Redexim 7117 Product manual

NOTE:
IN ORDER TO ENSURE THE SAFE USE AND TO ACHIEVE THE
BEST PERFORMANCE, IT IS ESSENTIAL THAT THIS
OPERATORS MANUAL IS CAREFULLY READ BEFORE THE
VERTI-DRAIN IS USED.
1703 English 911.120.411
Operator and
Parts manual
Verti-Drain®
Model 7117
Serial number:
Translation of the original operating instructions
Kwekerijweg 8
3709JA Zeist
The Netherlands
T: (31)306933227
F: (31)306933228
E: [email protected]
www.redexim.com

2
FOREWORD.
Congratulations on the purchase of your VERTI-DRAIN. To ensure the safe and lasting
operations of this VERTI-DRAIN you (and anyone using the machine) should read and
understand this user’s manual. A complete knowledge of the contents of the manual is
necessary in order to ensure the safe use of this machine.
The VERTI-DRAIN is not an independently operating machine. It is the responsibility of the
user to use the correct tractor. The user will also need to check the tractor / VERTI-DRAIN
combination on safety aspects, noise level, user instructions and risk analysis.
The VERTI-DRAIN is intended exclusively for grass fields or areas on which grass can
grow.
On the following page, we will begin with the safety instructions. Every user must be familiar
with these instructions and must follow them carefully. Below you will find a registration
card, which should be returned to us so that we are able to process any future claims.
In this manual, many instructions are given which are stated in a number sequence. The user
must follow the instructions according to this sequence. If the * appears this refers to safety
instructions. If the @ is used, this refers to a tip and/ or note.
All information and technical specifications provided at the moment that this document is
published are the most recent ones. Design specifications may be changed without prior
notice.
This document is a translation of the original operating instructions.
Upon request, the original operating instructions are available in Dutch.
GUARANTEE CONDITIONS.
THIS VERTI-DRAIN PRODUCT IS DELIVERED TO THE CUSTOMER
ACCOMMPANIED BY A GUARANTEE AGAINST DEFECTS IN THE MATERIALS
USED. THIS GUARANTEE APPLIES FOR A PERIOD OF 12 MONTHS AS OF THE
DATE OF PURCHASE.
VERTI-DRAIN GUARANTEES ARE SUBJECTED TO THE "GENERAL CONDITIONS
FOR SUPPLY OF PLANT AND MACHINERY FOR EXPORT, NUMBER 188", WHICH
ARE PUBLISHED UNDER THE AUSPICES OF THE UNITED NATIONS ECONOMIC
COMMISSION FOR EUROPE.
REGISTRATION CARD.
For your own record, copy the information from the registration card to the table hereunder
Serial number of machine
Name of your distributor
Date of purchase
Any remarks

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SAFETY INSTRUCTIONS.
1. Always use the VERTI-DRAIN with the correct tractor as described in the
technical information
2. The user is responsible for a safe Tractor/VERTI-DRAIN combination. The
combination must be tested for noise, safety, risk and easy usage.
3. The VERTI-DRAIN is suited exclusively to grass fields.
4. Every VERTI-DRAIN user must be fully informed of the information contained in the
user manual.
5. Inspect the ground where the VERTI-DRAIN is to be applied. Remove loose
obstacles, avoid uneven ground.
6. Never step off the tractor if the engine is still running.
7. Ensure that other people are standing at least 4 mtr. (14' ) away from the
VERTI-DRAIN.
8. Use appropriate clothing. Wear strong shoes with a steel inforced toe cap, long
trousers, tie up long hair. Do not have any loose pieces of clothing.
9. Never try to force the VERTI-DRAIN, a situation which is visible in the partial
loosening of the front roller from the ground and unstable behavior of the VERTI-
DRAIN.
10. Check the VERTI-DRAIN once a week to ensure there are no loose screws or
nuts and bolts.
11. The VERTI-DRAIN may never be used without protection covers and safety
stickers.
12. NEVER crawl underneath the VERTI-DRAIN. If you need to work underneath, turn
the VERTI-DRAIN on its frontside.
13. Always switch off the engine and uncouple the power take off, before starting any
maintenance, adjustment or repair. Also block the VERTI-DRAIN against sinking
and block it against forward/backward movement or sliding.
14. Use only the original VERTI-DRAIN spare parts/ tines in order to ensure the safe
operation of the machine.
15. Never use the VERTI-DRAIN in the dark, in heavy rain, on frozen ground, stormy
conditions or on slopes greater than 20 degrees.
16. Before operating the machine, also read the instructions and the maintenance
information for the power take off. This component has its own certification mark.
17. Maintain a log book of repairs.
18. If any modifications are carried out on the machine the CE certification mark will be
no longer valid. The User/Dealer himself must then have the machine re-certified.

