Reassemble Gearbox
1.Clean housing, paying specific attention to areas where gaskets will be installed.
2.Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.
3.Insert output bearings (6 & 7) in the housing, using a round tube of the correct diameter and a hand press.
4.Slide output shaft (4) through both bearings (6 & 7) until it rests against bearing (6).
5.Slide shim (15) over output shaft (4).
6.Press gear (5) onto output shaft (4) and secure with washer (20), castle nut (16), and cotter pin
(11).
7.Apply grease to lower seal lips (21) and press seal
(21)over output shaft (4), using a tube of the correct diameter. Be sure not to damage the seal lip.
Press in housing so that seal is recessed. Insert protective washer (19) by hand. Install snap ring
(10) and position it together with dual lip seal (21) by pressing it into position. Verify that snap ring is seated correctly.
8.Press bearing (8) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (15) and snap ring (12).
9.Secure snap ring (13) on input shaft (3) if not already secure.
10.Place gear (1) through top of housing and align gear (1) and gear (5) so that gear teeth are a match.
11.While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (8). Align splines on shaft (3) and gear (1).
12.Slide spacer (14) over input shaft (3) and press bearing onto input shaft (3), using a round tube of the correct diameter and a hand press.
13.Slide shim (15) over input shaft (3) and secure with snap ring (12).
14.Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012”, insert shim between input shaft (3) and rear bearing (8). Repeat until end float is less than 0.012". Check rotational torque by hand. The torque should be less than 2.2
15.Check that the gear backlash is between 0.006" and 0.016". You should not have to adjust the backlash.
16.Press in input oil seal (22), using tube of correct diameter. Be careful not to damage seal lip.
17.Press oil cap (23) on to cover the rear of housing, using a tube of the correct diameter.
18.Check gearbox housing for leaks by plugging all holes except one. Apply 4 psi compressed air and immerse the gearbox in water to verify that there are no leaks.
19.Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of side level hole. Tighten all plugs.
Reinstall Gearbox
NOTE: Gearbox is heavy: do not attempt to move without mechanical assistance.
1.Set gearbox on cutter and fasten with bolts and nuts. Torque bolts as follows:
BB48X, BB60X, BB72X . . . 175
BB84X . . . . . . . . . . . . . . . . 300
2.Attach crossbar (See Crossbar Installation, page 32).
26 Dealer Service
(Rev. 5/11/2010)
MAN0632 (5/15/2007)
