Installation

Operation &
Maintenance Data
I S SUED

ENGINEERING DEPT.
COTTA TRANSMISSION CO.
THIS SYMBOL MEANS A THIS SYMBOL IS USED TO
WARNING OR CRITCAL LIST ADDITIONAL
INFORMATION. INFORMATION AND TIPS.

PLEASE READ AND OBSERVE ALL THE INFORMATION IN THIS MANUAL.

FAILURE TO COMPLY WITH THE RECOMMENDATIONS AND PROCEDURES
DESCRIBED HEREAFTER CAN RESULT IN PREMATURE COMPONENT
FAILURE AND/OR WARRANTY DENIAL.

ALL PERSONNEL SERVICING THIS UNIT SHOULD EMPLOY SAFE

OPERATING PROCEDURES. COTTA TRANSMISSION CO, LLC (COTTA)
WILL NOT BE RESPONSIBLE FOR PERSONAL INJURY RESULTING FROM
CARELESS USE OF HAND TOOLS, LIFTING EQUIPMENT, POWER
TOOLS, OR UNACCEPTED MAINTENANCE/WORKING PRACTICES.
BECAUSE OF THE POSSIBLE DANGER TO PERSON(S) OR PROPERTY FROM
ACCIDENTS WHICH MAY RESULT FROM THE USE OF MANUFACTURED
PRODUCTS, IT IS IMPORTANT THAT CORRECT PROCEDURES BE
FOLLOWED. PRODUCTS MUST BE USED IN ACCORDANCE WITH THE
ENGINEERING INFORMATION SPECIFIED. PROPER INSTALLATION,
MAINTENANCE, AND OPERATION PROCEDURES MUST BE OBSERVED.
INSPECTIONS SHOULD BE MADE AS NECESSARY TO ASSURE SAFE
OPERATION UNDER PREVAILING CONDITIONS. PROPER GUARDS AND
OTHER SUITABLE SAFETY DEVICES OR PROCEDURES THAT MAY BE
DESIREABLE OR SPECIFIED IN SAFETY CODES SHOULD BE PROVIDED.
THESE DEVICES ARE NEITHER PROVIDED BY COTTA, NOR ARE THEY
THE RESPONSIBILITY OF COTTA.
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

GENERAL TECHNICAL MANUAL

INSTALLATION, OPERATION AND
MAINTENANCE FOR A
COTTA TRANSMISSION
TABLE OF CONTENTS:

RECEIVING INSTRUCTIONS PAGE 2

LONG TERM STORAGE PAGE 2
LIFTING AND HANDLING PAGE 2
INSTALLATION INSTRUCTIONS PAGE 3
FLYWHEEL COUPLING ADJUSTMENT AND OPERATION PAGE 4
LUBRICATION PAGE 6
LUBRICATION PUMP PAGE 7
HEAT EXCHANGER PAGE 7
OIL FILTER PAGE 7
ELECTRICAL PAGE 8
START UP PAGE 8
BREAK IN OPERATION PAGE 8
SAFETY NOTICE PAGE 8
OPERATION PAGE 9
MAINTENANACE PAGE 10
SERVICING PAGE 10
GENERAL NOTES PAGE 10
CONTACT INFORMATION PAGE 11

WARNING: THIS TRANSMISSION IS SHIPPED WITHOUT

OIL. FILL THE UNIT WITH OIL TYPE AND QUANTITY AS
SPECIFIED PRIOR TO OPERATION OF THE GEARBOX.

Page 1
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

NOTE: This manual provides information about the installation of Cotta Transmissions.
Detailed overhaul, assembly, and repair information is not part of this manual. For
repair information, consult the applicable blueprint drawing. To request the latest
revision blueprint, call the Customer Service department at 608-368-5600.
Operation and maintenance personnel responsible for this equipment should have this
manual at their disposal and be familiar with its contents. Applying the information in
the manual will result in consistent performance from the unit and help reduce
downtime.

