembly boltsdirectly to the frame structure through highinterference fit bushings with shims placed between it and the outboardwheel hub bearing to establish the wheel hub end play (axial movement).

The drive shaft has an internal spline on the inboard end and an external gear on the outboard end. It is installedinside the frame structure and engages the external spline of the rotor on the inboard end and the three gears of thehighspeed gear carrier on the outboard end. These three gears engage the inboard gear of the coupling plate/ringgear assembly (bolted to the frame) and drive the highspeed gear carrier that engages the minor diameter (inboard)portion of the sun pinion gear. The major diameter (outboard) portion of the sun pinion gear engages the four gears ofthe lowspeed gear carrier. These four gears engage the outboard gear of the coupling plate/ring gear assembly(bolted to the frame) and drive the lowspeed gear carrier. The lowspeed gear carrier is bolted to the torque tube,which is bolted to the wheel hub. These are the external rotating components of the motorized wheel (along with theportion of the disc brake assembly that the wheel hub is bolted to) that drive the vehicles rims/tires, which are mountedto the rim studs on the inboard and outboard ends of the wheel hub.

1.3. BASIC OPERATIONIn motoring, electrical energy is applied to the AC traction motor. The AC traction motor rotates and the rotational

force is transferred through the drive shaft to the highspeed gear carrier, through the sun pinion gear to the lowspeed


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gear carrier that is bolted to the torque tube which is, in turn, bolted to the wheel hub. The vehicle is propelled as thetires that are mounted to the wheel hub rotate.

In dynamic retarding (the primary means of speed reduction), the mechanical energy of the moving truck is con-verted to electrical energy by the AC traction motor and this electrical energy is dissipated as heat through the brakingresistor grids to slow the vehicle.

1.4. MECHANICAL BRAKESEach GDY85/106 motorized wheel contains an internal wet disc brake assembly that is controlled by the vehicles

braking system. For operation, maintenance, and troubleshooting of this brake assembly, refer to the brake manufac-turers instructions.

A parking brake gear is mounted on the inboard end of the rotor shaft to provide mounting for the disc of the ve-hicles dry disc parking brake assembly. For information on the parking brake assembly, refer to the brake manufactur-ers instructions

1.5. 5GDY85 AND 5GDY106 AC MOTORIZED WHEEL MODEL DIFFERENCESNOTE: The following is a summary chart of GDY85/106 motorized wheel basic model differences. Forcomplete OffHighway Vehicle (OHV) system component model information, refer to GEK91703A, ACOHV Drive System Pedigree File.

Model5GDY

Tire Size Application GearRatio

Motor5GEB

Trans7GA

Weight(Lbs.)

Features/Differences

85A1 48/95R57 Standard 31.5:1 16A1 80A1 31,866 Initial design for 320 Ton AC OHVdrive systems with standard sizetires, 31.5:1 gear ratio, 5GEB16 ACtraction motor and 7GA80 trans-mission.

85A2 48/95R57 Standard 31.5:1 16A1 80A2 31,866 Except uses the 5GDY85B1weightreduced frame design anduses different frame/transmissioninterface.

85B1 48/95R57 Standard 31.5:1 16A2 80B1 31,866 Except uses weight reduced framedesign.

85B2 48/95R57 Standard 31.5:1 16A2 80B2 31,866 Except uses new low speed sunpinion and cover plate. Not a pro-duction model.

85B3 48/95R57 Standard 31.5:1 16A4 80B1 32,546 Except uses the 5GEB13A3 trac-tion motor instead of the5GEB13A2.

85B4 48/95R57 Standard 31.5:1 16A4 80B2 32,546 Except uses 8 oil drain holes in lowspeed carrier.

85B4R 48/95R57 Standard 31.5:1 16A4 80B2 32,546 Field mod. of 5GDY85B4 which in-cludes new drive shaft, new singleinboard thrust washer design, andnew low speed carrier bolts.

85B4RX 48/95R57 Standard 31.5:1 16A4 80B2 32,546 Additional field mod. which in-cludes new sleeve design in lowspeed carrier gear shaft boss.


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Model5GDY

Features/DifferencesWeight(Lbs.)

Trans7GA

Motor5GEB

GearRatio

ApplicationTire Size

85B4RXP 48/95R57 Standard 31.5:1 16A4 80B2 32,546 Additional field mod. which in-cludes new low speed sun pinion.

85B4RXPB 48/95R57 Standard 31.5:1 16A4 80B2 32,546 Additional field mod. which in-cludes new frame coupling bush-ings.

85B5 48/95R57 Standard 31.5:1 16A4 80B3 32,650 Contains all field modifications in-corporated in the B4RXP modelwhich includes new drive shaft,new low speed carrier bolts, newinboard thrust washer, new sunpinion and new low speed carriersleeves.

85B6 48/95R57 Standard 31.5:1 16A4 80B4 32,650 Except uses new frame couplingbushings.

85B7 48/95R57 Standard 31.5:1 16A4 80B5 32,927 Except uses new low speed carrierin transmission.

85C1 48/95R57 Tar Sands 38.8:1 16A4 80C1 33,030 Except uses new transmission de-sign that includes a 38.8:1 gear ra-tio for oil sands application require-ments.

85C2 48/95R57 Tar Sands 38.8:1 16A4 80C2 33,045 Except uses new drive shaft as-sembly, new inboard thrust wash-er and new low speed carrier bolts.

85C3 48/95R57 Tar Sands 38.8:1 16A4 80C3 33,045 Except uses new frame couplingbushings.

85D1 53/80R63 Standard 31.5:1 16A4 80D1 36,130 Except uses different frame andwheel hub for wide tire require-ments.

85D2 53/80R63 Standard 31.5:1 16A4 80D2 36,130 Except uses new frame couplingbushings.

85D3 53/80R63 Standard 31.5:1 16A4 80D3 36,407 Except uses new low speed carrierin transmission.

