Section R 2F GEAR - BW7CONTENTS Gear Ratio ...e..e eee ee O41 Change . Special Tools ...... Adjusting Measures and Torques for BW7. Adjusting Measures and Torques for BW7. General Information for Work with the Gear we... Removal of Gear from Engine Dismantling of BW7 Gear ..... Removal of Input and Output Shafts..... - Dismantling of Shifting fork .... Dismantling of Output Shaft . Dismantling of Input Shaft . Dismantling of Lower Gearbox Half ..... ' Dismantling of Upper Gearbox Half ..... - Refitment of BW7 Gear .... Fitting of Input Shaft . Measuring of Tightening of Tapered Roller Bearing on Input and Output Shafts with Measuring Gauge ... Measuring of Tapered Roller Bearing Tightening on Input and Output Shafts without Measuring Gauge ........ Pre-Mounting of Shifting Fork .. Fitting of Bolts in Gearbox .......eee. - Fitting of Input and Output Shafts with Shifting Fork in Gearbox ....... Fitting of Shaft Seal Rings Supplement to Fitting of Shaft Seal Rings .... ooo > Dw wD a ee) ql 12 12 14 14 14 15 20 22 23 24 26 27 30 32Gear Ratio The BW7 gear is used on DV36. The reduction is 3:1 for AHEAD and 2.36:1 for REVERSE. when using the gear on DV10/20 the reduction is 2.5:1 for AHEAD and 2.77:1 for REVERSE. Qil Change The gear will need no other attendance than re-~ gular change of oil. This to be carried out after the first 25 hours of operation and then every 150 hours or once a year. The oil change is carried out by means of the hand bilge pump fitted on the engine and the three-way cock which should be set in the position shown on the sketch. Refill fresh oil to the quantity of 1.1 litres. Quality of lubricating oil marked Service CC or CD with firm viscosity of SAE20, alternatively SAE30 is used. Oils covering more viscosity numbers must not be used.gSpecial Tools Order No, 009P3187 Mounting punch for seal ring 25 x 33 x 6 at input shaft. Order No. 909P3188 Internal puller for tapered roller bearings/outer ring. Order No 009P3189 ae For fitting of tapered roller bearings/outer ring in connection with 009P3188. = Order No 9093190 Measuring instrument for adjustment of tapered roller bearings. Order No, 999P3191 Protective sleeve for seal ring 25 x 33 x 6 at input shaft. Order No 009P3192 Mounting punch for seal ring 32 x 45 x 7 at output shaft. Order No. 099P3193 Bush for stiffening of disc springs. AHEAD". 009P3194 Bush for stiffening of disc springs, "ASTERN RSAdjusting Measures and Torgues for BW? Statanent of Designation a : Gauge Remarks Axial tightening of| 0.03 - 0.08mml Dial indi- |adjusted by means of the tapered roller | with a load | cator or |washer(s) under bearingl bearings on input | of 30 N (3 kp} depth microfouter ring in the hous-| and output shafts meter ing. The bearings are fitted with Loctite 60L Axial clearance Sliding sleeve in Feeler shifting fork 0.1- 0.4mm | gauge New gear Axial clearance Sliding sleeve in shifting fork incl. permissible wear max. 0.8 mm | Feeler Clearance + wear gauge Limit Axial clearance. "AHEAD": Clearance ap~ ” ” ", pears when fitting and UREN and “ASTERNY> 1 ~ 0.4 m| popen |e caateseaTaetany a measure “ASTERN": Clearance car be adjusted by means of a thrust washer To be measured two Disc / plate places opposite one clearance per disc |0.9 - 1.0 mm| Feeler another. To be ad- clutch gauge justed by washer To be measured two Disc / plate places opposite one| clearance per disc 1.5 mm Feeler another. To be ad- clutch with max: : wear gauge justed by washer Tightening of disc leasured on disc | springs min. 1.1 mm] Depth e Depth [on the output. shate testing inatcation [E> 35-3." | pepen L = lengen of for pressure spring (3.89%0.24 kp) measure loaded spring 0732 041 225 in star bolts Weight P = spring powerAdjusting Measures and Torques for BH7 Designation Seatanent « Gauge Remarks Testing indication | L = 11.4 mm] Depth mea- | L = length of for pressure spring sure loaded spring Ore ae ee FOF |p agetsn | weight P = spring power ake pant | (4,640.5 kp) | Torque of hexagon | Secure after hav- | nut M20 x 1.5 on [100 Na (10 kgm] Torque ing packed with output shaft on the wrench Liquid jointing on output side the contact face | Torque of hexagon nut M 20x 1.5 on {100 Nn (10 km] Torque Secure after output shaft on the wrench tightening | input side | Secure after hav- Torque of hexagon ing packed with nut M 20 x 1.5 on ae heck bolts 50 Nn (5 kgm] Torque