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CONTENTS.
Paragraphe
Description Page
Foreword 2
Guarantee conditions 2
Registration card 2
Safety instruction 3
1.0 Technical specification 5
2.0 First setup, lifting machine from pallet 6
3.0 General controls 7
4.0 PTO 8
4.1 PTO length 8
4.2 Use of PTO 9
4.3 Slip clutch information and maintenance 9
5.0 Working depth adjustment 10
6.0 Tine angle adjustment 10
7.0 Groundspeed 11
8.0 Starting procedures 12
9.0 General usage of Verti-Drain 13
10.0 Transport of Verti-Drain 13
11.0 Uncoupling of the Verti-Drain 13
12.0 Problem analysis 14
13.0 Maintenance 15
14.0 EU-Declaration 15
15.0 Technical information 16
15.1 Torque settings 17
15.2 The crankshaft 17
15.2.1 Replacing the transmission oil seal 17
15.2.2 Replacing of a crank and crank bearing 18
15.2.3 Removing the crankshaft tension 18
15.3 Alignment of an element 18
15.4 Assembly of the crown wheel and pignon 19
16.0 Options, tines 21
16.0.1 Solid tines 21
16.0.2 Hollow tines 22
16.1 Options, Core Collector 22
16.2 Options, Turf hold down kit 24
16.2 Options, Windrow kit 25

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TECHNICAL SPECIFICATIONS.
Model 7117
Working width 1.70 mtr (68”)
Working depth Up to 150 mm (6”)
Tractor speed @ 500 rev’s at PTO
Hole spacing 55 mm (2-1/8”)
Hole spacing 90 mm( 3 ½”)
Hole spacing 125mm(5”)
Up to 2.0 km/h (1.25 mph)
Up to 3.2 km/h (2.0 mph)
Up to 4.3 km/h (2.7 mph)
PTO speed Up to 500 rpm in 1st and 2nd gear, 400 rpm in 3rd.
Weight 575 Kg (1265 lbs)
Hole spacing side-to-side 55 mm (2-1/8”)
Hole spacing in driving direction 25 – 125 mm ( 1 - 5”)
Recommended tractor size 28 HP with lift capacity of minimum 700 Kg
( 1550 lbs)
Capacity (maximum)
Spacing 55 mm (2-1/8”)
Spacing 90mm (3 ½ “)
Spacing 125mm (5”)
Up to 3300 sq.mtr (29500 sq ft)/ hour
Up to 5300 sq.mtr (47000 sq.ft)/ hour
Up to 7200 sq.mtr (63000 sq.ft)/ hour
Shipping dimensions 1900 x 750 x 1050 mm
(76”x 30”x 42”)
Maximum tine size Solid 12 x 150 mm (1/2”x 6”)
Hollow 19 x 150 mm (3/4”x 6”)
Slip clutch setting PTO Maximum 400 Nm. (3540 lb.inch.)
Three point linkage 3- point CAT 1
Transmission oil 80W90 (3 liters)
Lubrication grease EP 2
Standard items Set solid tines 12/150 (1/2”x 6”)
Front and rear roller with scrapers
3- shuttle gearbox
Toolbox with combi tool