85D4 53/80R63 Standard 31.5:1 16A4 80D4 36,407 Except uses ground ring gearteeth.

85E1 53/80R63 Tar Sands 38.8:1 16A4 80E1 37,095 Except uses different frame andwheel hub for wide tire require-ments.

85E2 53/80R63 Tar Sands 38.8:1 16A4 80E2 37,095 Except uses new frame couplingbushings.

85E3 53/80R63 Tar Sands 38.8:1 16A4 80E3 37,095 Except uses new low speed carrierbushing.

85E4 53/80R63 Tar Sands 38.8:1 16A4 80E4 37,272 Except uses new low speed carrierin transmission.

85E5 53/80R63 Tar Sands 38.8:1 16A4 80E5 37,272 Except uses ground ring gearteeth.


4

Model5GDY

Features/DifferencesWeight(Lbs.)

Trans7GA

Motor5GEB

GearRatio

ApplicationTire Size

85F1 48/95R57 Standard 32.5:1 16A4 80F1 32,876 Except uses low speed carrier from5GDY85E4 wheelmotor design andgear ratio changed to 32.5:1.

85J1 53/80R63 Standard 31.5:1 16A4 80J1 36,858 Same as D1 except different trans-mission (uses lowspeed carrierfrom E4).

106A1 53/80R63 Standard 32.5:1 16A4 83A1 39,975 Design for 320 Ton AC OHV drivesystems with 32.5:1 gear ratio,5GEB16 AC traction motor and7GA83 transmission.

106A2 53/80R63 Standard 32.5:1 16A4 83A1 39,975 Except thin Vespel washer, 3 pieceremovable retainer and modifiedsun pinion.

106A3 53/80R63 Standard 32.5:1 16A4 83A1 39,975 Except new drive shaft to acceptnew thrust plug, inboard thickbronze thrust washer, new thrustwasher plug with improved fit andoutboard thrust washer from Ves-pel to bronze.

106A4 53/80R63 Standard 32.5:1 16A4 83A1 39,975 Except modified pinion cover to al-low better lubrication.


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2. GDY85/106 MOTORIZED WHEEL MAINTENANCEThe information in this section is provided as a guideline for components that require inspection at the given operat-

ing intervals of GDY85/106 motorized wheels.

NOTE: For complete maintenance procedures on all components of the GE320AC propulsion system(alternator, grid blower motor, retarding grids, and controls), refer to Planned Maintenance publicationsGEK91714 (2700 HP) and GEK91722 (3500 HP). Also see Motorized Wheel Electric Drive Equipmentpublications GEK917259, GEK917269, and GEK917279 for listings of component publications ofthe applicable GE320AC propulsion system components.

2.1. DAILY

1. Check oil level.

2. Check wet disc brake seal.

3. Check for oil leakage.

4. Check for mud and stone buildup.

2.2. EVERY 250 OPERATING HOURS

Take an oil sample for analysis. (Refer to Section 2.6. for more information.)


NOTE: When the motorized wheel is new or recently overhauled, the gear oil should be changed or filteredafter the initial 500 hours of operation.

Repeat the inspections of the previous maintenance intervals plus the following additional inspections.

1. Inspect and clean the magnetic plugs (Figures 1 and 2).

1 2 3 4

FIG. 1. MAGNETIC PLUG CONDITIONS EXAMPLE. E45123

a. View 1 is a new magnetic plug.

b. View 2 shows a normal accumulation of metal particles.

c. View 3 shows an excessive accumulation of metal particles and further investigation into the cause is rec-ommended.


6

d. View 4 shows a plug with the magnet missing this plug should be replaced.

2. Remove and inspect the sun pinion gear (Figure 2). (Refer to Section 2.7. for complete procedure and removaltool information.)

FIG. 2. COVER PLATE REMOVED AND MAGNETIC PLUG LOCATIONS. E45119

2.4. EVERY 1500 OPERATING HOURS (wheels with removable retainer only)Repeat the inspections of the previous maintenance intervals plus the following additional inspections.

This procedure describes internal thrust washer inspection on GDY106A3 and later model wheels equipped withthe removable retainer and thick thrust washer. The only item serviceable in the field is the thrust washer itself.

Internal thrust washer wear can be checked by removing the sun pinion as is normally done for sun pinion, lowspeed carrier gear inspection.

1. Ensure the retainer plate is seated against the thrust washer.

Tap the retainer with a rod. It should be solid and not rattle; seat the retainer if loose.

2. Measure and record the dimension shown in Figure 3 (originally 0.687 in. to 0.705 in.).3. Any measurement over 0.750 in. should be considered suspect and removal of retainer should be performed.

4. A NoGo gauge can also be made for easier checking (Figure 4).NOTE: If in doubt, proceed with retainer disassembly for inspection of the thrust washer. Refer to Sec-tions 2.4.1. and 2.4.2. for retainer disassembly procedures.

2.4.1. Tooling Required For Disassembly Of RetainerFigure 5 shows required tooling. Contact GETS Product Service for detailed drawings of required tooling.

2.4.2. Disassembly Of Retainer For Thrust Washer RemovalIf the quick dimension check reveals an issue or doubt existed with the measurements, the thrust washer can be

removed and checked for wear. The following outlines the process to remove the internal thrust washer (Figure 6).


7

FIG. 3. THRUST WASHER DIMENSIONCHECK. E46255

CHECK ANDRECORDDIMENSION

FIG. 4. THRUST WASHER GO/NO GO GAUGE.E46256

WHEN A GAP IS NO LONGERPRESENT, DISASSEMBLERETAINER FOR FURTHERWASHER INSPECTION

0.750 IN 0.001 IN

FIG. 5. TOOLS REQUIRED FOR RETAINER DISASSEMBLY. E46260

SLIP COLLAR REMOVAL TOOL

RETAINER HOLDING TUBE

RETAINER DISASSEMBLY TOOL


8

FIG. 6. DISASSEMBLY OF RETAINER FOR THRUST WASHER REMOVAL. E46261

END PLATESCREEN

STABILIZERSSCREWS

ALIGNMENTTUBE

SUPPORT PLATE

2.4.2.1. Collar Removal

NOTE: Make an attempt to remove by hand prior to tool use.

