GEARBOX REASSEMBLY
Disassembly and assembly of the gearbox or of its parts is to be made by specialized technicians only.
•
Output shaft unit assembly: orderly assemble, starting from the end opposite the output flange, spacer ref.
16, bush ref. 25, cage ref. 15, gear ref. 17, spacer ref. 14, bearing cone ref. 11, nut ref. 12 (torque wrench
setting 155 Nm). Tighten the stop nut in the appropriate place on the shaft. Insert clutch unit ref. 36 and
moving toward the output flange end, assemble, in sequence, the following parts: ref. 16, 25, 15, 24, 14, 11.
•
Intermediate shaft unit assembly: upon positioning stop ring ref. 58 and distance ring ref. 57 assemble the
cups of the two bearings ref. 57 on gear ref. 21. Assemble the bearing cone on shaft ref. 56 making it close
on the shoulder. Insert the gear on the shaft and assemble the last cone. Assemble ring nut ref. 23 fastening
the ring nut very tightly in order to move bearings ref. 57 to the correct position; loosen the ring nut until
the gear can rotate smoothly, which corresponds to an adjustment leaving zero play of the bearing, and lock
the ring nut into place by means of the lock washer.
•
Input shaft unit assembly: the gears are enbloc with the shaft; therefore it is necessary only to assemble the
cones of bearings ref. 8 and 11.
•
Shafts assembly on cover: place cover ref. 7 on a horizontal surface with the bearing seat upward and an
opening which allows the protuding part of sahft ref. 9 and the spigot 88 mm to go through.
Place bearing cups ref. 8, 11 in the relevant cover seets. Insert both input and output shafts, which have
been previously assembled, in the relevant positions. Insert pins ref. 30. Assemble the cups of bearings
ref.11 on box ref. 4. Put sealing paste between the cover plate re. 4 and the shaft ref. 56, fasten the
previously assembled intermediate shaft ref. 56 to cover ref. 4 by means of screw ref. 33 and of washer
ref.54. Put sealing paste and close box ref. 4 using screws ref. 18.
Bearings will have to be shimmed using as many shims ref. 48 as required in order to build a preloading of
0,03 ± 0,02 mm. Shims must be inserted between the bearing cone and the reverse-gear cover seat ref. 46
and 53. Put sealing paste between the box ref. 4 and the covers ref. 46 and 53 and fasten with screws ref.47.
Assemble oil seals ref. 10 and 50. Insert flange ref. 49 on the output shaft spline, insert sealing paste and
tighten the lock nut ref. 51 by a 155 Nm torque wrench setting and lock it.
•
Control unit assembly: upon positioning spring ref. 32 on the stem of guide shoe ref. 16, insert it into the
hole of drive shaft ref. 40. Guide shoe ref. 30 must be positioned with its beveled side upward (behind the
v-shaped surface touching the clutch-unit). Insert the complete control unit (cover ref. 42, shaft ref. 40,
spring ref. 32, guide shoe ref. 30) into the reverse-gear unit box making sure to maintain the guide shoe
position described above and to avoid dropping the guide into the casing. Fasten both bolts ref. 34 and
assemble control level ref. 43 fastening it by means of screw ref. 33.
•
Clutch control unit adjustment: with the operating lever ref. 43 in neutral position, turn by hand the output
flange ref. 49 and screw at the same time the adjusting screw ref. 36 with an allen wrench (4 mm) until the
output flange rotation gets hard on a small arc only. Unscrew of ¾ of turn the adjusting screw ref. 36 and
fix it by locking the nut ref. 35.
