Service Manual BELL Drop Box

Land Systems
Gear Ratio
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BELL 17000: MAINTENANCE & SERVICE MANUAL

DOCUMENT NUMBER: R8503560-0787
SUBJECT: MAINTENANCE & SERVICE MANUAL
IMPLEMENTATION DATE:
AMENDMENT HISTORY
APPROVAL
ISSUE REFERENCE DATE AUTHOR
NAME SIGNATURE
7 CP: GR9964 2003-09-03 P. Calitz L. JV Veuren
8 CP: GR9981 2004-03-04 F. Greyling L. JV Veuren
9 CP: GR10045 2004-11-22 P. Calitz L. JV Veuren
10 CP: GR10092 2005-11-30 T. Westdorp L. JV Veuren
11 CP: GR10118 2006-08-17 T. Westdorp L. JV Veuren
CHANGE RECORD
ISSUE PAGE PARAGRAPH

7 P2 & P17 of 25; Annexure D 1.4.4, 21.7; Items 23,71,77
8 All All
9 P1–P2; P2 &P8 of 25 Cover Sheets; 1.4.2 & 11.1
10 2, 3, 9, B&C tools, D 1.4.1, 6, 12.3&fig.12, D1.3, 28, 35, 77&95.
11 4 1.4
DISTRIBUTION
COPY
NAME POSITION ADDRESS
NUMBER
MASTER Technical Admin Gear Ratio
1 Assembly Assembly Gear Ratio
2 Project Manager Gear Ratio
3 Strydom Fick strydomf@bell.co.za
4 Mike Dutton miked@bell.co.za
5 Allan Froneman allanf@bell.co.za
6 Pieter Mocke pieterm@bell.co.za
7 Dick Tebbut dickt@bell.co.za
8 Jabulani Mlondo jabulanim@bell.co.za
9 Thys du Plessis thysd@bell.co.za
10 Dave Swalwell davesw@bell.co.za
DOC NO.: R8503560-0787 ISSUE 10 Page 1 of 2

Land Systems
CONTENTS GearRatio
PARAGRAPH TITLE PAGE
1 TECHNICAL DATA 2
2 ASSEMBLY INSTRUCTION 3-17
3 DISASSEMBLY INSTRUCTION 18-25
ANNEXURE “A”
TECHNICAL INFORMATION
ANNEXURE “B”
SPECIAL ASSEMBLY TOOLING
ANNEXURE “C”
SPECIAL DISASSEMBLY TOOLING
ANNEXURE “D”
PARTS LIST
DOC NO.: R8503530-0787 ISSUE 10 Page 2 of 3

MAINTENANCE & BELL EQUIPMENT
SERVICE MANUAL DROPDOWN GEARBOX 17000
CONTENTS PAGE
1 Technical Data 2
2 Assembly of Dropdown Gearbox 3-17
3 Disassembly of Dropdown Gearbox 18-25
4 Annexure “A”
Technical Information
5 Annexure “B”
Special Tools for Assembly
6 Annexure “C”
Special Tools for Disassembly
7 Annexure “D”
Parts List
8 Annexure “E”
New Input Bearing Arrangement
Date: Page
Document No: R8503560-0787 Issue: 3 March 2004 Issue: 1 Page 1 of 25
TECHNICAL DATA
1 Performance Specifications
Input Torque Max 17000Nm

Output torque max front 5667Nm
Output torque max rear 11333Nm
Ratio 1:1
Power 340kW (approx.)
Weight 210Kg
1.1 Lubrication
Transmax “Z” is an approved oil for the Dropdown Gearbox Bell 17000. Other
reputable brands of oil with equal properties as Transmax “Z” can be used. The
lithium based grease can be Shell Retinax.
1.2 Oil Level

Fill the dropdown gearbox with approximately 5 litre of oil through the top filler hole
until oil is level with the bottom of the level hole, or is visible in the centre of the sight
glass or level gauge.
1.3 Service
1.3.1 The dropdown gearbox must be vented via a breather with a filtration rating not
exceeding 10 micron.
1.3.2 New dropdown gearboxes should be serviced within the first 100 operational hours.
1.3.3 Thereafter, dropdown gearboxes should be serviced every 1000 operational hours.
1.4 Alternative Configurations

1.4.1 For serial number 221 onwards a thicker wear washer (35) is used. The cavity in the
planet carrier (20) has been enlarged from 48,2 +0,2 to 49,2 +0,2 mm. If necessary,
the new configuration will be implemented during factory repair.
A further improvement is now on offer: Wear washer (35) is available in a bronze

material, but requires more and thinner spacers (28) to prevent contact with the
needle rollers. A replacement kit R8505177-0105 (6 off washers (35) plus 9 off
spacers (28)) fits in the 49,2 mm cavity, whereas replacement kit R8504659-0105
will fit in the 48,2 mm cavity.
1.4.2 For serial number 355 and onwards, as well as for the 17050, the input bearing
arrangement has changed. Annexure E shows the parts list of all new and changed
item numbers, as well as replacements for assembly paragraph 5 page 5 and
disassembly paragraph 14 page 24. If necessary, the new configuration will be
implemented during factory repair.
Date: Page
1.4.3 For serial number 857 and onwards, another fork (23) and M7 cap screw (71) is
used. A further change introduced a fork with bronze buttons since the beginning of
2005. All these assemblies are interchangeable.
1.4.4 The level gauge (76) was initially installed on a few factory repairs for field trails.
This is now in production. Please confirm casing preparation for ordering
replacement parts.
ASSEMBLY OF DROPDOWN GEARBOX BELL 17000
Notes:
1 The tightening of the input and output flanges, as well as the gear mounting screws
is critical and should be done according to the assembly instruction. Failure to
comply with this will result in damage to the dropdown gearbox and possible
damage to the prop shaft system of the vehicle.
2 Never swap raceways amongst separable bearings.
3 For new-built dropdown gearboxes: cover 6 to 8 teeth with Dykem Red on the
following gears:
Sun gear (13); ring gear (15); output gear (16); idler gear (17) and input gear (18).
4 Spray the housing bores with anti-scuff before assembling the mating parts.
5 Apply a thin layer of lithium based grease onto the seal lip and on the area of the
mating part where the seal lip interfaces.
6 For the preheating of bearings, use bearing heater with demagnetising features.
Some inserts have a helical groove in the bearing bore. They must be filled with
Loctite prior to the installation of the bearing.
7 Special tools and fixtures are listed in Annexure “B”. Fixtures to hold splined shafts
for the tightening of fasteners on sub–assemblies can be made from scrap mating
components. If no such is available, a soft jaw bench vice can be used.
8 The following sequence focuses on each stage separately (input, idler and output).
In production routine the sequence is optimised.
Date: Page
1 Housing Sub-Assembly (Fig. 1)

