b17c b25c Axles A

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DROP-BOX , AXLES AND BRAKES
PROPSHAFTS
MAINTENANCE
The maintenance of the propshafts is divided into three categories: Inspection, lubrication
and torque specs of retaining bolts lock nuts.
WARNING:
INSTALL ARTICULATION SAFETY BAR BEFORE

WORKING ON THE MACHINE
CAUTION:
DO NOT CLEAN THE PROPSHAFTS WITH STEAM, HOT

WATER PESSURE JETS, OR DETERGENTS
INSPECTION
• Before commencing with the inspection, clean the propshafts using suitable cleaning
apparatus
• Inspect the entire propshaft for cracks, impact distortion (e.g. dents) and material
wear. If any damage wear is evident, replace the propshaft immediately
• Ensure that all grease nipples, and circlips are correctly fastened to their respective
propshafts, plus balance plates where applicable
 COPYRIGHT REFERENCE PAGE

BELL EQUIPMENT TRAINING AXLES , BRAKES 1
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CAUTION:
WHEN CHECKING FOR BACKLASH, DO NOT TURN THE

PROPSHAFT AT THE FLANGE YOKE WITH ANY FORM
OF LEVER
• Inspect the propshaft for backlash by trying to turn the propshaft by hand. No
backlash or free play should be apparent at the propshaft flange or splines.
• The propshaft phasing is probably the most important part of the inspection routine
and can cause serious damage to drive train components.
Phasing insures you that all the propshafts universals are parallel to one another
Refer to the figure below

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LUBRICATION
GREASE NIPPLES
Before commencing with lubrication maintenance, check the latest Bell RSG on service
and lubrication intervals (When greasing observe the following).
• Clean the grease nipple of all grease and dirt

• The maximum permissible pressure for transferring the grease through the grease
nipples is 150 kPa
• To prevent possible damage to the propshaft seals, use a smooth flowing action when
pumping the grease through the grease nipples.
CAUTION:
EXCESSIVE PRESSURE MAY DISLODGE SEALS

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PROPSHAFT LAYOUT
ITEM DESCRIPTION
A Transmission to Drop Box
B Transmission to Pump
C Drop Box to Front Axle
D Drop Box to Oscillation Propshaft
E Oscillation shaft and bearings
F Oscillation Propshaft to Middle Axle
G Intermediate diff
H Middle Axle to Rear Axle

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RETAINING BOLTS AND LOCK NUTS TORQUE CHECK
P006599
The following points must be adhered to when checking the torque of each retaining bolt.
• Check the torque of each retaining bolt and lock nut at the flange in a diametrically
opposite pattern.
• If a lock nut or retaining bolt is missing or defective it must be replaced immediately
TORQUE VALUES
The retaining bolts of all the propshaft bolts are torqued to 120 nm.

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TROUBLESHOOTING
• Troubleshooting on the propshafts is carried out using visual checks and listening for
unusual noises or vibrations.
• The table below lists possible problems that may occur with the propshafts. This list is
not exhaustive.
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY

Vibration from a driveline Incorrect alignment Check alignment
Worn coupling Change coupling
Worn/tight universal joint Change propshaft
Balancing weight fallen Change propshaft
off
Sliding splines worn Change propshaft
Propshaft damaged Change propshaft
Kusel coupling seized up Change Kusel coupling
(B30C only)
Noises from a propshaft Worn universal joint Change propshaft
when rotating
Retaining bolt/lock nut Change/tighten retaining
missing/loose bolt/lock nut
Worn or defective Change propshaft
bearings
Lack of lubrication Lubricate as necessary
Metallic grating sound Worn universal joint Change propshaft
consistent with road
speed

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DROPBOX
The Dropbox used in the Bell B17C – B25C is very simple in design, the following
workshop manual details the overhaul procedure of the Dropbox.

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TECHNICAL DATA
Input torque Max 9000 Nm

Output Torque Max (Front) 3326 Nm
Output Torque Max (Rear) 6652 Nm
Ratio 1.109 : 1
Power 177 kW
Weight 204 Kg
Lubrication
Transmax ‘S’ and Transmax ‘Z’ are approved oil’s for the Bell Dropbox
Capacity 4,5 Litres
Oil level
Fill the dropbox with approximately 4,5 Litres of oil, Through the top filler hole until the oil
is level with the bottom level hole.
Note: Earlier models may have only one hole which should be used as a filler and oil
level check hole.
Service Schedule
Refer to the latest Bell RSG for the service interval.