1. UNIT RECEIVING INSPECTION

The gear units and/or parts are properly boxed when shipped from the factory. A
careful inspection should be made for in-transit damage when received. File all
claims with the carrier before accepting the shipment.
NOTIFY COTTA OF ANY DAMAGE TO THE GEARBOX UPON RECEIPT.

2. LONG TERM STORAGE

If the unit is to be stored or not used for a period of time exceeding (1) month, it
should be protected against corrosion. Coat all outside unpainted surfaces with a
rust inhibitor. Seal the gearbox from ambient air by plugging the breather and
covering any labyrinth seals with a protective film. If the unit is in storage, a
rust-inhibiting compound that is compatible with the lube oil should be applied to
all the internal components of the gearbox. The rust inhibitor can be applied
through a cover or inspection plate. If no plate is supplied, the unit can be
completely filled with lube oil. Note that the standard Cotta paint is not suitable
for storage outside or in corrosive environments.

3. LIFTING AND HANDLING

AVOID DIRECT SUNLIGHT ON THE GEARBOX WHILE IN STORAGE

TO PREVENT CONDENSATION.

LIFTING PROVISIONS ON COTTA COMPONENTS ARE FOR

LIFTING OF THAT COMPONENT ONLY AND MAY NOT BE
ADEQUATE TO LIFT CUSTOMER MOUNTED EQUIPMENT SUCH
AS SHAFT COUPLINGS, CLUTCHES, OR DRIVEN EQUIPMENT.

Page 2
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

Use of proper equipment, rigging techniques, and safety procedures relative to the
size and weight of the gearbox must be exercised in order to prevent personal
injury and product damage. Threaded holes or lifting tabs are provided for lifting.
These holes are for lifting the gearbox only. Select lifting eyebolts to obtain
maximum thread engagement without contacting the bottom of the hole.

4. INSTALLATION

Many gearboxes are mounted to an engine flywheel using a flexible coupling or

over center clutch. If the gearbox is mounted to an engine flywheel, several
checks should be made to insure successful operation. Contact the engine
manufacturer for their mounting procedure or use SAE specification
J1033(Procedure for measuring bore and face runout of flywheels, flywheel
housing, and flywheel adapters.) If the transmission exceeds the allowable
measurement, contact Cotta for assistance.
(PROPER INSTALLATION REDUCES THE POSSIBILITY OF BEARING
FAILURE, SHAFT BREAKAGE, AND EXCESSIVE DRIVING PLATE TOOTH
WEAR RESULTING FROM MISALIGNMENT.)
It is also necessary to check the engine crankshaft axial endplay prior to and
after mounting the gearbox. If the endplay measurement is not the same, this
would indicate possible interference. Remove the gearbox, determine the problem
source, and correct prior to reinstallation of the gearbox.

REGARDLESS OF THE PROBLEM SOURCE, COTTA WILL

NOT BE RESPONSIBLE FOR DAMAGE TO THE ENGINE OR
SYSTEM AS A RESULT OF POSSIBLE INTERFERENCE.

The gear units are supplied with a method of mounting to a base. Some units have
feet with clearance holes for direct mounting. Other gearboxes have threaded
holes on the face or on the side to mount with supports of the customer’s design.
After the engine is mounted to the base, the gearbox is to be shimmed under the
supports for proper alignment using the following procedure.
4.1 Attach a dial indicator to the engine block with the stem resting on the
top of the engine flywheel housing.
4.2 Set indicator to zero.

Page 3
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

4.3 Install the gearbox to the engine using enough shims to allow assembly.
4.4 Install mounting bolts to gearbox feet. Note any deflections on the
indicator, and shim as required to return the indicator to zero.
G E AR B O X

E N GIN E

SU P P ORT
P L ATE

F L Y WH E E L H S G

S H IM

WHEN ASSEMBLING A COUPLING OR SHEAVE TO A

GEARBOX SHAFT, NEVER HAMMER OR PRESS USING
THE GEARBOX BEARINGS AS A FULCRUM OR DAMAGE
WILL RESULT.

