120 Series - DT12 - PTO instructions - Bezares France - Premier fabricant hydraulique

Drain the oil from the transmission and the P.T.O. aperture­­­ cover plate.

Discard the cover plate and cover plate gasket then clean the aperture pad using a putty knife or wire brush.

NOTE: Stuff a rag in the aperture opening to prevent dirt from entering the transmission while you are cleaning it.

Using your hand, rock the P.T.O. driver gear in the transmission and the driven gear in the P.T.O. assembly. Rocking the gears provides two important factors:

A.- The amount of backlash that has been designed into each unit.

B.- Helps establishing the proper backlash when installing the P.T.O.

Install the proper studs (furnished with P.T.O.) in the P.T.O. aperture pad using a stud driver. Studs may have either interference fit threads (plain) or preapplied locking/sealing compound.

Secure P.T.O. to the transmission .
Gaskets are used as a guard against leaks under cap screw head.

NOTE: If holes in the P.T.O. aperture are not drilled through, discard the gaskets and replace them with lock washers.

Secure P.T.O. to the transmission .
Gaskets are used as a guard against leaks under cap screw head.

NOTE: If holes in the P.T.O. aperture are not drilled through, discard the gaskets and replace them with lock washers.

Secure P.T.O. to the transmission .
Gaskets are used as a guard against leaks under cap screw head.

NOTE: If holes in the P.T.O. aperture are not drilled through, discard the gaskets and replace them with lock washers.

Overtightening of studs may damage stud and / or transmission threads.

Remove the P.T.O. shift housing and/or inspection plate.

Mount the dial indicator so that it registers movement of the input gear (driven gear) of the P.T.O.

Hold the P.T.O. driver gear in transmission with a screwdriver or bar and rock the P.T.O. input gear (driven gear) back and forth with your hand.

Establish backlash at 0.006” – 0.012” (0.15 mm-0.30mm) by adding or subtracting gaskets.

General rule – A Bezares 0.010” gaskets will change backlash approx. 0.006”. A 0.020” gaskets changes backlash approx. 0.012”.

Replace the shift housing and/or inspection plate and retorque (4) four capscrews to 16-20 Ft. Lbs. (2.21-2.76 kg meters).

6 BOLT SPACERS

8 BOLT SPACERS

Install the snap ring onto the output shaft with snap ring pliers.

Press the output bearing onto the shaft up to the snap ring with 36mm ID tool. For Din output, press the output bearing onto the shaft up to the shoulder with 51mm ID tool.

Apply Bearing Grade Loctite to the end cover bearing race. Install the o ring to the end cover and apply assembly grease to the o ring diameter.

Press the end cover bearing race into the end cover with 60mm ID tool. Place the end cover gasket onto the end cover aligning the bolt holes.

Apply assembly grease to seal diameter of greaseable end cover and o ring. Install o ring and press the greaseable seal into the end cover with 28mm OD tool.

Install bearing race with 60mm OD tool and place end cover gasket onto the end cover. Insert the seal protector into the end cover over the greaseable port in the output shaft manually.

While holding the internal ratio gear in the housing, pass the output shaft through the gear noting position of parts per current arrangement.

Place the end cover bearing onto the end of the output shaft and press it up to the shoulder with 26mm ID tool.

Place the end cover on the end cover bearing side of the housing and tap it in with a dead blow mallet until it seats fully while aligning the bolt holes. Install bolts and washers with 19mm socket to approx. 25ft-lb.

Apply Bearing Grade Loctite to the output bearing race and press it into the housing manually to support the output shaft. A few light taps with a mallet will help to seat it.

Quality control check #1. Spin and pull the output shaft checking resistance and tolerance for radial and linear preload. Use a thinner end cover gasket under the end cover and/or the output flange if tolerance is loose. Install an additional gasket under the end cover if the tolerance is too tight.

Tap the wrench or use a torque wrench to fully tighten the lock nuts to approx. 25ft-lb.

 Place an end cover gasket over the flange studs and tap the flange into position over the output shaft. Place nuts and washers over the studs and tighten down the flange with 17mm speed wrench.

Apply assembly grease to seal diameter of output flange. Press the seal into the flange up to the shoulder with 70mm ID tool and install the snap ring into the groove in the flange. Position the weep hole in the flange to the furthest point from the shifter opening based on arrangement.

