Woods Equipment DS96 Dealer Service, Assemble Gearbox, Reinstall Gearbox, Side Drive Service

ASSEMBLE GEARBOX

Refer to Figure 20.

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.Install new bearing cup (16) in gearbox housing and bearing cup (13) in cover if these parts were previously removed.

4.Place bearing (16) and shim (5) on end of cross shaft (4), and insert shaft into housing.

5.Install spacer (20), key (21), crown gear (7), shim (18), and bearing (13) on opposite end of cross shaft.

6.Place cover (12) over bearings (13) and secure into position using eight cap screws (3). Torque cap screws to 29 lbs-ft.

7.Place seal (11) over cross shaft and press into housing. Use a round tube the same diameter of the seal and a handpress. Repeat process on opposite side of gearbox.

8.Install new bearing cup (16 & 13) into input housing if these parts were previously removed.

9.Place bearing (16) over end of input shaft (14) and insert shaft into front of input housing.

10.Place seal (17) over shaft and press into housing. Use a round tube the same diameter of the seal and a handpress.

11.Install bearing (13), shim (18), pinion gear (8), key (10), shim (9) over opposite end of input shaft (14).

12.Secure parts together using lock nut (2). Tighten lock nut (2) until shaft rolling torque is 3 to 9 lbs- inch.

13.Insert input housing assembly into front of gearbox housing and align teeth of the two gears. Secure with cap screws (3). Torque cap screws to 29 lbs-ft.

14.Check gear backlash; it should be .006" to .017" at outer tooth.

15.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.

16.Remove gearbox from water and dry off with compressed air. Add SAE 80W or 90W EP oil until it runs out of the lower level hole in front cover. Tighten all plugs.

REINSTALL GEARBOX

NOTE: Gearbox is heavy: do not attempt to move without mechanical assistance.

1.Install flex coupler driveline between side gearboxes and center gearbox.

2.Set gearbox on cutter and fasten with bolts and nuts. Torque bolts to 300 lbs-ft.

SIDE DRIVE SERVICE

		6.	Shaped washer
2.	Shaft	7.	Bushing
3.	Inner yoke	8.	Bolt
4.	Outer yoke	9.	Lock nut
5.	Rubber disc	11.	Set screw

Figure 21. Side Drive Assembly

The drives between the center and side gearboxes contain rubber shock-absorbing discs. To service or remove the side drives or remove a gearbox, the flexi- ble coupling must be disassembled.

Remove end yokes by removing nuts (9) and sliding bolt (8) inward to clear yoke. Do not remove bolt unless rubber discs (5) are to be serviced. Remove complete center section by lifting straight up on center shaft (2). The outer yoke can be slid off gearbox shaft. The inner yoke is held by two set screws (11).

Reassemble shaft as shown in Figure 21. End yokes (3

&4) do not bolt directly to center shaft (2). Use the spe- cial formed washer (6) and bushings (7) between the rubber discs (5) and under bolt head or nut near rubber disc. Tighten the nuts (9) evenly until the formed wash- ers (6) are slightly embedded into the rubber discs. Rubber discs (5) will warp and twist if bolts are over- tightened. Tighten set screw (11).

NOTE: Crossbar must be re-timed anytime a crossbar or a side drive is disconnected.

32 Dealer Service MAN0390 (Rev. 4/6/2007)