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Maintenance Procedure

1. General information

GA Gearbox Overhaul
Printed Matter Number

2946 1654 01

Applicable to

GA

Preliminary Operations:

Safety Instructions

General

Persons Required

Special Tools

Consumables

2. Safety First

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3. Service element

1.

Remove element from gearbox.

2.

Remove O-ring.

3.

Loosen disk.

4.

Remove disk.

5.

Remove bushing.

6.

Mount pump.

7.

Remove gear.

8.

Remove gear: take care that it


does not fall off.

9.

Remove key.

10. Remove spacer ring.

11. Clean shaft.

12. Remove retaining ring.

13. Pull out bearing (1).

14. Pull out bearing (2).

15. Mount new bearing.

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16. Mount new bearing: gently


hammer it using a tool.

17. Mount new retaining ring.

18. Mount spacer ring.

19. Insert new key.

20. Place gear in heater.

21. Heat up gear to 100C + room


temperature (212F + room temp.)

22. Mount gear.

23. Mount ring.

24. Use Loctite 243.

25. Mount disk.

26. Torque disk: 120Nm

27. Grease bearing: use a new, clean


brush.

28. Use a different brush for the O-ring


groove.

29. Mount O-ring.

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4. Service gearbox & reassemble with element

1.

Mount gear lock tool.

2.

Remove 3 bolts pinion.

3.

Mount pump to remove pinion.

4.

Pull of pinion.

5.

Removed pinion.

6.

Remove pinion key.

7.

Remove spacer.

8.

Loosen lipseal assy with a small


jimmy.

9.

Remove lipseal assy.

10. Remove O-ring.

11. Remove lipseal with a tool.

12. Remove tool.

13. Removed lipseal.

14. Mount shelves around bushing.

15. Pull off bushing.

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16. Removed bushing.

17. Remove spacer.

18. Remove bull gear bolts.

19. Remove gear lock tool.

20. Pull off bull gear.

21. Removed bull gear.

22. Mount pump on gear shaft.

23. Push out gear shaft.

24. Remove bearing using a tool and


a hammer.

25. Removed bearing.

26. Clean gearbox.

27. Place bearing in heater.

28. Heat up bearing to 100C + room


temperature (212F + room temp.)

29. Mount bearing on gear shaft.

30. Put some grease in the


gearcasing.

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31. Place gear shaft.

32. Mount lipseal housing over the


shaft (without lipseal!).

33. Push shaft with lipseal housing.

34. Check free rotation.

35. Remove lipseal housing.

36. Mount spacer.

37. Remove Loctite & clean lipseal


housing.

38. Install new lipseal: use Loctite 242.

39. Place new lipseal in the housing,


leave the carbon in place.

40. Mount the plate.

41. Gently push the lipseal in the


housing.

42. Remove the tool.

43. Mount new O-ring.

44. Spread the Loctite over the shaft.

45. Mount lipseal.

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46. Torque lipseal:

47. Check free rotation of the shaft.

48. Place bushing in the heater.

49. Heat up to 100C + room


temperature (212F + room temp.)

50. Mount bushing, be careful, do not


damage the lipseal.

51. Mount bushing, be careful, do not


damage the lipseal.

52. Mount bushing, be careful, do not


damage the lipseal.

Use the old bushing as a tool to push


the new one.

Mount bushing.

53. Mount spacer.

54. Mount key.

55. Put pinion in heater.

56. Heat up pinion to 100C + room


temperature (212F + room temp.)

57. Mount pinion.

58. Mount 3 pinion screws: use Loctite


242.

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59. Mount 3 pinion screws: cool down


before fixing.

60. Mount guides.

61. Put bull gear in heater.

62. Heat up bull gear to 100C + room


temperature (212F + room temp.)

63. Mount bull gear.

64. Place bolts to hold bull gear.

65. Remove guides.

66. Mount gear lock tool.

67. Use Loctite 242 and tighten bull


gear.

68. Torque bull gear: 285 Nm

69. Remove gear lock tool.

70. Mount guiding pins.

71. Mount element.

72. Tighten element and remove


guiding pins.

73. Torque element: 75 Nm

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