remember safety must come first....information contained in this bulletin, ask your supervisor or...

MLT 629.. . MLT 633.. MLT 730 ... ML 632 ...ML 635 ... MT 732 ...MT 835 ...MT 845 ...MT 932 ... MT 940 ... MT 1030 ... MT 1232 ... MT 1240 ... MT 1330 ...MT 1337 ... MT 1637 ... MLT 629 ... SA MLT 633 ... SA MLT 730 ... SAMT 732 ... SA MT 835 ... S2 MT 845 ... S2 MT 932 ... SA MT 940 ... S2MT 1233 ... S2 MT 1330 ... S2 MT 1240 ... S2 MT 1337 ... S2 MT 1637 ... S2MT 1740 ... S2 MLT 627 ... SB E2 MLT 630 ... SB E2 MLT 634 ... SB E2MLT 731 ... SB E2 MLT 735 ... S2 E2 MLT 741 ... S2 E2 MLT 742 ... S2 E2MLT 845 ... S2 E2 MLT 845 ... S3 E2 MLT 940 ... S3 E2 ML 635 ... S3 E2MT 728 ... SB E2 MT 732 ... SB E2 MT 928 ... SB E2 MT 932 ... SB E2MT 940 ... S3 E2 MT 1030 ... S2 E2 MT 1033 ... S2 E2 MT 1235 ... S2 E2MT 1235 ... S3 E2 MT 1240 ... S3 E2 MT 1335 ... S2 E2 MT 1335 ... S3 E2MT 1340 ... S3 E2 MT 1435 ... S2 E2 MT 1435 ... S3 E2 MT 1440 ... S3 E2MT 1740 ... S3 E2 MT 1745 ... S2 E2

N° : 1281CODE : 101 10DATE : 21/05/07

ACCEPTED UNDER WARRANTY

Yes No

Code A Code B Code C A = Compulsory and immediate B = Modification to be made C = For information

modification during maintenance visit

MACHINES CONCERNED :

Subject : SUMMARY OF THE CHANGES TO THE BEVEL GEARBOX AND ITS SETTINGS

ISSUED 20/11/06

CANCELS AND REPLACES THE ISSUE DATED 26/10/04.Addition: Evolution, outside bearing collage on input and output shaft.

This new issue contains a summary of the improvements made to the bevelgearbox and the adjustments to be made when re-installing this.Remember to check the alignment of the bevel gearbox to the engine using toolRef.: 662499 and adjust it if necessary.

After-Sales Service.

TIME REQUIRED FOR MODIFICATION : hour(s)

WEIGHT : - of 1 kg 1 to 5 kg 5 to 10 kg 10 to 25 kg + of 25 Kg

This bulletin is for the use of our distributors' Technical Services departments, is strictly confidential and may not becommunicated to third parties without express authorisation from MANITOU's After-Sales Service.

SAFETY NOTICE

Instructions in the SERVICE BULLETINS assume that the engineer has agood knowledge of safety procedures and has been trained in the

maintenance and repair of equipment. If you do not understand theinformation contained in this bulletin, ask your supervisor or contact

MANITOU SERVICE for advice.

REMEMBER SAFETY MUST COME FIRST.

RECAP OF BEVEL GEAR MODIFICATIONS AND ADJUSTMENTS

MLT 629 ...MLT 633 ..MLT 730 ...

ML 632 ...ML 635 ...

MT 732 ...MT 835 ...MT 845 ...MT 932 ...MT 940 ...MT 1030 ...MT 1232 ...MT 1240 ...MT 1330 ...MT 1337 ...MT 1637 ...

MLT 629 ... SAMLT 633 ... SAMLT 730 ... SA

MT 732 ... SAMT 835 ... S2MT 845 ... S2MT 932 ... SAMT 940 ... S2MT 1233 ... S2MT 1330 ... S2MT 1240 ... S2MT 1337 ... S2MT 1637 ... S2MT 1740 ... S2

D - 20/11/2006

TECHNICAL DATAN° : 1281 CODE : 101 10 PAGE : 2/16

MLT 627 ... SB E2MLT 630 ... SB E2MLT 634 ... SB E2MLT 731 ... SB E2MLT 735 ... S2 E2MLT 741 ... S2 E2MLT 742 ... S2 E2MLT 845 ... S2 E2MLT 845 ... S3 E2MLT 940 ... S3 E2

ML 635 ... S3 E2

MT 728 ... SB E2MT 732 ... SB E2MT 928 ... SB E2MT 932 ... SB E2MT 940 ... S3 E2MT 1030 ... S2 E2MT 1033 ... S2 E2MT 1235 ... S2 E2MT 1235 ... S3 E2MT 1240 ... S3 E2MT 1335 ... S2 E2MT 1335 ... S3 E2MT 1340 ... S3 E2MT 1435 ... S2 E2MT 1435 ... S3 E2MT 1440 ... S3 E2MT 1740 ... S3 E2MT 1745 ... S2 E2

D - 20/11/2006


IMPORTANT : When replacing a part on one of bevel drive shafts, you MUST check bearing preloadand clearance between teeth to ensure optimum bevel drive operation and also limitoperating noise as much as possible.