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DISASSEMBLY OF DROPBOX BELL 9100
1 During all repairs pay attention to cleanliness. Therefore, dropdown gearboxes

removed from vehicle must be cleaned (preferably steam cleaned), prior to
dismantling.
2 Disassembling, repair and assembly have to be carried out in a workshop
environment by adequately trained personnel.
3 Components such as: oil seals, O-rings, cap screws (40), screws (38 and 39) must
be generally replaced whereas bush (63) and thrust washer (64) should be
replaced if the "Teflon" coating is worn or damaged.
4 For the preheating of bearings use bearing heater with demagnetising features.

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1 Mount dropdown gearbox to assembly stand manipulator and

secure.
2 Removal of Flanges from Dropdown Gearbox (Fig. 1)
2.1 Remove nuts (15) from flanges (13 and 14).

2.2 Remove flanges (13 and 14).
3 Removal of Front Output Assembly from Gearbox (Fig. 2)
3.1 Remove screws (39) and washers (45) holding clutch housing sub-assembly (3) to
housing (1).
3.2 Clean 2 jacking holes M10 at clutch housing (3) and fit two eye bolts M10.
3.3 Clean 2 jacking holes M10 at cover (2). Fit two jacking screws M10 x 30 to cover
(2).Loosen and remove front output sub-assembly (3) from housing (1) by using a
lifting device. Remove jacking and eye bolts.
3.4 Rotate dropdown gearbox in stand manipulator 180°.
4 Removal of Rear Output Assembly from Housing (Fig. 3)
4.1 Remove screws (38) holding bearing housing (4) to housing (1).
4.2 Clean 2 jacking holes M10 at bearing housing (4). Fit two jacking screws M10 and
loosen bearing housing (4) from housing (1). Remove jacking screws.
4.3 Rotate dropdown gearbox in stand manipulator 180°.

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5 Removal of Idler Gear & Idler Shaft Assembly from Housing

(Fig. 4)
5.1 Remove screws (38). Clean jacking holes M10. Fit jacking screws M10 and
remove cover (5) from dropdown gearbox
5.2 Remove cap screws (40). Rotate dropdown gearbox in stand manipulator 180°.
5.3 Remove screws (50) and cover (48).
5.4 Remove screws (38). Clean jacking holes M10. Fit jacking screws M10 to cover
(6) and remove cover.
5.5 To loosen idler shaft (11) from idler gear (17), tap shaft lightly with plastic mallet
and remove idler shaft (11).
5.6 Secure idler gear (17), rotate dropdown gearbox in stand manipulator 180° and
remove idler gear (17).
6 Removal of Input Gear & Input Shaft Assembly from Housing

(Fig. 5)
remove cover (7).
6.2 Remove cap screws (40) and rotate dropdown gearbox in stand manipulator 180°.
6.4 Clean jacking holes M10. Fit jacking screws M10 and remove cover (8).
6.5 To loosen input shaft (12) from input gear (18), tap shaft lightly with plastic mallet
and remove input shaft(12).
6.6 Secure input gear (18) and rotate dropdown gearbox in stand manipulator 180°
and remove input gear (18).

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7 Remove Clutch Housing from Output Gear Assembly (Fig. 6)
remove clutch housing (3) from output gear assembly (16).
7.2 Remove circlip (43) from output gear assembly(16).
7.3 Place output gear assembly (16) on a set of parallels and press out gear assembly.
7.4 Turn over cover (2) and place on parallels. Press out bearing (24).
8 Remove Output Gear Sub-Assembly from Planet Carrier Assembly

(Fig. 7)
8.1 Remove grub screws (72).

Note: Heat area around grub screws with heating torch to break Loctite seal on
grub screws.
8.2 Remove cap screws (84) from planet carrier assembly and remove output gear (16).
8.3 Remove bush (63) and thrust washer (64) from output gear (16).
8.4 Removal of inner race (22/1) from output gear (16).
Note: Version A: Applicable to output gears (16) with configuration of "2 slots
Type 12". Use standard bearing puller.
Version B: Applicable to output gears (16) with configuration of 3 extraction
holes Ø 6.
8.5 Remove ring gear (51) from planet carrier assembly.
8.6 Remove thrust washer (64) from ring gear (51).
8.7 Remove sun gear (53), bush (63) and thrust washer (64) from planet carrier (25).
8.8 Remove clutch insert (54) from planet carrier (25).
8.9 Remove circlips (75) from planetary pins (61).
8.10 Press out planetary pins (61).
8.11 Remove planetary gears (52).

