Dealer Service 20 - Woods DS8.30E Manual Del Operador

The information in this section is written for dealer service personnel. The
repair described here requires special skills and tools. If your shop is not prop-
erly equipped or your mechanics are not properly trained in this type of repair,
you may be time and money ahead to replace complete assemblies.
WARNING

Before working underneath, disconnect driveline, raise cutter, lock in
transport position, and block cutter securely. Hydraulic system leak
down and failure of mechanical or hydraulic system can cause equip-
ment to drop.

Keep all persons away from operator control area while performing
adjustments, service, or maintenance.
CAUTION CAUTION

Always wear relatively tight and belted clothing to avoid getting
caught in moving parts. Wear sturdy, rough-soled work shoes and protec-
tive equipment for eyes, hair, hands, hearing, and head; and respirator or
filter mask where appropriate.
GEARBOX MAINTENANCE
NOTE: Read this entire section before starting any repair. Many steps are
dependent on each other.
1.
Fill gearbox with SAE 80W or 90W gear lube until it runs out the side
level plug.
NOTE:
Repair to this gearbox is limited to replacing bearings, seals,
and gaskets. Replacing gears, shafts, and a housing is not cost effective.
Purchasing a complete gearbox is more economical.
2.
Inspect gearbox for leakage and bad bearings. Leakage is a very serious
problem and must be corrected immediately. Bearing failure is indicated
by excessive noise and side-to-side or end-play in gear shafts.
SEAL REPLACEMENT
Recommended sealant for gearbox repair is Permatex
Gasket or equivalent.
Leakage can occur at the vertical or horizontal gaskets and shaft seals.
Leakage at the horizontal gasket or seal can be repaired without removing the
gearbox from the cutter.
SEAL INSTALLATION
NOTE: Proper seal installation is important. An improperly installed seal will
leak.
1.
Clean area in housing where seal outer diameter (OD) seats. Apply a thin
coat of Permatex.
2.
Inspect area of shaft where seal seats. Remove any burrs or nicks with
an emery cloth.
3.
Lubricate gear shaft and seal lips.
4.
Place seal squarely on housing, spring-loaded lip toward housing. Select
a piece of pipe or tubing with an OD that will sit on the outside edge of the
seal but will clear the housing. Tubing with an OD that is too small will
bow seal cage and ruin seal.
5.
Carefully press seal into housing, avoiding distortion to the metal seal
cage..
1. Seal
2. Pipe or tube
3. Seal seat
4. Casting
Pipe or tube must
press at outer
edge of seal.
Incorrect
Installation
Figure 18.
MAN1256 (3/23/2018)
DEALER SERVICE
®
Aviation 3D Form-A-
Seal Installation
GEARBOX REPAIR - DS8.30E
(Figure 19)
NOTE:
Repair to this gearbox is limited to replacing bearings, seals, and
gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchas-
ing a complete gearbox is more economical.
Gearbox is heavy: do not attempt to move without mechanical assistance.)
Remove Gearbox from Cutter
1.
Disconnect and remove the rear driveline from the gearbox.
2.
Remove vent plug (9) and siphon gear lube from housing through this
opening.
3.
Remove cotter pin or wire, washer, and nut from vertical shaft and
remove crossbar (see Crossbar Removal, page 37).
4.
Remove the four bolts that attach gearbox to cutter and remove gearbox.
Disassemble Gearbox
1.
Remove plug from side of gearbox and pour out remaining gear oil.
2.
Support housing in vise in a vertical position.
3.
Remove input seal (4) (to be replaced).
4.
Remove retaining rings (6) and (8).
5.
Remove the six cap screws (24), washers (23) and top cover (2) from
housing.
6.
Remove retaining ring (6) behind gear (3).
7.
Support gearbox in hand press and pull input shaft (5) through gear (3).
Remove ball bearing (21).
8.
Remove ball bearing (20) and gear spacer (7) from input shaft (5).
9.
Support housing in vise in a horizontal position.
10.
With the hub/stump jumper/crossbar, castle nut, cotter pin, wire and
washer already removed, remove the four cap screws (13), lock washers
(12) and output cap (17).
11.
Remove output gaskets (11) and (10).
12.
Push output shaft and pinion (19) down and remove ball bearing (20) or
tapered roller bearings (25), output bearing spacer (18), and retaining
ring (6). Remove output shaft and pinion (19).
NOTE:
On gearboxes with tapered roller bearings, it will be necessary
to use a punch to drive out bearing cups.
13.
Inspect gears for broken teeth and wear. Some wear is normal and will
show on loaded side. Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
14.
Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the
areas where the seals seat. Resurface any damage with emery cloth.
15.
Inspect housing and caps for cracks or other damage.
SEAL REPAIR - DS8.30E
(Figure 19)
Vertical Shaft Seal Repair
1.
Disconnect and remove the rear driveline from the gearbox.
2.
Remove vent plug (9) and siphon gear lube from housing through this
opening.
3.
Remove crossbar (see Crossbar Removal, page 36).
4.
Remove output cap (17) and output seal (16) by removing four cap
screws (13) and washers (12). Replace with new seal (see Seal
Installation, page 20).
Vertical seal should be recessed in output cap.
NOTE:
Distortion to seal cage or damage to seal lip will cause seal to
leak.
5.
Secure output cap (17) on to bottom of gearbox using four cap screws
(13) and lock washers (12).
NOTE:
Make sure output gasket (10) and (11) are in place.
6.
Fill gearbox with SAE 80W or 90W gear lube until it runs out the side
level plug.
7.
Remove and replace any seal damaged in installation.
Horizontal Seal Leak Repair
1.
Disconnect and remove the rear driveline from the gearbox.
2.
Remove vent plug (9) and siphon gear lube from housing through this
opening.
3.
Remove input seal (4). Replace with new one (refer to Seal Installation,
page 20).
Fill gearbox with SAE 80W or 90W gear lube until it runs out the side level plug.
Reassemble Gearbox - DS8.30E
1.
Clean housing, paying specific attention to areas where gaskets will be
installed.

Dealer Service 20