1. Insert collar removal tool. Puller jaws will grip on the outside groove of the collar.2. Tighten three bolts on the support plate to secure jaws in groove.3. Tighten center stud to pull collar from retainer.

4. Remove entire puller assembly with collar.

2.4.2.2. Retainer Disassembly

1. Insert the tube to hold the lower portion of the retainer in a fixed position.

a. The tube has internal teeth which index in the same slots as the collar removed in Section 2.4.2.1.

b. Once indexed, push the tool in by hand and install four bolts through the plate into the mounting holes for thesun pinion cover. Tighten these with hand wrench.

c. The lower half of the retainer is now fixed to facilitate disassembly.

2. Insert the retainer disassembly tool.

a. The tool has two pins and two holes to align with the threaded holes in the top half of the retainer.

b. The pins will index in two holes aligning the other two for attaching.

c. Thread the two rods into the holes and tighten with hand wrench.

d. The upper half of the retainer is now attached to the removal tool.

3. Place the support plate over the attaching rods. It will fit into the tube supporting the lower half of the retainer.This plate aligns and supports the tooling assembly for loosening the retainer.

4. Mark a line on the tube and the support plate. When reassembling, these marks will align again allowing foreasier installation.

5. Attach a standard 3/4 in. drive to the center post and loosen assembly (original torque is 200 ftlb).


9

6. Once the upper retainer is unscrewed from the lower retainer, this retainer disassembly tool can be removed asit is still attached to the upper retainer.

NOTE: Do not remove or loosen the tube holding the lower retainer half. There is no need to remove theupper retainer from the tooling. Upper and lower retainer halves are matched and must be kept as a set.

7. Reach through the tube and remove the thrust washer from the plug.

2.4.2.3. Checking Thrust Washer

The thrust washer can now be inspected for any signs of cracking or abnormal wear. The original thickness of thethrust washer is 0.558 in. +/ 0.002 in. The thrust washer should be replaced if the oil grooves on either side are wornaway. Installation procedures for the thrust washer are covered in Section 2.4.3.

2.4.3. Installation Of Thrust Washer And Reassembly Of Retainer

Use this procedure to replace the thrust washer if inspection showed that the part is no longer serviceable. Inspec-tion procedures are covered in Sections 2.4., 2.4.1., and 2.4.2.

Clean the threads on the upper retainer half with a suitable cleaner or solvent. Keep this upper half attached to thetooling aids in reassembly by allowing the alignment marks to show under or over tightening conditions with each half.This alignment is required to reinstall the retainer collar.

2.4.3.1. Thrust Washer Installation

Slip the thrust washer over the drive shaft plug and ensure it is seated. It is no longer a press fit.

2.4.3.2. Retainer Reassembly

1. Insert the retainer assembly tool with the upper retainer half attached.

a. Start threading the upper half and lower half of retainers by hand.

b. Using a standard 3/4 in. drive, tighten the assembly.

c. The torque should be 200 ftlb but this will vary slightly from use. The alignment marks must align to ensurethe collar slots will line up.

NOTE: If alignment marks are unavailable, torque to 200 ftlb.

d. Remove the support plate.

e. Loosen and remove the two rods.

f. Remove assembly tool.

g. Identify any misalignment in the retainer collar slots.

h. Reinstall assembly tool as required to slightly tighten or loosen the retainer to align collar slots.

2. Remove the bolts attaching the lower retainer half anchoring tube to the sun pinion cover mounting holes.

3. Remove the lower retainer anchoring tube from wheel.

NOTE: If tube does not come out, the collar slots were not correctly aligned. The retainer must be tight-ened or loosened slightly to align correctly.


10

4. Install retainer collar on assembly.

5. Reinstall the sun pinion.

6. Reinstall the sun pinion cover with original shims (if present).Contact the GE OHV Product Service team with any questions or for more information.


Repeat the inspections of the previous maintenance intervals plus the following additional inspection.

Change the transmission oil. (Refer to Section 2.8. for more information.)

2.6. OIL ANALYSIS GUIDELINES

The following elements must be monitored from an oil analysis chromium, nickel, iron, sulfur, phosphorus, cal-cium, and zinc.

Chromium Indicates planetary gear bearing or wheel hub bearing wear.

Nickel Indicates planetary gear wear.

Iron Indicates planetary gear or drive shaft spline wear. In combination with chromium and nickel, it is also an indica-tion of planetary bearing or wheel hub bearing wear.

Copper Indicates wear on the thrust bearing washers in the planetary drive.

Sulfur This element is part of the additive package in the Mobilgear SHC gear oils and the Mobilfluid FourTwentyFour (424), which is the hydraulic fluid used in the disc brakes. Trace amounts of sulfur are present in the gear oil, butexcessive amounts combined with calcium and zinc indicate contamination of the gear oil with brake fluid. This situa-tion indicates failure of the Duocone seal that separates the two systems.

Phosphorus This element is part of the additive packages in the Mobilgear SHC gear oils and Mobilfluid FourTwentyFour (424), which is the hydraulic oil used in the disc brakes.

Trace amounts of phosphorus are present in the gear oil, but excessive amounts combined with calcium and zinc indi-cate contamination of the gear oil with brake oil. This situation indicates failure of the Duocone seal that separates thetwo systems.

Calcium This element is part of the additive package of Mobilfluid FourTwentyFour (424), which is the brake oil.Indications of calcium in combination with excessive amounts of sulfur and phosphorus indicate failure of the Duoconeseal.

Zinc This element is part of the additive package of Mobilfluid FourTwentyFour (424), which is the brake oil. Indi-cations of zinc in combination with excessive amounts of sulfur and phosphorus indicate failure of the Duocone seal.