1.1 Steam clean housing (1) thoroughly. (Oil channels; threaded holes).
1.2 Fit lifting lug (50) to housing (1).
1.3 Check all joint-sealing faces and dress with oilstone, if necessary.
1.4 Fit filler plug (44 x 5) and drain plug magnetic (43) each with a copper washer (47x5)
to housing (1) and torque to 50Nm. In later models the level filler plug is replaced by
a sight glass (76) and quantities of items (44) and (47) may vary. If a level gauge is
fitted, refer to Annexure “D” for component list. Fit item (76.3) with Loctite 243 and
torque to 8 Nm.
1.5 Fit copper washer (46) to plug (45); install to housing (1). In later models items (45)
and (46) are no longer used.
1.6 Apply “UHU-Plus” to 3 M10 plug screws and fit to housing (1).
Note: Housing (1) has to be pressure tested after “UHU-Plus” has set. Curing time
24 hours.
1.7 Fit 44 helicoils (HCM) to housing (1).

Note: 16 Threaded inserts were fitted during the machining operation.
2 Front Bearing Housing Sub-Assy (Fig. 2)

2.1 Preheat bearing housing (2) with heating plug R8503529/A02. Fit bearing (59) to
bearing housing (2).
3 Clutch Housing Sub-Assembly (Fig. 3)

3.1 Apply “UHU-Plus” to M10 plug screw and magnet. Fit to clutch housing (3).
4 Rear Bearing Housing Sub-Assembly (Fig. 4)

4.1 Apply “UHU-Plus” to M10 plug screw and fit to bearing housing (4).
Date: Page
5 Input Shaft Sub-Assembly (Fig. 5)

5.1 Apply a thin layer of Loctite 638 to the outside diameter of bearing (61) and press
into rear input insert (8). Fit spacer (27) and secure with circlip (65).
Note: Open end of circlip (65) to be aligned with oil access hole of cover (8).
5.2 Preheat the inner race of bearing (61) to 850C. Use heating plug no. R8503443/A02.
Fit input shaft (12) into bearing (61). Fit retainer plate (34), apply Loctite 270 to
threads of bolts (69), secure and torque to 88Nm.
6 Front Input Insert Sub-Assembly (Fig. 6)

into front input insert (7). Use press tool R8503547/A01.
6.2 Apply a thin layer of lithium based grease to lip of seal (77). Apply Loctite 518 to OD
of seal and fit to front input insert (7). Use seal-punch R8503445/A01.
6.3 Preheat and demagnetise inner race (56/1) to 850C (use bearing heater) and fit to
shaft (12).
6.4 Fit pre-assembled front input insert (7) to input shaft sub-assembly (Fig. 5).
7 Idler Shaft Sub-Assembly (Fig. 7)

into front idler insert (6). Use press tool R8503547/A01. Two such items (6) are
required.
7.2 Preheat and demagnetise the inner races (55/1) to 850C (use bearing heater) and fit
to idler shaft (11).
7.3 Fit idler inserts (6 & 6) to idler shaft (11). See note 2 on p 3.
Date: Page
8 Flange Sub-Assembly (Fig. 8)

8.1 Apply Loctite 638 to ID of mud shield (37) and press onto flange (31). Use jig no.
R8503439/A01.
8.2 Apply Loctite 638 to ID of mud shield (37) and press onto flange (30). Use jig no.
R8503439/A01. Two such items (30) are required.
9 Rear Bearing Housing Sub-Assembly (Fig. 9)

9.1 Preheat bearing housing (4) to 850C on hotplate and fit bearing (60) into bore of
housing (4).
9.2 Fit circlip (65) into groove of bearing housing (4). Allow to cool.
into bore of bearing housing (4). Use press tool R8503442/A03.
Note: Keep inner race (57/1) with assembly.
9.4 Preheat and demagnetise inner race (60/1) to 850C and fit to rear output shaft (10).
Use tool R8503490/A01.
9.5 Integrate pre-assembled bearing housing (4) with rear output shaft (10).
9.6 Preheat and demagnetise inner race (60/2) to 850C and fit to rear output shaft (10).
Use tool R8503490/A01.
Note: Allow unit to cool down prior proceeding with the following operation.
9.7 Apply a thin layer of lithium based grease to lip of seal (77). Apply Loctite 518 to OD
of seal (77) and tap seal into bearing housing (4). Use seal punch R8503445/A01.
Date: Page
10 Front Output Shaft Sub-Assembly (Fig. 10)

10.1 Apply anti-scuff spray to receiving bore of front output shaft (9) and Lithium based
grease to OD and bore of bush (51). Press bush (51) into front output shaft (9). Use
pressing fixture R8504573/A01.
10.2 Press bearing (58) with press tool R8503443/A01 into bore of clutch housing (3).
10.3 Fit circlip (65) into groove of clutch housing (3).
10.4 Preheat bearing (58) to 850C. Use heating plug R8503443/A02. Fit front output shaft
(9) into bearing (58).
Note: Allow unit to cool down prior proceeding with the following operation.
10.5 Apply a thin layer of lithium base grease to lip of seal (77). Apply Loctite 518 to OD
of seal (77) and tap seal into clutch housing (3). Use seal punch R8503445/A01.
Date: Page
11 Clutch Sub-Assembly (Fig.11)

