Service And Repair Manual - Allotment & Gardens
ServiceandRepair Manual
Service ManualINTRODUCTIONThis service manual has been compiled t o give HOWARD Dealers and theirstaff, a sequence of operations t o enable the servicing and repair of aHOWARD GEM ROTAVATOR t o be carried out quickly and effectively.Because of our policy of continuous improvement, this manual shouldalways be used in conjunction with the latest service bulletins covering theGEM. These service bulletins are distributed t o all HOWARD horticulturaldealers when they are first printed, and back issues are available from us onrequest. HOWARD GElVl service bulletins after bulletin H.63, should bekept with this manual, and a note added t o the index of each sectionaffected, so that an up t o date record of modifications is kept.A t the start of each section, there i s a list of ordinary workshop tools thatwill be required when carrying out the repairs covered by that section.Some 'special tools' may also be required, of which a complete list can befound under 'special tools' section 'A'.In addition to the special tools and equipment used during some repairs, ahydraulic or hand operated fly press (of the type found in most workshops)will be required when removing and fitting oilseals and bearings.Before assembly of component parts, remove dirt and grease and, in thecase of new parts, remove the special rust inhibitor, otherwise the functionof the component may be restricted when in operation. When orderingspare parts, DO NOT confuse the illustration numbers used in this manualwith the TRUE part numbers found in the official parts list, form numberL.693.While every effort is made t o ensure that the information contained withinthis manual is correct, any errors which may occur, should be brought t othe attention of our Service Department.Specifications, torque loadings, special tools.Engine removal, clutch, clutch shaft, air cleaner.Gearbox, wheels and hubs.Controls.Main frame, handlebars, shields.Rotor, rotor clutch, drive chain, backplate.Lubrication, maintenance and fault finding.SECTIONPAGEABCDEFG371937455161Although this manual refers t o machines in current production, referencei s made, where possible, to the history of the various assemblies andcomponents.ILLUSTRATION REFERENCEThe figures in brackets after component names refer t o the illustrationnumber of the component, within thediagram specified by that instruction.e.g. (C25-35) is Section 'C' illustration '25' illustrated component35-Reverse idler gear.
Howard GemHISTORY OF THE GEMThe HOWARD GEM has been developed over a period of many years.Since its introduction in 1942, there have been five series of GEM, eachseries being an improved version of i t s predecessor.SERIES IThe original GEM was fitted with 'bicycle type' handlebars, but was notequiped with either a differential or a reverse gear. Series 1 machines wereproduced from serial number 101 up t o machine serial number 4800, andthese machines were fitted with the HOWARD B.J. engine.SERIES ll'Swinging type' handlebars and a differential were introduced a t the startof the series I I GEM, and later they were equiped with a reverse gearoperated by a lift up lever. Series I I machines were produced from serialnumber 4801 up t o machine serial number 14784, and these machineswere fitted with the original HOWARD B.J. or a J.A.P. 600cc engine.SERIES Ill AND I VProduction of series I II and I V machines overlapped. The basic machineremained the same for both, only the engines were different.Series I l l machines were produced from serial number 14785, and werefitted with either the HOWARD B.J. or a J.A.P. 600cc engine. Duringproduction of the series I II, the first series IV machines were phased in.These machines were fitted with a new HOWARD engine, the 180 Twin.From machine serial number 38760 series l V machines only were produced,but were fitted with an improved version of the twin engine-theHOWARD 360 Twin -or alternatively a water cooled Sachs diesel engine.Series IV machines were discontinued a t machine serial number 47066.SERIES VThis is the current series of GEM, which was introduced a t machine serialnumber 47067. Machines up t o serial number 2541824 were fitted withan up-rated version of the HOWARD 360 Twin engine, or the Sachsdiesel. From machine serial number 2541825, a Kohler K.301T engine hasbeen fitted in place of the twin, or from machine serial number 2571945,an alternative diesel engine, the Hatz ES.780, has been used. An improvedversion of the Hatz engine has been fitted from machine serial number250A1021, and is designated the Hatz ES780U.SUPER GEMThe super GEM is an up-rated version of the Series V model producedspecifically for contract work where greater strength and power arerequired. Super GEM machines are fitted with either a Kohler K341 petrolor Hatz E785 diesel engine.