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9 Removal of Fork Mechanism from Clutch Housing (Fig. 8)

9.2 Remove cap screw (41).
9.3 Remove switch (70) and washer (71) from cover (56).
9.5 Remove spring (69) from housing (3).
9.6 Unscrew piston (59) from housing (3).
9.7 Remove fork (60) from clutch slide (55).
9.8 Remove clutch slide (55) from shaft (20).
10 Removal of Output Shaft from Front Cover Assembly (Fig. 9)
10.1 Remove oil seal (26) from housing (3).

10.2 Press out shaft (20). Use hydraulic press
10.3 Remove circlip (44) from housing (3).
10.4 Press out bearing (23).

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11 Removal of Output Shaft from Cover (Fig. 10)

11.1 Remove oil seal (26).
11.2 Place cover assembly (4) on support with threaded end of shaft(10) facing up.
Tap down shaft (10) with plastic mallet until inner race (65/2) comes loose, then
remove it.
11.3 With cover assembly (4) remaining mounted to support press out shaft (10). Use
hydraulic press
11.4 Tap off inner race (65/1) from shaft (10). Use copper drift.
11.5 Remove bearing (22) from housing (4). Use bearing puller. Remove circlip (44).
11.6 Press out bearing (65).
12 Removal of Cover Intermediate from Shaft (Fig. 11)
12.1 Remove covers (5 & 6) from shaft (11).

12.2 Remove inner races (21/1) from shaft (11). Use bearing puller.
12.3 Remove bearing (21) from covers (5 & 6). Use bearing puller.

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13 Removal of Input Cover Front from Shaft (Fig. 12)
13.1 Remove cover (7) from shaft (12).

13.2 Remove inner race (21/1) from shaft (12). Use bearing puller.
13.3 Remove bearing (21) from cover (7). Use bearing puller.
13.4 Remove seal (26) from cover (7).
14 Removal of Input Cover Rear from Shaft (Fig. 13)
14.1 Remove circlip (42) from shaft (12).

14.2 Remove circlip (44) from cover (8).
14.3 Place housing (8) on top of support and press out shaft (12).
14.4 Remove bearing (23) from cover (8). Use bearing puller.

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ASSEMBLY OF THE DROPBOX

General
The tightening of the input and output flanges as well as the dropbox mountings are
critical and should be torqued according to spec. Failure to comply with this will result in
serious damage to the dropbox and drive train.
Never swop or change bearing races (taper roller) Keep them as a matched set.
When pre-heating bearings use a bearing heater with de-magnetising features.
Make sure all components are clean and free from dirt before assembly.

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1 Housing Sub-Assembly (Fig 1.)

1.1 Steam clean housing (1) thoroughly. (Oil channels; threaded holes).
1.2 Fit lifting lug (37) to housing (1)
1.3 Mount housing to assembly stand manipulator and secure.
1.4 Check all joint-sealing faces and dress with oilstone, if necessary.
1.5 Fit filler plug (33 x 3) with copper washer (35 x 3) and drain plug magnetic (34)
with copper washer (35) to housing (1) and torque to 25Nm.
1.6 Fit copper washer (D3) to plug (D4), apply “UHU-Plus” to thread of plug and
install to housing (1).
!.7 Apply “UHU-Plus” to screw plug M10 and fit to housing (1).
Note: Housing (1) has to be pressure tested after “UHU-Plus” has set. Curing
time 24 Hrs.
1.8 Fit 48 helicoils (HCM) to housing (1).
Note: 16 Threaded inserts were fitted during the machining operation.
2 Cover Sub-Assembly (Fig. 2)

2.1 Fit 8 helicoils to cover (2).
3 Clutch Housing Sub-Assembly (Fig. 3)

3.1 Apply “UHU-Plus” to screw plug M10 and magnet plug M10 and fit “UHU-Plus” to
clutch housing (3).
4 Bearing Housing Rear Sub-Assembly (Fig. 4)

4.1 Apply “UHU-Plus” to screw plug M10 and fit to bearing housing (4).

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37
33, 35
HCM
HCM
33, 35
HCM
D3, D4
M10
34, 35
Fig. 1
3
82
HCM M10
4
Fig. 3
Fig. 2
M10
Fig. 4