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2.0 FIRST SETUP, LIFTING MACHINE FROM PALLET.
The machine stands vertically up on the pallet. To remove the pallet and get the machine
horizontal on the ground, handle as follows (see fig.1 ):
1. Open the rear cover
2. Connect a cable to lift point
* ensure the cable/crane/lift truck can lift minimum 1000 Kg.(2200 lbs).
3. Raise machine with pallet 50 mm (2")from the ground.
4. Remove pallet by sliding it over the bottom 3-point pins
* Do not crawl under the machine
5.Lower the machine gentle till 3-point connecting plates contact the ground.
6. Drop the machine further, enabling it to rotate on its front roller.
7. Gently lower the machine till it stands on the front and rear roller.
8. Connect the machine to a tractor.
* Use correct tractor see specifications.
9. Lift the machine from the ground.
10. Remove the rear roller lock pins. Put pins in hole 4.
11. Lower the machine on the ground and adjust the angle of 90 degrees with top link
@ this angle is very important, see further.
12. Adjust tractor lower link stabilizers to limit sideways movement to about 100 mm (4”).
13. Fix tine angle adjustment lever to machine (separately packed ).
14. Mount the tines. Use some grease on the shank.
15. PTO length, see 3.1
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16. When machine is taken of the pallet, remove the upper plug of the gearbox and replace it
with the supplied breather.
3.0 GENERAL CONTROLS
In fig.2. some key details of the machine are shown, as follows:
1. Safety decal RA, before using machine read manual. Decal is located at the toolbox with
manual and combi-tool.
2. Safety decal RB, Keep 4 mtr (14') distance to the machine
3. Safety decal RC, Turn engine off when maintaining or repairing machine
* All decal should be on the machine and understood all the time
4. Serial number of machine can be found inside
5. Spindle to adjust working depth.
6. Working depth indicator. Note the indication is related to maximum tine length.
7. Tine angle adjustment lever.
8. Clamps for securing the rear access door of the VERTI-DRAIN.
* rear access door should always be closed and free of any damage.
9. Rubber stops for supporting the rear access door when opened.
10. Rear roller support guide.
11. Rear roller lock pin. Lock only when machine is stored or roller is raised from the ground.
12. Front roller support lock nuts.
13. Lower 3-point linkage pins. May be repositioned and facing in or out.
14. PTO protection covers at the machine. Top one can be removed for maintenance.
15. PTO input shaft. Slip clutch should be assembled at this shaft.
16. Rear roller scraper, can be adjusted.
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
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
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

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


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4.0 PTO.
The PTO is a very important item. It drives the machine from the tractor and ensures the safe
operations when correctly maintained and installed. The PTO shaft has its own CE certification. Read
the PTO shaft manual, which is connected to the shaft itself.
4.1 PTO LENGTH.
The length of the PTO is very important. When too long, the transmission of the tractor and/or
VERTI-DRAIN may be damaged. When the overlap length of the tubes drops under 150 mm (6")
anytime, the PTO may be damaged.
* the length changes when the machine is raised or when another tractor is used.
To cut the standard PTO from new or for another tractor, work as follows (see fig. 3):
1. Measure the distance A between tractor PTO shaft and VERTI-DRAIN PTO shaft from groove to
groove when machine is on the ground at correct angle and attached to the tractor.
2. Measure the length B of the PTO in its shortest position from lock pin to lock bolt.
3. Split PTO in two pieces and remove safety cover from each end
4. Both tubes and safety cover ends should be shortened: (B - A) + 75 mm (3").
5. Deburr all items, use some grease and put all parts together.
6. Assemble the slip clutch side of the PTO to the VERTI-DRAIN transmission.
* Torque for lock bolt should be 80 Nm (700 lb.in.)and checked every 40 hours
7. Connect other side to the tractor.
8. Check overlap of tubes.
* Never run machine with a damaged PTO safety cover. Replace it first.


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4.2 USE OF PTO
For the correct use of the PTO, the following items need to be checked:
1. During work the angle of the joints may never exceed 30 degrees
2. The joints have to be in line all the time
3. The tube overlap should always be minimal 150 (6") mm
4. Never use the machine with a damaged PTO protection cover.
5. For greasing see par. 13.0 Maintenance.
4.3 SLIPCLUTCH INFORMATION AND MAINTENANCE.
The slip clutch will protect your machine against breakages when correctly used and maintained. The
following items are important.
1. The spring length is standard set at 34.0 mm , 1.339".
2. When the slip clutch slips, the bolt/nuts may be tightened a quarter of a turn at a time, till the
minimum length of 32.5mm, 1.280" on the spring is reached. Any further compression will overload
the machine.
@ If too tight the machine may break down in the end or unsafe situations may occur.
3. The slip clutch should be maintained every month. Work as follows;
- Remove the top PTO protection cover of the machine
- Loosen up all bolts/ nuts two turns.
- Run the machine in the field at very low rpm's
- If the clutch slips, stop after 10 seconds.
- If it doesn't slip, loosen bolts more or go to (annual) maintenance.
- When the slip clutch has slipped, tighten the bolts/nuts up to the point the slip clutch works fine.
* Do not tighten it to the previous setting right away.
4. Annual maintenance:
- remove PTO from machine.
- inspect PTO shaft parts. Damaged parts should be replaced.
- disassemble the slip clutch by removing all bolts/nuts that hold the springs
- the slip clutch should fall apart in pieces.
- lay down the pieces and inspect parts. If parts are damaged or weared, replace them.
- clean all mating surfaces.
- assemble all parts and tighten bolts/nuts till the springs are all set at 34.0 mm , 1.339".
- Grease both tubes and assemble both PTO parts to each other.
- Assemble the PTO and mount it to the machine.
- Readjust the springs of the slip clutch when necessary as previously described.
@ The slip clutch protects the machine only against peak loads, when correctly adjusted. A
continuous overload will damage the machine in the long run and is not protected by the slip clutch.
Do not overload your machine.

