Service Manual
440 SerieS Digger MoDelS
440 81 4 example Part number
4 f 95 D 9
Model Ratio Shaft Bail Boss
ThiS Service Manual iS effecTive:
S/n: 70000 To currenT
DaTe: 5-2006 To currenT
verSion: SMD44081-44f95D9
Motor
Supplier
Motor
Number
Cover Input
noTe: Individual customer specifications (spindle mounting, sprocket pilot, brake assembly, etc.) may vary from exploded drawing and standard part numbers shown. If applicable, refer to customer drawing for details.
5
ITEM
1
2
3
4
5A
5B
5C
5D
5E
5F
5G
6
6A
6B
7
7A
7B
7C
7D
7E
7F
7G
8
8A
8B
8C
9
9A
9B
9C
9D
9E
9F
9G
10
10A
10B
10C
10D
10E
11
11A
11B
11C
12
12A
12B
12C
12D
13
14
14A
14B
14C
15
15A
15B
15C
15D
16
15E
15F
15G
15H
13A
13B
13C
13D
13E
Eskridge
exploded view Drawing
44081-44f95D9
13A
QTY
1
1
1
1
MODEL 44081-44F95D9 DIGGER
DESCRIPTION
BASE-"F" FLANGLESS
OUTPUT SHAFT-4" SQUARE
COVER (4 BOLT "D')
INPUT GEAR
PART NO.
42-004-3022
42-004-4102
25-004-1232
25-004-1762
(1)
3
120
1
3
1
1
1
6
9
3
(1)
6
9
3
3
36
1
3
(1)
6
6
3
3
60
1
3
1
1
1
1
1
1
2
1
2
3
1
1
1
1
1
20
20
40
4
4
1
3
1
1
1
1
1
1
*
1
1
CARRIER ASSEMBLY- STAGE 1
CARRIER
PLANET GEAR
PLANET SHAFT
PLANET ROLLER
THRUST WASHER
ROLLER SPACER WASHER
ROLL PIN
SUN GEARS
SUN GEAR (STAGE 2)
SUN GEAR (STAGE 3)
CARRIER ASSEMBLY- STAGE 2
CARRIER
PLANET GEAR
PLANET SHAFT
PLANET ROLLER
THRUST WASHER
ROLLER SPACER WASHER
ROLL PIN
RING GEARS
RING GEAR (STAGE 1)
RING GEAR (STAGE 2)
RING GEAR (STAGE 3)
CARRIER ASSEMBLY- STAGE 3
CARRIER
PLANET GEAR
PLANET SHAFT
PLANET ROLLER
THRUST WASHER
ROLLER SPACER WASHER
ROLL PIN
THRUST WASHERS & BEARINGS
THRUST SPACER
THRUST WASHER
THRUST BEARING
CARRIER THRUST WASHER-STAGE 1
CASE THRUST WASHER-STAGE 1
SEALS & O-RINGS
O-RING - STAGE 1
O-RING - STAGES 2 & 3
OUTPUT SHAFT SEAL
OUTPUT SHAFT BEARINGS
OUTER CONE
OUTER CUP
INNER CONE
INNER CUP
25-005-2201
25-004-1692
25-004-1712
25-004-1442
01-106-0010
13-004-1582
13-004-1592
01-153-0020
42-004-1512
42-004-1472
42-005-0101
42-004-1062
42-004-1102
42-004-1342
01-106-0040
42-004-1362
42-004-1352
01-153-0220
25-004-1562
42-004-1042
42-004-1032
42-005-0131
42-004-1402
42-004-1092
42-004-1332
01-106-0040
42-004-1362
42-004-1352
01-153-0220
25-004-1842
01-112-0510
01-112-0500
25-004-1132
25-004-1752
01-402-0020
01-402-0840
01-405-0770
01-102-0290
01-103-0290
01-102-0280
01-103-0280
HARDWARE
HEX CAP SCREW - 5/8-11 UNC - 9.5
HEX CAP SCREW - 5/8-11 UNC - 4.0
5/8 HELICAL SPRING LOCK WASHER
HEX CAP SCREW 3/4-10 UNC - 1.75
3/4 HELICAL SPRING LOCK WASHER
PLUGS/ZERK
HOLLOW HEX PLUG -12 SAE
PIPE PLUG (3/4 NPT MAGNETIC)
PIPE PLUG (1/4 NPT)
01-150-1950
01-150-1880
01-166-0040
01-150-1890
01-166-0360
01-208-0030
01-207-0100
01-207-0020
MISCELLANEOUS
STAGE 1 RING ADAPTER
BAIL ASSEMBLY
SHIM
LOCK RING
42-004-2072
42-005-0171
42-004-1202
42-004-1212
SPLIT RING (L-SEGMENT-425) 42-004-1222
SUN GEAR RETAINGING RING - STAGE 2 01-160-0740
SUN GEAR RETAINGING RING - STAGE 3 01-160-0690
CARRIER RETAINING RING - STAGE 3 01-160-0680
MOTOR 01-304-0950
13C
13D
13E
14A
10A
10B
10E
10D
4
11A
15F
6A
11B
15D
15C
14B
5A
8A
7A
8B
6B
15H
9A
8C
14C
11C
15B
16
2
X44081-44F95D9ab 03-22-10 HWP Model D440 service manual, SM 44081-44f95D9 Page 2 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
13B
13C
10C
3
5E
5F
5C
5G
5D
5B
15A
15G
15E
9E
9C
9G
9B
9D
9F
12C
12D
1
7E
7F
7C
7G
7B
7D
12B
12A
lubricaTion & MainTenance
Using the chart below, determine an appropriate lubricant viscosity. Use only EP (extreme pressure) or API GL-5 designated lubricants.