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5 Input Shaft Sub-Assembly (Fig. 5)

5.1 Preheat input insert rear (8) to 85°C on hotplate. Fit bearing (23) to insert input
rear (8) and secure with circlip (44).
Note: Open end of circlip (44) to be aligned with oil access hole of cover (8).
5.2 Preheat inner race of bearing (23) to 85°C. Fit shaft input (12) into bearing (23)
and secure with circlip (42).
6 Input Insert Front Sub-Assembly (Fig. 6)

6.1 Preheat input insert front (7) to 85°C on hotplate and fit bearing (21) to input
insert front (7).
Note: Allow unit to cool down prior proceeding with the following operation.
6.2 Apply a thin layer of lithium based grease to lip of seal (26). Apply Loctite 518 to
OD of seal and fit same to input insert front (7).
6.3 Preheat and demagnetise inner race (21/1) to 85°C (use bearing heater) and fit to
shaft (12).
6.4 Fit pre-assembled input insert front (7) to sub-assembly input shaft (Fig. 5).
7 Idler Shaft Sub-Assembly (Fig. 7)

7.1 Preheat insert idler PTO (6) to 85°C on hotplate and fit bearing (21) to bore of
insert idler (6).
shaft idler (11).
7.3 Preheat insert idler front (5) to 85°C on hotplate and fit bearing (21) to insert idler
front (5).
shaft idler (11).
7.5 Fit insert idlers (5 & 6) to shaft idler (11).

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42
12 44
23
Fig. 5
21 21/1
[Fig 3]
7
12
26
21
21/1
Fig. 6
21/1 6
21
11
Fig. 7

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8 Flange Sub-Assembly (Fig. 8)

8.1 Apply Loctite 638 to ID of mud shield (19) and press onto flange (14).
8.2 Apply Loctite 638 to ID of mud shield (19) and press onto output flange (13).
Note: Flange (13) is required 2 x per main assembly. (Also see Fig. 20)
9 Bearing Housing Rear Sub-Assembly (Fig. 9)

9.1 Preheat bearing housing (4) to 85°C on hotplate and fit bearing (65) into bore of
housing (4).
9.2 Fit circlip (44) into groove of housing (4).
9.3 Fit bearing (22) into bore of housing (4).
shaft (10).
9.5 Integrate pre-assembled bearing housing (4) with shaft (10).
9.6 Preheat and demagnetise inner race (65/2) to 85°C and fit to shaft (10).
Note: Allow unit to cool down prior proceeding with the following operation.
9.7 Apply a thin layer of lithium based grease to lip of seal (26). Apply Loctite 518 to
OD of seal (26) and tap seal into bearing housing (4).

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19
19
13 14
Fig. 8
26
65/2
65/1
10
22
4
65
22/1 44
Fig. 9

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10 Front output shaft sub-assembly (Fig 10 )
10.1 Preheat clutch housing (3) on hotplate to 85°C and fit bearing (23) to bore of
clutch housing (3).
10.2 Fit circlip (44) onto grove of clutch housing.
10.3 Preheat bearing (23) to 85°C. Fit output shaft (20) into bearing (23).
Note: Allow unit to cool down before proceeding with the following operation.
10.4 Apply a thin layer of Lithium based grease to lip of seal (26) Apply loctite 518 to
OD of seal (26) and tap seal into clutch housing (3).

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20
3
44
26
23
Fig. 10

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11 Clutch Sub-Assembly (Fig.11)

11.1 Fit clutch slide (55) over shaft (20) of front output shaft sub-assembly. Ensure
free movement between slide (55) and shaft (20) over the entire splined length.
11.2 Install screw (41) into fork (60), screw piston (59) into fork (60), tighten screw (41)
until all thread clearance between fork (60) and piston (59) has been taken up,
but free rotation is still possible.
Separate fork (60) and piston (59) without disturbing setting of screw (41). Insert
fork (60) to clutch slide (55) in housing (3).
11.3 Apply a thin layer of lithium based grease to lip of seal (66) and fit to piston (59).
Note: Seal lip of seal (66) facing away from body of piston.
Apply a thin layer of lithium based grease to piston bore of clutch housing (3).
Slightly lubricate the two support journals for piston (59) at housing (3) with
grease.
11.4 Insert spring (69) to housing (3), screw piston (59) into fork (60).
11.5 Fit cover (56) with O-ring (67) to housing (3), fasten cover (56) with screws (38)
and torque to 54Nm.
11.6 Fit switch (70) with washer (71) to cover (56) and torque switch (70) to 25Nm.
Install cover (D1) to switch (70).