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5.0 WORKING DEPTH ADJUSTMENT.
The working depth can be adjusted when the machine is lifted from the ground as follows, see fig. 4:
Unscrew nuts 1 at each side of the machine one turn. Screw spindle 3 in or out. Every revolution is 4
mm (0.160"). The decal 2 at each side of the machine shows the actual depth. When the correct depth
is reached, tighten the nuts 1 at each side.
@ Never adjust one side more than 4 turns. Compensate the other side first before proceeding.
@ The adjustment can be done with a special tool in the machine tool box.
@ The value at the decal’s is only true when 150 mm (6") long tine are used. When shorter
tines are used, deduct the length difference to the 150 mm (6") from the actual decal reading.
@ Clean and spray the spindle and nut with anti-sticking grease oil every 100 hours, to prevent dirt
sticking on the nut.
6.0 TINE ANGLE ADJUSTMENT.
The adjustment of the angle of all tine holders is centrally located at the right side of the machine,
see fig.5..
Raise the machine above the ground, slacken the nuts 2 at each side of the machine and nuts 3 at the
center of the machine, one turn each.
Adjust the tine angle by rotating the lever 1. The angle-value can be read from the decal 4 next to
the handle.
After the correct angle is set, tighten all nuts.
@ An angle of 90 degrees means almost no tine movement in the ground. This is required for hollow
coring tines and advised for thinner tines.
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@ From 90 to 75 degrees means more "kick action". This is advised for solid tines, depending on
ground conditions, tine size and customer requirements.
@ The angle of 90 degrees means that the tines penetrate perpendicular into the ground. This is only
true if the machine is correctly set, see fig.1. If this isn't correct a push force F, see fig 5. is applied,
which can seriously damage the machine.
@ The length of the draw rod assembly should be 290 mm (11.437"), which can be set by the
calibrating shimms, see the spare part page.
7.0 GROUNDSPEED.
The groundspeed determines the hole spacing D in the drive direction, see fig.6. The VERTI-DRAIN
doesn't need a creeper gear, however if the customer wants a close hole spacing, the groundspeed
should be low enough, which depends on the tractor.
The gearbox has standard three different gear setting, resp. 1,2 and 3. When set in 3, reduce PTO revs
till 400 rpm’s max, otherwise damage may occur.
The input speed R on the PTO may be maximum 500 rpm. When stones or rocks are expected, the input
speed should be lowered.
With heavier tines or attachments, the tine holders may start to float. Lower rpm's at that time, before
the tine holders start to turn upwards. We advise using 400 revs on PTO all the time.
In Fig.6., a graph is drawn in which the relation between the groundspeed, the gear setting and the hole
spacing is given. If the tractor groundspeed is known at 500 rpm's of the PTO, the hole spacing can be
determined at different gearbox settings.
@ If the machine is not set correctly behind the tractor, see fig.1., different angles at the PTO may
cause vibration into the drive line of the VERTI-DRAIN. This vibration can hurt the machine and also
the performance of the holes in the ground.
@If the gear box setting is hard to shift, rotate the crankshaft a little till the shifting is possible.
@ If the PTO shaft is incorrectly fitted (too long or too short), extra forces are applied to the input shaft
of the gearbox. Damage may occur.
* When the gearbox is shifted, shut off the tractor engine.