NOTA : Refer to machine repair manual when removing and refitting bevel drive and components.

CONTENTS

1 - BEVEL DRIVE CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

- Parts required for refitting bevel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

ADJUSTMENT

2 - INPUT AND OUTPUT GEAR IDENTIFICATIONAND POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

3 - BEARING PRELOAD - OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7

4 - BEARING PRELOAD - INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

5 - CLEARANCE ADJUSTMENT BETWEEN TEETH OF TWO GEARS . . . . . . . . Page 11

6 - CLEARANCE ADJUSTMENT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15

7 - BEVEL DRIVE / ENGINE ALIGNMENT ADJUSTMENTAND CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16

D - 20/11/2006


1 - BEVEL GEAR CHANGES

*: CHANGE 1MODIFICATION TO BEVEL DRIVE DIPSTICK (SEE I. T. 1013)

- Modification to position of MIN and MAX marks and addition of approximately 0.2 l of oil.

**: CHANGE 2- Calibrated spacers and spring washer replace originally fitted spacers and shims.

***: CHANGE 3- Compression washer on output shaft replaces retaining plate.

**** : CHANGE 4- Bonding external bearings to shaft at entry and exit.

ORIGINAL ASSEMBLYspacer + shims

CHANGE 1*modification to dipstick

CHANGE 3***compression washer

ORIGINAL ASSEMBLYspacer + shims

INPUT SHAFT OUTPUT SHAFT

CHANGE 2**calibrated spacer

4th CHANGE****bearing adhesive

4th CHANGE****bearing adhesive

CHANGE 2**calibrated spacer

+spring washer

Bevel gear ref.

206 542 C01 . 6146 - -224 053 C01 . 3070 G02 . 05382 B04 . 8006222 758 C01 . 12045 G02 . 17703 B04 . 24930229 493 C01 . 138 - B03 . 160229680 C01 . 11 - -

MIN MAX

122 mm

132 mm

BEFORE

MIN MAX

112 mm

122 mm

AFTER

part to be removed

* : On assy line from bevelgear no.

** : On assy line frombevel gear no.

*** : On assy line frombevel gear no.

Bevel gear ref.

206 542 -224 053 L06 . 1355222 758 L06 . 43448229 493 -229680 -

**** : On assy line frombevel gear no.

D - 20/11/2006


Parts required for refitting bevel drive

1 compression washer Ref. 703 039 Item 11 tube of fixing product 649 Ref. 562 227 Item 2or 1 tube of fixing product 648* Ref. 62 157 Item 31 tube of thread lock 24 Ref. 187 526 Item 42 seals Ref. 550 597 Item 52 O rings Ref. 550 596 Item 61 spring washer Ref. 704 973 Item 71 set of calibrated spacers Ref. 704 982 Item 8- 0,5 mm shim** Ref. 550 587 Item 9- 0,25 mm shim** Ref. 550 588 Item 10- 0,10 mm shim** Ref. 550 589 Item 11- 0,075 mm shim** Ref. 550 590 Item 12- 0,05 mm** shim Ref. 550 591 Item 131 alignment checking tool Ref. 662 499 Item 141 bolt Ref. 561 810 Item 15- HR 16.5 - 60 - 4 washer** (page 16) Ref. 202 946 Item 16- HM 16 - 60 zinc plated bolt** (page 16) Ref. 58 590 Item 17

* NOTA : Fixing product 648 has minimum setting time of 12 hours.**: To be ordered as required

Composition of kit Item 8 :

4

2

3

or

1 11,57mm / 11,59mm calibrated spacer: 702 7791 11,60mm / 11,62mm calibrated spacer: 702 7801 11,63mm / 11,65mm calibrated spacer: 604 7741 11,66mm / 11,68mm calibrated spacer: 604 7751 11,69mm / 11,71mm calibrated spacer: 604 7761 11,72mm / 11,74mm calibrated spacer: 604 7771 11,75mm / 11,77mm calibrated spacer: 604 7781 11,78mm / 11,80mm calibrated spacer: 604 779