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41
60
3 55
20
69
59
66
67
38
D1
56
70, 71
Fig. 11

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12 Splitter Sub-Assembly (Fig. 12)
Note: It is a pre-requisite to keep the planetary gears (52) in their original

matched set of three.
12.1 Apply lithium based grease to bore of planetary gears (52). Place 28 needle
rollers (62) to bore on one side of planetary gear (52) and turn gear over. Insert
spacer (81) and place second row of 28 needle rollers (62) to bore of planetary
gear (52). Apply lithium based greases to both sides of planetary gear (52) and
attach wear washer (85 x 2) to either side of gear.
12.2 Preheat planetary carrier (25) to 75°C on a hot plate. Immerse planetary pins
(61) into liquid nitrogen.
12.3 Apply anti- scuff spray into receiving bores of planetary pins (61).
Place planet gear assemblies (52) into position. Alignment of needle races and
wear washers with the receiving bores of the planet pins (61) can be facilitated
using a dummy pin.
12.4 When installing the planetary (61) to planetary carrier (25) ensure that the oil hole
identification notch at the planetary pinhead faces radially outwards.
12.5 Fit circlips (75) to planetary pins (61) with the open ends facing radially outwards.
12.6 Check for free rotation on all the planetary gears. Blow compressed air through
lubrication holes of planetary pins (61) to clear oil passages from residual grease.
12.7 Fit pin spring (76) to clutch insert (54).
Note: Protrusion of pin (76) must not exceed 1.3 ± 0.2mm.
12.8 Integrate clutch insert (54) with planetary carrier (25)
12.9 Apply Loctite 270 to thread of set screws (72). Fit to planetary carrier (25) and
torque set screws to 12Nm Take care that clutch insert (54) does not lift whilst set
screws (72) are tightened. Caulk set screws (72) with one centre punch mark.
12.10 Apply a thin layer of lithium based grease to thrust washer (64) and fit to
Planetary carrier (25) over spring pin (76)
Note: Metallic face of thrust washer (64) facing clutch insert (54).

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12.11 Apply anti-scuff spray to receiving bore of bush (63) at planetary carrier (25). Apply
a thin layer of lithium based grease to O/D of bush (63) and press bush into
planetary carrier (25).
Note: Bush has to be flush with inner face of planetary carrier.
12.12 Integrate sun gear (53) with planetary carrier (25).
12.13 Fit spring pin (76) into ring gear (51).
Note: Protrusion of spring pin must not exceed 1.3 ± 0.2mm.
12.14 Apply a thin layer of lithium based grease to thrust washer (64) and fit over spring
pin (76) to ring gear (51).
Note: Metallic face of thrust washer facing ring gear (51).
12.15 Integrate ring gear (51) with planetary carrier (25). Check free rotation of planetary
gear set.
12.16 Fit spring pin (76) into output gear (16).
Note: Protrusion of spring pin must not exceed 1.3 ± 0.2mm.
12.17 Apply thin layer of lithium based grease to thrust washer (64) and fit over spring pin
(76) to output gear (16).
12.18 Apply anti-scuff spray to receiving bore of bush (63) at output gear (16). Apply a
thin layer of lithium based grease to O/D of bush (63) and press bush into output
gear (16).
12.19 Note: Bush (63) bottom must be against thrust washer (64).
Prior to integration of sub-assemblies: Output gear (16) and planetary carrier (25),
apply a thin layer of lithium based grease to thrust washers (64) and I/D of bushes
(63).
12.20 Integrate output gear assembly with planetary carrier (25) and align bolt holes.
Note: The operational torque is transferred between output gear assembly (16)
and planetary carrier assembly (25) by means of friction, therefore, it is important to
keep the interface dry and clean during assembly.
12.21 Fit two cap screws (84) without Loctite and torque to approx. 80 Nm. Check free
rotation of planetary gear set.
12.22 Apply Loctite 243 to thread of cap screws (84) and torque cap screws to 156Nm