Apply assembly grease to seal diameter of output flange. Press the seal into the flange up to the shoulder with 70mm OD tool and install the snap ring into the groove in the flange.

Tap the flange into place with a gasket over the output bearing and output shaft while aligning the bolt holes. Install bolts and washers with 19mm socket to tighten flange to approx. 25ft-lb. Place a key in the keyway and wrap shaft with tape to secure.

Quality control check #1. Spin and pull the output shaft checking resistance and tolerance for radial and linear preload.

Apply assembly grease to the seal diameter of output flange.

Press the seal into the flange up to the shoulder with 70mm OD tool and place an output gasket over the studs. Tap the flange into place over the output bearing and output shaft. Install an output gasket, nuts, and washers over the studs.

Quality control check #1. Spin and pull the output shaft checking resistance and tolerance for radial and linear preload.

Place a shifter gasket on the fully assembled shifter while aligning the mounting holes. Install the shifter into the shifter opening in the housing while aligning the shifter fork with the groove in the internal gear. Install backlash tag and shifter retaining screws manually with a flat head screw driver. For manul shifter, follow same procedures for air shifter, and manually shift the lever to ensure proper shifter engagement.

Apply thread grade loctite to the preload nut and place it on the thrust washer.

Place the ratio gear onto the splines of the input gear and install the snap ring. Apply assembly grease to the thrust washer and install it over the idler bearings within the gear.

Install backlash tag and shifter retaining screws manually with a flat head screw driver.

Insert the gear stack into the input opening in the housing.

Install o rings into the grooves in the idler pin and apply assembly grease to the diameters of the o rings. Use 100 grit emery cloth to deburr the set screw port in the idler passage. Align the machined flat in the idler pin with the set screw port in the housing.

Install a snap ring to the top end of the idler pin and drive the idler pin through the gear stack at approx. 850psi with 25mm OD tool aligning all components in the housing up to the snap ring on the pin.

Ensure the idler pin o rings are not damaged or extruded beyond the housing. Install a snap ring onto the opposite end of the idler pin.

Apply thread grade loctite to the set screw and install it into the set screw port in the housing until fully seated against the idler pin machined flat with a 3mm hex bit.

Insert a 3/16” pin bar into the opening in the preload nut and leverage it against the housing. Apply WD40 to the preload bearings and tap the gear with a mallet to fully seat the preload stack. Tighten the preload nut with a 1-7/16” wrench until desired resistance is found in the preload bearings.

The gears must spin freely without coasting and must make no noise or contact any other part of the assembly. Use a pin punch to pierce the indent in the preload locking nut.

Quality control check #2. Spin the input gear stack to test for proper preload resistance.

Insert the needle bearings into the input gear with the spacer between them. Hang tab washers in the hosuing idler grooves and insert the gear stack into the housing.

Drive the idler pin through the gear stack at approx. 850psi with 25mm OD tool aligning all components in the housing up to the snap ring on the pin.

Place an end cover gasket over the Din studs, install the stub shaft or bearing assembly into the Din shaft, place the output flange over the bearing, and install nuts and washers onto the output studs with 17mm socket to approx. 25ft-lb.

Install outer flange if applicable and tighten to approx. 25ft-lb. with 19mm socket. Do not install a seal to the Din flange when using an adapter that contains an output bearing.

Quality control check #3. Apply air pressure (recommended 100psi) to the port in the air shifter several times to check for leaks and proper gear engagement.

Install an ID Plate with two rivets with the top of the tag toward the shifter. The tag must include product part number and a serial number containing a builder code.

Apply thread grade loctite to the fork bushing threads and install it in the fork with 1-1/4” socket to approx. 25ft-lb. considering shifter arrangement.

Insert the fork with bushing and the spring into place in the shifter housing considering shifter arrangement.

Install the o rings and seal onto the shifter piston and apply assembly grease to the seal diameters. Insert the piston into the housing and through the spring and bushing.

Compress the spring by pushing the piston flush into the housing. Install the end cover o ring and apply assmebly grease to the diameter.

Place the end cover over the piston on the end of the shifter and install the two end cover bolts with an M6 hex bit tightening to approx. 25ft-lb. Install the plastic plugs into the shifter ports.

Quality Control Check #1. Apply air pressure (recommended 100psi) to the end port to activate the piston checking for full stroke and leaks.