0335412 JOHNSON SEAL, Lower

TWO PUMP DRIVE GEARBOX ASSEMBLY (FUNK SPEC. NO. 10560A, MODEL 28102BA)The gearbox has two output gears driven by a single input gear or pinion, all of which are straddle mounted between ball bearings. Power is transmitted from the engine to the pinion by a splined input shaft that mates with the pinion on one end and with the hub of the drive plate on the other end. The drive plate bolts to the engine flywheel. The gearbox flywheel housing bolts to the engine flywheel housing and supports the rest of the gearbox.Lubrication
The oil level in the gearbox should be kept at check plug level to ensure proper lubrication of internal components.Under normal operating conditions the SAE 90 gear lubricant (GL) specified in "Service Data" should be used; however, the lubricant should be changed if the operating temperatures are higher or lower than normal: 1. If the gearbox case temperature is consistently above 220°F, use an oil with a viscosity of SAE 140.2. If the atmospheric temperature is 30°F and above, use an oil with a viscosity of SAE 90.3. If the atmospheric temperature is 50°F and below, use an oil with a viscosity of SAE 30.Internal and external splines should be liberally greased whenever the gearbox drive shaft or a hydraulic pump is replaced.Removing The Gearbox
STARTING OF THE ENGINE CAN CAUSE INJURIES TO ANYONE WORKING ON THE PUMP DRIVE GEARBOX. SHUT ENGINE B (CATERPILLAR 3208) DOWN, TAG THE ENGINE CONTROL AND LOCK THE MAIN BATTERY SWITCH AT "OFF" TO REMOVE THE GEARBOX.
1. Close the two pump suction shutoff valves.
PUMPS VIEWED FROM BELOW
PUMPS VIEWED FROM ABOVE2. Mark all the hoses connected to the hydraulic pumps for identification when installing the pumps, thoroughly clean around the connections, then disconnect the hoses from the pumps. Cap or plug all openings immediately.3. Support the track drive and control (auxiliary) pumps (about 120 pounds, total), remove the track pump mounting bolts, pull the pumps straight back from the gearbox until the track pump shaft is free, then move the pumps away.4. Support the conveyor pump (about 26 pounds), remove the pump mounting bolts, pull the pump straight back from the gearbox until the shaft is free, then move the pump away. Cover the opening in the gearbox. 5. Attach fabricated lifting lugs to the gearbox.6. Attach a lifting beam and lifting device to the lifting lugs and support the weight of the gearbox (about 150 pounds).Two Pump Drive Gearbox Assembly (Funk Spec. No. 10560A, Model 28102BA) 7. Remove the bolts from the flywheel housing.8. Pull the gearbox straight back from the engine, using care to avoid letting the gearbox drive shaft support the weight of the gearbox.9. After the shaft is free, lift the gearbox away.10. If necessary, remove the drive plate from the flywheel.Disassembling The Gearbox
1. Pull the input shaft and shaft adapters from the gearbox, if still installed. Mark the shaft adapters for identification during reassembly.2. Unbolt and remove the adapter plates.3. Pull the gear-and-bearing assemblies from the gearbox.4. Unbolt and remove the flywheel housing.5. Pull the pinion-and-bearing assembly from the gearbox.6. Pull the bearings off the gear shafts.7. Remove the input shaft seal, if not already removed.8. Inspect the case for cracks or other damage, especially around the bolt holes and shoulders that support bearings.9. Clean and inspect gears and shafts for chipped, broken or cracked teeth or splines.10. Clean and inspect the bearings.Assembling The Gearbox
Reassemble in reverse order of disassembly, placing the gear-and-bearing sub-assemblies first in the housing. Guide the adapter plate or flywheel housing over the exposed bearings and tap the plate or housing sharply to ensure that the bearings have moved into the bores completely. Use a new gasket between the flywheel housing and gearbox housing. Turn the input shaft by hand to ensure that the unit is free running. (Any binding of bearings in housing bores will load the bearings endwise and cause excessive heat when running). Install a new input shaft seal.Installing The Gearbox
The operating lifetime of the gearbox depends a great deal on proper installation and initial startup. Misalignment between engine components and/or gearbox components can drastically reduce the life of the gearbox. It is, therefore, good practice to check the flywheel and flywheel housing runout before installing the gearbox.
CHECKING FLYWHEEL HOUSING FACE1. Check the flywheel housing face by bolting a dial indicator to the flywheel so that the indicator is perpendicular to the housing face and the indicator stem rides on the housing face. The reading should not exceed the following: Hsg. Bore Dia.: 23"-30" 16"-21" 10"-15"Max. Allowed: .010" .008" .006"
CHECKING FLYWHEEL HOUSING BORE2. Check the flywheel housing bore by moving the stem of the indicator so it rides on the bore of the flywheel housing. The reading should not exceed the following: Hsg. Bore Dia.: 23"-30" 16"-21" 10"-15"Max. Allowed: .010" .008" .006"
CHECKING FACE OF FLYWHEEL3. Check the face of the flywheel by bolting the indicator to the flywheel housing with the stem riding on the face of the flywheel. The total variation should not exceed .0005 inch per inch of diameter.
CHECKING FLYWHEEL PILOT BORE4. Check the eccentricity of flywheel pilot bore by moving the stem of the indicator so it rides on the flywheel pilot bore. The total variation should not exceed .005 inch.If any of the readings exceed the limits specified, contact the engine manufacturer's representative for corrective action to be taken. To install the gearbox:1. Bolt the drive plate to the flywheel. Tighten the bolts evenly and alternately. Be sure the hub of the drive plate extends away from the gearbox.2. Grease the splines of the drive shaft and move the gearbox into position so the shaft splines are aligned with the hub splines of the drive plate.3. Carefully move the gearbox toward the engine until the engine flywheel housing mates with the gearbox flywheel housing.4. Insert the bolts through the flywheel housing and tighten the bolts evenly and alternately. 5. Grease the shaft adapters and install them in the appropriate gear hubs.6. Coat the conveyor pump shaft with non-corrosive