Section A - SrpecificationsSPEC1FICATIONSSTANDARD GEMKohler K301T 4 stroke petrol, producing 11h.p. (rnax.) at 2800 r.p.m.governed engine speed 22 Ib-ft (30Nm) torque a t 2200 r.p.m.SLIPER GEMKohler K341T 4 stroke petrol, producing 15h.p. (rnax.) a t 2800 r.p.rn.governed engine speed 28 Ib-ft (38Nrn) torque a t 2100 r.p.rn.STANDARD GEMHatz ES780U stroke diesel producing 9h.p. (max.) a t 3000 r.p.m.governed engine speed 19 Ib-ft (25.75 Nm) torque a t 2100 r.p.m.SUPER GEMHatz E785 4 stroke diesel producing 1 'I h.p. (rnax.) a t 3000 r.p.m. governedengine speed 23 Ib-ft (31Nm) torque a t 2100 r.p.rn.These engines are air cooled and fitted with an automatic compressionrelease for easy starting.TRANSiVllSSlON3-forward gears and one reverse. Full differential with an automaticlocking device on engaging the rotor. Rotor safety clutch with a slip actionwhen under shock load.ENGINE CLUTCHSingle plate, heavy duty, dry friction plate.CONTROLSAll situated within easy reach of the operator, and are as follows:1.Clutch lever.2.Throttle lever.Gear lever with spring out safety device when using reverse gear.3.Handlebars adjustable for height and side swing.4.Rotor selector and differential lock control.5.6.Depth setting lever.ROTORRotor speed 188 rpm a t an engine speed of 2800 rprn. Rotor widths of20" (51 em), 24" (61 cm) and 30" (76 cm). Tillage depth is adjustabledown to 9" (23 crn).WHEELS20" overall diameter using 4.00 x 12 2-ply pneumatic tyres. Tyre pressureis 20 1blin2 (1.4 kg/cm2).LANDSPEEDSAt 2800 rprn. engine speed:-1st gear - 0.96 mph. - 1.4 kph2nd gear - 1.46 mph. - 2.3 kph3rd gear - 3.05 mph. - 4.9 kphReverse - 1.85 rnph. - 2.9 kphThe above landspeeds refer t o machines built after serial number250A1021 only. These machines are the current production model,fitted with either the Kohler K.301TIK341T or the Hatz ES.780UIE785engines and the l a t e s t 3617 ratio crownwheel and pinion. (See the crownwheel and pinion history in section 'B').
SectionA - SpecificationsWEIGHTPetrol modelDiesel model20" - 644 Ibs (292 kg)24" - 672 Ibs (305 kg)30" -652 Ibs (296 kg)674 Ibs (306 kg)790 Ibs (358 kg)SUPER GEMPetrol model24"30"Diesel model630 Ibs dead weights 746 Ibs (338 kg)862 Ibs (391 kg)-RECONlNlENDED LUBRICANTSGearbox and chaincase - SAE 90 gear oil, all others oiling points useengine oil.-TORQUE LOADINGSAll nuts and bolts must be kept tight, and as a guide the following table oftorque loadings may help. In the absence of a suitable torque wrench,spanners of the length specified in the right hand column of the tablebelow, will, if used to maximum effect by the average man, give comparableloadings.Thread sizet"BSWBSW2'' BSW & UNCg'BSW & UNC1," BSW & UNC2'' BSW2" BSF5" BSFBSF161," BSF5" BSF2" BSF5"-i6Blade bolt and nutTorque loadinglbs/f tkg/mSpanner 12.51520254591.530SPECIAL EQUIPMENTHERMATITE- is a sealing compound used, where specified, to prevent the possibilityof oil leaks.Manufactured by :Kenilworth Manufacturing Co. Ltd.Hermatite Works,West Drayton,Middlesex,ENGLAND.SAMPSON C. 110 GLUE- is an Amyl Acetate glue used, where specified, to secure the fibre discsto the rotor clutch drive discs.Manufactured by :Samuel Jones & Co. Ltd.,Sampson Adhesive Mill,St. IVeots,Huntingdonshire,ENGLAND'
