Assemble transmission

AR26.10-W-0010HD

Assemble transmission

07.06.2018

Transmission

715.508

with code G1H (Transmission G 230-16/14.2-0.83)

Transmission

715.518

with code G1I (Transmission G 231-16/17.0-1.0)

Transmission

715.528

with code G1J (Transmission G 260-16/11.7-0.69)

2

Splitter group shift cylinder

18

Shim

31

Retaining ring

3

Splitter group shift rod

19

Tapered roller bearing outer race

32

Reverse idler shaft

8

Sliding blocks

20

Main shaft

35

Screw

9

Oil pipe

21

Synchronizer cone with synchronizer ring and annular spring

36

Shift housing

10

Shift fork for splitter group

22

Sliding sleeve

37

Front section of transmission housing

11

Countershaft

23

Drive shaft

38

Bearing pin

12

Tapered roller bearing outer race

25

Shift

B29

Countershaft rpm sensor

13

Shift unit

26

Bearing pin

B79

Transmission oil temperature sensor

14

Center section of transmission housing

27

Tapered roller bearing outer race

S28

Neutral position switch

15

Reverse gear

28

Tapered roller bearing outer race

S29

Reverse gear switch

16

Reverse gear cap

29

Countershaft bearing cap

17

Range group

30

Drive shaft bearing cap

9

Oil pipe

11

Countershaft

13

Shift unit

14

Center section of transmission housing

20

Main shaft

50

Holding device

14

Center section of transmission housing

33

3rd/4th gear shift fork

38

Bearing pin

20

Main shaft

69

Oil restrictor

72

Transmission

73

Assembly device

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on compressed air connection systems

AH00.18-N-0001-01A



Assemble

1

Assemble countershaft (11)

AR26.50-W-4775HD

2

Assemble drive shaft (23)

AR26.50-W-4744HD

3

Assemble main shaft (20)

AR26.50-W-0426HD

4

Attach assembly device (73) to transmission housing center section (14) and place in upright position

AR26.10-W-0001-01HE

 Assembly device

*715589083100

5

Coat the tread of the tapered roller bearing outer race (19) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

6

Slide spacer washer (18) onto tapered roller bearing outer race (19) and install using suitable drift from the inside up to the contact surface in the center section of transmission housing (14)

7

Apply coating of lubricant to contact surface of tapered roller bearing outer race (12)

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

8

Drive tapered roller bearing outer race (12) into center section of transmission housing (14) from the inside as far as the contact surface using a suitable drift

9

Install main shaft (20), countershaft (11) and shift unit (13) using holding device (50) into center section of transmission housing (14)

Transmission 715.508/518

AR26.50-W-4000-02HDA

Transmission 715.528

AR26.50-W-4000-02HDB

 Retaining device

*715589013100

 Clamping device

*315589023100

10

Install sliding sleeve (22)

 The long collar must point towards the output.

11

Coat tapered roller bearing (pilot bearing) on drive shaft (23) with lubricant and install drive shaft (23)

 Push the countershaft (11) to one side.

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

12

Install both bearing pins (38)

 Note the different lengths of the various bearing pins; both bearing pins (38) are longer than the other bearing pins (26).
Coat thread of bearing pins (38) with sealant and lift the guide rails of shift unit (13) slightly.

Loctite 5203 sealant

*BR00.45-Z-1015-01A

13

Check bearing and bushing of reverse idler gear (15) for wear and damage

If wear or damage is present:



Replace appropriate component.

14

Install reverse idler gear (15) with bearing and bush

 The long collar of the reverse idler gear (15) must point towards the output.

15

Align reverse idler gear (15) and insert reverse idler shaft (32)

 Bolt, reverse idler shaft retaining plate to transmission housing

*BA26.40-N-1007-01HA

16

Install radial shaft sealing ring and pilot bushing for splitter group shift rod (3) into transmission housing front section (37)

 For this, coat radial shaft sealing ring with lubricant.

Synthetic grease 50 g

*BR00.45-Z-1027-06A

 Drift

*714589051500

17

Clean sealing surfaces on transmission housing front section (37) and transmission housing center section (14) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

18

Mount transmission housing front section (37)

AR26.40-W-2470-08HD



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

 Splitter group shift rod lock to transmission housing

*BA26.35-N-1003-01HA

 Shift fork bearing pin at transmission housing

*BA26.35-N-1001-01HA

Loctite 5203 sealant

*BR00.45-Z-1015-01A

 Drift

*715589091500

 Puller

*715589083300

 Retaining device

*715589053100

 Alignment punch

*715589031500

19

Screw in screws/bolts around circumference of transmission housing center section (14)

 Pay attention to different lengths of bolts.