5. FLYWHEEL COUPLING

The gearbox may be equipped with several types of flywheel couplings including
overcenter clutches, torsional couplings, and drive plates. Some of these may have
pre-operational checks or initial adjustments that must be made. If anything other
than an overcenter clutch is used, refer to the manufacturer’s instructions or contact
Cotta for instructions. Overcenter clutch information is included in the following.
5.1. Before operation, lubricate the throwout collar using the grease fitting
provided on the outside of the bell housing. Observe through the access hole in
the bell that the collar is sufficiently greased but not over greased. A bronze
collar should be re-lubed every 10 hours, a ball bearing collar should be re-
lubed every 100 hours with any high grade, lithium based, short fiber grease
approved for use with anti-friction bearings with operating temperatures of
200 degrees F (NLGI #2 grease).
5.2. The clutch remains in or out of engagement until changed by the operator.
Engagement should progress from “release” to “on center” to slightly “over
center” where the clutch locks firmly. Disengagement is positive, using a toggle

Page 4
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

arrangement. A new clutch may require several adjustments until the friction
material is worn in. If the clutch will not pull the load or heats excessively, it
may need adjustment.

THE CLUTCH IS NOT ADJUSTED BY COTTA. DO NOT

OPERATE THE GEARBOX UNTIL INITIAL CLUTCH
ADJUSTMENTS ARE MADE.

5.3. To adjust a Twin Disc clutch, remove the hand hole cover on the bell housing
and rotate clutch until adjustment lock pin can be reached. Disengage the lock
pin and turn the adjusting yoke or ring to the right, or clockwise, until the
operating lever requires the correct force to engage. Force required for
various clutches are listed below. The length dimension given is the distance in
inches from the hand lever cross shaft centerline to the area on the hand lever
to place a spring scale. Maximum and minimum values in pounds are given for
measuring the spring force. If the gearbox is equipped with any other
manufacturer's clutch, see the manufacturer’s instructions.

Clutch Model Length Dimension Force in Pounds

C106, C107 13.6 58 to 76
C108 13.6 63 to 83
C110 13.6 78 to 103
SP111 13.6 96 to 125
SP211 13.6 118 to 156
SP114, SP214, SP314 21.3 123 to 163
IBF214, IBF314 21.3 135 to 180
SP218, SP318 27.3 226 to 297
IBF318 39.7 172 to 227
SP321, IBF321 39.7 155 to 204

Page 5
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

6. LUBRICATION

The gearbox is shipped from the factory empty except some residual oil from
testing and must be filled to the proper level with lubricant specified on the
nameplate. Cotta technical bulletin TB97-101 (Lubrication of Cotta Transmissions)
lists recommended oil viscosities. In addition, the nameplate lists the
recommended oil viscosity based upon the ambient temperature in which the
gearbox will be operated. The 80VX1023 and 80VX1048 nameplates are not
superceded by TB97-101. In these cases, the oil viscosity is listed on the
nameplate.
Fill the gearbox to the proper level as indicated by sight glass, dipstick, or level
plug, and run the gearbox for 5 minutes. (This will ensure that all of the hoses and
manifolds are full.) Check the oil level in the box, and add any additional oil
needed to achieve the proper oil level. (AVOID ANY CONTAMINATION OF
THE OIL WHEN FILLING THE GEARBOX) A good grade of clean hose or pipe
should be used if user is supplying any plumbing.

DO NOT CHECK THE OIL LEVEL WITH THE UNIT

RUNNING. SOME GEARBOXES HAVE INTERNAL OIL
RESERVOIRS THAT REQUIRE A DRAIN BACK PERIODS.
GEARBOXES OF THIS TYPE HAVE A SPECIAL NAMEPLATE
ADJACENT TO THE LEVEL GAGE.

DO NOT USE SEALANT TAPE TO SEAL PIPE THREADS OR

FITTINGS.
THE USE OF SEALANT TAPE VOIDS ANY WARRANTY!