liguid jointing on s wrench the contact face | Torque of M 8 screws | in the halves of the Add U-washers | | gearbox h7 nm (1.7 xam} Torque | wrench i | rorque of the M8 x 25| screws at the gear [17 Nm (1.7 kpm)| Torque ‘ wheel bolts wrench Secure with | Loctite 241 Torque of vent valve [Lo Nn (1.0 kgm) Torque _ wrench finding with Shaft seal rings Seal ring for input Pratt | ey inserted with : asting of half] sealing compound Depth of compression bf gearbox (unhardening) Output shaft seal ring | Depth of compression Shaft seal ring | Ressured from front’ | 22.50.5 mn | Depth inserted with | | of output shaft to | measure sealing compounc front of shaft seal (unhardening) ringGeneral Inf: ion for Work with the Show cleanliness when repairing the gear and before the gear is opened it must be carefully cleaned. Use special tools as stated earlier in this section when removing and fitting the gear. The seal face between the two parts of the house is tighten- ed with liguid jointing. When dismantling the halves of the gearbox from each other, loosen the screws in the flanged joint first and push/press back the fitting pins. Press the two halves of the gearbox from each other by means of two rods or the like. Do not use chisels. Use special tools for loosening parts fixed to the shafts such as bearings, gear-wheels etc.. When assembling the gear and fitting the bearings it is necessary to heat the cylinder bearings in oil bath before fitting them. The temperature must not exceed 120°C. When fitting the bearing outer rings the house should be heated and the bearing outer rings should be fitted with loc- tite. of Gear from Engine re the gear can be dismantled it must be removed from the engine: 1. Loosen the propeller shaft flange and push the propeller shaft a little backwards. 2, Loosen the gear from the engine by removing the bolts of the intermediate flange between engine and gear. 3. Lift clear the gear of the engine. 4. Dismantle the flexible coupling by loosening the central put and pulling off the coupling half from the input shaft of the gear with special tool No. T 41069.Dismantling of BW7 Gear Pull out the dip stick of the house. Remove the locking ring on the input shaft. Remove the shifting arrange- ment with gasket. There are two different shifting levers which, however, can be built in without any problems 3. in either cases. Press the shifting lever out of the shifter shaft and take out the O-ring 12 x 2.4 and the pin and the pressure spring. Before the shifting lever is pressed out it should be marked in propor- tion to the shaft out of consideration for the later assembling of the arran- gement. shifter shaft pin pressure spring shifting housing O-ring shifting lever grease lubricating = screw capz 10 Unscrew the nut of the output shaft flange Pull off the output shaft flange he fixing h hold the halves of the gear- box togetherDrive back the fitting pins 2 -3 mm in the gearbox and lift one gearbox half with reversing shaft, input and output “shafts free of the other gearbox half. Protective sleeve 1 x 56 136 992 may be fitted on the input shaft before the dismantling. tara Gz WKS a os oa) Removal of Input and Output Shaft Take out the screws M8 x 25 and the gear-wheel bolts and remove the washer plate. At the fitting the screws have been| smeared with loctite and conse~ quently it may be necessary to heat before they are loosened. Loctite No. 241 has been used. Lift the complete arrangement with input and output shafts and shifting fork out of the house. Now the arrangement can be lifted free of each other. input shaft wheel ASTERN L 2 3 = wheel AHEADDismantling of Shifting Fork Screw out the pin M 6 x 12 of the shifting fork and press out the reversing shaft of the shifting fork. At the fitting the thread- ed pin has been smeared with loctite No. 241 and so it may be necessary to heat. 1 = shifting fork 2 = threaded pin 3 = reversing shaft Dismantling of Output shaft Remove nut with washer ASTERN. Pull off the wheel ASTERN with a special tool and take up washer, disc springs and tapered roller bearing inner collar. 