2.7. SUN PINION GEAR INSPECTION

Use the procedures below for inspection of the sun pinion gear when the GDY85/106 motorized wheel is mountedon a truck or when the wheel is in the horizontal position.


11

2.7.1. Removal1. Take appropriate precautions to prevent truck movement and have a jib hoist available to lift the sun pinion gear

when removed.

2. Remove the sun pinion gear cover, any shims, and the thrust washers from the outboard side of the sun piniongear (Figures 7, 8, and 9).

FIG. 7. SUN PINION GEAR ACCESS WITH SUNPINION GEAR COVER REMOVED. E45120

FIG. 8. THRUST WASHERS IN SUN PINIONGEAR COVER RECESS. E45122

CAUTION: Be very careful not to drop any parts inside the gearcase when removing the sun pinion gearcover, especially on original GDY85B1, B2, and B3 models. Sun pinion gear covers on these older modelshould be upgraded to B4, or production part number covers with the cast GE monogram on the outsideshould be fitted.

3. Visually inspect the thrush washers for an abnormal conditions (Figure 9). The stackup of washers is steel bronze steel and must be in this order.

1 2 3

4

FIG. 9. ABNORMAL THRUST WASHER CONDITIONS. E45124

a. Views 1 and 2 show washers worn and discolored from high stress loads.

b. View 3 shows a bronze thrust washer discolored by heated oil congealing on and coating it.


12

c. View 4 shows a bronze thrust washer with imbedded metal particles.

NOTE: If the sun pinion cover is the newer design used to improve lubrication to the thrust washer, ensurethe cap is installed in the correct orientation (Figure 10). Mounting the cover other than shown will makethe cover inoperable in its oiling function. Care should be taken when installing the sun pinion gear cover;the Oring can be pinched and/or broken. It is recommended to upgrade current wheels to the new designusing the procedure in Section 2.7.4. Contact OHV Product Service for ordering and modification details.

FIG. 10. ALIGNMENT OF CAP. E46257

HOLE CENTEREDON WEDGE

MUST ALIGN WITH ONEOF THESE FOURHOLES

Hole Centered On Wedge Must Align With One Of These Four Holes.This Will Make The Wedge Open Towards One Of The Four Bosses.Any Other Mounting Location Will Make Cap Completely Ineffective.

4. Slide the tube into the sun pinion gear until it engages the plug in the drive shaft. (Refer to Figure 11 for removaland reinstallation tool parts.)

5. Screw the two 3/8 in.16 x 18 in. long threaded rods into the tapped holes in the end of the sun pinion gear.

6. Place the end plate onto the threaded rods (through the appropriate holes) over the end of the tube, then place awasher and thread a nut onto each rod.

7. Install the handle to help steady the assembly and pull/push the sun pinion gear when it moves freely as follows:

a. Thread a nut approximately 1 in. onto each rod.

b. Place the handle onto the two threaded rods and secure it by threading another nut onto each rod and tight-en.

8. Tighten the inboard nuts (alternately) against the end plate to pull the sun pinion gear out (it should come outrelatively easy).

9. Continue tightening the inboard nuts until half of the sun pinion gear is past the end of the motorized wheel, thencinch a lifting strap around the assembly and hook a jib hoist to the strap for support.

NOTE: Use the handle to maintain inward pressure on the tube to keep it engaged on the plug and act as aguide for the sun pinion gear. (If the tube comes off of the plug, no parts should fall into the transmission.)


13

1/213

FIG. 11. SUN PINION GEAR REMOVAL TOOL. E45113


14

10. Continue tightening the inboard nuts until the sun pinion gear is free from the low speed carrier, then use thehandle to balance the assembly and pull it out of the motorized wheel.

11. Lower the sun pinion gear with puller assembly onto a suitable work surface and remove the puller assemblycomponents from the sun pinion gear.

2.7.2. Inspection

Refer to Section 8.3. for inspection information.

1. Inspect the sun pinion gear to determine its reusability. (Replace the sun pinion gear if it does not meet thecriteria.)

2. Visually inspect the exposed teeth of the low speed carriers gears.

2.7.3. Reinstallation

Refer to Figure 11 for removal and reinstallation tool parts.

1. Slide the tube (only) into the transmission until it engages the plug in the drive shaft.2. Cinch a strap around the sun pinion gear, lift it with a jib hoist, and slide it onto the tube.3. Rotate the sun pinion gear to engage the low speed gear carriers gears and insert it as far as possible by hand.

4. Thread a 1/2 in.13 x 18 in. long rod into the three oclock and nine oclock position sun pinion gear covermounting holes.

5. Slide the pushplate onto the two rods and the tube, then thread a nut onto each rod up to the pushplate.

6. Tighten the nuts (alternately) against the pushplate to push the sun pinion gear in until the pushplate is up tothe sun pinion gear cover mounting surface.

7. Remove the nuts and slide the pushplate off from the rods and tube, slide the spacer onto the tube, then slidethe pushplate back onto the two rods and tube and tighten the nuts up to the pushplate (with the spacer nowbetween it and the sun pinion gear).

8. Continue to tighten the nuts (alternately) against the pushplate until the sun pinion gear is pushed all of theway in.

9. Remove the nuts, pushplate, spacer, tube, and rods from the motorized wheel.

10. Reinstall the sun pinion gear cover (with the thrust washers and shims present at removal) and torque the 121/2 in.13 bolts to 58 + 2 ftlb.

NOTE: If the sun pinion cover is the newer design used to improve lubrication to the thrust washer, ensurethe cap is installed in the correct orientation (Figure 10). Mounting the cover other than shown will makethe cover inoperable in its oiling function. Care should be taken when installing the sun pinion gear cover;the Oring can be pinched and/or broken. It is recommended to upgrade current wheels to the new designusing the procedure in Section 2.7.4. Contact OHV Product Service for ordering and modification details.