Page 6
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

7. LUBRICATION PUMP

Some gearboxes are supplied with lube pumps. A variety of different pumps are
supplied depending on the requirements of the gearbox. If removing the pump for
service, note the orientation of the pump inlet and outlet ports relative to the
shaft centerline. Improper orientation will result in the suction and pressure
ports to be reversed, which can cause damage to the gearbox.

8. HEAT EXCHANGER

A heat exchanger is used on some gearboxes to keep the lube oil temperature
within the operating range. If the lube system includes a heat exchanger, the
customer is to furnish an adequate coolant supply at the proper temperature. In
some areas, raw water is extremely corrosive and should be treated to prevent
damage to the heat exchanger. Treating the water will also increase the time
interval between cleanings of the heat exchanger. It is the users responsibility to
insure that the coolant is compatible with the heat exchanger.

IF USING SALT WATER FOR COOLANT, MAKE SURE

THAT THE HEAT EXCHANGER AND ALL PLUMBING ARE
DESIGNED FOR USE WITH SALT WATER.

9. FILTER

An oil filter will be supplied with a gearbox if the lube system requires the
filtration of larger particles from the oil. Replace the filter element when the
pressure drop through filter is greater than the bypass pressure. Read bypass
pressure when oil is at normal operating temperature. When element replacement
is required, do not substitute a different filtration level without written approval
from Cotta.

USE OF THE WRONG SIZE FILTER COULD RESTRICT OR

BLOCK THE OIL FLOW IN THE GEARBOX. POOR OIL
CIRCULATION CAN SEVERLY DAMAGE THE GEARBOX.
Page 7
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

10. ELECTRICAL

Some gearboxes may be supplied with an interlock switch to protect the unit from
damage caused by a pressure lube system failure or improper cooling. The switch
may be wired by the user to shut off the rotating equipment, operate a warning
light, or sound an alarm.

11. START UP

Prior to starting the gearbox, make sure that the oil level is correct. Some
gearboxes with a pressurized lube oil system will be supplied with a lube manifold.
The pressure at the manifold is set at the factory, but should be checked and
adjusted at the relief valve by the user if necessary. The pressure should only be
checked after the gearbox has reached the normal operating temperature.
If starting the gearbox below 50 degrees F., Cotta recommends the gearbox be
run with no load or a slight load until the lube oil temp has reached 90 degrees F.
If this is not possible, oil sump heaters may be required.

12. BREAK-IN OPERATION

After 100 hours or 3 months of operation, whichever occurs first, the oil should
be drained, the case flushed with a fluid that is compatible with the gearbox oil,
and the case refilled with clean oil of the proper specification. After the first oil
change, the oil should be changed every 2500 hours or 6 months, whichever occurs
first. (UNLESS OTHERWISE NOTED ON THE NAMEPLATE.) When operating
in a severe environment(i.e. moist, dusty, outdoors, or in a hazardous environment)
more frequent oil changes may be necessary.

13. SAFETY NOTICE

Safe operating practices should be employed by all personnel servicing this unit.
Cotta will not be responsible for personal injury resulting from careless use of
tools, lifting equipment, or unaccepted maintenance/working practices. Because of
possible danger to person(s) or property from accidents which may result from

Page 8
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

the use of manufactured products, it is important that correct procedures be

followed. Products must be used in accordance with the engineering information
specified. Proper installation, maintenance, and operation procedures must be
observed. Daily and/or periodic inspection should be made as necessary to assure
safe operation under prevailing conditions. Proper guards and other suitable safety
devices or procedures that may be desirable or specified in safety codes should
be provided. These devices are neither provided by Cotta nor are they the
responsibility of Cotta.

14. OPERATION

It is the customer’s responsibility to install, maintain, and operate the unit in

accordance with the manufacturer’s specifications and recommendations. It is up
to the customer to ensure that:

14.1. Maximum operating speeds are not exceeded.

14.2. Maximum acceleration/deceleration rates are not exceeded.
14.3. Maximum operating torques are not exceeded.
14.4. Only lubricants specified on the nameplate are used.