11.1 Press a spring pin (23.3) each into a pair of buttons (23.2) and insert them into fork
(23.1). Press a second pair of buttons into the reverse side of the fork until they
bottom.
11.2 Fit clutch slide (22) over front output shaft (9) of front output shaft sub-assembly.
Ensure free movement between clutch slide (22) and front output shaft (9) over the
entire splined length.
11.3 Install screw (71) into fork (23), screw piston (24) into fork (23), and tighten screw
(71) until all thread clearance between fork (23) and piston (24) has been taken up,
but free rotation is still possible.
Separate fork (23) and piston (24) without disturbing setting of screw (71). Insert fork
(23) to clutch slide (22) in clutch housing (3). For ease of in-vehicle service, the head
of screw (71) must point to the left.
11.4 Apply a thin layer of lithium based grease to lip of seal (78) and fit to piston (24).
Note: Seal lip of seal (78) facing away from body of piston.
11.5 Apply a thin layer of lithium based grease to piston bore of clutch housing (3).
Slightly lubricate the two support journals for piston (24) at clutch housing (3) with
grease to prevent rust. Do not contaminate M18 X 1,5 threads.
Insert spring (41) to clutch housing (3), screw piston (24) into fork (23). Use special
spanner R8503512/A02.
11.6 Fit cover (26) with O-ring (80) to clutch housing (3), fasten cover (26) with screws
(67) and torque to 54Nm.
Date: Page
12 Splitter Sub-Assembly (Fig.12)

12.1 Fit spring pin (40) into carrier (20), using inserting tool R8503499/A01.
Note: Protrusion of spring pin must not exceed 1.3 + 0.2mm.
Apply lithium based grease to both sides of thrust washer (53) and fit to planetary
carrier (20) over spring pin (40).
Note: Metallic face of thrust washer (53) facing planet carrier (20).
12.2 Apply anti-scuff spray to receiving bore of bush (52) at planetary carrier (20). Apply
lithium based grease to O/D and bore of bush (52) and press bush into planetary
carrier (20). Use pressing fixture R8503552/A01.
Note: Bush has to be flush with inner face of planetary carrier.
12.3 Note: It is a pre-requisite to keep the planetary gears (14) in their original matched
set of three.
Apply lithium based grease to bore of planetary gears (14). Place 24 needle rollers
(54) to bore on one side of planetary gear (14) and turn gear over. Insert spacer (28)
and place second row of 24 needle rollers (54) into bore of planetary gear (14).
Insert the additional 2 off spacers (28) on either side of the needle rows. Apply
lithium based grease to both sides of planetary gear (14) and attach washer wear
(35 x 2) to either side of gear.
12.4 Preheat planetary carrier (20) to 750C on hotplate. Immerse planetary pins (19) into
liquid nitrogen.
12.5 Apply anti-scuff spray into receiving bores of planetary pins (19).
Place planet gear assemblies (14) into position. Alignment of needle races and wear
washers with the receiving bores of planet pins (19) can be facilitated using a
dummy pin.
12.6 When installing planetary pins (19) to planetary carrier (20) ensure that the oil hole
identification notch at the planetary pinhead faces radially outwards.
12.7 Fit circlip (62) to planetary pins (19) with the open ends facing radially outwards.
12.8 Check for free rotation on all planetary gears. Blow compressed air through
lubrication hole of planetary pins (19) to clear oil passages from residual grease.
12.9 Insert sun gear (13) into planetary carrier (20).
12.10 Fit spring pin (40) into ring gear (15), using inserting tool R8503499/A01.
Date: Page
12.11 Apply lithium based grease to both sides of thrust washer (53) and fit over spring pin
(40) to ring gear (15).
Note: Metallic face of thrust washer facing ring gear (15).
12.12 Integrate ring gear (15) with planetary carrier (20). Check free rotation of planetary
gear set.
12.13 Fit spring pin (40) into output gear (16) using inserting tool R8503499/A01.
12.14 Apply lithium based grease to both sides of thrust washer (53) and fit over spring pin
(40) to output gear (16).
12.15 Integrate output gear assembly with planetary carrier (20) and align bolt holes.
Note: The operational torque is transferred between output gear assembly (16) and
planetary carrier assembly (20) by means of friction, it is therefore important
to keep the interface dry and clean during assembly.
12.16 Fit two cap screws (72) without Loctite and torque to approx. 80Nm. Check free
rotation of planetary gear set.
12.17 Place sub-assembly onto torque fixture R8504578/A01. Apply Loctite 270 to thread
of cap screws (72) and torque cap screws to 156Nm. The preliminary fitted screws
of 12.16 must also be re-fitted as the others.
Date: Page
13 Front Output Sub-Assembly (Fig. 13)

13.1 Preheat inner race of bearing (59) to 850C. Use heating plug/press tool
R8504571/A01. Integrate cover (2) with splitter sub-assembly. Fit circlip (64) and
allow bearing to cool down.
13.2 Fit O-Ring (85) to clutch housing sub-assembly (3) and O-Ring (79) to output gear
sub-assembly (16) with lithium based grease.
13.3 Preheat bearing bore of clutch housing sub-assembly (3) to 850C.