11. Remove the wheel chocks before attempting to move the truck.

2.7.4. Modification of Lube Cap for 5GDY106 Wheels

For caps being modified for the oil port:


15

1. Enlarge hole 180 degrees from welded oil port cover (Figure 12) to 13/16 in.

FIG. 12. LOCATION OF 13/16 IN. HOLE. E46270

WELDED OILPORT COVER.DRILL A 13/16 INCH HOLE

180 DEGREES FROMWELDED COVER.

INSERT 1/213 (1/2 INCHLONG) SOCKET HEADBOLT INTO WHEELMOTOR

For caps being modified in the field:2. Repeat step 1 above.3. Accompanying shims can either be drilled or bolted in place using the socket head bolt.4. Apply Locktite to the threads of a 1/213 (1/2 in. long) socket head bolt and insert into a threaded bolt hole that is

used to fasten the pinion lube cap to the wheelmotor.CAUTION: The bolt must be in line with one of the four bosses.

5. Assemble the cap as shown in Figure 13 with the 13/16 in. hole assembled over the socket head bolt. This willallow the lube cap to be installed in only one orientation and more effectively supply oil to the thrust washers.

6. Fill socket head screw with RTV.


16

FIG. 13. ALIGNMENT OF SOCKET HEAD SCREW. E46271

SOCKET HEAD SCREWMUST BE IN LINE WITHONE OF FOUR BOSSES

2.8. LUBRICATION SPECIFICATIONS FOR OHV EQUIPMENT

For optimum mechanical equipment and bearing life, only lubricants that meet specifications established by Gen-eral Electric Company through controlled field tests should be used. GE specification numbers for approved lubricantsare included in this document.

NOTE: Refer to disc brake assembly manufacturer for disc brake oil specifications.

In order to establish standards for comparison, the American Society For Testing Materials (ASTM) has devised aseries of tests that are common to the industry. Some of these tests are described in Table 1.

The recommended lubricants and approved sources for GDY85/106 applications are specified in Table 2. Forcomplete OHV lubrication specifications covering all OHV propulsion systems, refer to GEK30375.

CAUTION: Use only GE Specification D50E27E, ISO Viscosity Grade 680 gearcase oil in the GDY85/106gearcase. Use of any other oil must be approved by GE OHV Product Service. Use of an unapproved gear-case oil may affect product warranty.

The fill level for the gearcase is to the bottom of the lowest magnetic inspection plug. Amount will vary by model, butwill be 24 gallons.


17

TABLE 1. SUMMARY OF ASTM STANDARD TESTS

Parameters, Units of Measure Description of TestWorked Penetration (Millimeters) The penetration of a test cone dropped into the grease

is measured after the grease has been worked.Dropping Point (Degrees Fahrenheit) The grease is heated until the oil begins to separate

from the thickener.Mineral Oil Viscosity (Saybolt Seconds) The flow of oil through an orifice of a designated size is

measured.Oxidation Resistance Time (Hours) The rate at which the grease absorbs oxygen over a

given amount of time is measured.Evaporation and Oil Bleeding The rate at which the oil will flow out of the heated

grease and evaporate is measured.Corrosion A mirror finished piece of copper is submersed in the

grease for an extended period, then checked to see ifthe surface of the copper is adversely affected.

NOTE: The amount of free acid or alkali, the percentage of soap content, and many other factors that af-fect lubricant quality and purity are also tested. After a lubricant has passed all of the laboratory tests, it issubjected to extensive field testing.

TABLE 2. GE SPECIFICATIONS FOR GEARCASE OIL

GE Specification D50E27E Gearbox Oil (Gearcase Oil)ISO Viscosity Grade 680, For Ambient Temperatures Between 23 C to 50 C (9 F to 122 F)Gravity (ASTM D1298), API 27.5Pour Point (ASTM D97), C (F), maximum 23 (9)Flash Point (ASTM D1310), C (F), minimum 232 (450)Viscosity of Oil (ASTM D445):

cSt at 40C 645cSt at 100C 59.5

Viscosity Index (ASTM D2270) 160Rust Test (ASTM D665A and B) PassWear Test (ASTM D2782), Timken OK Load, lb., minimum 60Performance evaluation (OHV Field Test) PassSources of Supply Brand NameMobil Oil Corporation Mobilgear SHC 680Shell Oil Company Shell Hyperia S680Anderol, Inc. Anderol 5680Valvoline Company Syngard G680Cognis Corp. Emgard 680EPConoco Phillips Syncon Emgard 680EP


18


19

3. GDY85/106 MOTORIZED WHEEL LIFTING DEVICES AND SPECIAL TOOLS

Whenever it becomes necessary to disassemble the GDY85/106 motorized wheel for overhaul, it is absolutelyessential that the repair shop doing the work have suitable crane capacity, lifting devices, puller/removal tools, andinstallation tools to perform the overhaul in a safe and efficient manner.

The following sections describe the necessary tools for GDY85/106 overhaul, their purpose, and recommendedsources for obtaining them. Where GE drawing numbers for devices are shown, the drawings for local manufacture ofthe devices can be obtained from:

GE Transportation Systems2901 East Lake RoadErie, PA 16531Attn: OHV Product ServicePhone: 8148756262Fax: 8148756250

WARNING: Lifting devices per the recommended drawings have been individually manufactured, tested,and safety certified. To comply with varying local safety regulations, lifting devices manufactured by otherfacilities per these recommended drawings should also be individually safety tested and certified by anappropriate outside testing agency before use.

3.1. 40TON CAPACITY DUALHOIST CRANE

A dualhoist crane with 20ton capacity on the main hoist and 20ton capacity on the auxiliary hoist is necessary tolift and rotate the GDY85/106 during overhaul procedures.

Source:Any reputable manufacture of heavy duty cranes

3.2. 25TON SHACKLES

The total GDY85/106 motorized wheel assembly weighs approximately 17 to 22 tons (depending on model). Twoheavyduty 25ton capacity shackles per motor with a throat opening of 2.88 inches to fit over wheel mounting flangeare required for safe handling.