THE USE OF SUBSTITUTE LUBRICANTS MAY

GENERATE UNACCEPTABLE HEAT AND
INSUFFICIENTLY LUBRICATE INTERNAL
COMPONENTS. THIS MAY RESULT IN
IMMEDIATE COMPONENT DAMAGE.

14.5. Appropriate warm-up procedures are adhered to.

IT IS REQUIRED TO WARM UP THIS

EQUIPMENT TO MAINTAIN PROPER
OPERATION. LACK OF A WARM-UP PERIOD MAY
RESULT IN IMMEDIATE COMPONENT DAMAGE.
SEE START UP SECTION.

Page 9
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

15. MAINTENANCE

Operational maintenance consists of routine care at regular intervals.

15.1. Inspect oil level at startup and add oil as required.

15.2. Check shaft alignment occasionally and correct if necessary.
15.3. Keep all bolts and fittings properly torqued.
15.4. Replace leaky gaskets and seals.
15.5. Prevent inside and outside corrosion.
15.6. Should any adverse operating conditions occur, internal inspection may be
required. Consult with Cotta in this instance. Note that any disassembly
without prior express written consent from Cotta voids any warranty.
15.7. Maintain proper oil change intervals, see section 12.

16. SERVICING

No attempt should be made to service this unit with any substitute parts without
written approval from Cotta. The main Case and Cover of the gearbox are
sometimes manufactured as a set and should not be individually replaced. Contact
Cotta with the unit serial number for part availability.

17. GENERAL NOTES

17.1. Oil will aerate in the gearbox under normal operating conditions.
17.2. The temperature of the gearbox casing should not exceed 220 degrees F.
17.3. Cotta manufactures many different models of gearboxes, so step by step
assembly and disassembly instructions are not part of this manual. The
following is a list of general assembly comments.
Note: The warranty is void in the event that repairs of the goods are
made by anyone other than Cotta without prior authorization from Cotta.
17.3.1. Assembly and disassembly of the gearbox should be done with the
shafts vertical. The case and cover are dowel pinned together,
threaded puller holes are provided to aid separation.

Page 10
 Beloit, WI

Service Bulletin 99-103 Rev 2 Revision date: May-01

17.3.2. Cotta uses a silicone rubber sealant or Loctite 515 instead of

gaskets on newer designs where possible. Gaskets cannot be
replaced with sealant or vise versa.
17.3.3. Most gearboxes use tapered roller bearings. These bearings must
be shimmed to achieve the end play setting noted on the assembly
drawing. Endplay setting and checking should be done with the
shaft vertical.
17.3.4. Most gears are assembled to mating shafts using a key and
interference fit. A hydraulic press will be required to separate
them. Heating the gear to re-assemble is recommended. Do not heat
any component more than 300 degrees F.
17.3.5. Some shafts use tapered roller bearing kits. These consist of two
bearings and two spacers. Do not replace individual components in
the kit without insuring proper bench endplay. Contact Cotta for
more information.
17.3.6. Bearing locknuts and lockwashers should not be reused.

18. CONTACT INFORMATION

COTTA TRANSMISSION COMPANY, LLC

1301 PRINCE HALL DR.
BELOIT, WI USA 53511-4439
(608) 368-5600 (PHONE)
(608) 368-5605 (FAX)
www.cotta.com

Page 11
Page 12
Page 13
Page 14
 PRODUCT SPECIFICATION

The TR2205 Transfer Case is designed for TR2205 Transfer Case

maximum application flexibility. The T-
case is completely symmetrical with four
identical Input/output stations. Each station
has a 2.75 X 10 spline shaft which can be
used as either an input or output.

Each station can also be fitted with an

optional disconnect. These disconnects will
accept companion flanges or yokes and
can be used as axle disconnects or as
PTO disconnects. An alternate line of
disconnects is offered with integral SAE
pump pads.