Use heating plug R8503469/A05.
13.4 Integrate sub-assemblies and secure temporary with 2 bolts and nuts M10.
14 Integration of Sub-Assemblies with Housing (Fig. 14)

14.1 For ease of assembly, preheat housing in oven to 105 °C. Mount housing to
assembly stand manipulator R8503470/A01 and rotate till bottom bore faces
upwards.
Notes: Preheating can also be done with a heating torch in case of partial strip-
down and re-assembly.
Always rotate assembly stand manipulator in the direction where input and
idler gears (18 and 17) will not fall out.
14.2 Load input gear (18) with ground mounting face towards housing through bottom
bore of housing (1). Slide in position.
14.3 Rotate housing in stand manipulator 1800.
Date: Page
15 Fitment of Input Sub-Assembly to Housing (Fig. 15)
Note: The operational torque between input shaft (12) and input gear (18) is
transferred by friction. Therefore it is critical to keep the interface dry and
clean during assembly.
15.1 Apply a thin layer of lithium based grease to O-Ring (83) and fit to rear input insert
(8) of sub-assembly (12).
15.2 Fit two M16 guide pins to input shaft (12) sub-assembly and two M10 guide pins to
housing (1) to align holes. Install input shaft (12) to housing (1).
15.3 Apply a thin layer of lithium based grease to O-Ring (83) and fit to face groove of
rear input insert (8). Fit input lid (32) to rear input insert (8). Remove guide pins. Fit
screws (68) and torque to 54Nm.
15.4 Rotate housing in stand manipulator 1800. Remove M16 guide pins. Apply Loctite
270 to cap screws (74) and fit to input shaft (12). Secure input shaft (12) with locking
fixture R8503558/A01. Torque cap screws (74) to 340Nm. Remove locking fixture.
Note: The first two cap screws to be tightened incrementally, diagonally across to
ensure that input gear (18) is seated square on input shaft (12).
15.5 Apply a thin layer of lithium based grease to O-Ring (83) and fit to front input insert
(7). Fit two M10 guide pins to housing (1).
15.6 Fit sub-assembly of front input insert (7) to housing (1). Remove guide pins; secure
front input insert (7) with screws (67), torque to 54Nm.
Date: Page
16 Fitment of Idler Gear to Housing (Fig. 16)

16.1 Load idler gear (17) with ground face toward housing, through bottom bore of
housing (1), slide in position.
Date: Page
17 Fitment of Idler Assembly to Housing (Fig. 17)

17.1 Apply a thin layer of lithium based grease to O-Ring (83) and fit to idler insert (6).
17.2 Fit two M12 guide pins to idler shaft sub-assembly (11) and integrate with idler gear
(17).
17.3 Fit two M10 guide pins to housing (1) and fit idler shaft sub-assembly (11) to housing
(1). Remove guide pins M10 and secure idler insert (6) to housing (1) with screws
(67) and hand tighten only.
17.4 Rotate housing in stand manipulator 1800. Remove two guide pins M12. Lock input
shaft with R8503432/A07. Apply Loctite 270 to thread of cap screws (73) and fit to
idler shaft (11). Torque cap screws (73) to 156Nm.
Note: The first two cap screws to be tightened incrementally, diagonally across, to
ensure that idler gear (17) is seated square on idler shaft (11).
17.5 Measure axial clearance of bearing (55) at the idler shaft (11). For axial clearance
refer to annexure “A”.
Note: Bottom bearing (55) to be at zero clearance.
17.6 Apply a thin layer of lithium based grease to O-Ring (83) and fit to idler-insert (6).
17.7 Fit 2 guide pins to housing (1). Fit sub-assembly of idler insert (6) to housing (1).
Remove guide pins; secure idler insert, with screws (67) and torque to 54Nm.
17.8 Rotate housing in stand manipulator 1800. Torque screws (67) at idler insert (6) to
54Nm.
17.9 Apply a thin layer of lithium based grease to O-Ring (82 x 2) and fit to idler inserts
(6).
17.10 Fit PTO lids (33 x 2) to idler inserts (6) and secure with screws (69) and torque to
88Nm. Refer to annexure “A”. Check backlash between input gear (18) and idler
gear (17). Lock input gear (18) with R8503432/A07 and clock gauge to measure
backlash of gears.
Date: Page
18 Fitment of Rear Bearing Housing Assembly to Housing (Fig. 18)

18.1 Apply a thin layer of lithium based grease to O-Rings (84) and (79). Fit O-Ring (84)
to bearing housing (4) and O-Ring (79) to housing (1).
18.2 Fit 2 guide pins M10 to housing (1) and integrate sub-assembly of bearing housing
(4) with housing (1). Remove M10 guide pins and secure sub-assembly of bearing
housing (4) with screws (67) and torque to 54Nm.
19 Fitment of Front Output to Housing (Fig. 19)

19.2 Preheat inner race (57/1) to 850C and demagnetise. Use bearing heater. Fit inner
race (57/1) to front output sub-assembly (16).
19.3 Apply a thin layer of lithium based grease to O-Ring (86) and fit to clutch housing
assembly (3). Fit O-Ring (79) to housing (1) with grease.
19.4 Fit 2 guide pins M10 to housing (1) and integrate front output sub-assembly with
housing (1). Secure with screws (68) and torque to 54Nm.
CAUTION: Injury possible.

If the temporary M10 bolts and nuts (paragraph 13.4 page 11) are removed and the
assembly is lifted by the clutch housing (3), the splitter sub-assembly (16) can drop
out untimely.
Date: Page
20 Flange Installation (Fig. 20)

20.1 Apply Loctite 641 to splines of output shafts (9) and (10). Fit flanges (30) to output
shafts. Heating of the flange may be necessary to ease assembly.
Note: It is recommended that the orientation of the rear output flange relative to the
pattern of screws (72) be as square as possible.
20.2 Fit O-Ring (81 x 2) to groove of flanges (30).
20.3 Apply Loctite 270 to thread of cap screws (72). Use fixture R8503434/A01. Fit flange
plates (29) to flanges (30) and secure with cap screws (72). Torque to 156Nm.
20.4 Apply Loctite 641 to splines of input shaft (12). Fit flange (31); heating of flange may
be necessary. Fit O-Ring (81) to groove of flange (31).
20.5 Apply Loctite 270 to threads of cap screws (72). Fit flange plate (29) to flange (31)
and secure with cap screws (72). Torque to 156Nm. Use fixture R8504581/A01.
Date: Page
21 Dog Clutch Final Adjustment (Fig. 21)

