AIRLESSCO SL6500 Service & Operation Manual - Clutch Replacement
24
25
REMOVING CLUTCH
Refer to Figures 25-31
1. Remove the gear box cover (Fig 30, item 1) by discon-
necting the fluid hose to the manifold filter and by un-
screwing the four allen head bolts (Fig 30, item 35).
2. Disconnect the fluid pump as described on page 16.
3. Pull off the spacer tubes (Fig 30, item 29) and drop the
sleeve bearing down and off. Slide the connecting rod off
the gear box.
4. Remove the top cover (Fig 30, item 2) by unscrew-
ing the 6 mounting screws. be careful not to lose the 6
matching grommets.
5. Remove the bottom cover (Fig 30, item 14) by un-
screwing the 2 bolts and nuts.
6. Remove the splash cover (Fig 30, item 39) from the
clutch brackets and spacer tubes.
7. Disconnect the two clutch leads from the electrical
control board leads and the clutch spring (Fig 27, item 9)
from the spacer tube.
8. Loosen (do not remove completely) the block tension-
er's set screws (Fig 26, item 6) to detension the belt.
9. Loosen (do not remove yet) the four plate bolts.
10.Pull the cog belt loose from the engine shaft cog
pulley and let hang loose on the clutch cog pulley.
11.Remove the two vertical bracket screws (Fig 30, item
19 & 20).
12.Remove the four horizontal screws throught the
gearbox plate (Fig 26, item 5) and lift the gear box off the
machine.
13. Place gearbox in vice by gripping the flat part of the
drive crank allowing the clutch assembly to face up.
Use caution and not allow gearbox to swing and
damage casting against vice.
14. Hold coupling screw, with 13/16" wrench, then with
5/16" allen wrench, screw differential screw out of cou-
pling screw and gearbox shaft.
15.Remove the coupling screw from the clutch bore.
NOTE: After extended use the coupling screw can
hang up
inside of the clutch bore. Tapping on the
side of the coupling screw and/or the use of a light-
weight oil or break free product can ease the removal
process. In extreme cases, screw the differential
screw large thread size in, then place a washer and
nut on the small thread side. This allows the pulling
or prying on the coupling screw in order to remove it.
CLUTCH REPLACEMENT
INSPECTING CLUTCH AND BELT
1. Inspect clutch and belt, replace as neccessary.
INSTALLING CLUTCH
Refer to Figures 26-30
1. With gearbox held in a vice vertically as previously
described, place first spacer, and bearing, onto gearbox
shaft. See Fig. 27
2. Insert snap rings (2), into recesses of cog pulley
portion of clutch. Place cog pulley portion of clutch with
cog belt attached onto shaft.
3. Place second spacer, into cog pulley portion of clutch.
This spacer will rest on the first bearing, installed.
4. Insert second bearing, on top of upper snap ring,
5. Lay removable spacer on top of last bearing. If the
clutch air gap is larger than .028", do not use removable
spacer. Put spacer over removable spacer, if used, and
top bearing.
6. Place coil portion of clutch down onto cog pulley
portion of clutch and center on gearbox shaft.
7. Screw differential screw, into coupling screw
and nut until 1/16" is showing. See Fig. 28
8. Push coupling nut assembly, into clutch assembly
until it comes to a positive stop. (Differential screw
comes into contact with the threaded gearbox shaft.)
9. With 13/16" wrench on coupling screw and 5/16"
allen wrench in differential screw, simultaneously
with both wrenches screw coupling nut assembly
into gearbox shaft by turning clockwise until a
positive stop is reached.
10. Hold coupling nut ass'y and tighten diffential screw
to 30 ft.-lbs. This will expand the coupling assembly,
thereby holding the clutch assembly to gearbox
shaft. Turn clutch observing clutch gap. The pulley
should turn freely with a gap of .012 to .024" between
the two clutch faces. If the gap is greater than .028,
remove the removable spacer . Reassemble and check
gap for proper clearance.
11. Place cog belt over cog pulley portion of clutch.
Set gearbox and clutch assembly on the support
brackets (Fig 30, items 24 & 25), screw in the two
vertical bracket screws (Fig 30, item 19) and start the
four horizontal screws throught the gearbox plate (Fig
30, item 8) and into the back of the gearbox.