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13 Front Output Sub-Assembly (Fig. 13)
13.1 Preheat cover (2) on hotplate to 85°C. Fit bearing (24) to cover (2).
13.2 Secure bearing (24) to cover (2) Allow cover to cool down prior proceeding with
the following operation.
13.3 Determine dimension from outer race of bearing (24) to cover (2) at three points
120° apart. This dimension should be between 13.70 and 14.00mm with a
permissable variation of 0.055mm, to ensure proper seating of bearing (24).
13.4 Preheat inner race of bearing (Integrate cover (2) with splitter sub-assembly [Fig.
12] with bearing fixture 24) to 85°C.
Allow bearing to cool down and fit circlip (43).
13.5 Determine dimension between joint face and bearing seat at clutch housing (3).
This dimension should be between 14.00 and 14.10mm within a permissible
variation of 0.02mm. Fit O-rings (27) and (68) to clutch housing sub-assembly
(3).
13.6 Preheat bearing bore of clutch sub-assembly to 85°C.
13.7 Fit bolt (38) and torque to 54Nm.
14 Integration of Sub-Assemblies with Housing (Fig. 14)
14.1 Mount housing to assembly stand manipulator and secure.

14.2 Load input gear (18) with ground face toward housing through bottom bore of
housing (1). Slide in position and secure.
14.3 Rotate housing in stand manipulator 180°.

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15 Fitment of Input Sub-Assembly to Housing (Fig. 15)
Note: The operational torque between input shaft (12) and gear (18) is
transferred by friction. Therefore it is critical to keep the interface dry and clean
during assembly.
15.1 Preheat bore of input gear (18) to 85°C and preheat receiving bore for gear (18)
at housing (1) to 85°C. Use heating torch.
15.2 Apply a thin layer of lithium based grease to O-ring (30) and fit to insert (8) of
sub-assembly (12).
Note: Mating faces between items (1) and (8) must remain dry and clean.
15.3 Fit two guide pins to Insert (12). Fit two guide pins to housing (1) and install
insert (12) to housing (1).
15.4 Apply a thin layer of lithium based grease to second O-ring (30) and fit to cover
(8). Fit cover (8) to insert (12) and cover (9) to cover (8). Secure with 2 screws
(39). Remove guide pins ; fit remaining screws (39) and torque to 54Nm.
15.5 Rotate housing in stand manipulator 180°.Remove guide pins. Apply Loctite 243
to cap screws (40) and fit to input shaft (12). Torque cap screws (40) to 156Nm.
Note: The first two cap screws to be tightened incrementally, diagonally across
to ensure that input gear (18) is seated square on input shaft (12).
For axial clearance refer to clearance table on page 50
15.6 Protect bearing on input shaft (12).Fit two guide pins to housing (1). Preheat
receiving bore for cover (7) at housing (1) to 85°C. Use heating torch.
15.7 Apply a thin layer of lithium based grease to O-ring (30) and fit to cover (7).
15.8 Fit sub-assembly of cover (7) to housing (1). Remove two guide pins ;
secure cover (7) with screws (38), torque to 54Nm.

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16 Fitment of Idler Gear to Housing (Fig. 16)
16.1 Load idler gear (17) with ground face toward housing, through bottom bore of
housing (1), slide in position and secure.

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17 Fitment of Idler Assembly to Housing (Fig. 17)
17.1 Preheat bore of idler gear (17) to 85°C. Apply anti-scuff spray to receiving bore of
idler shaft sub-assembly (11) at housing (1). Preheat bore of housing (1) to75°C.
17.2 Apply a thin layer of lithium based grease to O-ring (30) and fit to cover of sub-
assembly (6).
Note: Keep mating faces between items (1) and (6) dry and clean.
17.3 Fit two M12 guide pins to idler shaft sub-assembly (11) and integrate with idler
gear (17).
17.4 Fit two guide pins to housing (1) and fit cover sub-assembly (6) to housing (1).
Remove guide pins M10 and secure cover (6) to housing (1) with screws (38) and
hand tighten only.
17.5 Rotate housing in stand manipulator 180°. Remove two guide pins M12. Apply
Loctite243 to thread of cap screws (40) and fit to idler shaft (11). Torque cap
screws (40) to156Nm.
Note: The first two cap screws to be tightened incrementally, diagonally across,
to ensure that idler gear (17) is seated square on idler shaft (11).
17.6 Measure axial clearance of bearing (21) at the idler shaft (11). For axial clearance
refer to clearance table on page 50
17.7 Protect idler shaft (11) Preheat receiving bore for cover (5) at housing (1) to 85°.
Use heating torch.
17.8 Apply a thin layer of lithium based grease to O-ring (30) and fit to sub-assembly
cover (5). Note: Keep mating faces between items (1) and (5) dry and clean.
17.9 Fit 2 guide pins to housing (1). Fit sub-assembly of cover (5) to housing (1).
Remove guide pins and secure cover with screws (38) and torque to 54Nm.
17.10 Rotate housing in stand manipulator 180°. Torque screws (38) at cover (6) to
54Nm.
17.11 Apply a thin layer of lithium based grease to O-ring (49) and fit to cover (6).
17.12 Fit cover (48) to cover (6) and secure with screws (50) and torque to 54Nm. Refer
to clearance table on page 50