21.1 Apply air pressure (6-9.1 bar max) to engage clutch.
Note: Thread at air connection is M12 x 1.5.
21.2 Ensure that teeth of clutch slide (22) and carrier (20) are fully engaged.
21.3 The face of the fork (23) pointing towards the planetary splitter assembly must clear
the side of the groove at clutch slide (22) by 0.20 to 0.40mm, with the aim towards
maximum setting of 0.40mm. Adjustments can be made by rotating piston (24). Use
flat spanner 13mm A/F.
If the fork assembly with buttons is used, the minimum running clearance on any one
button is 0,1mm. The clearance on the other button is the same or more due to
tolerance stacking, but may not exceed 0,25mm.
21.4 Apply air pressure several times to engage clutch. Check setting and function of dog
clutch. Check for air leaks.
21.5 With clutch disengaged and the axial clearance between fork (23) and clutch slide
(22) is at the side of the planetary splitter assembly, check that the tips of the dog
teeth clear by at least 0,4mm.
21.6 After adjustment has been completed remove screw (71). Apply Loctite 243 to
thread. Re-install screw and torque to 18Nm (M6) or 30Nm (M7). Check that piston
(24) does not slip in fork (23) when 30Nm torque is applied.
Note: With dog clutch released, the fork (23) and screw (71) must clear casting of
clutch housing (3).
21.7 Apply Loctite 518 to sealing area for clutch cover (36) at clutch housing (3). Fit
screws (66) and torque to 12Nm.
21.8 Fit breather extension (96) to housing (1). Fit plastic protection plug (95) to air supply
port at clutch housing (3) and breather extension (96).
21.9 For new-built, stamp model number, serial number and date onto main housing (1);
serial number on clutch housing (3) and rear bearing housing (4). For location see
R8503560-0103 Sheet 1.
Date: Page
DISASSEMBLY OF DROPBOX BELL 17000
Notes:
1 For the preheating of bearings use bearing heater with demagnetising features.
2 Special tools and fixtures are listed in Annexure “C”. Fixtures to hold splined shafts
for the loosening of fasteners on sub-assemblies can be made from scrap mating
components. If no such is available, a soft jaw bench vice can be used.
3 Components such as: seals, O-Rings and cap screws must generally be replaced,
whereas bushes (51 + 52) and thrust washer (53) should be replaced if the “Teflon”
coating is worn or damaged. Bearings (58, 59 and spherical roller bearing 61) should
not be re-used if pressed from their shaft journals.
4 The sequence of disassembly can be adapted to suit a partial strip down to reach
trouble spots.
Date: Page
1 Mount the dropdown gearbox to assembly stand manipulator R8503470/A01. Rotate

till the input side faces upwards.
2 Removal of Input Flange and Clutch Housing from Dropdown

Gearbox (Fig. 1)
2.1 Hold flange (31) with R8504581/A01. Remove cap screws (72), flange plate (29) and
jack off flange (31) from input shaft (12) with a puller.
2.2 Remove screws (68) from clutch housing (3). Fit jacking screws M10 or M12. Jack
off and remove clutch housing (3) from housing (1).
3 Removal of Front Bearing Housing (Fig. 2)

3.1 Fit 2 jacking screws M10 or M12 to bearing housing (2). Remove bearing housing
(2) with output gear (16) from housing (1).
4 Removal of Front Input Insert and Idler Insert (Fig. 3)

4.1 Remove screws (67) from front input insert (7). Fit M10 or M12 jacking screws.
Remove front input insert (7) from housing (1).
4.2 Remove cap screws (74). Use R8503558/A01 to lock input shaft.
4.3 Remove screws (69) and PTO lid (33). Remove screws (67). Fit 2 jacking screws
M10 or M12. Remove idler insert (6) from housing (1).
4.4 Remove cap screws (73) and R8503558/A01.
4.5 Rotate dropdown gearbox in stand manipulator 1800.
Date: Page
5 Removal of Input Shaft Sub-Assembly from Housing (Fig. 4)

5.1 Remove screws (68) and input lid (32) from rear input insert (8). Fit 2 jacking screws
M10 or M12. Jack off and remove rear input insert (8) from housing (1).
Note: To loosen input shaft (12) from input gear (18) tap shaft lightly with plastic
mallet.
6 Removal of Idler Shaft Sub-Assembly from Housing (Fig. 5)

6.1 Remove screws (69) and PTO lid (33) from idler insert (6). Remove screws (67). Fit
2 jacking screws M10 or M12. Jack off and remove idler insert (6) from housing (1).
Note: To loosen idler shaft (11) from idler gear (17) tap shaft lightly with plastic
mallet.
7 Removal of Rear Bearing Housing from Main Housing (Fig. 6)

7.1 Remove screws (67) from rear bearing housing (4). Fit jacking screws M10 or M12.
Jack off and remove rear bearing housing (4).
7.2 Rotate housing (1) in the stand manipulator 1800.

Note: Always rotate assembly stand manipulator in the direction where input and
idler gears (18 and 17) will not fall out.
Date: Page
8 Removal of Idler and Input Gears from Housing (Fig. 7)

8.1 Slide idler gear (17) out of bottom bore of housing (1).
8.2 Slide input gear (18) out at bottom bore of housing (1).
Date: Page
9 Removal of Fork Mechanism from Clutch Housing (Fig. 8)

9.1 Remove screws (66) and cover (36).
9.2 Remove cap screw (71).
9.3 Remove screws (67) and cover (26).
9.4 Unscrew piston (24) from fork (23). Use special two pin spanner R8503512/A02.
9.5 Remove spring (41) from clutch housing (3).
9.6 Remove fork (23) from clutch slide (22).
9.7 Remove clutch slide (22) from front output shaft (9).
9.8 Remove cap screws (72), flange plate (29) and jack off flange (30) with a puller.
10 Removal of Front Output Shaft from Clutch Housing (Fig. 9)

10.1 Place clutch housings (3) on top of press fixture R8503486/A02 and press out front
output shaft (9).
10.2 Remove circlip (65) from clutch housing (3).
10.3 Press out bearing (58). Use heating plug R8503443/A02 as press tool.
10.4 Remove oil seal (77).
Date: Page
11 Removal of Output Shaft from Rear Bearing Housing (Fig. 10)

