22
Dealer Service
32394 (Rev. 9/3/2004)
Leakage at the top cover, horizontal seal or between
horizontal housing and gearbox housing can be
corrected without removing gearbox from cutter.
Top Cover Leakage
Repair top cover leakage by removing cover. Use care
when cleaning top of gearbox to prevent foreign
material from entering gearbox. Clean top cover and
top of gearbox. Apply a thin coat of Permatex to top of
gearbox and cover bolt threads. Install a new gasket
and replace cover.
Horizontal Seal or Housing Leakage
Remove top cover and siphon gear lube from gearbox.
Remove leaking seal and replace (refer to seal
installation).
Repair leakage between horizontal housing and
gearbox by removing housing and replacing square cut
O-ring. Make sure you install shims (if removed) when
installing horizontal housing.
Removing Gearbox from Cutter
Remove top cover and siphon gear lube from box.
Remove crossbar (see Crossbar Removal
instructions). Remove safety shields. Remove PTO
driveline. Remove mounting bolts and remove gearbox
from cutter. It may be necessary to pry gearbox out of
cutter. To support gearbox neck bearing, the neck fits
into deck bearing support plate tightly.
Gearbox Disassembly
Remove horizontal housing.
Remove set screw and dowel pin from nut on
horizontal shaft and remove nut.
Remove seals from housings.
Remove vertical and horizontal shafts from respective
housings.
Support housings and press shafts out. Several tons of
force will be required as bearings and cups are press fit
to shafts.
Remove bearings from shafts with a bearing separator.
Carefully drive cups out of housings with a hammer
and soft drift.
Inspect gears for excessive wear. Some wear is
normal. 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.
Damage Inspection
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,
nicks or bumps. If damage cannot be repaired by
resurfacing with emery cloth, replace damaged part.
Inspect housings for damage, paying specific attention
to areas where seals seat. Replace housing if
damaged area cannot be resurfaced with emery cloth.
Gearbox Assembly
Bearing cups, cones and sleeves are a press fit.
Press bearing cups into vertical and horizontal
housings until they seat tightly against machined
shoulders.
Press bearing cones onto vertical and horizontal shafts
until they seat against machined surface next to gear.
Insert vertical shaft into gearbox housing and seat
inside bearing cone into inside bearing cup. Insert
horizontal shaft into horizontal housing and seat inside
bearing cone into inside cup.
Place outside bearing cones on their respective shafts
and press on with sleeve until all free play is removed
(similar to adjusting front wheel bearings on an
automobile).
Check adjustment by spinning housing. It should turn
freely. If bearings are too tight, hold housing and rap
gear shaft with lead hammer. Readjust bearings.
Proper bearing adjustment is essential to good bearing
life. Do not leave bearings adjusted too tightly.
Bearings should turn freely without any noticeable end
play.
Bearing adjustment on the vertical shaft is set with the
sleeve and maintained with proper crossbar shimming.
Bearing adjustment on the horizontal shaft is set with
the sleeve. When this bearing is adjusted, tighten nut
against sleeve, insert dowel plug into hole in nut and
lock onto threaded shaft with set screw.
Seal Installation
An improperly installed seal will leak and could result in
gearbox failure.
Clean area in housing where outer diameter of seal
seats and apply a thin coat of Permatex.
Lubricate seal lip and carefully guide over sleeve and
shaft using a blunt tool such as a letter opener. Use
care to prevent seal lip from rolling under. Do not use a
knife blade as it will nick and ruin seal.