 Bolt, transmission housing front section to transmission housing center section

*BA26.40-N-1001-01HA

20

Coat tread of tapered roller bearing outer races (27, 28) with lubricant

Grease, silicone-based, 100 g

*BR00.45-Z-1008-06A

21

Using a suitable drift, install tapered roller bearing outer races (27, 28) up to contact surface

22

Pull out splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

23

Determine shims of drive shaft (23) and countershaft (11)

AR26.50-W-0410-03HD


Only use a torque wrench with slave pointer.
Otherwise the tapered roller bearing outer races (27, 28) may be damaged.

Setting tolerance of bearings on countershaft

*BE26.50-N-1004-01HA

Drive shaft bearing pretension

*BE26.50-N-1003-01HA

 Preload of bushings on drive shaft and countershaft for determining shims

*BA26.50-N-1003-01HA

 Clamping plates

*715589156300

 Pliers

*715589013700

 Torque wrench

*000589672100

24

Install drive shaft bearing cap (30) and countershaft bearing cap (29) with the determined shim

25

Clean sealing surfaces on center section of transmission housing (14) and reverse idler gear cap (16) and coat with sealant

Loctite 5203 sealant

*BR00.45-Z-1015-01A

26

Install reverse idler gear cap (16)

 Bolt, reverse idler gear cap to transmission housing center section

*BA26.40-N-1008-01HA

27

Detach assembly device (73) from transmission (72) and move transmission (72) to horizontal position

AR26.10-W-0001-01HE

 Assembly device

*715589083100

28

Press in splitter group shift rod (3) using assembly tool



Assembly tool for installing shift rod of splitter group

WF58.50-N-2635-02A

29

Install shift piston of splitter group

AR26.35-W-0001HD

30

Install splitter group shift cylinder (2)

AR26.18-W-1001HD

31

Install shift mechanism (25)

AR26.60-W-0001HD

32

Install transmission oil temperature sensor (B79)

Transmission 715.508/518/528

AR26.19-W-0017HD

33

Install countershaft rpm sensor (B29)

AR26.19-W-0018HD

34

Install reverse gear switch (S29)

AR26.19-W-0010HD

35

Install neutral position switch (S28)

AR26.19-W-0003HD

36

Install oil restrictor (69) into main shaft (20)

AR26.50-W-0004H

37

Install range group (17)

AR26.31-W-3100HD

38

Install release lever

Transmission 715.508/518/528

AR25.20-W-0200H

39

Mount bracket of compression air lines and electrical lines at transmission (72)

 Screw/bolt, bracket to transmission

*BA26.40-N-1009-01HA

40

Connect electrical connectors

41

Attach compressed-air lines

Test and adjustment values for gear set

Number

Designation

Transmission 715.508/518/528

BE26.50-N-1003-01HA

Drive shaft bearing pretension

mm

0,0...-0,15

Test and adjustment values for gear set

Number

Designation

Transmission 715.508/518/528

BE26.50-N-1004-01HA

Setting tolerance of bearings on countershaft

mm

-0,10...+0,05

 Splitter group

Number

Designation

Transmission 715.508/518/528

BA26.35-N-1001-01HA

Shift fork bearing pin at transmission housing

Nm

120

 Splitter group

Number

Designation

Transmission 715.508/518/528

BA26.35-N-1003-01HA

Splitter group shift rod lock to transmission housing

Nm

30

 Housing

Number

Designation

Transmission 715.508/518/528

BA26.40-N-1001-01HA

Bolt, transmission housing front section to transmission housing center section

Nm

80

 Housing

Number

Designation

Transmission 715.508/518/528

BA26.40-N-1007-01HA

Bolt, reverse idler shaft retaining plate to transmission housing

Nm

70

 Housing

Number

Designation

Transmission 715.508/518/528

BA26.40-N-1008-01HA

Bolt, reverse idler gear cap to transmission housing center section

Nm

50

 Housing

Number

Designation

Transmission 715.508/518/528

BA26.40-N-1009-01HA

Screw/bolt, bracket to transmission

M6

Nm

10

M8

Nm

25

M10

Nm

50

 Gear set, shafts

Number

Designation

Transmission 715.508/518/528

BA26.50-N-1003-01HA

Preload of bushings on drive shaft and countershaft for determining shims

Nm

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1008-06A

Grease, silicone-based, 100 g

A 001 989 28 51

BR00.45-Z-1015-01A

Loctite 5203 sealant

A 002 989 71 20 10

BR00.45-Z-1027-06A

Synthetic grease 50 g

A 001 989 32 51 10