11.1 Remove cap screws (72), flange plate (29) and jack off flange (30) with a puller.
11.2 Place rear bearing housing assembly (4) on support fixture R8503471/A01 and
press out rear output shaft (10).
11.3 Press off inner race (60/1) from rear output shaft (10) by supporting it in a tube with
ID 76.
11.4 Remove bearing (57) from rear bearing housing (4). Use bearing puller. Remove
circlip (65).
11.5 Remove oil seal (77). Press out bearing (60). Use press fixture R8503490/A01.
12 Removal of Idler Inserts from Idler Shaft (Fig. 11)

12.1 Remove inner races (55/1) from idler shaft (11). Use bearing puller.
12.2 Remove bearing (55) from idler insert (6). Use bearing puller (x 2).
Date: Page
13 Removal of Front Input Insert from Input Shaft (Fig. 12)

13.1 Remove inner race (56/1) from input shaft (12). Use bearing puller.
13.2 Remove bearing (56) from front input insert (7). Use bearing puller.
13.3 Remove seal (77) from front input insert (7).
14 Removal of Rear Input Insert from Input Shaft (Fig. 13)

14.1 Remove screws (69) and retainer plate (34) from input shaft (12).
14.2 Remove circlip (65) and spacer (27) from rear input insert (8).
14.3 Place rear input insert (8) on top of support fixture R8503518/A02 and press out
input shaft (12). Use press fixture R8503432/A02 and hydraulic press.
14.4 Remove bearing (61) from rear input insert (8).
Date: Page
15 Remove Front Bearing Housing from Output Gear Assembly

(Fig. 14)
15.1 Remove circlip (64) from output gear assembly (16).
15.2 Place output gear assembly (16) on a set of parallels and press out gear assembly.
Use heating-plug/press tool R8503529/A02 and hydraulic press.
15.3 Turn over front bearing housing (2) and place on parallels. Press out bearing (59).
Use heating-plug/press tool R8503529/A02 and hydraulic press.
16 Remove Output Gear Sub-Assembly from Planet Carrier Assembly

(Fig. 15)
16.1 Place output gear assembly onto torque fixture R8504578/A01. Remove cap screws
(72) from planet carrier assembly and remove output gear (16).
16.2 Remove thrust washer (53) from output gear (16).
16.3 Remove inner race (57/1) from output gear (16) with puller or induction heater.
16.4 Remove ring gear (15) from planet carrier assembly.
16.5 Remove thrust washer (53) from ring gear (15).
16.6 Remove sun gear (13).
16.7 Remove circlips (62) from planetary pins (19).
16.8 Press out planetary pins (19). Use press fixture R8503486/A02.
16.9 Remove planetary gears (14).
16.10 Bush (52) is destroyed for removal. Remove thrust washer (53).
Date: Page
ANNEXURE “A”
TECHNICAL INFORMATION
1 AXIAL CLEARANCES
1.1 Inside planetary output stage 0.07 to 0.82mm.
1.2 Output cylindrical roller bearing (57) 0.4 to 1.05mm.
1.3 Idler shaft cylindrical roller bearing (55) 0.4 to 1.2mm.
1.4 Input shaft cylindrical roller bearing (56) 0.4 to 1.2mm.
2 GEAR BACKLASH
2.1 Input – idler gear mesh 0.25 to 0.42mm.
2.2 Idler – output gear mesh 0.25 to 0.42mm.
2.3 Sun gear – planetary gear mesh 0.154 to 0.234mm.
2.4 Planetary gear – ring gear mesh 0.199 to 0.328mm.
Date: Page
ANNEXURE “B”
SPECIAL ASSEMBLY TOOLING

PARAGRAPH WHERE
TOOL NO. DESCRIPTION
USED
R8503558/A01 LOCKING FIXTURE 15.4
R8503434/A01 TIGHTENING FIXTURE 20.3
R8503439/A01 SHIELD PUNCH 8.1
R8503443/A02 HEATING PLUG 5.2 / 10.4
R8503445/A01 SEAL PUNCH 6.2 / 9.7 / 10.5
R8503490/A01 PRESS TOOL BEARING 9.4 / 9.6 / 5.6 Alt. E
R8503499/A01 PIN INSERTING TOOL 12.1 / 12.10 /12.13 / 5.8 Alt. E
R8503512/A02 SPEC. 2-PIN SPANNER 11.5
R8503529/A02 HEATING PLUG/PRESS TOOL 2.1
R8503547/A01 CLAMPING PLATE 6.1 / 7.1 / 5.1 Alt. E
R8504573/A01 PRESSING FIXTURE 10.1
R8503552/A01 PRESSING FIXTURE 12.2
R8504578/A01 TORQUE FIXTURE 12.17
R8504571/A01 HEATING PLUG 13.1
R8503470/A01 ASSEMBLY STAND 14.1
R8503432/A07 HOLDING DEVICE 17.4 / 17.10
R8503442/A03 PRESS TOOL 9.3
R8503468/A05 HEATING BUNG 13.3
Date: Page
ANNEXURE “C”
SPECIAL DISASSEMBLY TOOLING

PARAGRAPH WHERE
TOOL NO. DESCRIPTION
USED
R8503443/A02 PRESS TOOL/HEATING PLUG 10.3
R8503471/A01 SUPPORT FIXTURE 11.2
R8503486/A02 PRESS FIXTURE 10.1 / 16.8
R8503490/A01 PRESS FIXTURE 11.5
R8503512/A02 SPEC. 2-PIN SPANNER 9.4
R8503518/A02 SUPPORT FIXTURE 14.3 / 14.2 Alt. E
R8503529/A02 HEATING PLUG/PRESS TOOL 15.2 / 15.3
R8503470/A01 ASSEMBLY STAND 1
R8503558/A01 LOCKING FIXTURE 4.2 / 4.4
Date: Page
ANNEXURE “D”
PARTS LIST
Item Figure Figure
Part No. Description
No. Assembly Disassembly
1 15 16 17 18 1 2 3 4 5
1 R8504575-0102 Housing M/C
14 19 21 6 7
1
SA005121-300 Helicoil HCM
R8504594-0300/ Insert Threaded 1

