﻿GET_GEVOMechL2_08_01_01_93 - ANIMATION Screen
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Gear Case Assembly

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1. Clean the surface of the bull gear flinger on which the motor-side gear case seal (gutter) rides, then lubricate this surface with D50E25C gear oil or equivalent.

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2. Install the motor-side axle seal to the axle assembly with the lip of the seal located over the flinger.

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3. Add a 0.25-inch (6.4-mm) minimum bead of the approved sealant in the groove and latch the seal.

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4. Clean the surfaces of the wheel and gear hubs on which the wheel-side gear case seal (gutter) rides, then lubricate these surfaces with D50E25C gear oil or equivalent.

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5. Install the wheel-side axle seal to the axle assembly with the lip of the seal located over the wheel gear and gear hubs.

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6. Add a 0.25-inch (6.4-mm) minimum bead of the approved sealant in the groove and latch the seal.

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7. Add a 0.25-inch (6.4-mm) maximum bead of the approved sealant to the joint where the latch occurs, ensuring that all sealing surfaces are not pinched or folded.

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8. Fill the groove in the bottom half of the gear case at the armature bearing cap bore with the approved sealant.

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9. Apply an additional 0.25-inch (6.4-mm) bead by 3-inch (76.2-mm) long of the approved sealant to both sides of the split line.

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Repeat this step for the top half of the gear case, except apply the additional 0.25-inch (6.4-mm) bead of sealant to the entire semicircle.

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10. Install the bottom half of the gear case, ensuring that the gear case groove engages with the bearing cap lip and the inner and outer axle seals in the gear case opening.

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11. Mount a washer or washer assembly on a 12-point flanged 1.00-8 bolt, then install the first gear case mounting bolt and washer assembly as follows:

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a. If a Nord lockwasher is used, lubricate the threads of the gear case mounting bolt and both faces of the washer with a Wabtec approved Moly-based lubricant (84B565364A1) and wait until dry to touch (approximately 5 minutes) before assembly, and then install the bolt and washer in the top hole and hand tighten.

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b. If a solid washer assembly is used, without lubrication, install the bolt and washers in the top hole and hand tighten.

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c. If a 4-component load washer/spacer assembly is used, without lubrication and while ensuring that the chamfered (colored) side of the load washer is against the bolt head, install the bolt and washers/spacer assembly in the top hole and hand tighten.

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12. On the top gear case half, apply a 0.13-inch (3.2-mm) maximum bead of the approved sealant along the engine joint face between the gear case halves and do not allow the approved sealant within 1 inch (25.4 mm) of the split line bolt holes.

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13. Install the top half of the gear case and verify engagement of the gear case groove with the bearing cap lip and the axle seals in the gear case opening.

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14. Install in pairs and evenly tighten the eight bolts that hold the gear case halves together, starting at the top.

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15. Torque the three 3/8-inch bolts to 22.5 ± 1.5 lb.-ft. (30.5 ± 2 Nm).

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16. Torque the five 3/4-inch bolts to 198 ± 13 lb.-ft. (268 ± 18 Nm).

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17. Install the gear case mounting bolts as follows as the preferred method of installation:

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a.Lubricate the gear case mounting bolt threads and both faces of the washer with a Wabtec approved Moly-based lubricant (84B565364A1) and wait until dry to touch (approximately 5 minutes) before assembly.

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b. Using a reduced shank, 1.00-8 threaded bolt (84B534558P1), and Nord lockwasher (84B534568P1) for each bolt position, install the two remaining bolts and install one Nord lockwasher on each of the bolts.

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c. Using a Norbar torque/angle tool (or equivalent), apply a 425 ± 20 lb.-ft. (576 ± 27 Nm) torque plus a 45° angle to each of the three gear case mounting bolts.

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d. Using a paint pen, draw a line across the top and sides of each bolt head that extends onto the gear case on both sides of the bolt.

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18. An alternate method to install the gear case mounting bolts is as follows:

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a. Using a solid washer assembly on 1.00-8 bolts, mount the two remaining bolts and washer assemblies and hand tighten.

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b. Torque the three gear case mounting bolts to 400 lb.-ft. (542 Nm) and then turn them to 55° using the torque/angle wrench.

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19. Another method to install the gear case mounting bolts is as follows:

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a. Using 4-component load washer assemblies mounted on 12-point flanged 1.00-8 bolts, install the two remaining bolts and washer assemblies and hand tighten.

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b. Tighten all three load washer and bolt assemblies by inserting a pin or small Allen wrench in one of the holes in the outer ring of the load washer assembly, then tighten the bolt while rotating the ring back and forth.

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c. Torque all three gear case mounting bolts until the inner ring of the load washer assembly compresses and the outer ring is just seized between the two flat washers.

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20. Verify that a bead of the approved sealant is visible at the joints after the bolts have been torqued and that a bead of sealant is visible around the pinion end armature bearing cap, and that the armature bearing cap overboard drain slots are free of sealant.

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21. Attach a nylon lifting strap to each axle journal bearing, then lift the traction motor, axle, and wheel assembly and rotate 90° to return the traction motor combo to the horizontal position.

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22. After the 24 hours sealant cure time is over, apply D50E25C gear oil or equivalent to the gear case.

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23. Check the gear case lubricant level using a dipstick (Part Number 41C637237G1), then install and torque all pipe plugs to 100 to 110 lb.-ft. (136 to 150 Nm).

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24. Apply a safety lock wire to the fill plug and the drain plug.
