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22 Dealer Service
15916 (Rev. 5/11/2007)
DEALER SERVICE
On pull-type units, a pin is installed to prevent
the height adjustment crank from detaching. Do
not operate or service unit unless pin is installed.
Before performing any service or maintenance,
lower equipment to ground or block securely, turn
off engine, remove key, and disconnect driveline
from tractor PTO.
Keep all persons away from operator control
area while performing adjustments, service, or
maintenance.
Always wear relatively tight and belted clothing
to avoid getting caught in moving parts. Wear
sturdy, rough-soled work shoes and protective
equipment for eyes, hair, hands, hearing, and head;
and respirator or filter mask where appropriate.
The information in this section is written for dealer ser-
vice personnel. The repair described herein requires
special skills and tools. If your shop is not properly
equipped or your mechanics are not properly trained in
this type of repair, you may be time and money ahead
to replace complete assemblies.
GEARBOX MAINTENANCE
Before beginning any gearbox repair, please read this
entire section. Many steps are dependent on each
other.
Always make sure proper vent plug is installed in top of
gearbox. Proper gear lube level for gearbox is half full.
Never operate cutter unless gearbox is half full of SAE
90W gear lube.
Troubleshooting is an important part of gearbox main-
tenance. Check for leakage and bad bearings.
Bearing Check
Bearing maladjustment or failure is indicated by exces-
sive noise and noticeable side or end play in gear
shafts.
Possible Leakage Causes
Leakage may be caused by an improperly operating
vent plug. The plug has a check valve in it; remove and
apply very low pressure air to the bottom to check for
proper venting.
Check housing for visible signs of leakage.
Check for leaks at vertical and horizontal seals and
gaskets.
Take necessary corrective action and clean area where
leakage was evident. Place cutter in service and check
to ensure leakage has stopped.
Leakage Repair
Permatex Aviation 3D Form-A-Gasket® or equivalent
is the recommended sealant for gearbox repair.
Leakage at the horizontal seal or gasket can be cor-
rected without removing gearbox from cutter.
Remove fill plug and siphon gear lube from gearbox.
Remove and replace leaking seal or gasket. Refer to
Seal Installation section, page 23.
Removing Gearbox from Cutter
Remove nut from belt tension idler adjustment rod.
Remove belt shields. Remove belts.
The front gear stand bolts are tack welded in place.
Loosen the nuts to protect bolt threads and break tack
welds by rapping them with a hammer. Remove nuts
and bolts.
Remove nuts from the rear gear stand bolts. Tip rear of
gear stand up over bolts and slide the stand rearward.
Cut the safety wire and remove bolt from drive pulley
under gearbox.
Disassemble split taper bushing (located on bottom of
drive pulley) by removing the three bolts and inserting
two of them into the threaded holes. Tighten alternately
to press bushing off.
Remove the four gearbox attaching bolts from the gear
stand and remove gearbox from stand.
Gearbox Disassembly
(Refer to illustration on page 45.)
Remove the horizontal and vertical gear shaft housings
from gearbox housing. Remove seals. Remove tack
weld, holding sleeve to shaft, by grinding. Press gear
and shaft from housing. Remove cups from housing.
Damage Inspection
Inspect gears for excessive wear. Some wear is nor-
mal. Gears will show more wear on loaded side. They
are forged and surfaces will appear rough, even when
new. The wear pattern should be smooth.
Do not replace gears unless deep gouges, chips, deep
pitting or deep wear grooves are present.
Inspect gear shafts and sleeves. Pay specific attention
to areas where seals seat. Check for cracks, grooves,
WARNING
CAUTION
CAUTION