Change the lubricant after the first 50 hours of operation and at 500 hour intervals thereafter. The auger drive should be partially disassembled to inspect gears and bearings at 1000 hour intervals.
recommended ambient and operating temperatures for conventional and synthetic gear lubricants
-50 -25 0 25 50 75 100 125 150 175 200 225 250 F
80W90 conventional
75W90 conventional
85W140 conventional
Min ambient/operating temp Max ambient temp Max operating temp
75W90 synthetic
80W140 synthetic
-45 -32 -18 -4 10 24 38 52 66 79 93 107 121 C note: ambient temperature is the air temperature measured in the immediate vicinity of the gearbox. a gearbox exposed to the direct rays of the sun or other radiant heat sources will operate at higher temperatures and therefore must be given special consideration. The max operating temp must not be exceeded under any circumstances, regardless of ambient temperature.
If your unit was specified “shaft up” or with a “-Z” option, a grease zerk was provided in the base housing. For shaft-up operation, the output bearing will not run in oil and must be grease lubricated. Use a lithium based or general purpose bearing grease sparingly every
50 operating hours or at regular maintenance intervals. Over-greasing the output bearing should be avoided as it tends to fill the housing with grease and thicken the oil operating Position
Horizontal Shaft
Vertical Shaft (Pinion Down)
eSKriDge MoDel D440 oil caPaciTieS
Single stage
oil capacity
Double stage oil level
Triple stage
-
4.4 GAL/ 16.8 liters
To horizontal centerline of auger drive
To midway on upper/ primary gear set
!
Warning: While working on this equipment, use safe lifting procedures, wear adequate clothing and wear hearing, eye and respiratory protection.
eSKriDge ParT nuMber inTerPreTaTion
note: all non custom eskridge geardrives are issued a descriptive part number which includes information regarding the Model, means of shaft retention, base style, shaft style, input mounting, input shaft size, overall ratio and various available options. for a detailed breakdown of this information, please refer to eskridge product specification sheets found at: http://www.eskridgeinc.com/diggers/diggerprodspecs.html
Model D440 service manual, SM 44081-44f95D9 Page 3 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
unit Disassembly Procedure
1) Scribe a diagonal line across the outside of the unit from the bail (15b) to the base (1) before disassembly to aid in the proper positioning of pieces during reassembly.
Stage i carrier Subassembly
(items 5a, 5b, 5c, 5D, 5e, 5f & 5g)
2) Remove magnetic drain plugs (14b) and drain oil from unit.
The oil will drain out faster and more completely if warm.
3) Remove the twenty hex-head capscrews (13a) and lockwashers (13c).
4) Separate bail (15b) from ring gear adapter (15a) and remove from digger assembly.
5) Install two hex-head capscrews (13a) into ring gear adaptor
(15a) to retain gearbox assembly together.
6) Remove motor (16) from cover (3).
7) Remove the twenty hex-head capscrews (13b) and lockwashers (13c).
8) Remove cover (3), thrust bearings (10a, 10b, 10c, 10D &
10e), remove input gear (4). Inspect o-ring (11a); discard if damaged or deformed.
5A
5E
5F
5C
5G
5D
5B
9) Remove retaining ring (15f) from stage II sun gear.
Lift Stage I planet carrier assembly out of the unit
(5). Remove ring gear (8a) and inspect o-ring (11a); discard if damaged or deformed.
