AB repair.pdf
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647058EN (20/11/2008)
Angle gear box 15930 / 15932 Repair manual
MANITOU BF B.P 249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com
1st Date of Issue : 20 / 11 / 2008
647058EN
ISSUES
20 / 11 / 2008
OBSERVATION
- 1st ISSUE
THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE R EPRODUCED, EITHER PARTL PARTLY Y OR TOTALLY TOTALLY.
CONTROL AND ADJUSTMENT ANGLE GEAR BOX TRANSMISSION
pages
ANGLE GEAR BOX MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ANGLE GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - Main housing - Input shaft - Output shaft GENERAL INFORMATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ReASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - Input shaft - Output shaft - Main housing SHIM PACK CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CHECK ADJUSTMENT OF THE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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ANGLE GEAR BOX MAINTENANCE RECOMMENDED LUBRICANTS Oil used by MANITOU Oil MANITOU Mechanical transmission for axles and box SAE 80W90
Capacity 2.5 l
For good lubrication and a good operating temperature, it is very important to use an specified oil and to maintain the correct lever.
Oil replacing It is recommended to change the oil in the following working periods : After first 50 hours services. Every 800 hours max. Many factors having an influence on the oil changing require to increase the oil changing frequency.
Oil level
The level must be checked with the oil gauge dipstick, the oil must be located between both mini. and maxi marks.
* Do not fill above the maxi. level , then this could lead to an increase in temperature, because of the oil splash lubrication by the drive gears (emulsion and destruction of oil). This could also provoke outer leaks. The purpose of drains is also to eliminate metallic particles of intern components, these metallic particles being the result of normal use.
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ANGLE GEAR BOX (DETAILS)
2 E B . 2 S E - U B . S S L o o 2 E b r b r u u B T T . 1 1 S 3 3 2 7 7 3 / / 9 0 4 / 3 3 2 6 6 3 T T 7 L L T M M M
E O L G E U E L G L E N O L G A N G O R N R E U G A ' O D T N D V E A I D O ' I R O A V D V R N E O N N E L I : V E H E G : N e f R A R N I p y é A R Z A R T R U R R R R O A O E U P F P F P
2 8 3 5 9 7 5 2 1 2 2
m y l . b N m 0 e 4 s : s e 2 a u 0 d q n r o 1 2 t 2
m . N 8 5 9 3 e u q r o t
1 4 a 0 4
: e g a r m y r . l e b s N m e 0 e d 3 s 2 e s l a p 0 t 9 s u o 0 3 1 c 2
1 4 0 4
8 3
3 3
4 3
2 3
1
6 3
1 3 9 2
5 3 7 4
3 1 1 2
2 2
7 3
4 5 2 2
6 1 7 8 1 1 5 6 4 4 3 4 4 4
3 0 7 7 1 . 2 0 G
0 9 2 1
m . N : e 0 u 3 q r 0 o t 2
3 2
m . N : e 0 u 3 q r 0 o t 2
6 2 7 2
3 1
4 1 5 1
O L U G O E E N L L G A O G E E G L N N A A E D ' ' G O D I N D I R V R O O O N I V V E U T V D E E N N I A E R R R R R N L E L U E L E H D D D A G Z R R R I I N I T R T A T : E R R R ° M A D A O A N P B P R P A A A F A
7 4
2 1 2 4
4
1
2
m . N : e 8 u 5 q r 9 o t 3
3 5
7
6 8 9
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ANGLE GEAR BOX (DETAILS) 1 - Shim
27 - Seal
2 - Flange
29 - Bearing
3 - Screw
31 - Flange
4 - Bearing
32 - Screw
5 - Seal
33 - Bearing
6 - Coupling flange
34 - Seal
7 - O ring
35 - Flange
8 - Washer
36 - O ring
9 - Screw
37 - Flange
12 - Bearing
38 - Washer
13 - Bevel gear assy
39 - Screw
14 - Key
40 - Washer
15 - Axle
40a - Lock washer
16 - Housing
41 - Nut
17 - Sludge door
42 - Bevel gear
18 - Screw
43 - Gauge
19 - Plug
44 - O ring
20 - Seal
45 - Plug
21 - Plug
46 - Seal
22 - Seal
47 - Gauged strut
23 - Air breather 24 - Key 25 - Drive shaft 26 - Roller bearing
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DISASSEMBLY -1-
MAIN HOUSING DISASSEMBLY - Remove 6 bolts retaining the drive plate. (17mm socket).
-2- Remove the drive plate.
-3- Remove 6 bolts r etaining the inp ut shaft housing (17mm socket).
-4- Separate the input shaft housing using the levering slots if required.