R8504657-0300 M16
Screw Plug 1 3 4
R8503462-0300
M10x10
Bearing Housing 2 13 19 1 14 2
2 R8504582-0102
Front
Clutch Housing 3 10 11 13 21 1 4 8 9
3 R8503557-0102
M/C
3
R8503528-0300 Magnet
Bearing Housing 9 4 18 6 10
4 R8503471-0102
Rear
7 17 3 5 11
6 R8503472-0102 Insert Idler PTO
6 15 7 12
7 R8503427-0102 Insert Input Front
5 15 4 13
8 R8503544-0102 Insert Input Rear
10 11 20 8 9
9 R8504578-0102 Shaft Output Front
9 20 10
10 R8504579-0102 Shaft Output Rear
7 17 5 11
11 R8504580-0111 Shaft Idler
7 17 5 11
R8504586-0102 Bush Splined
5 6 15 20 12 13
12 R8503558-0102 Shaft Input
12 15
13 R8503562-0102 Sun Gear
Date: Page
ANNEXURE “D”
PARTS
Item Figure Figure
12 15
14 R8503553-0111 Gear Planet Set
12 15
15 R8503561-0102 Gear Ring
12 18 19 2 14 15
16 R8503555-0102 Gear Output
16 17 5 7
17 R8504574-0102 Gear Idler
14 15 7
18 R8503559-0102 Gear Input
12 15
19 R8503554-0102 Pin Planetary
Planetary Carrier 12 21 15
20 R8504596-0102
(with Clutch)
11 21 8
22 R8504577-0102 Clutch Slide
R8503556-0102/ 11 21 8
23 Fork
R8505074-0102
11
23 R8505450-0103 Fork Assembly
11
23.1 R8505378-0102 Fork
11
23.2 R8505424-0102 Button
11
23.3 R8505451-0300 Spring Pin Ø3x6
11 21 8
24 R8503512-0102 Piston
11 21 8
26 R8504572-0102 Cover Actuator
5 13
27 R8503548-0102 Spacer Bearing
R8503501-0102/ 12 15
28 Spacer see p2; 1.4.1
R8505176-0102
Date: Page
ANNEXURE “D”
PARTS
Item Figure Figure
20 1 10
29 R8504640-0006 Plate Flange
8 20 10
30 R8503434-0102 Flange 8.5C
8 20 1
31 R8504581-0102 Flange 180 KV70
15 4
32 R8503517-0102 Lid Input
17 3 5
33 R8503513-0102 Lid Input
5 13
34 R8503549-0102 Plate Retainer
R8503524-0102/ Washer Wear (0,5/ 12 15

35
R8504821-0102 0,8mm) see p2; 1.4.1
R8504659-0102/ Bronze Washer 12 15
35
R8505177-0102 (0,5/0,8) see p2; 1.4.1
21 8
36 R8504585-0102 Cover Clutch
8
37 R8503439-0003 Mud-Shield
12
40 R8503499-0302 Pin Spring ø4 mod.
Spring 11 8
41 R8503489-0301
compression
Plug Drain 1
43 R0015159-0102
Magnetic
1
44 R0015158-0300 Plug Filler M22x1.5
1
45 371982 Plug M14x1.5
1
47 SA014034-300 Washer A22x27Cu
1
50 R8505391-0300 Eye Bolt
10 9
51 R8504573-0300 Bush MB 3030 DU
Date: Page
ANNEXURE “D”
PARTS
Item Figure Figure
12 15
52 R8503487-0300 Bush MB 8530 DU
Washer Thrust 12 15
53 R8503488-0300
WC60DU
12
54 R8503523-0300 Needle Roller
7 11
55 R8503546-0300 Bearing Cyl. Roller
6 12
9 18 10 15
Bearing deep 10 9
58 R8503443-0300
groove ball
Bearing deep 2 13 14
59 R8504571-0300
groove ball
9 10
60 R8503490-0300 Bearing Four Point
5 13
61 R8503547-0300 Bearing Spherical
12 15
62 R8503498-0300 Circlip Shaft ø20
13 14
64 R8503497-0300 Circlip Shaft ø110
5 9 10 9 10 13
65 R8503461-0300 Circlip Bore ø120
21
66 R8503494-0300 Screw Hex M6x10
8
Screw Hex 11 15 17 18 21 3 6 8
67 R8503454-0300
M10x22
Screw Hex 15 19 1 4
68 R2002688-AH00
M10x30
Screw Hex 5 17 5 13
69 R2002695-AH00
M12x20
Date: Page
ANNEXURE “D”
PARTS
Item Figure Figure
R8503522-0300/ Screw Cap M6x30/ 11 21 8
71
R8505075-0300 Screw Cap M7x35
Screw Cap 12 20 1 10 15
72 R0012900-0310
M12x30
Screw Cap 17 3
73 R8503455-0300
M12x40
Screw Cap 15 3
74 R8503564-0300
M16x45
1
76 R8504826-0301 Sight Glass
1
76 R8505068-0103 Level gauge assy
76.2 R8505067-0102 Frame 1

76.3 R2002611-AH00 Screw Hex M6x16 1
76.4 R8505065-0300 Glass 1
76.5 R8505076-0300 “O”-Ring 1
R8504866-0300/ Seal 80x100x10 6 9 10 9 10 12
77
R8505459-0300 SL
11 8
78 SA065624-301 Seal Piston
13 18
79 R8503446-0300 “O”-Ring 9x2.5
18
84 SA021049-300 “O”-Ring 144.5 x 3
13
85 R8503492-0300 “O”-Ring 189,2x5.7
19
86 R8504583-0300 “O”-Ring 270x6
Dykem Red DX
87
296
88 Loctite 243
89 Loctite 270
Date: Page
ANNEXURE “D”
PARTS
Item Figure Figure
90 Loctite 641
91 Loctite 518
92 Anti-Scuff Spray
Grease Lithium
93
based
21
95 R8505457-0300 Plastic Plug
UHU Plus/
Loctite 638
Date: Page
ANNEXURE “E”
NEW INPUT BEARING ARRANGEMENT