The shackle as purchased will have to be modified per Figure 14. This modification is necessary, as the pin size ofthe shackle with the correct size throat opening to fit over the flange will not pass through the flange hole. Equivalentmay be available from other source (Figure 15).

Screw Pin Shackle: 1018632Source:

Crosby Group Inc.P.O. Box 3128Tulsa, Oklahoma 74104Phone: 9188344611Fax: 9188320940


20

FIG. 14. SHACKLE PIN MODIFICATION. E45179

1 1/4

THREAD 1 1/48

2

THREAD O.D. 2 4 1/2

2 TK.

M.F.M.S.

THREAD I.D. 1 1/47

DRILL AND TAPFOR 1032INSERT S.S

DRILL, TAP SHACKLE 2 4 1/2INSERT PLUG

2

FIG. 15. SCREW PIN SHACKLE. E45049

3.3. HEAVYDUTY HYDRAULIC TORQUE WRENCHES

Overhaul procedures for the GDY85/106 require that certain bolts must be torqued to 2000 ftlbs. to ensure theintegrity of the assembly (untorqued from this value at disassembly). The position of the bolts within the assembly, theextremely high torque requirements, and the number of bolts makes the use of hand tools and torque multipliers im-practical. Hydraulic torque wrenches are required.

Wrench Model: HYTORC HY4XLCTPower Unit Model: Model SST10 Power Pac Electric, 115 volt, 10,000 P.S.I. maximum pressure, 20 remotecontrol, 15 twin hydraulic hose with precision pressure gage, 720 cu. in./minute flow rate.


21

Source:HYTORC Division Unex Corp.120 Wesley StreetSouth Hackensack, New Jersey 076069925Phone: 2014889200 (Call for nearest distributor)Fax: 2014889414

3.4. TRANSMISSION COUPLING BUSHING PULLER

When the GDY85/106 motorized wheel must be disassembled for repair or overhaul it is necessary to pull thebushings which reinforce the joint of the transmission coupling to the frame.

The bushings that are used in this joint are frozen prior to assembly, therefore providing an extremely tight fit. It isimpossible to disassemble the transmission coupling from the frame without first pulling the bushings. Since the bush-ings are a blind assembly and the removal force is measured in tons, this puller is the only practical, efficient way toremove them (Figure 16).

FIG. 16. BUSHING PULLER TOOL. E45063These pullers require the use of a hydraulic pump to power the puller cylinder. Due to the number of bushings that

must be replaced and the length of the bushings, the use of a hand pump is not recommended. See Section 3.6. forinformation about the required pump. It is also recommended that this puller be equipped with one Enerpac CR400female halfflow coupler to facilitate pump utilization.

NOTE: For the GDY85C, GDY85E & GDY106 wheels it is necessary to change the bushing puller com-ponents as these model wheels have a different size bushing. Details for the new puller are on GE drawing41E931185.

GE drawings for local manufacture:Bushing Puller: 41E931065, 41E931185Puller Details: 41D797317 (also required)


22

3.5. C FRAME HYDRAULIC PRESS

Due to the extremely tight fit of the wheel studs in the wheel hub, it is necessary that a hydraulic press be used toinstall the knurled studs used to secure the tire rim to the wheel. Use of a sledgehammer and drift is not recommendbecause of the number of studs required. Heating the hub to 100C and cooling the studs will aid in installation.

A C arbor press frame with 6 inch throat depth and 10 1/4 inch throat opening is required. The press must beequipped with matching, compatible 30ton hydraulic cylinder. It is also recommended that this assembly be matchedwith a suitable electrically powered or pneumatically assisted hydraulic pump. See Section 3.6. for recommendedpump. Two CR400 female couplers are also required. The cylinders have this coupler as standard equipment whenordered. This press will also require a special press block.GE drawing for local manufacture:

Press Block: 41D797514Hydraulic Press: Model A33Hydraulic Cylinder: RR308 or RR3014

Source:Enerpac Division of Applied Power Inc.1300 West Silverspring DriveBulter, Wisconsin 53007Phone: 4147816600

3.6. HYDRAULIC PUMP

A hydraulic pump provides hydraulic power to actuate the wheel stud press and the bushing puller. It is necessaryto insert and remove the wheel hub tire rim retaining studs and to pull the frame coupling bushings for disassembly.Because of the number of studs and bushings that must be handled, use of a hand pump or mechanical means toperform the necessary operations is not recommended. The recommended pump is an electric powered hydraulicpump equipped with, remote control switch with manual valve, twogallon fluid reservoir, minimum 10 foot hoseequipped with quick connect male fitting compatible with female fittings on puller cylinders (Figure 17).

Pump: Enerpac PER 2032Hose: Enerpac HC97

Source:Enerpac Division of Applied Power Inc.1300 West Silverspring DriveBulter, Wisconsin 53007Phone: 4147816600

3.7. TRANSMISSION END LIFTERS

Transmission end lifters are used to turn the GDY85/106 upright into a vertical position for disassembly of trans-mission components. The transmission assembly (without the GEB16 motor) weighs approximately 18 tons. Whenit is necessary to rotate the transmission assembly into a vertical position to remove components, properly designed,manufactured, and certified specialized lifting devices are required. Two lifters per motorized wheel are required.

CAUTION: The transmission end lifters must be manufactured exactly as specified on the drawing usingonly the prescribed material and heat treatment if required. The use of substitute materials and alternativeheat treatment is not acceptable.


23

FIG. 17. HYDRAULIC PUMP. E45056

GE drawings for local manufacture:Trans. End Lifter GDY85B, C models: 41D797367G1/2Trans. End Lifter GDY85D & E models: 41D797810G1Trans End Lifter GDY106 models: 41D798177G1

3.8. HEAVYDUTY HOIST RINGS

Heavyduty hoist rings (also called swivel lifters) are needed to lift and turn GDY85/106 motorized wheel hub,highspeed gear carrier, and lowspeed gear carrier during the disassembly and assembly processes. Two hoistrings are required for the lowspeed carrier and wheel hub and three for the highspeed carrier. The use of properlifting tools is the only correct method for handling these components (Figure 18).