-Section A - Special ToolsSPECIAL TOOLSThe following special tools w,ill be required when carrying out certainrepairs, and as they are simple in design, can be easily produced from thefollowing dimensioned drawings.SPECIAL TOOL S.1:i s a clutch shaft puller used, as specified in instruction '3a' Section 'B', toremove a broken clutch shaft.SPECIAL TOOL S.2:is a hub puller used, as specified in instruction '2' Section 'C', t o removethe wheel hubs.SPECIAL TOOL S.3:is a pegged tool used, as specified in Section 'C'. 'To dismantle the axleassembly: t o remove the loose hub gear bearing.SPECIAL TOOL S.4:is an axle shaft puller used, as specified in Section TF'Rotor stub axle-toremove', to remove the unbroken stub axle.SPECIAL TOOL S.5:is a pegged tool used, as specified in Section 'F' Rotor drive shaft - t oremove', t o remove the rotor drive shaft sprocket bearing.SPECIAL TOOL S.6:is a pegged tool used, as specified in instruction '89' Section 'C' t o removethe bearing from the gearbox jackshaft.SPECIAL TOOL S.7:is a pointer used in conjunction with 2-2 " BSW nuts, as specified ininstruction '5b' Section 'B', t o enable the crownwheel to pinion backlasht o be assessed.
Section A - Special Tools72D r i l l and t a p t u b et o accep'I L .-.r.,-5. UIVLx 1" l o n gsquare headedsetscrewsD r i l l and t a p bar t o accept 23,8 ' U N F x 2" l o n g setscrews.SPECIAL T O O L S . l6" dia.IS P E C I A L T O O L S.3%" U N C x 2" l o n g%" U N C x 3" l o n g setscrew."U N C n u t weldedS P E C I A L T O O L S.2IS P E C I A L T O O L S.4w e l d t h e n f i l e t o shapeof stub axle.2 pinsS P E C I A L T O O L S.6S P E C I A L T O O L S.52 Holes\c'Dia.S P E C I A L T O O L S.7
Section BCONTENTSSubjectActionADJUSTMEIVTSBELL H SHAFT AND PINION HISTORYCLUTCH SHAFTFittingRemovalCLUTCH SHAFT BEARINGFittingRemovalDRIVE ADAPTORFitting-Hatz-KohlerRemoval-Hatz-KohlerENGl FittingRemovalENGINE 0816131515111011981710817913121611SERVICE BULLETINS APPERTAINING T O THIS SECTION ARE:DateBulletin No.----------TOOLS LISTNo. o f fNo. o f f11111111 Small punch1 CopperIRawhide mallet1 Pair 6" engineers pliers1 Pair right angled internal circlip pliers1 Pair straight internal circlip pliersSmall (electrical) screwdriverLarge screwdriverM" BSW Open ended spannerM" BSW Box spanner;"BSW Open ended spanner;"BSW Ring spanner'-" BSW Ring spannerAF Ring spanner2"AFBoxspannerg" AF Open ended spanner;" AF Ring spanner,'," Sq. Extended box spanner12mm Open ended spanner13mm Open ended spanner'Z,r111111SPECIAL EQUIPMENTHermatiteSteel ruleContainerltray of a t least 6 pints capacitySPECIAL TOOLSSpecial tool S. 1Special tool S.7 and 2.;" BSW Nuts
Section BHISTORYENGINESThe Kohler K.301T has been fitted from machine serial number 2541 825and is a 477cc 4-stroke petrol engine of 10hp.From machine serial number 2571945, the Hatz ES.780 diesel engine hasbeen available as an alternative t o the Kohler engine. The Hatz i s a 500cc4-stroke diesel engine of 10 hp. An improved version of the Hatz engine,having an antivibration front cover and designated ES.780U, has been fittedfrom machine serial number 250A1021.ENGINE CLUTCHAll Kohler and Hatz engined machines are now fitted with a single plateclutch. Machines prior t o serial number 2571414, were fitted with a doubleplate clutch, and the following parts are required i f converting the clutchassembly t o the single plate version.Part numberPart description288255250Thrust sleeveDistance pieceSpecial boltNo. Off144The clutch assembly should be rebuilt substituting these parts for theexisting components, and one fibre disc and one loose plate should bediscarded from the original assembly. A new clutch shaft - part number25009 - will also be required.CLUTCH SHAFTICROWIUWHEEL AND PINIONThe crown wheel and pinion were changed on GEM 24" models - machineserial numbers 2592305 and 2306; GEM 30" models - machine serialnumbers 2591063, 1067, 1069, 1070, 1138, 1139, 1189, 1190, 1191, 1394and 1451, and all GEM V models from machine serial number 250A1021.The ratio of the gears was changed from 3619 t o 3617 in order t o reduce theforward travel speed of the machine, and thus increase i t s performance.The later ratio gears can be supplied and