Assemble transmission

AR26.10-B-0010TKA

Assemble transmission

12.02.16

02.09.14

Mandrel special tool, including

Work step 19

02.09.14

Remove the assemblage device (73) from the gearbox (72) and put the gearbox in the horizontal position

Work step 32

AR26.10-B-0001-01HE

02.09.14

Install the oil choke (69) on the main shaft (19)

Work step 40

AR26.50-B-0004TH



Assemble

1

Assemble the counter shaft (11)

AR26.50-B-4775TB

2

Assemble the drive shaft (21)

AR26.50-B-4744TKB

3

Install the main shaft (19)

AR26.50-B-0426TKA

4

Measure the distance (A) from the sealing surface to the bearing lodging in the central housing (17)

 With the distance (A) = 327,5 mm:



Do not install the shim (18.1).

 With the distance (A) = 328,5 mm:



Install the shim (18.1) under the tapered roller bearing cap (18).

5

Install the main shaft (18) bearing cap and the counter shaft (12) bearing cap if necessary with the shim (18.1) in the central housing (17)

 Put multi-use grease on the tapered roller bearing caps (12, 18).

*BR00.45-B-1056-06A

 Utilize an appropriate mandrel.

6

Assemble the reverse gear (13) with the bearing and bushing

 The long collar of the reverse gear (13) must point the output side.

7

Install the immobilizing device (31) in the oil passing hole in the main shaft (19)

 Immobilizer device.

*715589013100

8

Assemble the coupling forks (26, 27) with the sliding shoes in the main shaft (19) and assemble the coupling rails (28, 29, 30) in the immobilizer device (31)

Pay attention to the correct sequence.

Engage the 1st/2nd speed gear rail in the 2nd speed gear.

9

Assemble the counter shaft (11) in the immobilizing device (31)

10

Assemble the main shaft (19), the counter shaft (11) with the coupling forks in the central housing (17)

11

Install the fork pins (15, 16)

 Put a chemical bond on the fork pins (15, 16).

*BR00.45-B-1033-02B

 Bearing pin in the gear shift fork (main axle).

*BA26.40-B-1003-01L

12

Remove the immobilizing device (31)

13

Install the synchronizing cone with the synchronizing ring and the ring spring (20)

 The long collar must point towards the motion output.

14

Assemble the drive shaft (21)

 Move the counter shaft (11) aside.

Put multi-use grease on the drive shaft tapered roller bearing.

*BR00.45-B-1056-06A

15

Centralize the reverse gear (13) and put the axle (24)

 Reverse gear axle fastening plate.

*BA26.40-B-1007-01L

16

Assemble the oil tube (10)

17

Assemble the splitter group coupling fork (9) with the sliding shoes (8)

18

Put he centering mandrel in the oil tube (10)

 Centralizing mandrel.

*715589031500

19

Put the mandrel in the front housing (7)

 Mandrel.

*715589091500

20

Fit the front housing (7) on the central housing (17)

 Put sealing compound on the sealing surfaces.

*BR00.45-B-1029-02B

The coupling rails must slide on the front housing guide (7).

21

Assemble the lock (6) in the oil tube (10) and remove the centering mandrel from the oil tube (10)

22

Remove the mandrel from the front housing (7) and put the front housing fastening bolts (7)

 Pay attention to the different sizes of the bolts.

 Front housing in the central housing.

*BA26.40-B-1001-01L

 Mandrel.

*715589091500

23

Assemble the tapered roller bearing caps (2, 4)

 Put multi-use grease on the tapered roller bearing caps (2, 4).

*BR00.45-B-1056-06A

 Utilize an appropriate mandrel.

24

Assemble the radial seal and the guide bushing of the splitter group control rod

AR26.35-B-1000-03TA

 Mandrel.

*714589051500

Synthetic grease.

*BR00.45-B-1021-06A

25

Install the splitter group control bar

 The coupling fork of the splitter group (9) must engage in the control rod's recess.

AR26.35-B-1000TA

26

Assemble the splitter group's coupling fork pin (23)

 Put quick drying adhesive on the splitter group's engaging fork pin (23).

*BR00.45-B-1033-02B

 Selection fork retaining pin in the gearbox .

*BA26.35-B-1001-01C

27

With the fastening device (33), immobilize the coupling rails (28, 29, 30) in the coupling rails guide (32) in the neutral position

 Immobilizing device.

*715589186300

28

Determine shims for the drive shaft (21) and counter shaft (11)

Counter shaft brake with 5 inner blades.

AR26.50-B-0410-03TKB

Counter shaft brake with 3 inner blades.

AR26.50-B-0410-03TKA



Assembly tool for the installation of the splitter group control rod

WF58.50-B-2635-01A

Drive shaft bearing pre-load.

*BE26.50-B-1006-01G

Counter shaft bearing adjustment tolerance.

*BE26.50-B-1007-01G

 Pre-load of the drive shaft and counter shaft bearings.

*BA26.50-B-1003-01C

 Torque wrench.

*001589802100

 Tensioning plates.

