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the
respective
dowty washers pos.
n°8
(supplied
with
accessories),
taking
care
to
gradually
"B"
screw the screws in a
circular direction (not
in
the
diametrically
opposite direction) until
completely
clamped
using a torque given in
"A1"
the "tightening torque"
table, paragraph 8.1
(screw classes 8.8),
"A" = Obligatory locking groove
"A1" or "B" = alternative extraction groove
by means of medium
loctyte.
- Assemble all the other screws and relative dowty washers pos.
n°9 (omitting one at the top),insert further lubricant in the hole
which has been left open; then assemble this last screw as well
to thus close the coupling in a lubricated hermetic chamber, by
means of medium loctyte.
5.4.5 Disassembling the gear unit with an FP output
- Whilst suitably supporting the reduction gear free the torque
arm.
- Remove the screws pos.n°9 replacing them with longer screws,
suitable for the room available.
- Remove the screws pos. N°8; then screw the screws pos. n°9
gradually in a circular direction (not in the diametrically opposite
direction) until the reduction gear is unlocked.
WARNING: the dowty type washers in pos. N°8 and 9 cannot
be reused when reassembling the reduction gear after repairs
or any other type of operation; they must always be replaced
with new washers.
5.5 Installing the gear unit type "RPR"
- The units must be fixed to a rigid structure and the supporting
surface should be thoroughly clean, with no trace of soldering
waste, at right angles to the driving axes.
- The centring and coupling surfaces of the gear unit must be
clean and dent free.
The measures described above are essential for ensuring
perfect meshing between the gear pinion and the fifth wheel.
Fifth wheel constructors usually mark three teeth of the fifth
wheel green; the point of major ovality of the pitch ø used for
positioning the gear unit.
ATTENTION It is advisable to contact the constructors of the fifth
wheel direct if there are no coloured (usually green) teeth on the
fifth wheel, or other distinguishing marks.
If the gear unit is of the type with a rest and an eccentric to
regulate the clearance between the pinion and the ring gear,
then there should be a notch on the fifth wheel (see fig.) which
indicates the point of major eccentricity, corresponding to the
maximum meshing reached between the pinion and the fifth
wheel; whether the gear unit is placed inside or outside the fifth
Notch
32
7
4
3
9
5
6
2
1
8
Painted Teeth
wheel. (see fig.)
The value of clearance between the sides of the pinion teeth
and the fifth wheel, is obtained by multiplying the value of the
teething module by the two fixed values of 0.03 and 0.04.
Example:
for teething of m = 20, simply multiply 20 x 0.03
= 0.6 and 20 x 0.04 = 0.8, to obtain two values
of 0.6 and 0.8; this means that the clearance of
the sides of the teeth for perfect meshing must
have a value which falls between 0.6 and 0.8
mm., thus the gear unit is placed with the notch
in correspondence with the three coloured teeth,
(usually green), of the fifth wheel, turn the gear
unit to move it closer to the fifth wheel, inserting
the shim value as resulting from the described
calculation in the sides of the teeth which are
meshed with the fifth wheel or the pinion; then
clamp the gear unit.
Check the clearance between the sides at different points around
the pitch circle of the fifth wheel a second time.
After having positioned the gear unit and checked the situation,
tighten the fixing screws (minimum recommended class 8.8) by
applying a tightening torque as shown in the "tightening torque"
table, paragraph 8.1, making sure that they are compatible with
their counterparts (nuts and/ or fixing structure).
ATTENTION when positioning gear unit with eccentric, all
the holes for oil level, load and discharge, engine controls,
laminated brake etc .etc.- will be moved out of place with
respect to the "BREVINI" drawings.
5.6 Installation instructions for gear unit-coupler assembly
with active clutch safety system
When preparing to install this kind of assembly, the first thing to
remember is that the whole internal drive is held in place by the
clutch on the assembly.
Consequently, if the output shaft doesn't rotate, it will be difficult
to install the assembly in its housing if the gear unit fitting holes
do not coincide with the holes in the interface on the vehicle
itself.
To line up these holes, you have to release the clutch so that the
output shaft can rotate freely.
To do this, use a hand-operated hydraulic pump, as the clutch
can be opened with a minimum pressure of 3 to 5 bar, then
proceed carefully with the steps listed below:
(for the location of the symbols see chapter 2.2.1)
- lift the assembly with suitable lifting equipment and fit the
gear unit output shaft into its housing on the vehicle, keeping it
supported all the time and trying to mate the fitting holes in the
assembly with those in the vehicle.
- connect the hand-operated hydraulic pump to the assembly
via the 1/4 gas hole
- power up (12 Volt) the solenoid valve on the on the power pack
so that the valve is excited.
- Using the pump, increase the pressure on the assembly slowly
and gradually it can be rotated by hand.
ATTENTION: if the solenoid valve is not excited, the hydraulic
pump simply pumps the oil into the assembly.
- at this point, the assembly can be rotated easily so as to align
the fitting holes with the interface on the vehicle; this done,
insert the pins (if needed) and attachment bolts (recommended
minimum class 8.8) , applying torque as indicated in the "torque
setting" table, paragraph 8.1, making sure that these settings are
compatible with the nuts and/or structure.
- if this operation is performed with the gear unit output shaft not
inserted in its housing, it will be very difficult to get the assembly
fitting holes in phase with the shaft spline, and the only way to
set the timing will be by trial and error.
- After fixing the assembly in position, cut off the current to the
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