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28 Dealer Service
MAN0810 (9/24/2009)
ASSEMBLE GEARBOX
Refer to Figure 11.
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 (15) in the housing, using a
round tube of the correct diameter and a hand
press.
4. Slide output shaft (19) through both bearings (15)
until it rests against top bearing (15).
5. Slide shim (14) over output shaft (19).
6. Press gear (13) onto output shaft (19) and secure
with washer (25), castle nut (12), and cotter pin
(18).
7. Apply grease to lower seal lips (16) and press seal
(16) over output shaft (19), using a tube of the
correct diameter. Be sure not to damage the seal
lip.
Press in housing so that seal is recessed. Install
protective screen (17) and position it together with
dual lip seal (16) by pressing it into position. Verify
that snap ring is seated correctly.
8. Press bearing (7) into the housing, using a round
tube of the correct diameter and a hand press.
Secure with shim (5) and snap ring (9).
9. Place gear (6) through top of housing and align
gear (6) and gear (13) so that gear teeth are a
match.
10. While holding gear (6) in place, slide input shaft
(11) through gear (6) and bearing (7). Align splines
on shaft (11) and gear (6).
11. Slide bearing (23) over input shaft (11) and press
bearing onto input shaft (11), using a round tube of
the correct diameter and a hand press.
12. Slide shim (5) over input shaft (11) and secure with
snap ring (9).
13. Check input shaft end float by moving the input
shaft (11) by hand. If end float is higher than
0.012", insert shim between input shaft (11) and
rear bearing (23). Repeat until end float is less than
0.012". Check rotational torque by hand. The
torque should be less than 2.2 lbs-inch.
14. Check that the gear backlash is between 0.006"
and 0.016". You should not have to adjust the
backlash.
15. Press in input oil seal (10), using tube of correct
diameter. Be careful not to damage seal lip.
16. Press oil cap (24) on to cover the rear of housing,
using a tube of the correct diameter.
17. 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.
18. 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 to 300 lbs-ft.
2. Attach crossbar (See “CROSSBAR REMOVAL” on
page 31.).