fitted t o machines prior t o machineserial number 250A1021, but as a pair only, as the new and the old bevelgears are not interchangeable and must be used with their respective pinions.New partsOld partsPart number 27367 Bevel gearPart number 27368 Clutch shaftPart numberPart numberPart numberPart numberPart number25008 Bevel gear25009 Clutch shaft25007 Pinion25061 Special nut208010160 Split pin.NOTEThe new 7- tooth pinion i s an integral part of clutch shaft - part number27368 - and this shaft can only be used with the single plate clutchassembly.When fitting the new bevel gear - part number 27367 - t o the gearboxjackshaft 6-hr'dia. x "long rivets (part number 208023040) will be requiredin place of the original ,&"dia. x " long rivets, which are too short LO securethe new bevel gear.a
Section BTO REMOVE THE KOHLER ElUGllVE1.Refer t o illustration "B 1 " unless otherwise stated.la.Disconnect the throttle control (569) from the engine by releasing thesmall clamp bolt and cable clamp on the side of the engine.Ib.Slacken the jubilee clip on the carburettor induction elbow end of theair cleaner hose (595), and remove the hose from the elbow.Ic.Disconnect the stop switch cable (573) from the engine mountedcondenser.Id.Turn off the fuel supply from the petrol tank a t the fuel filterbowl, and disconnect the pipe from the tank. Drain off any fuel in thepipe before removing from the engine.le.With the engine suitably supported (on blocks etc.), remove the8-setscrews (558) from around the perimeter of the clutch bellhousing (556). The machine may then be moved clear of the engine.TO FIT THE ENGl NE-See instruction 6.TO REMOVE THE DRIVE ADAPTOR (551)'- KOHLER ENGINETo remove the drive adaptor from the engine crankshaft, remove the squareplug (557) from the side of the bell housing (556), and loosen the squareheaded setscrew (554) using an extended k" square box spanner throughthe hole in the side of the housing. Slide the adaptor from the housing,and retain the locating key (555) (and spacer if fitted).I f the drive adaptor bearing (553) is to be renewed, the old bearing may bepressed out from the back of the adaptor, with the aid of a 1" dia. drift.The new bearing can then be pressed into its location, greased, and securedby positioning the special washer (552) over the bearing (domed sideoutermost), and with the aid of a small punch, burr the lip of the bearinghousing over the washer in 3 or 4 places.
Section BTO REMOVE THE BELL HOUSING (556) - KOHLER ENGINEHaving removed the drive adaptor as previously described, remove the4-setscrews (560) and spring washers (561) from inside the bell housing,thus allowing the bell housing t o be removed from the engine.TO FIT THE BELL HOUSllVG (556) - KOHLER ENGINEPosition the bell housing qgainst the engine crankcase (with the plug holeto the left), and secure using the 4-setscrews (560) and spring washers (561),located inside the housing.TO FIT THE DRIVE ADAPTOR (551) - KOHLER ENGINEWith the clutch bell housing in position, slide the spacer (when fitted)onto the engine crankshaft and up to the engine casing.Position the locating key (555) in .the slot in the engine crankshaft, andslide the drive adaptor into position.Using an extended ,%"square box spanner through the hole in the side ofthe bell housing, tighten the square headed setscrew which secures the driveadaptor to the engine crankshaft. Replace the plug in the side of the bellhousing.TO REMOVE THE HAT2 ENGINE1.Refer to illustration "82" unless otherwise stated.la.Disconnect the large fuel pipe from the injection pump on the engine.NOTEOnce this fuel line is disconnected, the fuel in the tank will drain outdue t o gravity, and suitable precautions should be taken.