10) Remove two hex-head capscrews before, discard if damaged.
(13a) and ring gear adapter
(15a). Inspect o-ring (11b) as before; discard if damaged.
11) Remove retaining ring (15g) from stage III sun gear.
Lift the Stage II planet carrier assembly out of the unit
(7).
12) Remove the Stage II ring gear (8b). Inspect o-ring (11b); as
13) Using a screwdriver, seal pick or similar tool remove the retaining ring (15h), which retains the Stage III planet carrier to the output shaft. The retaining ring can be left in the carrier but must be removed from the groove.
14) With a suitable lifting apparatus and a hoist, lift the Stage III planetary assembly out of the unit (9).
15) Remove Stage III ring gear (8c). Inspect o-ring (11b); as before, discard if damaged or deformed.
16) The unit is now separated into subassemblies. The area(s) requiring repair should be identified by thorough inspection of the individual components after they have been cleaned and dried.
Disassembly
1) Rotate planet gears (5b) to check for abnormal noise or roughness in bearings (5D) or planet shafts (5c). If further inspection or replacement is required, proceed as follows.
noTe: Support only the carrier (5a) while pressing out planet shafts.
2) Drive roll pins (5g) completely into the planet shafts (5c).
3) Press or drive planet shafts (5c) out of carrier (5a).
4) Remove planet gears (5b) and thrust washers (5e) from the carrier (5a).
5) Inspect the planet gear (5b), bearing bore, planet shaft (5c) and rollers (5D). Check for spalling, bruising or other damage.
Replace components as necessary; rollers should be replaced only as a set of 12..
6) Check primary planet shafts (5c) for any abnormal wear, especially ones where bearings needed to be replaced.
If any abnormal wear is found, replace planet shafts.
7) Use 3/16 inch pin punch to remove roll pins (5g) from planet shafts (5c).
noTe: if either the rollers or the planet shafts (pins) are damaged, both components should be replaced.
reassembly
1) To install rollers in planet gear bore: a) Set planet washer (5e) on work table, insert planet shaft in washer then slide one spacer (5f) over shaft (5c).
b) Place planet gear (5b) centered over planet shaft
(5c).
c) Install tweleve rollers into planet gear bore.
Slide two spacers (5e) onto planet shaft, slide planet washer (5f) onto planet shaft (5c).
d) Carefully remove planet shaft from this assembly and move the gear with bearings and washers to the carrier.
e) Slide the gear into place. (Oriented as shown.)
2) Planet shafts (5c) should be installed with chamfered end of
Model D440 service manual, SM4408144f95D9Page 4 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
3/16 inch hole toward outside diameter of the carrier (5a).
This will aid in alignment of holes while inserting roll pins
(5g).
3) Drive a roll pin (5g) through the carrier hole and into the planet shaft to retain the parts. Repeat for other planet gears.
Stage ii carrier Subassembly
(items 7a, 7b, 7c, 7D, 7e, 7f, & 7g) h) Align the planet gear/bearing assembly inside the carrier and install the planet shaft through the entire assembly.
3) Planet shafts (7c) should be installed with the chamfered end of the 3/16 inch hole towards the outside diameter of the carrier (7a); this will aid in alignment of holes while inserting roll pins (7g).
4) Drive roll pin (7g) into the carrier hole and into the planet shaft to retain the parts. Repeat for remaining planet gears.
7A
7E
7F
7C
7G
7B
7D
Disassembly
1) Rotate planet gears (7b) to check for abnormal noise or roughness in bearings (7D). If further inspection or replacement is required, proceed as follows.
Stage iii carrier Subassembly
(items 9a, 9b, 9c, 9D, 9e, 9f, 9g & 15h)
2) Drive roll pins (7g) completely into the planet shafts (7c).
3) Slide planet shafts (7c) out of carrier (7a).
4) Remove planet gears (7b), washers (7e) and rollers (7D) from carrier (7a).
5) Inspect the planet gear (7b), bearing bore, planet shaft (7c) and rollers (7D). Check for spalling, bruising or other damage. Replace components as necessary; rollers should be replaced only as a set of 20.
15H
9A
9B
9D
9F
9E
9C
9G
6) Remove roll pins (7g) from primary planet shafts (7c) using a 3/16 inch pin punch.
reassembly
1) Rebuild primary planet carrier assembly in reverse order using any needed new parts.
Disassembly
2) Install rollers in gear as follows:
1) Rotate planet gears (9b) to check for abnormal noise or roughness in bearings (9D). If further inspection or replacement is required, proceed as follows. a) Set planet washer (7e) on work table with planet gear
(7b) positioned on top of washer. Center the planet washer to the planet gear as closely as possible.
