Here is an instruction show you procedures on how to assemble gear case for Kubota U48-4 and U55-4 excavators.
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Assembly Procedures
Gear Case Assembly
1.Set the bearing (angular) (26) in the gear case and install it with a press.
2.After installing it, check and make sure the groove (a) around the circumference of the bearing comes right to the center.
(a) Circumference groove
3.Put the 99 steel balls (25) inside.
(25) Ball
4.Wrap the plug (7) with plumber’s tape and install it.
5.Set the floating seal installation tool (a) on the gear case (6).
(6) Gear case
6.Apply grease to the O-ring of the seal and install the seal.
7.Set the seal (24) in the gear case.
(24) Seal
8.Install the seal in the gear case with the floating seal installation tool (b).
(b) Floating seal installation tool (pusher)
9.Apply a little gear oil to the sliding surface of the seal. (4 places,every 90º)
(24) Seal
10.Set the holder (flange) on the assembly platform.
Set the floating seal installation tool on the holder (flange).
(c) Floating seal installation tool guide (for flange holder)
11.Apply grease to the O-ring of the seal and install the seal.
12.Set the seal (24) in the holder (flange).
(24) Seal
13.Install the seal on the holder (flange) with the floating seal installation tool.
(b) Floating seal installation tool (pusher)
14.Apply a little gear oil to the sliding surface of the seal. (4 places,every 90º)
(24) Seal
15.Install the gear case.
(6) Gear case
16.Use clamps to press the gear case onto the holder (flange).
Tool to use: Clamp
17.Install the nut (ring).
IMPORTANT
• Make sure the nut (ring) is securely engaged with the holder (flange) before removing the clamps.
18.Tap around the outside of the gear case (6) with a hammer.
(4 places, every 90º)
Rotate the gear case by hand to seat the bearing (angular).
• Tool to use: Plastic hammer
(6) Gear case
19.Install the plate (thrust, D) (16).
IMPORTANT
• Be careful that it faces the right direction.
• Install with the R face down.
(16) Plate (thrust, D)
20.Install the set screws (27) for preventing rotation of the nut
(ring).
21.Install the plate (thrust, B2) (22).
IMPORTANT
• Be careful that it faces the right direction.
• Install with the R face down.
(22) Plate (thrustB, 2)
22.Install the collar (19).
IMPORTANT
• Be careful that it faces the right direction.
• Bevel side down.
(19) Collar
23.Install the needle bearing (20).
(20) Needle bearing
24.Install the gear (planetary B) (21).
(21) Gear (planetary B)
25.Install the plate (thrust, B2) (18) and then the 4 axle snap rings (17).
• Tool to use: Snap ring pliers
(17) External snap ring
26.Install the gear (sun) (15).
27.Install the metal holder (14).
(14) Holder
28.Install the plate (thrust, A) (13).
IMPORTANT
• Be careful that it faces the right direction.
• Install it with the R side down.
(13) Plate (thrust, A)
29.Install the collar (12).
(12) Collar
30.Install the bearing (roller)(11).
(11) Bearing (roller)
31.Install the gear (planetary A) (10).
IMPORTANT
• Be careful that it faces the right direction.
• Install with the convex side up.
(10) Gear (planetary A)
(11) Bearing (roller)
(12) Collar
(13) Plate (thrust, A)
32.Install the gear (drive) (9).
(9) Gear (drive)
33.Measure the distance between the edges of the holder and the gear case.
This is measurement A (A).
Measure the distance between the gear case tooth surface and the gear case.
This is measurement B (B).
• Tool to use : Depth gauge
Subtract measurement B (B) from measurement A (A) to
calculate measurement C.
Select the appropriate plate (thrust, C) to suit measurement C.
Measurement A (A) minus measurement B (B) =
measurement C.
Ex.) 23.1 mm (0.909 in.) – 21.5 mm (0.846 in.) = 1.6 mm (0.063 in.)
34.Install the selected plate (thrust, C) (8).
(8) Plate (thrust, C)
35.Install the O-ring (4) on the cover (3).
IMPORTANT
• Apply grease to the O-ring.
• Install so the hole in the gear case aligns with the hole in the cover.
(3) Cover (4) O-Ring
36.Tap the spring pins (5) in. (4 places)
IMPORTANT
• Be careful to orient the split in the spring pins correctly.
• The split must face to the side.
• Tool to use: hammer
(5) Spring Pins (a) Split
37.Rotate the assembly platform 90 ° and pour in gear oil.
Fill it with gear oil until it flows out of the inspection port and then install the plug.
More repair case for Kubota,please refer to:Kubota Trouble Repair