Assemble main shaft

AR26.50-G-0428AE

Assemble main shaft

04.03.2019

Transmission

715.537/538/539 in model 800

1

Locknut

19

Annular spring

33

Synchronizer cone

3

Tapered roller bearing (pilot bearing)

20

Synchronizer ring

34

Needle bearing

4

Shim

21

Gear wheel for 3rd gear (for transmission 715.537/538)

35

Synchronizer ring

6

Tapered roller bearing

21

Gear wheel for 4th gear (for transmission 715.539)

36

1st gear wheel

7

Annular spring

22

Needle bearing

37

Reverse gear synchronizer body

8

Synchronizer cone

23

Main shaft

38

Sliding blocks

9

Synchronizer ring (only with transmission 715.537/538)

24

Needle bearing

39

Reverse gear shift fork

10

Constant speed gear 2

25

2nd gear wheel

40

Sliding sleeve

11

Synchronizer ring

26

Synchronizer ring

41

Jack

12

Tapered roller bearing

27

Synchronizer cone

42

Needle bearing

13

Synchronizer cone

28

Annular spring

43

Reverse gearwheel

14

Annular spring

29

Sliding sleeve

44

Tapered roller bearing

15

Sliding sleeve

30

Synchronizer body

46

Sun gear

16

Retaining ring

31

Retaining ring

47

Retaining ring

17

Synchronizer body

32

Annular spring

A

Installation position (pin)

18

Synchronizer cone

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A



Assemble

1

Clamp main shaft (23) into clamping device.

 Clamping device

*315589023100

2

Oil needle bearing (24) and thrust collar of gearwheel for 2nd gear (25).

3

Push gearwheel of 2nd gear (25) with needle bearing (24) onto main shaft (23).

4

Mount synchronizer ring (26) onto gearwheel for 2nd gear (25).

5

Check annular spring (28) for wear; replace if necessary.

6

Insert annular spring (28) into synchronizer cone (27) and press into synchronizer ring (26).

7

Oil annular spring (28) and conical contact surfaces.

8

Slide on synchronizer body (30) and insert retaining ring (31) with zero clearance.

 If necessary install circlip (31) of a different thickness

Axial play of retaining rings

*BE26.50-N-1001-01HA

9

Install sliding sleeve (29).

 The long chamfer must face the output end.

10

Check annular spring (32) for wear; replace if necessary.

11

Insert annular spring (32) into synchronizer cone (33) and press into synchronizer ring (35).

12

Oil annular spring (32) and conical contact surfaces.

13

Install synchronizer ring (35) with synchronizer cone (33).

14

Oil needle bearing (34) and thrust collar of gearwheel for 1st gear (36).

15

Slide gearwheel for 1st gear (36) with needle bearing (34) onto main shaft (23).

16

Slide reverse gear synchronizer body (37) onto main shaft (23).

 The collar should point to the 1st gear wheel (36).

17

Heat up bush (41) to approx. 100 °C and slide on.

 Adjust bushing (41) to be free of axial play.

18

Install sliding sleeve (40) with reverse gear shift fork (39) and sliding blocks (38).

 Note installation position (A) of pin.
The rounded teeth of the sliding sleeve (40) with reverse gear shift fork (39) and sliding blocks (38) must point toward the power output.

19

Oil needle bearing (42) and thrust collar of reverse gear gearwheel (43).

20

Slide reverse gear gearwheel (43) with needle bearing (42) onto main shaft (23).

21

Heat tapered roller bearing (44) to approx. 100 °C and slide on.

 Adjust tapered roller bearing (44) for zero axial play.

22

Install sun gear (46) and retaining ring (47).

 The chamfer on the internal toothing of the sun gear (46) must point toward the tapered roller bearing (44), the flat side must point toward the retaining ring (47).

23

Turn over main shaft (23) in the clamping device and clamp.

 Clamping device

*315589023100

24.1

Oil needle bearing (22) and thrust collar of gearwheel for 3rd gear (21).

With transmission 715.537/538

24.2

Oil needle bearing (22) and thrust collar of gearwheel for 4th gear (21).

With transmission 715.539

25.1

Slide gearwheel for 3rd gear (21) with needle bearing (22) onto main shaft (23).

With transmission 715.537/538

25.2

Slide gearwheel for 4th gear (21) with needle bearing (22) onto main shaft (23).

With transmission 715.539

26.1

Mount synchronizer ring (20) onto gearwheel for 4th gear (21).

With transmission 715.539

26.2

Mount synchronizer ring (20) onto gearwheel for 3rd gear (21).

With transmission 715.537/538

27

Check annular spring (19) for wear; replace if necessary.

28

Insert annular spring (19) into synchronizer cone (18) and press into synchronizer ring (20).

29

Oil annular spring (19) and conical contact surfaces.

30

Install synchronizer body (17), insert retaining ring (16) with zero clearance.

 The long collar must point to the power output. If necessary, install a retaining ring (16) with a different thickness.

Axial play of retaining rings

*BE26.50-N-1001-01HA

31

Heat tapered roller bearing (12) to approx. 100 °C and push on.

 Adjust tapered roller bearing (12) for zero axial play.

32

Coat tapered roller bearing (12) with lubricant.

 The tapered roller bearing (12) must have cooled down.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

33

Install sliding sleeve (15).

 The long chamfer must face the output end.

34

Check annular spring (14) for wear; replace if necessary.

35

Insert annular spring (14) into synchronizer cone (13) and press into synchronizer ring (11).

36

Oil annular spring (14) and conical contact surfaces.

37

Install synchronizer ring (11) with synchronizer cone (13).

38

Install gearwheel for constant speed gear 2 (10).

39

Heat tapered roller bearing (6) to approx. 100 °C and push on.

40

Grease tapered roller bearing (6) with lubricant.

 The tapered roller bearing (6) must have cooled down.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

41

Determine shim (4) for main shaft (23).

AR26.50-W-0420-11HA

Axial play of constant speed gear 2 tapered roller bearing

*BE26.50-N-1002-01HA

 Extension

*366589002105

 Setting gauge

*714589042100

 Adjusting sleeve

*715589002100

 Dial gage

*001589532100

42

Install determined shim (4).

43

Heat tapered roller bearing (3) to approx. 100 °C and push on.

 Adjust tapered roller bearing (3) for zero axial play.

44

Tighten lock nut (1).


Never tighten lock nut (1) with an impact wrench/driver.
Otherwise the main shaft (23) may break.

45

Mount synchronizer ring (9) on gearwheel for constant speed gear 2 (10).

Only with transmission 715.537/538.

46.1

Oil annular spring (7), insert into synchronizer cone (8) and press into synchronizer ring (9).

With transmission 715.537/538

46.2

Oil annular spring (7), insert into synchronizer cone (8).

With transmission 715.539

Test and adjustment values for gear set

Number

Designation

Transmission 715.537/538/539

BE26.50-N-1001-01HA

Axial play of retaining rings

mm

< 0,08

Test and adjustment values for gear set

Number

Designation

Transmission 715.537/538/539

BE26.50-N-1002-01HA

Axial play of constant speed gear 2 tapered roller bearing

mm

0,02...0,08

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51