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-5- Remove the input shaft housing and shims.
-6- Remove the 6 bolts retaining the output shaft housing. (17mm socket)
-7- Remove the output shaft housing and shims.
-8- Using a suitable lever, remove the input shaft oil seal from the case.
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-9- Using a suitable sized drift, drive the input shaft needle bearing out of the case.
- 10 -
INPUT SHAFT DISASSEMBLY - Remove the input flange retaining bolt. (17mm socket)
- 11 - Remove the bolt, washer and o-ring.
- 12 - Remove the input flange assembly.
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- 13 - Remove the housing from the shaft assembly.
- 14 - Remove the gauged strut.
- 15 - Using a suitable press, drive the shaft through the bearing and gear to remove them. Then remove the woodruff key from the slot.
- 16 - Using a suitable lever remove the oil seal from the input shaft housing.
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- 17 - Remove the outer bearing cone.
- 18 - Remove the bearing cups from the housing using a suitable drift.
- 19 -
OUTPUT SHAFT DISASSEMBLY - Flatten the tab washer and undo the output flange retaining nut. (46mm socket)
Rondelle frein
- 20 - Remove the nut and tab washer. (1st version) - Remove the nut and lock washer. (2nd version)
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- 21 - Remove the o-ring.
- 22 - Remove the output flange.
- 23 - Remove the housing from the output shaft.
- 24 - Remove the gauged strut.
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- 25 - Using a suitable press drive the shaft through the bearing and gear to remove them. Then remove the woodruff key from the slot.
- 26 - Using a suitable lever remove the output shaft oil seal from the housing.
- 27 - Remove the bearing cone. - Then using a suitable drift remove the bearing cups from the housing.
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INFORMATIONS GÉNÉRALES - 28 - The bevel gear are manufactured in matched pairs and should not be replaced individually. - Pairs are marked with a three figure identification number. - The correct mounting distance is also marked Measurement G on the gears.
- 29 - The input gear can be easily identified as it has a machine groove and the output gear does not.
- 30 - The tooth marked ”X” on the input gear
- 31 - Must be fitted between the two teeth marked ”X” on the output gear. - Paint teeth marked with «X» on both gears, to locate them more easily during assembly.
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REMONTAGE - 32 -
INPUT SHAFT REASSEMBLY - Using suitable sized tubes, refit the bearing cups into the input shaft housing.
- 33 - Refit the inner bearing cone.
- 34 - Using suitable equipment measure the distance from the input housing mounting face to the rear of the inner bearing.
Measurement A :
- 35 - Using a suitable press refit the input gear to the shaft taking care to correctly align the woodruff key with the keyway.
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- 36 - Using a suitable tube press the iner bearing cone onto the shaft.
- 37 - Refit the housing to the input shaft assembly.
- 38 - Refit the gauged strut. NOTE : If your bevel drive has a spacer + set of shims, you must replace them with a calibrated spacer** of same thickness. **: Bevel drive change 2.
- 39 - Clean and degrease the flutings of the shaft and disk with some cleaning agent, while avoiding allowing it to flow over the bearings. - Refit the outer bearing cone on the input shaft.
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- 40 - Lightly coat the flutings of the shaft with some fixing agent 649; Réf.- 562227. - Refit the input flange and the elastic washer. - Coat the screw threading of the 19MM screw, of brake net 243 Réf.187526, and refit it. - Torque : 95-120 Nm
- 41 - Measure the torque, which must be comprised of between 1,1 et 2,2 Nm. - If necessary adjust the shim pack to give correct torque. - If one increases the value of the shim pack, the torque decreases. - If one increases the value of the shim pack, the torque increases.
- 42 - When the correct shim pack has been found, remove the shaft. - Assembly from the housing and using a suitable tool. - Replace the input shaft oil seal to a depth of 1.5mm below the housing face.
- 43 - Rebuild as previously described. - On final assembly fit the o-ring under the flange retaining washer and use stop threaded to secure the bolt (Ref. 187526).
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- 44 - Measure and note the diameter of the inuput shaft.
Measurement B :
- 45 -
OUTPUT SHAFT REASSEMBLY - Using suitable sized tubes, refit the bearing cups into the output shaft housing.
- 46 - Refit the inner bearing cone.
- 47 - Using suitable equipment measure the distance from the output housing mounting face to the rear of the inner bearing.
Measurement C :
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- 48 - Using a suitable press refit the output gear to the shaft taking care to correctly align the wodruff key with the keyway.
- 49 - Using a suitable tube press the inner bearing cone onto the shaft.
- 50 - Refit the housing to the output shaft assembly.