10,R13 Remove thrust collar with bolts and washers together with needle bearing bushing, sliding sleeve and pressure spring. Remove the wheel AHEAD with a special tool and take off all parts "AHEAD".Rida Squeeze off the tapered roller bearing inner collar. Dismantling of Lower Gearbox Halt Pull out the tapered roller bearing outer collars of the lower gearbox with an inner puller No. 1x 56122 208 *% and auxiliary tool No. 1x 56 122 227 and take up the washers. At the fitting the tapered roller bearing outer collars have been smeared with loc- tite No. 601 and so heating may be necessary. At the dismantling: mark the adjust- ing washer(s) which lie be- low the bearing rings in proportion to the bore. Dismantling of Upper Gear- box Half _ Pull off the tapered roller bearings/outer collars as described under picture No. 16 above. Loosen the nuts at the wheel] and press out the bolt of the house, Remove slotted pin and washer.Refitment of BW7 Gear Before refitment of the gear examine,” the different components for cracks and wear. In the following description only the fitting of output shaft for "AHEAD" is described as the fitting for “ASTERN" is chiefly correspon ing. If it is necessary reference will be made to the paragraph marked "NOTE". Picture 19: Insert the sliding Sleeve in the shifting fork and measure the axial clearance of the sliding sleeve. The axial clearance below the wear limit must be 0.1 - 0.4 mn. "NOTE": Axial clearance inclusive of @ permissible wear must be max. 0.8 mm. Picture 20: Insert the locking bolt in the thrust collar. The locking bolt should be able to turn easily in its bore in the thrust collar. The head of the locking bolt must adjoin the thrust collar. Picture 21: Insert thrust collar with locking bolt in sliding sleeve. Check torsion in sliding sleeve. The locking bolts must not pinch by this.Fit the tension rollers on the shafts for sus- pension by rollers. "NOTE": The tension rollers must be placed so that the big surface lies outwards . Pit the pressure springs in the check bolts. Fit the check bolts in the corresponding bores. The point of the check bolts should turn so that it is horizontal. Press the sliding sleeve from the bottom against the check bolts. Press the check bolts back with a screwdriver and at the same time press the sliding sleeve upwards. The bolts should rest in the points of rest of the sliding sleeve.Ri 25. Fit needle bearing housing, wheel for "AHEAD" and washer. Check the axial clearance of wheel for "AHEAD". It should be 0.1 - 0.4 mm. "NOTE": For “ASTERN" the axial clearance can be adjusted by fitting an intermediate washer (thrust wash- & er). xst fit a washer. Then fit an inner disc and then an outer disc. Fit 4 inner and 3 outer discs in this order. Fit wheel for “AHEAD” with clutch discs on the thrust collar. First fit the driving pins through the thrust collar and then fit the thrust collar with clutch discs and wheel for "AHEAD" over the needle case on the input shaft in the sliding sleeve.Fit thrust washer, the oil pockets of which should turn towards the wheel for "AHEAD" Fit the disc springs which should touch with the outside diameter. Check the tightening of the disc springs. The inside diameter of the disc springs must, when slack,in proportion to the front be min. 1.1 mm (measure A). Tighten the disc springs 30- with bush 1 x 56 136 994. Measure disc clearance between inner disc and washer with a fecler gauge in two places which are opposite one another. The disc clearance to be 0,75-0,85 mm. Deviations should’be adjusted with + washer available in dif- erent thicknesses. NOTE": Tighten the disc springs on the side for "ASTERN with bush No. 1 x 56 136 995,Heat the tapered roller bearing inner collar to about 85°C and fit it with the thin end of the taper roller facing the shaft end of the output shaft until it fits tightly | against the disc springs. Tighten the tapered roller bearing with bush No. 1 x 56 136 995 and original hexagon nut until it fits tightly against the shaft assembly. (See picture No. 33 overleaf too). "NOTE": Fix the tapered roller bearing for "ASTERN" with supporting washer and original hexagon nut. The torque of the nut is 100 Nm (10.0 kpm). Secure the nut.The picture shows the ready-mounted output shaft. Heat the tapered roller bearing inner collars to about 85°C and fit it with the thin end of the bear- ings towards the shaft’ ends. "NOTE": Fit wide tapered roller bearing on the input side.Measuring of Tightening of Tapered Roller Bearing on Input and Output Shafts with Measuring Gauge house input shaft = depth micrometer 1 3 output shaft 2 4 = measuring gauge 