*715589156300

29

Assemble the drive shaft (3) cover with the determined shim

AR26.30-B-1020TKB

30

Assemble the counter shaft (1) cover with the determined shim

Counter shaft brake with 3 inner blades.

*BA26.30-B-1005-01L

31.1

Assemble the counter shaft brake (5)

Counter shaft brake with 3 inner blades.

AR26.50-B-6000TKA

 The brake blades oil grooves must be aligned.

31.2

Assemble the counter shaft (5) brake with the determined shim

Counter shaft brake with 5 inner blades.

AR26.50-B-6000TKB

 The brake blades oil grooves must be aligned.

32

Remove the assemblage device (73) from the gearbox (72) and put the gearbox in the horizontal position

AR26.10-B-0001-01HE

 Assemblage device.

*715589083100

33

Determine the compensation washer for the splitter group control piston

AR26.35-B-1000-01A

Splitter group control piston adjustment dimension.

*BE26.35-B-1001-01A

34

Remove the control rod with the assembly tool



Assembly tool for the installation of the splitter group control rod

WF58.50-B-2635-01A

35

Assemble the double groove seal and the control piston

 Put synthetic grease on the double groove seal.

*BR00.45-B-1021-06A

Lock the control piston with a quick drying bond.

*BR00.45-B-1024-02B

 Fastening of the splitter group control piston.

*BA26.35-B-1002-01C

 Socket.

*715589020700

36

Determine the compensation washer for the splitter group control cylinder

AR26.35-B-1000-02TA

Splitter group control cylinder adjustment dimension.

*BE26.35-B-1002-01A

 Inner puller.

*000589303300

 Counter support.

*000589343300

 Put synthetic grease on the sealing rings.

*BR00.45-B-1021-06A

37

Assemble the compressed air tubes of the counter shaft brake (25) in the front housing (7)

With the “VOSS 230” air connection system.

AR42.10-B-0900TA

With the “VOSS 232” air connection system (NG 8, 12) or “SCHAFER SDF” (NG 6).

AR42.10-B-0900TC

38

Remove the coupling rails fastening device (29, 30)

39

Assemble the gearbox control (22)

AR26.60-B-0001TH

40

Install the oil choke (69) on the main shaft (19)

AR26.50-B-0004TH

41

Assemble the splitter group (14)

AR26.31-B-3201TA

42

Install the splitter group (14)

AR26.31-B-3102TA

43

Install the oil temperature sensor (B47)

 Transmission oil temperature sensor.

*BA26.19-B-1004-01G

44

Install the counter shaft rpm sensor (B3)

 Counter shaft rpm sensor.

*BA26.19-B-1005-01G

45

Connect the electric cables to the connectors and supports

46

Install the uncoupling lever

 Fork in the gearbox.

*BA25.20-B-1001-01L

Número

Denominação

Gearboxes 715.531, 715.535

BE26.35-B-1001-01A

Adjusting measurement of the split group shift piston

mm

0,3...0,5

BE26.35-B-1002-01A

Adjusting measurement of the split group shift cylinder

mm

0,4...0,5

Número

Denominação

Gearbox 715.531/535

BE26.50-B-1006-01G

Pre-load of the drive shaft bearing

mm

0,00...-0,15

BE26.50-B-1007-01G

Adjusting tolerance of the counter shaft bearing

mm

-0,10...+0,05

Número

Denominação

Chassis 934.2, 958.2, 958.4

BA25.20-B-1001-01L

Fork in the gearbox

M12

Nm

90

M10

Nm

60

Número

Denominação

Gearboxes 715.372/382, 715.531/535

BA26.19-B-1004-01G

Transmission oil temperature sensor

Nm

60

BA26.19-B-1005-01G

Revs sensor, countershaft

Nm

40

Número

Denominação

Gearbox 715.531/535

BA26.30-B-1005-01L

Intermediate shaft bearing cover

Nm

25

Número

Denominação

Gearbox 715.531, 715.535

BA26.35-B-1001-01C

Selector fork retaining pin in the gearbox

Nm

120

BA26.35-B-1002-01C

Attachment of the command piston of the reduction group

Nm

95

Número

Denominação

Gearbox 715.531/535

BA26.40-B-1001-01L

Front case on center case

M12

Nm

70

BA26.40-B-1003-01L

Bearing pin on the shift fork (main shaft)

Nm

120

BA26.40-B-1007-01L

Reverse gear shaft fastening plate

Nm

60

Número

Denominação

Gearboxes 715.531/535

BA26.50-B-1003-01C

Primary and intermediate shaft bearings pre-tension

Nm

15

Número

Denominação

Número de pedido

BR00.45-B-1024-02B

Loctite 270

Henkel Loctite

BR00.45-B-1029-02B

Surfaces sealing product Loctite 5203

Henkel Loctite

BR00.45-B-1033-02B

Loctite 243

Henkel Loctite

Número

Denominação

Número de pedido

BR00.45-B-1021-06A

Synthetic grease

A 001 989 32 51

BR00.45-B-1056-06A

Vaseline - DBL 6850.00

A 000 989 15 51