1 11,81mm / 11,83mm calibrated spacer: 604 7801 11,84mm / 11,86mm calibrated spacer: 604 7811 11,87mm / 11,89mm calibrated spacer: 604 7821 11,90mm / 11,92mm calibrated spacer: 604 7831 11,93mm / 11,95mm calibrated spacer: 604 7841 11,96mm / 11,98mm calibrated spacer: 604 7851 11,99mm / 12,01mm calibrated spacer: 702 7811 12,02mm / 12,04mm calibrated spacer: 702 782

Thread lock to be appliedto threads after adjustingpreload

Adhesive product tobe placed in splinesand bearing surfacesfor bearings A afteradjusting pre-loading

8

5

A

A6

19

10

11

12

13

13

12

7156

5

8

9

10

11

2

3

4or

8

17

9

10

11

12

13

56

1

157

1416

D - 20/11/2006


2 -INPUT AND OUTPUT PINION IDENTIFICATION AND POSITION

- 28 -

- Bevel gears are manufactured in pairs andmust not be replaced separately.

- Pairs are marked by an identical identificationnumber.

- 29 -

- A channel machined into input gear ensureseasy identification.

- 30 -

IMPORTANT :

- Tooth marked with an "X" on input gear.

- 31 -

- Must be positioned between teeth marked with"X" on output gear.

- Paint teeth marked with "X" on both gears, tolocate them more easily during assembly.

D - 20/11/2006


- BEARING PRELOAD - OUTPUT SHAFT

- 26 -

- Using suitable tool, remove seal from outputshaft housing as preload must be checkedwithout this seal.

- 51 -

- Refit calibrated spacer.NOTE : If your bevel drive has a spacer + set ofshims, you must replace them with a calibratedspacer** of same thickness.**: Bevel drive change 2.

- 52 -

- Clean and degrease shaft splines and flangewith cleaning product. Avoid letting it run ontobearings.

- Refit bearing on output shaft.

- 53 -

- Refit output flange without new compressionwasher 1.

NOTE: New compression washer 1 will be fittedafter adjusting preload.

- Refit 46 mm nut.

- Tightening torque: 210-240 Nm.

1

D - 20/11/2006


Resistant torque check - Method 1


- 54 -- Using a strain gauge, measure resistant torque

which must be between 1.1 and 2.2 Nm.- If necessary, change calibrated spacer to obtain

correct torque.

• Resistant torque decreases if calibrated spa-cer thickness is increased.

• Resistant torque increases if calibrated spacerthickness is decreased.

- Secure output shaft housing in vice.- Position bolt A in end plate B.- Secure rope to bolt and wrap around end

plate B two or three times.- Secure end of rope to 0 - 10 daN max spring

balance C.- Measure resistant torque which must be bet-

ween 1.8 and 3.6 daN.- If necessary, change calibrated spacer to obtain

correct torque.



NOTE : Before assembling output shaft definiti-vely, measure dimension C page 13 for inter-tooth adjustment.

- When resistant torque is adjusted, fit new seal 5in housing D.

- Place adhesive product 2 or 3 in the shaft splineand on bearing D1 bearing surfaces.

**** : Bevel drive change 4.- Apply thread lock 4 to shaft threads.- Fit new O ring 6.- Fit new compression washer 1 and tighten

nut E.*** : Bevel drive change 3.- Tightening torque: 210 - 240 Nm.

CA

B

D

5

D1

61

E

2

3

4or

NOTE : Fixing product 648 Item 3 has minimumsetting time of 12 hours.

washer 1 assem-bly direction

1

D - 20/11/2006


4 - BEARING PRELOAD - INPUT SHAFT

- 16 -

- Using suitable tool, remove sealing ring frominput shaft housing as preload must be checkedwithout this seal.

- 38 -

- Refit calibrated spacer.NOTE : If your bevel drive has a spacer + set ofshims, you must replace them with a calibratedspacer** of same thickness.**: Bevel drive change 2.

- 39 -

- Clean and degrease shaft splines and flangewith cleaning product. Avoid letting it run ontobearings.

- Refit bearing on input shaft.

- 40 -

- Refit input flange.

- Bolt tightening torque: 95-120 Nm

D - 20/11/2006




- 41 -

- Using a strain gauge, measure resistant torquewhich must be between 1.1 and 2.2 Nm.

- If necessary, change set of shims to obtain cor-rect torque.