2) Drive roll pins (9g) completely into the planet shafts (9c).
b) Center the planet shaft (7c) in the planet gear (7b) bearing bore. Install roller spacer (7f) onto planet shaft.
3) Slide planet shafts (9c) out of carrier (9a).
4) Remove planet gears (9b), washers (9e), spacers (9f) and rollers (9D) from carrier (9a).
c) Begin placing rollers (7D) around the shaft (7c). There should be clearance for the last roller to slide in. Be sure to install 20 rollers in each planet gear.
d) Place spacer washer (7f) onto planet shaft.
5) Inspect the planet gear (9b), bearing bore and planet shaft
(9c) and rollers (9D). Check for spalling, bruising or other damage. Replace components as necessary; rollers should be replaced only as a set of 40 (2 rows of 20). e) Place a washer over the gear (7e) onto the shaft (7c).
f) Carefully slide the assembly off the table, holding the lower planet washer (7e) and planet gear (7b).
6) Remove roll pins (9g) from secondary planet shafts (9c) using a 3/16 inch pin punch.
reassembly g) Slide the planet shaft (7c) out of the assembly and slide the assembly into the carrier.
1) Rebuild Stage III planet carrier assembly in reverse order using any needed new parts.
Model D440 service manual, SM4408144f95D9Page 5 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
2) Place the spiral-wound retaining ring (15h) in the depression at the center of the carrier (9a) in preparation for installation onto the output shaft (2).
3) Install rollers in gear as follows: a) Set planet washer (9e) on work table with planet gear
(9b) centered on top of washer. Center the planet washer and the planet gear as closely as possible.
b) Slide a spacer (9f) over the planet shaft.
c) Center the planet shaft (9c) in the planet gear (9b) bearing bore.
d) Begin placing rollers (9D) around the shaft (9c). There should be clearance for the last roller to slide in. Be sure to install 20 rollers per row in the planet gear (9D).
e) Slide a spacer (9f) over the first row of rollers (9D).
f) Place a second row of rollers (9D) around the planet shaft (9c) as before.
g) Slide a spacer (9f) over the second row of rollers (9D).
h) Place a washer (9e) over the gear (9b) onto the shaft
(9c).
i) Carefully slide the assembly off the table, holding the lower planet washer (9e) and planet gear (9b).
j) Slide the planet shaft (9c) out of the assembly and slide the assembly into the carrier (9a).
k) Align the planet gear/bearing assembly inside the carrier and install the planet shaft through the entire assembly.
4) Planet shafts (9c) should be installed with the chamfered end of the 3/16 inch hole towards the outside diameter of the carrier (9c). This will aid in alignment of holes while inserting roll pins (9g).
5) Drive roll pin (9g) through the carrier hole and into the planet shaft to retain the parts. Repeat for the other planet gears.
base Subassembly
(items 1, 2, 11c, 12a, 12b, 12c, 12D, 14b, 14c,
15c, 15D, & 15e)
15D
15C
14B
14C
11C
15E
12C
12D
1
12B
12A
2
Disassembly
1) Remove the lock ring (15D) using a heel bar or puller; if using a heel bar, be sure not to pry against the cage of the inner output shaft bearing (12c). Remove the split ring segments
(15e) and shims (15c).
caution: Since the output shaft is no longer retained, care should be taken to avoid personal injury. care should also be taken not to damage it when it is pressed through base.
2) Base (1) should be set pinion side down, as shown, on a plate or table. Press output shaft through the bottom of base by applying a load to top end (internal end) of shaft until it passes through inner shaft bearing cone (12c). note: removing the shaft from the base assembly damages the shaft seal and the seal will need to be replaced.
3) A gear puller may be used to remove the outer bearing cone
(12a) from the shaft (2). If reusing old bearing cone, do not pull on or damage roller cage. Remove the shaft seal (11c) from the shaft for replacement.
4) Inspect inner and outer bearing cups (12b & 12D). If cups are damaged, drive them out using a brass drift and utilizing the bearing knock-out notches in the base (1) reassembly
1) Clean all foreign material from magnetic oil plug (14c) located on the side of the base (1).
2) Place base (1) (output side up, opposite shown) on the table.
3) Apply a layer of lithium or general purpose bearing grease to the roller contact surface of outer bearing cup (12a).
4) Press outer bearing cone (12b) (large end down as shown) onto the shaft until it seats against the shoulder. note: Press bearing cone onto output shaft by pressing on inner race only. Do noT press on roller cage, as it may damage bearing.
