Instruction

1. General information

GA7-15VSD+: Drive train overhaul

Printed Matter Number : 2946 1855 00

Applicable to : GA7-15VSD+

Preliminary Operations :

Safety Instructions :

Persons Required :

Special Tools :

Consumables :

2. Document Overview
This document covers the following:

1. General information ........................................................................................................................................................... 1

2. Document Overview........................................................................................................................................................... 1
3. Safety First ......................................................................................................................................................................... 2
4. Disassemble top cover ....................................................................................................................................................... 3
5. Remove stator.................................................................................................................................................................... 5
6. Remove anchor.................................................................................................................................................................. 6
7. Install rotor ......................................................................................................................................................................... 7
8. Install stator........................................................................................................................................................................ 8
9. Install top cover .................................................................................................................................................................. 9
10. Install bearing & finalize ................................................................................................................................................. 10
3. Safety First

SAFETY = THINK BEFORE YOU ACT

1. STOP 3. THINK 2. ACT

EVALUATE RISKS SEEK PROPER SOLUTION CARRY OUT SOLUTION

KNOW THE SAFETY

KNOW THE SAFETY
RULES OF YOUR
INSTRUCTIONS OF
CUSTOMER
YOUR MACHINE

LOCK OUT / TAG OUT

PERSONAL PROTECTION KEEPS YOU SAFE TAKE AWAY THE RISKS
4. Disassemble top cover

1. Warning: magnetic field in 2. Remove non return valve. Remove nipple.

place.

3. Remove cover. Remove bearing cover. Remove wave spring.

Note: Screws can not be removed
in one time. Loosen alternately.

4. Remove O-rings. 5. Remove nut & washer. 6. Remove plate.

Note: Left hand thread.

7. Loosen screws connector. 8. Remove threaded rods. 9. Install push rod.

Note: Left hand thread.

10. Pull off cover with bearing. 11. Make sure to place a protection on 12. Remove puller.
the push rod!
13. Remove push rod. 14. Remove bearing. 15. Remove cover.
Note: Left hand thread.
:

16. Remove oil seal.

17. Two suggested methods to First method: Suck with a plastic bottle. Second method: Adsorp with a cloth.
remove the oil from the housing

18. In case of a plastic connector: 19. In case of a plastic connector: 20. In case of a plastic connector:
Remove connector. Mount O-rings on new connector Assemble new connector.
pins.

21. In case of a plastic connector: In case of a metal connector: In case of a metal connector:
Mount connector. Remove connector. Remove O-ring connector.
Torque value: 2Nm.
22. Remove O-ring. 23. Remove O-ring cover.

5. Remove stator

1. Install stator protection. 2. Install lifting eyes. 3. Remove stator. Warning:

magnetic field in place.

4. Remove lifting tool. 5. Remove lifting eyes. 6. Remove stator protection.

6. Remove anchor

1. Remove O-rings. 2. Install push rod. 3. Install shells.

Note: Left hand thread.

4. Install connection rods. 5. Install plate. 6. Install pump.

7. Pull off rotor. 8. Maximum 26 mm! 9. >150 bar = Stop.

<150 bar = OK.

10. Remove pump. 11. Remove push rod. 12. Remove rotor.
Note: Left hand thread.

13. Carefully handle rotor. 14. Remove tools. 15. Remove threaded rod.
7. Install rotor

1. Apply Loctite 243 before mounting 2. Mount threaded rod. 3. Mount rotor.
threaded rod.
Note: Left hand thread.

4. Assemble mounting assembly. 5. Install mounting assembly. 6. Install pump.

Note: Left hand thread.

7. Press rotor. 8. >150 bar = Stop. 9. Remove pump.

<150 bar = OK.

10. Remove mounting assembly.

8. Install stator

1. Change gloves 2. Clean inside. 3. Apply vaseline.

4. Mount O-rings. 5. Install stator protection. 6. Mount housing. Always use a

gantry!

7. The magnetic force pulls the stator 8. Position rib to fit in cutout. 9. Remove lifting tools.
downwards: risk of injuries when
fingers are between stator and
element!

10. Remove lifting eyes. 11. Remove stator protection.

9. Install top cover

1. In case of a metal connector: 2. In case of a metal connector: 3. Apply vaseline on housing.

Mount O-ring connector. Mount connector.

4. Apply vaseline on cover. 5. Mount new O-ring housing. 6. Mount new O-ring cover.

7. Mount cover. 8. In case of a metal connector: In case of a plastic connector:

Mount connector. Use tool to tighten connector.

9. In case of a plastic connector: 10. Position cover correctly. 11. Rib fits in cutout.
Tighten connector. Plastic
connector: do not overtorque!

12. Mount threaded rods. 13. Fix threaded rods with 2 nuts. 14. Mount new washers & nuts.
15. Torque cover crosswise. 16. Mount oil seal.
Torque: 20 Nm.

10. Install bearing & finalize

1. Mount new bearing. 2. Install bearing push plate. 3. Install mounting assembly.
Note: Left hand thread.

4. Install pump. 5. Press bearing . 6. >150 bar = Stop.

<150 bar = OK.

7. Remove pump. 8. Remove mounting assembly. 9. Apply Loctite 243 before mounting
washer & nut.

10. Mount washer. 11. Mount nut. 12. Torque nut.

Torque: 20 Nm.
Note: Left hand thread.
13. Apply vaseline. 14. Mount new O-rings. 15. Mount new wave spring.

16. Mount bearing cover. 17. Torque bearing cover. 18. Mount new seal.
Torque: 20 Nm.

19. Mount cover. 20. Check if the nozzle is not 21. Mount nozzle.
obstructed.
Note: Tighten screws alternately.

22. Make sure the arrows on the non 23. Mount non return valve. 24. Tighten non return valve.
return valve point at the right
direction.