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18 Fitment of Rear Output to Housing (Fig. 18)
18.1 Preheat receiving bore for bearing housing rear sub-assembly (4) at housing (1) to
85°C. Use heating torch.
18.2 Apply thin layer of lithium based grease to O-rings (31) and (27). Fit O-ring (31) to
bearing housing (4) and O-ring (27) to housing (1).
Note: Keep mating faces between items (1) and (4) dry and clean.
18.3 Fit 2 guide pins to housing (1) and integrate sub-assembly of bearing
housing (4) with housing (1). Remove M10 guide pins and secure sub-assembly of
bearing housing (4) with screws (38) and torque to 54Nm.
19 Fitment of Front Output to Housing (Fig. 19)

19.2 Preheat inner race (22/1) to 85°C and demagnetise. Use bearing heater. Fit inner
race (22/1) to front output assembly (16).
19.3 Protect output shaft and preheat receiving bore at housing (1) to 75°C. Use
heating torch.
19.4 Apply thin layer of lithium based grease to O-ring (32) and fit to front output housing
(2).
Note: Keep mating faces between item (1) and (2) dry and clean.
19.5 Fit 2 guide pins to housing (1) and integrate front output sub-assembly (16) with
housing (1). Secure with screws (39) and washers (45) and torque to 54Nm.

ADT ‘C’ SERIES

ADT ‘C’ SERIES
20 Flange Installation (Fig. 20)
20.1 Apply copper compound to splines of output flange (14) and fit to output shaft (10).
20.2 Apply thin layer of copper compound to O-ring (28) and fit to groove of flange (14).
20.3 Clean and degrease nut (15) and thread at output shaft (10) prior assembly. Apply
Loctite 277 to thread and a slight layer of copper compound to face of nut (15). Fit
output flange (14) to output shaft (10). Fit nut (15) and torque to 845Nm.
Note: Take care not to contaminate threads with copper compound.
20.4 Apply copper compound to splines of flanges (13) and fit to input shaft (12)
respectively to output shaft (20). Apply a thin layer of copper compound to O-rings
(28) and fit to groove of flanges (13).
20.5 Clean and degrease nuts (15) and thread at shafts (12) and (20) prior assembly.
Apply Loctite 277 to threads and a slight layer of copper compound to face of nuts
(15). Fit one flange (13) to output flange (20) and one flange (13) to input shaft
(12). Fit nuts (15) and torque to 845Nm.
Note: Take care not to contaminate threads with copper compound.

ADT ‘C’ SERIES

ADT ‘C’ SERIES
21 Dog Clutch Final Adjustment (Fig. 21)
21.1 Apply air pressure (6-8.1 bar max) to engage clutch.