Section B-Ib.Disconnect the small injector spill pipe from the engine.Ic.Disconnect the throttle cable clevis (626) from the engine,and having removed the 2-bolts (630) from the throttlebracket (629), move the cable assembly aside.Id.Release the engine starting handle from the spring clip(619) and withdraw the handle from the main frame tube.le.With the engine suitably suppor-red (on blocks etc.), removethe 8-setscrews (617) which secure the bell housing t o thegearbox flange, and retain the spring clip (619).The machine may then be moved clear of the engine.TO FIT THE ENGINE - See instruction 6.TO REMOVE THE BELL HOUSllVG (616) - H A T 2 ENGINERemove the 10 setscrews (620) and 2-bolts (622) which secure the bellhousing to the engine, and hence remove the housing.TO REMOVE THE DRIVE ADAPTOR (611) - H A T 2 ENGINERemove the bell housing as previously described, then remove the6-setscrews (614) and spring washers (615) which secure the driveadaptor to the engine. If the drive adaptor bearing (613) is to berenewed, the old bearing may be pressed out from the back of theadaptor, with the aid of a 1" dia. drift. The new bearing can thenbe pressed into its location, greased, and secured by positioningthe special washer (612) over the bearing (domed side outermost),and with the aid of a small punch, burr the lip of the bearinghousing over the washer in 3 or 4 places.TO FIT THE DRIVE ADAPTOR (611) - HATZ ENGINEPlace the drive adaptor against the engine flywheel, and secure inposition using the 6-setscrews (614) and spring washers (615).TO FIT THE BELL HOUSING (616) - HATZ ENGINEWith the drive adaptor in position, locate the bell housing againstthe engine so that the 2-bolts (622) are positioned a t the top.Secure the be1l housing using these 2-bolts (622) and the 10-setscrews(620).TO REMOVE THE ElVGllVE CLUTCHIllustration '8.3:2.Remove the engine as described in instruction "1"proceed as follows :then2a.Remove the split pin from the end of the clutch shaft, andwhile restraining the clutch using a flat bladed screwdriver,as shown in illustration "B3", remove the special nut fromthe end of the clutch shaft.
Section B2b.Remove the spacer (fitted to double plate clutches only),and hence remove the clutch plate assembly by holding theclutch operating arm back in the "disengaged position",and using a soft headed hammer, tap the end of the shaft.This will release the clutch assembly from the splines on theclutch shaft.TO DISMANTLE THE CLUTCH UNIT (Refer to illustration "B4" unless otherwise stated).If possible, mount the clutch unit on an old drive adaptor, whichshould be clamped upright in a vice as shown in illujstration "B5",as i t will make dismantling easier.Illustration 'B4'distance pieces (75)clutch plate*. *,., -%*I.clutch thrustplate (71)clutch plate fixed (77)friction discs (78)0*clutch plateloose (79A)Illustration '8.5'.Y*
Section BRemove the locking wire from the 4 special bolts (73); and so remove thksebolts.The individual components may now be removed in the following order:Clutch thrust plate (71), distance pieces (75) and springs (76), clutch platefixed (77), disc (78) 2-friction discs and 1-loose plate (79A) ( i f of the doubleplate version), and lastly the bottom loose plate (79).TO ASSEMBLE THE CLUTCH U N l T (refer t o illustration "B.4" unless o:herwise stated).Assembly of the clutch unit i s the reverse of the dismantling procedureWhen fitting the friction disc(s), check that the plates are central. F i t the4 special bolts (73) and tighten evenly to a torque of 31 Ibslft. (4.2 k g ' l t i .Secure the special bolts using a new piece of 12" long 16 swg locking 1:dlrct.TO FIT THE CLUTCH UNlT-See instruction 5TO REMOVE THE CLUTCH SHAFTSpecialremovebrokenbehindwill benote: I t is
250A1021, and is designated the Hatz ES780U. SUPER GEM The super GEM is an up-rated version of the Series V model produced specifically for contract work where greater strength and power are required. Super GEM machines are fitted with either a Kohler K341 petrol or Hatz E785 diesel engine.
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