1 x 56 136 978 30 N (3.0 kp) Heat the bearing bores in the house to about 85°C and fit the taper- ed bearing outer collars with loctite No. 601. Build in the tapered roller bearings on input and output shafts with a tightening of 0.03 to 0.08 mm after the cooling. Measure the tightening as shown on the pictures 35, 36 and 37 and adjust it with adjusting washers (measure G). Measure G: measure F (difference measure) plus tightening. Fit the input and output shafts in the house and fit the measuring gauge on the house by means of the pins. Fit the tapered roller bearing outer collars in the measuring gauge until they fit tightly against the taper rollers while constantly turning the input and output shafts with a pressure of F = 30 N (3.0 kp) on the bearing outer collars. Measure A = B + C, B= thickness of measuring gauge, C = bearing outer collar above measuring gauge.Ze 1 = bearing bushing 2 = measuring gauge 3 depth micrometer Fit the measuring gauge on lower gearbox half. Calculate follows: Establish gauge) . calculate No. 35 on calculate the thickness of the intermediate washer G as measure E as D minus B (thickness of measuring the difference measure F as E minus A (See picture last page). itermediate washer G for input shaft as F plus tightening 0.03 - 0.98 mm. At the calculations the thickness of the liquid jointing,when compressed,should be included and an empirical value of 0.02 mm should be considered. Then fit the necessary intermediate washers in the bearing bores (max. 2 washers per bore) and heat the bearing bores to about 85°C and fit the roller bearing outer collars with loctite No. 601.Measuring of Tapered Roller Bearing Tightening on Input and Output Shafts without Measuring Gauge 1 = dial indicator holder 4 = driving arrangement output shaft = dial indicat 3 = dial indicator 5, It would be an advantage, if the input shaft and the output shaft are measured individually for the adjusting of the tapered roller bearing tightening. The measuring procedure is the same both for input as well as for output However, only the procedure for the input shaft is described here. when measuring the output shaft it should be as described at picture No. 31. Turn the shafts when measuring in order to compensate for possible deviations,and a fixed point of measuring should be chosen for marking of the axial clearance. Heat the bearing bore to about 85°C and fit the outer collar of the tapered roller bearing with loctite No. 601. In order to be able to adjust the tightening of the roller bearing it is necessary that the shafts show axial clearance. This is ob- tained by fitting intermediate washers which are 0.2 mm thinner that those which were removed and marked as described at picture No. 16. Heat the bearing bore to about 85°C and fit the bearing outer collar without loctite in the bore. Place the input shaft in the house after the cooling and fit the lower gearbox half without any packing and drive in the guide pins. Fit the contact point of the dial micrometer on the front of the input shaft and turn the shaft backwards and forwards. During this the shaft should show axial clearance. If there is no clearance shown,fit thinner washers under the bearing outer collar. Add the roller bearing tightening of 0.03 - 0.08 mm plus further 0.02 mm (Liquid jointing compressed) to the measured axial clearance and thus we get the thickness of the intermediate washer.24 Picture No. 37 continued Measuring example: ‘Thickness of intermediate washer during the measuring procedure 0.60 mm Measured axial clearance of shaft 0.08 mm Correct tightening 0.03 - 0.08 mm (average value) 0,055 mm Thickness of compressed liquid jointing 0.02 mm Theoretical thickness of interm. washer 0.755 mm In practice the intermediate washer will be 0.73 - 0.78 mm. Then insert the correct intermediate washers in the bores (max. 2 washers in each bore) and fit the bearing outer collars after heating with loctite No. 601. Pre-Mounting of Shifting Fork Place the reversing shaft in the shifting fork and secure it with the threaded pin and smear it with loctite No. 241. "NOTE": the long side of the reversing shaft points to the left when the position of the shifting fork is as shown on the drawing. 38. SS KI N! A IN —— oS= shifter shaft shift pin pressure spring gearbox O-ring shift control lever grease lubricating 3. screw cap a oiled shifter shaft and O-ring in the gearbox. 