Note: Thread at air connection is M12 x 1.5.
21.2 Ensure that teeth of clutch slide (55) and clutch insert (54) are fully engaged.
21.3 The face of the fork (60) pointing towards the planetary splitter assembly must
clear the side of groove at clutch slide (55) by 0.20 to 0.40mm, with the aim
towards maximum setting of 0.40mm. Adjustments can be made by rotating piston
(59). Use flat spanner 13.
21.4 Apply air pressure several times to engage clutch. Check setting and function of
dog clutch. Check for air leaks.
21.5 While clutch is disengaged, check clearance of 1.0mm between tip of dog clutch
teeth at clutch slide (55) and clutch insert (54).
21.6 Rotate output flange by hand until teeth of clutch slide (55) and clutch insert (54)
are aligned to each other on top. Connect test lamp to switch (70). At this setting
the test lamp must not light up, indicating (open circuit) dog clutch disengaged.
If at the same setting the test lamp lights up indicating (closed circuit) dog clutch
Engaged, the aluminium sealing washer (71) has to be replaced by the thinner
3/4" fibre washer.
21.7 After adjustment has been completed remove screw (41). Apply Loctite 243 to
thread.Re-install screw and torque to 18Nm.
Note: With dog clutch released, the fork (60) with screw (41) must clear casting of
clutch housing.
21.8 Apply Loctite 518 to sealing area for cover (57) at clutch housing (3). Fit screws
(73) and torque to 12Nm.
21.9 Fit plastic protection plug (D2) to air supply port at clutch housing (3) and breather
connection at housing (1).
21.10 Insure model number, serial number and date are on main housing; clutch
housing and rear bearing housing.

ADT ‘C’ SERIES

ADT ‘C’ SERIES
1 AXIAL CLEARANCES TABLE
1.1 Inside planetary output stage 0.1 to 0.95mm.
1.2 Output cylindrical roller bearing 0.4 to 1.05mm.
1.3 Idler shaft 0.4 to 1.2mm.
1.4 Input shaft 0.4 to 1.2mm.
2 GEAR BACKLASH
2.1 Input - idler gear mesh 0.262 to 0.500mm.
2.2 Idler - output gear mesh 0.262 to 0.382mm.
2.3 Sungear - planetary gear mesh 0.154 to 0.234mm.
2.4 Planetary gears - ring gear mesh 0.199 to 0.328mm


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ADT ‘C’ SERIES

DROP-BOX , AXLES AND BRAKES

INSTALL ARTICULATION SAFETY BAR BEFORE

DO NOT CLEAN THE PROPSHAFTS WITH STEAM, HOT

 COPYRIGHT REFERENCE PAGE

WHEN CHECKING FOR BACKLASH, DO NOT TURN THE

 COPYRIGHT REFERENCE PAGE

• Clean the grease nipple of all grease and dirt

EXCESSIVE PRESSURE MAY DISLODGE SEALS

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

RETAINING BOLTS AND LOCK NUTS TORQUE CHECK

 COPYRIGHT REFERENCE PAGE

SYMPTOM POSSIBLE CAUSE REMEDY

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

Input torque Max 9000 Nm

Refer to the latest Bell RSG for the service interval.

 COPYRIGHT REFERENCE PAGE

DISASSEMBLY OF DROPBOX BELL 9100

1 During all repairs pay attention to cleanliness. Therefore, dropdown gearboxes

 COPYRIGHT REFERENCE PAGE

1 Mount dropdown gearbox to assembly stand manipulator and

2.1 Remove nuts (15) from flanges (13 and 14).

3 Removal of Front Output Assembly from Gearbox (Fig. 2)

4 Removal of Rear Output Assembly from Housing (Fig. 3)

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

5 Removal of Idler Gear & Idler Shaft Assembly from Housing

6 Removal of Input Gear & Input Shaft Assembly from Housing

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

7 Remove Clutch Housing from Output Gear Assembly (Fig. 6)

8 Remove Output Gear Sub-Assembly from Planet Carrier Assembly

8.1 Remove grub screws (72).

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

9 Removal of Fork Mechanism from Clutch Housing (Fig. 8)

9.1 Remove screws (73) and cover (57).

10 Removal of Output Shaft from Front Cover Assembly (Fig. 9)

10.1 Remove oil seal (26) from housing (3).

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

11 Removal of Output Shaft from Cover (Fig. 10)

12 Removal of Cover Intermediate from Shaft (Fig. 11)

12.1 Remove covers (5 & 6) from shaft (11).

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

13 Removal of Input Cover Front from Shaft (Fig. 12)

13.1 Remove cover (7) from shaft (12).

14 Removal of Input Cover Rear from Shaft (Fig. 13)

14.1 Remove circlip (42) from shaft (12).

 COPYRIGHT REFERENCE PAGE

 COPYRIGHT REFERENCE PAGE

ASSEMBLY OF THE DROPBOX

When pre-heating bearings use a bearing heater with de-magnetising features.

 COPYRIGHT REFERENCE PAGE

1 Housing Sub-Assembly (Fig 1.)

2 Cover Sub-Assembly (Fig. 2)

3 Clutch Housing Sub-Assembly (Fig. 3)