HighSpeed Carrier Hoist Ring:23324 (Qty. 3)

LowSpeed Carrier & Wheel Hub Hoist Ring:23401 (Qty. 2, order with 11/4 in./12 bolt)

Source:American Drill Bushing Co.2000 Camfield AvenueLos Angeles, CaliforniaPhone: 2137251515Fax: 2137258740

3.9. FRAME LIFTERS

Frame lifters are needed for safe lifting and movement of the GDY85/106 frame about the shop in the verticalposition with the flange end down. Properly designed, manufactured, and certified special lifting devices are required.Two lifters per motorized wheel are required.


24

FIG. 18. HOIST RINGS. E45048

CAUTION: The frame lifters must be manufactured exactly as specified on the drawing using only the pre-scribed material and heat treatment if required. The use of substitute materials and alternative heat treat-ment is not acceptable.

GE drawing for local manufacture:Frame Lifters: 41D797367G3

3.10. MOTOR ASSEMBLY HOIST PLATES

The motor assembly hoist plates are needed for safe lifting and rotating of the GEB16 motor during assembly tothe wheel frame. It is necessary to lift the motor with the parking brake end up and the shaft vertical. The use of correct-ly designed lifters is essential to eliminate the possibility of an accident.

CAUTION: Due to the configuration of the spider on the motor end housing, the use of nylon slings orcables is not recommended because they could possibly be cut while rotating the motor.

GE drawing for local manufacture:Hoist Plates: 84C600550

3.11. DUOCONE SEAL INSTALLATION TOOL

This is used to install Duocone oil seal components into the disc brake assembly and seal carrier. When the Duo-cone seal halves are installed into the disc brake assembly and the seal carrier, it is essential that the seal be properlylocated in the bore of the brake and carrier and that the sealing faces and ramp at the rubber toric ring not be damagedin any way. The only way to ensure that a proper assembly is done is by using the correct tool and procedure.Installation Tool: ED3347 (for seal #PB603800)Source:

Komatsu America International Co.2300 N.E. Adams StreetPeoria, Illinois 616500240Phone: 3096727567Fax: 3096727379


25

3.12. SEAL COMPRESSOR

The seal compressor is used to compress the Duocone seal during wheel assembly (four per wheel). It is neces-sary to compress the Duocone seal that is located between the brake assembly and the seal carrier, which is the seatfor the inboard wheel hub bearing. If the seal is not fully compressed and the seal carrier seated on the frame lip, thebearing may move during operation resulting in loss of wheel hub endplay and further consequential damage.GE drawings for local manufacture:

Seal Compressor GDY85B & C: 41D798242Seal Compressor GDY85D & E and GDY106: 41D798241

3.13. WHEEL HUB AND OUTBOARD WHEEL HUB BEARING PULLER

This puller assembly is used to remove the GDY85/106 wheel hub and outboard bearing at overhaul. The hubbearings are shrunk on when the wheel is assembled by heating them in an oven and the fit is extremely tight. As thebearing may be suitable for reuse, it is essential that the proper tooling be used to remove it without damage. The pullerassembly consists of three (or more) 25ton hydraulic jacks and special support plates.GE drawing for local manufacture:

Hub and Outboard Hub Bearing Puller: 41E931653Hydraulic Jacks: Model RR308 (Qty. 3)Source:Enerpac Division of Applied Power Inc.1300 West Silverspring DriveBulter, Wisconsin 53007Phone: 4147816600

3.14. INBOARD WHEEL HUB BEARING PULLER

This puller assembly is used to remove the inboard wheel hub bearing at overhaul. It is necessary to remove theinboard wheel hub bearing to access the disc brake assembly. The hub bearing is shrunk on when the wheel is as-sembled by heating it in an oven and the fit is extremely tight. Due to the configuration of the parts and the tight spacesinvolved, it is necessary to have this puller assembly to facilitate removal of the bearing without damage.

NOTE: This puller assembly also uses the same hydraulic jacks defined previously (Enerpac ModelRR308, Qty. 3 or more).

CAUTION: Do not substitute mild steel for the SAE 4140 steel as mild steel lacks sufficient strength and willcrack in the corners.

GE drawings for local manufacture:Inboard Hub Bearing Puller GDY85B & C models 84C600549

Inboard Hub Bearing Puller GDY85D & E models and GDY106 models 41E931346

3.15. COUPLING BUSHING INSTALLATION MATERIAL

Certain specialized materials are necessary to aid installation of the transmission coupling bushings. These bush-ings couple the GDY85/106 frame to the transmission coupling plate/ring gear assembly, are assembled with a tightinterference fit. The bushings are coated with Dow Corning dry film lubricant and then frozen in liquid nitrogen to facili-tate assembly. Freezing the bushing in a sub zero freezer to 40C is not sufficient.


26

CAUTION: Extreme care should be taken when using liquid nitrogen to prevent burns due to extreme lowtemperatures. It is recommended that suitable gloves and other protective clothing be used when handlingfrozen parts.