1 Press the shift control lever on to the shifter shaft so that shift control lever is placed in neutral position at 90° + 30! to the gear shaft length. Fit the screw cap with grease lubricating after the pressing on. cm ZL26 Fitting of Bolts in Gearbox Drive in the slotted pins 4x 16 in the bolts and fit the washers on the bolts so that the lubri- cating groove in them point to the wheel. "NOTE": the bolt must be fitted in pos. 1 on the transmis- sion. Transmissio: GLL GGL AHEAD ASTERN Heat the gearbox and fit the bolts with slotted ping in pos. 1 or 2 all depend- ing on the transmission. Fit the hexagon nut and tighten it with 100 Nm (10 kpm) . Fit the sleeve in the bolt bore nearest the centre of the gear (see the arrow). Smear the hexagon nut with unhardening packing material before the fitting.Fitting of Input and Output Shafts with Shifting Fork in Gearbox Place the shaft arrangement as shown on the picture. “wor! the long side of the reversing shaft faces the input side. AN E=3 = = = iad / 45. Fit intermediate wheel and needle bearing. Lift intermediate wheel with stop © plate (see the illustration). The intermediate wheel should be lifted about 25 mm,otherwise fitting is not possible. 65 28 LE measures in mm Sketch of Stop Plate 27R 28 Place the house so that the opening of it turns up. Oil the roller bearings and the reversing shaft and fit them together in the house. Remove the stop plate. "NOTE": the long side of the reversing shaft points up- wards to the input side. Fit retaining plate for intermediate wheel and before that smear the screws M 8 x 25 with loctite No. 241. Torque 17 Nm (1.7 kpm). 46.Smear the seal faces of the gear- box halves with permanently plastict liquid jointing. Oil the bearings on the input and output shafts. Assemble the gearbox and drive in the guide pins. Tighten the screws M 8 x 25 with a torque of 17 Nm (1.7 kpm).R SU Fitting of shaft Seal Rings Fit the protective cap No. 1 x 56 136 992 over the input shaft. Smear the seal ring 50: 25 x 33 x 6 with a thin layer of grease on the lip ring and smear with a thin layer of permanently plastic liquid joint- ing on the outside. Fit the seal ring with punch No. 1 x 56 199 916 so that it fits tight- ly against the bore of the house. Smear the similar seal ring 32 x 45 x 7 for the output shaft in the same way as the seal ring for input shaft and fit it by means of punch No. 1 x 56 136 993 in the house so that it fits tightly against the tapered roller bearing inner collar. 5).R31 Supplement to Fitting of Shaft Seal Rings A = distance to shaft seal ring 22.5 +/- 0.5 mm. B= shaft seal ring binding with surface of casting on lower gearbox half. The picture shows the necessary mounting dimensions for the shaft seal rings on the input and output shafts.Heat the output flange to about 85°C and fit it on the output shaft. Smear the nut with permanent~ > ly plastic liquid jointing and secure it with a torque of 100 Nm (10 kpm).Picture 55 Fit the screws M 8 x 25 with washers in the gearbox. Put the gear shift lever in "neutral" (the sliding sleeve is also in "neutral" position) . Place gearbox with gasket in the opening of the house and press the ifting eccentric down into the shifting fork. In connection with this check at the same time with a light pressure of the eccentric pointing to the assembly the axial clearance between the sliding slee- ve and the shifting fork. Secure the shifter housing in this position. "NOTE": When checking the axial clearance it must be checked whether the fixing screws hit against the walls of the gearbox because of the slots which may lead to wrong adjustments. 56. Adjustment can be carried out by axial displacement (angle 90° must be maintained, see picture 40). Picture 56 Tighten the shifter housing with a torque of 17 Nm (1.7 kpm). Shift the shift control lever in both directions and check the func- tion of the reversing. The sliding sleeve should be con- nected (click) in both directions when the angles of engagement are as equal as possible. Besides, it must always be possible to turn the shift control lever 37° in either direction without much resistance. Picture 57 At last fit the dip stick and the locking ring at the end of the in- put shaft when fitted. Pill oil in the gearbox to a quantity corresponding to the up- per mark on the dip stick.