- Secure input shaft housing in vice.- Position bolt F in end plate G.- Secure rope to bolt and wrap around end

plate G two or three times.- Secure end of rope to 0 - 10 daN max spring

balance H.- Measure resistant torque which must be bet-

ween 2.2 and 4.4 daN.- If necessary, change calibrated spacer to obtain

correct torque.



NOTE : Before assembling input shaft definitive-ly, measure dimension page 13 for inter-toothadjustment.

- When resistant torque is adjusted, fit new seal 5in housing I.

- Place adhesive product 2 or 3 in the shaft splineand on bearing I1 bearing surfaces.

**** : Bevel drive change 4.- Fit new O ring 6.- Apply thread lock 4 to threads of new bolt 15.- Refit washer J, new spring washer 7 and tigh-

ten new bolt 15.** : Bevel drive change 2.- Tightening torque: 95 - 120 Nm.

H

15 7 J 65

I

I1

2

3

4

or

F

G

NOTE : Fixing product 648 Item 3 has minimumsetting time of 12 hours.

D - 20/11/2006


5 - CLEARANCE ADJUSTMENT BETWEEN TEETH OF TWO GEARS

D - 20/11/2006


CALCULATING SET OF SHIMS:

See pages 13 and 14 for measurement of dimensions A - B - C - D - E - F - G - H.

Input shaft- Calculate thickness of set of shims for assembling input shaft:

A + G - J = X (thickness of set of shims)

Output shaft- Calculate thickness of set of shims for assembling output shaft:

C + H - K = X' (thickness of set of shims)

- Refit input and output shafts using calculated set of shims.- Tighten 12 mounting bolts.- Tightening torque: 38 - 58 Nm.

J = D x 0,5 + E

K = B x 0,5 + F

- 0.5 mm shim Ref. 550 587- 0.25 mm shim Ref. 550 588- 0.10 mm shim Ref. 550 589- 0.075 mm shim Ref. 550 590- 0.05 mm shim Ref. 550 591

D - 20/11/2006


Dimension A:

- Using depth gauge, measure and note downdistance between bearing face of input housingand rear of bearing.

Dimension B:

- Measure and note down diameter of input shaft.

Dimension C:

- Using depth gauge, measure and note downdistance between bearing face of output hou-sing and rear of bearing.

Dimension D:

- Measure and note down diameter of outputshaft.

D - 20/11/2006


Dimension E:

- Measure dimension between bearing face ofinput housing and output shaft.

Dimension F:

- Measure dimension between bearing face ofoutput housing and input shaft.

Dimension G:

- Assembly dimension is marked on input gear.

Dimension H:

- Assembly dimension is marked on output gear.

D - 20/11/2006


6 - CLEARANCE ADJUSTMENT CHECK

- 66 -

- Fit a bolt and nut on input flange.

- Lock output shaft.

- Fit a gauge and check bevel gear return clearance.

- Return clearance must be between 0.12 - 0.18 mm.If necessary, check shim clearance again to obtain specified dimension.

- When return clearance is correct, remove then refit input and output shafts, using sea-ling paste between housings and shims.

D - 20/11/2006


7 - BEVEL DRIVE / ENGINE ALIGNMENT ADJUSTMENT AND CHECK

- Refit bevel drive on machine.- Secure tool 14 to engine in place

of universal joint A.

NOTE: You can choose betweentwo sockets: moving socket withflange or moving socket with point.

- Push moving part towards beveldrive and check alignment withengine.

• If using moving socket with flan-ge, check that flange and bevelgear mounting holes line up.

• If using moving socket withpoint, check that point arrives incentre of bevel drive bolt head.

- If necessary, add washers 16between rubber mountings Band engine supports C (flywheelside).

NOTE: If you have to f i t twowashers 16 on each rubber moun-ting on flywheel side, you must fitone on each rubber mounting onopposite side. (In this case, checkposition of fan in radiator outlet).When assembling using twowashers 16, use new fixing screws17 (HM 16 - 60 ref. 58 590).- Tighten rubber mounting nuts as

shown.

- When alignment is adjusted, remove tool 14 and refit universal joint A.• Universal joint mounting bolt tightening torque A: 61-73 N.m (bolts are fitted with thread lock

ref. 187 526).

14

A

moving socketwith flange

moving socketwith point

16 = HR 16.5 x 60 x 4 washers ref. 202 946

Nut tightening torque:100-120 N.m

16

16

16

16C B

B

B

B

C 17

17

16

remember safety must come first....information contained in this bulletin, ask your supervisor or...

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