Materials:Liquid nitrogen in specially insulated containerDow Corning #321 Dry Film Lubricant (11 oz. Aerosol Can)

Source:Liquid Nitrogen: Local Welding SupplyDry Film Lubricant: Dow Corning CorporationDow Corning CorporationMidland, Michigan 484840944Phone: 18005377, Ext. 5537

(for name of local distributor)

3.16. BRAKE OIL DRAIN FIXTURE

This fixture provides a means to drain the disc brake cooling oil with minimum spillage when the GDY85/106 isdisassembled. Without a proper drain device, the oil has a tendency to spill on the floor and on the wheel flange. Thisrequires unnecessary time and effort for cleanup, and creates a slipping hazard. This plate is designed to fit onto theentrance and exit holes for the cooling oil in the disc brake assembly. In addition to the plate shown on the drawing, itwill be necessary to add the following items:

Four 3/4 inch pipe short nipplesTwo 3/4 inch 1/4 turn valvesTwo lengths of 3/4 inch inside diameter (ID) hoseTwo hose clampsTwo AS223 O rings, 1.875 OD x 1.58 ID x 1/8Eight 1/2 13 x 1/1/4 long bolts and washers

GE drawing for local manufacture:Brake Oil Drain Fixture 41B585916

3.17. WHEEL STUD REMOVAL PRESS

The wheel stud removal press is used to remove studs from wheel in the overhaul facility (not when mounted on thetruck). During tire change on the truck, the wheel studs are often damaged and it is necessary to change them atoverhaul. Use of a heavy hammer is not an acceptable means of stud removal due to the number of studs and thepotential damage to adjacent parts. This press will also require use of the hydraulic pump described in Section 3.6.GE drawing for local manufacture:

Wheel Stud Removal Press 41E931198

3.18. SCOTTPURE WIPING CLOTHS

These lint free disposable paper cloths are used to clean the Toric seal prior to assembly. When the Toric seal is tobe installed, it must be wiped clean to prevent scratching in operation. The Scottpure towel, in combination with isopro-pyl alcohol, does an excellent job and leaves lint free surfaces.Source:

Scott Paper Company (check phone book for local distributor/dealer)


27

3.19. SHIMS FOR SETTING HUB BEARING END PLAY

These shims space the outboard wheel hub bearing up so that an accurate end play setting can be obtained. They(Qty. 3) set the proper gap when the bearing is hot. This allows it to be pulled down when the coupling plate is as-sembled with the shims to set the end play to drawing requirements. Shims should be made from a polyethylene mate-rial.

GE drawing for local manufacture:Polyethylene Shims 41A286415

3.20. GEB16 AC MOTOR PULLER TOOLS

Specialized puller tools (Figure 19) are used for removal of the rotor bearings and various collars from the rotorshaft of the GEB16 AC traction motor at overhaul. However, depending on overhaul facility practices and/or availabil-ity of alternate equipment and tooling, not all of the puller components shown may be required. An alternative methodof suspending the rotor vertically from a crane and heating the components carefully with a torch fitted with a rosebudtip can be used to remove some of these components. It is therefore recommended that the puller tools shown bereviewed, along with those that the overhaul facility may already have available, prior to manufacturing any of the re-quired tools.

A separate puller arrangement is required for removing the parking brake gear (Figure 20).GE drawing for local manufacture:

GEB16 Puller Tools 41D736039G1, G3, G5, G6, G8GE drawing for local manufacture:

GEB16 Parking Brake Gear Puller Tool 41C63386G5

3.21. GEB16 AC TRACTION MOTOR ROTOR ASSEMBLY GUIDE

Use of the rotor assembly guide is recommended when installing the rotor into the stator to guide the rotor into theinner race of the parking brake end ball bearing (Figure 21).GE drawing for local manufacture:

Rotor Assembly Guide 41D797016


28

16BEARING PUSHER (C.E.)PART 41D736039G7

COLLAR PULLER (P.E.)PART 41D736039G5

OUTER RACE PUSHER (P.E.)PART 41D736039G8

41D736039G9 COVERS ALL PARTS INSUFFICIENT QUANTITY TO MAKE UPASSEMBLIES 1 WITHOUTDUPLICATION OF PARTS.

COLLAR & INNER RACE PULLER (P.E.)PART 41D736039G6

19

LOCATE FLAT ON P13TO CLEAR SP. SENSORPROJECTION ON FR. HEAD

1718

COLLAR PULLER (C.E.)PART 41D736039G3

3

6310

1112

6 3

259

63

2

58

14

5

1615

3

3 6 2

BEARING PULLER (C.E.)PART 41D736039G2

5

13

20

3 6

7

2

COLLAR PULLER (C.E.)PART 41D736039G1

45

1523

21

ASM. # 8

ASM. # 7

ASM. # 6ASM. # 5

ASM. # 2

ASM. # 3

ASM. #1

ASM. # 4

OBSOLETE FORNEW DESIGN

FIG. 19. GEB16 PULLER GROUPS. E45145

REF. DESCRIPTION1 RING, SPLIT (2) 41B538458P22 CLAMP PLATE (1) 41B535992P13 HYDRAULIC JACK (1) 41B532564P34 PRESS CAP (1) 41B535988P25 BOLT, 1/213 X 13/4 (8) N22P29028B136 PRESS CAP 41B535988P17 RING HALVE (2) 41C635988P28 RING, SPLIT (2) OBSOLETE WITH NEW DESIGN 41B538464P29 RING, SPLIT (2) 41B538465P210 CLAMP PLATE (1) 41B538485P111 BOLT, 5/811 X 11/2 (4) N22P3302412 RING HALVE (2) 41C635973P613 CLAMP PLATE (1) 41B538468P114 PLUG (1) 41C635984P315 CLAMP RING (1) 41B538467P116 BOLT, 1/213 X 5 (4) N22P29080B1317 CENTER PLATE (1) 41C635974P318 BOLT, 1/213 X 11/4 (4) N22P29020B1319 CLAMP (2) 41C635974P220 PLATE (1) 41C635974P121 NUT, 1/213 N203P29B13


29

REF. DESCRIPTION11 PRESS CAP (1), 41B535988P144 HYDRAULIC CYLINDER (1), 41B532564P956 PULLER PLATE (1), 41A239824P157 PIPE (16), 41A230742P1958 STUD, 5/811 (16), 41A233719P959 HARDENED WASHER, 5/8 (16), 41B537660P960 NUT, 5/811 (16), N20P33

FIG. 20. GEB16 PARKING BRAKE GEAR PULLER. E45144

GEK91680A, GDY85

Documents

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