PARTS LIST
Item Figure Figure
5E 15 4 13E
8 R8504892-0102 Insert Input Rear
5E 13E
25 R8504894-0102 Extension Shaft
27 Not Required
15 5E 4 13E
32 R8504893-0102 Lid Input
34 Not Required
5E 13E
61 R8504895-0300 Brng. QJ 213 Mod.
5E 13E
Brng. Cyl. Roller
63 R8504896-0300
Nu 213
5E 13E
Screw Cap
75 R8504897-0300
M12 x 35
Date: Page
ANNEXURE “E”
5 Input shaft sub-assemblies (Fig. 5)
into rear input insert (8). Use press tool R8503547-A01.
5.2 Preheat and demagnetise race (63/1) to 85 °C (use bearing heater) and fit to input
shaft (12).
5.3 Fit pre-assembled rear input insert (8) to shaft sub-assembly (12).
5.4 Preheat and demagnetise inner race (61/1) to 85 °C and fit to input shaft (12).
5.5 Drop bearing (61) with slot facing away from input shaft (12) into input insert (8).
5.6 Preheat and demagnetise inner race (61/2) to 85 °C and fit to shaft (25). Use tool
R8503490/A01.
5.7 Place shaft (25) into position. Apply Loctite 270 to cap screws (75). Tighten to
156Nm.
5.8 Fit spring pin (40) into input lid (32) using inserting tool R8503499/A01.
Note: Protrusion of spring pin (40) must not exceed 1,3 ±0,2 mm.
Date: Page
ANNEXURE “E”
14 Removal of Rear Input Insert from Input Shaft (Fig. 13)
14.1 Remove screws (75)
14.2 Place rear input insert (8) on top of support fixture R8503518/A02. Tap input shaft
(12) with a pin punch in the bottom of the threaded holes so that extension shaft
(25) pops loose and can be removed.
Note: Take care not to damage thread.
14.3 Use press to remove race (61/1).

Note: This will damage bearing (63) and should be discarded after removal from
rear input insert (8).
14.4 The inner race of bearing (63) must be removed from shaft (12) by heating it.
Date: Page

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Land Systems

BELL 17000: MAINTENANCE & SERVICE MANUAL

SUBJECT: MAINTENANCE & SERVICE MANUAL

ISSUE PAGE PARAGRAPH

DOC NO.: R8503560-0787 ISSUE 10 Page 1 of 2

PARAGRAPH TITLE PAGE

2 ASSEMBLY INSTRUCTION 3-17

3 DISASSEMBLY INSTRUCTION 18-25

DOC NO.: R8503530-0787 ISSUE 10 Page 2 of 3

2 Assembly of Dropdown Gearbox 3-17

3 Disassembly of Dropdown Gearbox 18-25

Input Torque Max 17000Nm

1.2 Oil Level

1.4 Alternative Configurations

A further improvement is now on offer: Wear washer (35) is available in a bronze

ASSEMBLY OF DROPDOWN GEARBOX BELL 17000

2 Never swap raceways amongst separable bearings.

1 Housing Sub-Assembly (Fig. 1)

1.2 Fit lifting lug (50) to housing (1).

1.7 Fit 44 helicoils (HCM) to housing (1).

2 Front Bearing Housing Sub-Assy (Fig. 2)

3 Clutch Housing Sub-Assembly (Fig. 3)

4 Rear Bearing Housing Sub-Assembly (Fig. 4)

5 Input Shaft Sub-Assembly (Fig. 5)

6 Front Input Insert Sub-Assembly (Fig. 6)

7 Idler Shaft Sub-Assembly (Fig. 7)

8 Flange Sub-Assembly (Fig. 8)

9 Rear Bearing Housing Sub-Assembly (Fig. 9)

10 Front Output Shaft Sub-Assembly (Fig. 10)

10.3 Fit circlip (65) into groove of clutch housing (3).

11 Clutch Sub-Assembly (Fig.11)

12 Splitter Sub-Assembly (Fig.12)

12.9 Insert sun gear (13) into planetary carrier (20).

13 Front Output Sub-Assembly (Fig. 13)

13.3 Preheat bearing bore of clutch housing sub-assembly (3) to 850C.

14 Integration of Sub-Assemblies with Housing (Fig. 14)

14.3 Rotate housing in stand manipulator 1800.

15 Fitment of Input Sub-Assembly to Housing (Fig. 15)

16 Fitment of Idler Gear to Housing (Fig. 16)

16.2 Rotate housing in stand manipulator 1800.

17 Fitment of Idler Assembly to Housing (Fig. 17)

18 Fitment of Rear Bearing Housing Assembly to Housing (Fig. 18)

19 Fitment of Front Output to Housing (Fig. 19)

CAUTION: Injury possible.

20 Flange Installation (Fig. 20)

20.2 Fit O-Ring (81 x 2) to groove of flanges (30).

21 Dog Clutch Final Adjustment (Fig. 21)

DISASSEMBLY OF DROPBOX BELL 17000

1 Mount the dropdown gearbox to assembly stand manipulator R8503470/A01. Rotate

2 Removal of Input Flange and Clutch Housing from Dropdown

3 Removal of Front Bearing Housing (Fig. 2)

4 Removal of Front Input Insert and Idler Insert (Fig. 3)

4.4 Remove cap screws (73) and R8503558/A01.

4.5 Rotate dropdown gearbox in stand manipulator 1800.

5 Removal of Input Shaft Sub-Assembly from Housing (Fig. 4)

6 Removal of Idler Shaft Sub-Assembly from Housing (Fig. 5)

7 Removal of Rear Bearing Housing from Main Housing (Fig. 6)

7.2 Rotate housing (1) in the stand manipulator 1800.

8 Removal of Idler and Input Gears from Housing (Fig. 7)

9 Removal of Fork Mechanism from Clutch Housing (Fig. 8)

9.2 Remove cap screw (71).

9.3 Remove screws (67) and cover (26).

9.5 Remove spring (41) from clutch housing (3).