Model D440 service manual, SM4408144f95D9Page 6 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
5) Place the shaft (2) with the bearing (12a) into the base (1).
6) Flip this assembly, resting the base (1) on the end of the output shaft (2).
7) Apply a layer of lithium or general purpose bearing grease to the roller contact surface of the inner cup (12D). Press the inner bearing cone (12c) (large end up as shown) onto the shaft (2) until it is seated against inner bearing cup (12D).
8) Without the shaft seal (11c) installed, the preload may result in a rolling torque that varies between 50 to 300 in-lb. The bearing preload should be tailored to your application; a lowspeed application may require a high pre-load, high-speed applications usually benefit from low pre-load. Adding shims
(15c) will increase the pre-load on the bearing set. Determine your pre-load requirement and install shims to obtain this pre-load. Install the Load-N-Lock™ segments (15e) over the shims (15c) and into the groove in the shaft (2). Finally, install the lock ring (15D) over the segments (15e).
9) Lubricate inner lip of new shaft seal (11c) and slide it onto the shaft (2) and over the shaft seal diameter then press the seal into the base bore (1).
all subassembly service or repairs should be complete at this time. continue to unit assembly to complete unit buildup.
Stage I gear adapter (15a) and temporally install two fasteners ( 13a) to hold assembly together.
11) Install the Stage II input gear (6a) and Stage I carrier assembly (5) onto the Stage II input gear. Place retaining ring (15f) onto sun gear groove using a spiraling motion.
12) Align gear teeth of ring gear (8a) with the gear teeth of the planet gears (5b) and place on ring adaptor. Align mounting holes of ring gear with holes in base. Using the scribed line made during disassembly for reference.
13) Install the input gear (4) then thrust bearings in the following order onto the input gear: carrier thrust washer (10D), case thrust washer (10e), one thrust washer (10b), thrust bearing
(10c), one thrust washer (10b), and thrust spacer (10a).
15) Lubricate o-ring ( 11a) and install on the pilot of the cover
(3).
16) Noting the scribed line made during disassembly, install the cover (3).
17) Install and torque the 20 5/8-11 hex-head cap-screws (13b) with lockwashers (13c). The torque for the cap-screws: 220
ft-lb dry, 170 ft-lb if the fasteners are lubricated.
18) Ensure the unit spins freely by using a splined shaft to drive the input gear (4).
19) Install motor (16) onto cover (3b) and align motor shifting mechanism with bail relief hole. Install motor fasteners.
unit assembly
1) When all subassemblies are complete, the unit is ready to be assembled.
2) Install the Stage III carrier assembly onto the output shaft; align the splines of the carrier (9a) with the splines of the shaft (2) and slide the carrier onto the shaft.
3) Install the retaining ring (15h) onto the groove of the shaft (2), using a spiraling motion.
4) Lubricate o-ring (11b) and install on the pilot of the
Stage III ring gear (8c). caution: hold ring gear by outside or use lifting device to prevent injury.
5) Install Stage III sun gear (6b) into Stage III carrier assembly.
6) Align gear teeth of ring gear (8c) with the gear teeth of the planet gears (9b) and place on base. Align mounting holes of ring gear with holes in base. Using the scribed line made during disassembly for reference.
20) Remove two temporally fasteners installed in step 10. Place bail (15b) onto assembly and aligning holes in bail and cover using scribed line made during disassembly as a reference.
Install and torque the 20 5/8-11 hex head capscrews (13a) with lockwashers (13c). The torque for the capscrews is
220 ft-lbs dry, 170 ft-lbs if fasteners are lubricated.
21) Fill the unit to the proper level, as specified, with GL5 EP
80/90 gear oil after it is sealed with a brake and/or motor.
The digger is now ready to use.
7) Slide Stage II carrier (7a) onto Stage III sun gear (6b) then install retaining ring (15g) onto sun gear groove using a spiraling motion.
8) Lubricate o-ring (11b) and install on the pilot of the
Stage II ring gear (8b).
9) Align gear teeth of ring gear (8b) with those of the planet gears and place on Stage III ring gear. Align mounting holes of ring gear with holes in base. Use the scribed line made during disassembly for reference.
9) Lubricate o-ring (11b) and install on the pilot of the Stage I ring gear adaptor (15a).
10) Noting the scribed line made during disassembly, install the
Model D440 service manual, SM4408144f95D9Page 7 eskridge, inc. olathe, KS. 913-782-1238 www.eskridgeinc.com