- 51 - Refit the gauged strut. NOTE : If your bevel drive has a spacer + set of shims, you must replace them with a calibrated spacer** of same thickness. **: Bevel drive change 2.
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- 52 - Clean and degrease the flutings of the shaft and disk with some cleaning agent, while avoiding allowing it to flow over the bearings. - Refit the outer bearing cone on the output shaft.
- 53 - Lightly coat the flutings of the shaft with some fixing agent 649; Réf.- 562227. - Refit the output flange and the lock washer. - Coat the screw threading of brake net 243; Réf.187526. - Refit the 46MM nut.
- 54 - Measure the torque, which must be comprised of between 1,1 et 2,2 Nm. - If necessary adjust the shim pack to give correct torque. - If one increases the value of the shim pack, the torque decreases. - If one increases the value of the shim pack, the torque increases.
- 55 - When the correct shim pack has been found, remove the shaft. - Assembly from the housing and using a suitable tool. - Replace the output shaft oil seal to a depth of 1.5mm below the housing face. (20/11/2008)
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- 56 - Rebuild as previously described. - On final assembly fit the o-ring under the tab washer..
- 57 - Retorque the flange retaining nut and bend the tab washer using a suitalbe tool.
- 58 - Measure and note the diameter of the output shaft.
Measurement D :
- 59 -
MAIN HOUSING REASSEMBLY - Using a suitable tool refit the output shaft needle bearing. - Into the case to a depth of 1.5mm below the housing face.
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- 60 - Refit the output shaft rear oil seal. - Into the case to a depth of 1.5mm below the housing face using a suitable tool.
- 61 - Refit the output shaft assembly and shim pack into the case. - Secure with 2 bolts. Do not use any sealant at this stage.
- 62 - Measure the distance from the input housing mounting face to the previously measured diameter on the output shaft.
Measurement E :
- 63 - Remove the output shaft assembly then refit the input shaft assembly and shim pack onti the case. - Secure with 2 bolts. Do not use any sealant at this stage.
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- 64 - Measure the distance from the output housing mounting face to the previously measured diameter on the input shaft.
Measurement F :
SHIM PACK CALCULATIONS : -
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Angle gear box - For this formula the mounting dimensions marked on gears will be called (See fig. 28). • Input gear = Cote A Cote B Measurement G • Output gear= Measurement H
- The shim pack thickness required for the input shaft assembly is calculated as follows : D x 0,5 + E = J A+G-J = Re qui re d sh im p ac k thickness (X) Cote C • • • •
Picture Picture Picture Picture
34= 58= 62= 28=
measurement measurement measurement measurement
A D E G
- The shim pack thickness required for the output shaft assembly is calculated as follows : B x 0,5 + F = K C + H - Cote E Required shim pack thickness (X’) • • • •
Picture Picture Picture Picture
44= 47= 64= 28=
measurement measurement measurement measurement
Cote D
K
Cote F
=
B C F H
- Select the shims required to give the thickness calculated and refit input and output shaft Cote G assemblies into the case.
Cote H
- Torque the 12 bolts to 39 - 58 Nm.
List of calculated shim packs. Dimensions (mm) 11.57-11.59 11.60-11.62 11.63-11.65 11.66-11.68 11.69-11.71 11.72-11.74 11.75-11.77 11;78-11.80 (20/11/2008)
References 702 702 604 604 604 604 604 604
779 780 774 775 776 777 778 779
Dimensions (mm) 11.81-11.83 11.84-11.86 11.87-11.89 11.90-11.92 11.93-11.95 11.96-11.98 11.99-12.01 12.02-12.04
References 604 604 604 604 604 604 702 702
780 781 782 783 784 785 781 782
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- 65 - To aid assembly it may be helpful to highlight the teeth markes ”X” with a suitable dye.
CHECK ADJUSTMENT OF THE PACK - 66 - Using a dial gauge and a bolt and nut fitted ti the input flange. - Install a comparator and check the backlash of the bevel gears.
Note : The output shaft should be stationary during this measurement. - The backlash when measured by this method should be 0.12 - 0.18 mm. If necessary adjut both the shim packs equally to achieve the correct blacklash. - Once the correct backlash has been achieved remove and refit the input and output shaft assemblies using golden hermatite or an equivalent sealant between the housings, shim packs and case.
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- 67 - Refit the drive plate. Torque the bolt to 39 - 58 Nm.
- 68 - Photo showing breather, dipstick and filter plug.
- 69 Photo showing drain plug.
Note : - Oil seal lips should be lubricated with a light grease on assembly. - Bearings should be lubricated with an appropriate oil on assembly. - Drain, filler, and oil level plugs should be torqued to 20 - 30 Nm.
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