Depending upon disconnect selection, the

TR2205 can be configured as a drop box,
transfer case, pump drive or PTO.

A lubrication pump for oil circulation is

optional and can be installed on either side.

Capacity: 17,000 lb-ft. max input torque

Maximum input speed: 2,800 RPM for short duration

Center distance: 17 inches

Rotation: Output same as input

Lubrication: Pump/splash

Ratio: 1:1

Gears Precision ground helical

Bearings: Tapered roller

Mounting: 4 holes each side

Weight: 600 lbs.

Disconnects: 2-3/4X10 spline

B,C,D,E Pump pads.

Page 15
 12.2 REF.

Pump pad disconnect

2-3/4 - 10 SPLINE
TYP
ROTATION

17
Splined shaft disconnect
34.5

(4)mountng holes
per side.

9.0

RATIO: 1 TO 1
7.5 7.5
15.0

TR2205 TRANSFER CASE

 www.ramdeinternational.com

TRANSFER CASE SPARE PARTS – FALCON 550 RIG

P/N Description
01AR219 KEY, 5/8 X 5/8 X 2.19
0620577B PLATE-LIFTING
0620433B HOSE ASSEMBLY 1/2 X 35
02PD12152B HOSE ASSEMBLY 1/2 X 15
0626408B SHIM SET
0627446B DIPSTICK
0628352B Bracket
0628016B Plate, Clamp
0631168F Case
0629578D Gear 79T
0629579D Gear 125t
0629580D Shaft
0629581D Shaft
0631171D Pump HSG
0629583D Seal HSG
0629584B Pilot Ring
0629585B Assembly, dipstick tube
80AX105 HHCS 3/8-16x1 PLN G5
80AX530 SHCS 1/2-13X2-3/4 PLN
80AX352 SHCS 1/2-13X3 PLN
80AX385 HHCS 5/16-18X3-1/2 PLN G5
80AX224 HHCS 5/8-11X1-1/4 PLN G5
80AX113 HHCS 1/2-13X1-1/4 PLN G5
80BX161 Nut-Flexloc 20FAF813 1/2-13
80DX103 Lockwasher 5/16 MED
80DC104 Lockwasher 3/8 MED
80DX106 Lockwasher 1/2 MED
80GX948 BRG Cone 482
80GX1427 BRG Cup 472
80IX159 Rollpin 1/2 DIA x 1-1/4LG
80JX190 Nipple-3/4 Close
80JX107 Plug-3/4 SQ HD Pipe
80JX226 Elbow 3/4X90 Deg STD BM
11425 Hufsmith Kuykendahl  Tomball, TX. 77375
 Phone: 713-609-9802  Fax: 281~255-6993  E-mail: ramde@ramde.net
 www.ramdeinternational.com

80JX337 Plug-3/8 STL CSNK Hex HD Pipe

80JX340 Plug-3/4 STL CSNK Hex HD Pipe
80JX349 Plug-3/4 MAG Pipe 4054121
80JX633 Elbow 90 DEG 3/4MNPTX1/2T
80JX645 Elbow 90 DEG 3/8MNPTX3/8T
80JX686 Elbow 45 DEG 3/8MNPTX1/2T
80TX282 Seal C/R 34861
80TX151 Seal C/R 32395
80VX2183 Breather FBS-75-1
80VX842 Window-oil level
80VX1692 Tag-oil empty
80VX1755 Pump Delta D4
80VX2195 Nameplate
0630319B Spacer
TR2206-18 Disconnect Assembly
0631169F Shaft
0621609D Seal HSG
80GX1000 BRG Cone HM516449C
80GX1001 BRG Cup HM516410
80VX744 Shim Set AL-22
02G2864A Spacer

11425 Hufsmith Kuykendahl  Tomball, TX. 77375

 Phone: 713-609-9802  Fax: 281~255-6993  E-mail: ramde@ramde.net