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8.0 STARTING PROCEDURES.
The starting procedure is VERY important. If the start up is not done as described hereunder, serious
damage to the machine may occur. Proceed as follows, see fig.7.:
1. Drive to the spot you want to start the operation.
2. Lower the machine, till the lowest tines are almost on the ground.
3. Set tractor engine at app. 1200 rpm's
4. Put tractor in correct gear, and start moving forward (A)
5. Engage PTO at tractor (B)
6. DURING rolling forwards with the machine RUNNING, GENTLY lower the machine in the
ground (C), till front roller is tight on the ground.
7. Increase engine rpm's till the maximum value advised.
At the end of a pass, quit the operation as follows:
1. Lower engine rpm's till about 1200.
2. Raise machine out of the ground.
3. As soon as all tines are out of the ground, disengage PTO.
4. Raise machine further, till the lowest tines are at least 120 mm (5") above the ground.
5. Move to the next spot and start again as described above.
@ It is absolutely necessary to proceed as described above. If the machine is put into the ground first,
without the PTO running, serious damage may occur.
@The machine needs to be lowered GENTLY.
@ Be careful with driving backwards.
During work the front roller needs to be stable on the ground. If the machine starts to be unstable,
change the rpm's on the PTO. If this doesn't make any difference, adjust the working depth or change
to other tines who penetrate easier.
@ If nothing is done on the instability of the machine, serious troubles may arise afterwards.
The machine is NOT protected against these circumstances on the long term.
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@ Never drive backwards with the tines in or close to the ground.
@ NEVER drive backwards, when the lowest tines are less than 120 mm (5") above the ground. If the
tines get caught, serious damage will appear on the machine.
@ Do not use a hydraulic top link.
9.0 GENERAL USAGE OF VERTI-DRAIN.
The VERTI-DRAIN can only be used when the circumstances are right. Check the following items:
1. Are there any loose objects on the field. If so, these must be removed first.
2. Are there any slopes. The maximum slope for the VERTI-DRAIN is 20 degrees. Always operate the
VERTI-DRAIN from the top to the bottom of a slop.
3. Are there any pipes/wires/cables in the ground. If so, ascertain at what depth and set the working
depth at a maximum of 60% of the pipe etc. depth.
4. Are there any hard objects in the ground. If so, operate the VERTI-DRAIN with a very low PTO
speed, or adjust working depth.
5. Is there any danger of flying objects such as golf balls, which could distract the attention of the
driver ? If so, the VERTI-DRAIN can not be operated at that moment.
6. Is there any danger of subsidence or land/mud slides ? If so, the VERTI-DRAIN cannot be operated
on the field at that moment.
7. Is the ground frozen or very wet. Postpone operation till circumstances are better.
8. When ground is very compacted, use shorter thinner tines to penetrate, or adjust working depth.
10.0 TRANSPORT OF VERTI-DRAIN.
The user is responsible for the transport of the VERTI-DRAIN behind the tractor along the public
streets. Check on the national legislations. Across open ground a maximum speed of 12 km/h (8 mph)
applies. In view of the weight of the VERTI-DRAIN, a higher speed could be dangerous for the driver
and bystanders. The machine could also suffer damage due to jolt which can occur with higher
speeds.
* At least 20% of the tractor weight should rest on the front axle when machine is lifted.
11.0 UNCOUPLING OF THE VERTI-DRAIN.
The machine can be disconnected from the tractor as follows:
1. Open the rear cover.
2. Rotate the crankshaft, until both central tine holders right/left from the gearbox, are at their highest
position.
3. Turn all other tine holder upwards against the stop
4. Lower the machine on a firm surface
5. Lock pin 3 into a corresponding hole, see fig.1.
6. Block the rear and front roller against rolling away.
7. Remove the top link.
8. Disconnect the PTO shaft from the tractor side
9. Disconnect the lower three point linkage arms.
*Shut down the tractor engine during walking around the VERTI-DRAIN.

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12.0 PROBLEM ANALYSIS.
Machine vibrates Crankshaft rotates irregular
Tough circumstances
Machine not at 90 degrees
PTO joint angles different
PTO joints not in line
Adjust working depth
Use thinner/ shorter tines
If dry, irrigate first
Solid/ hollow tines
Are bending/ breaking
Wrong tine
Tough circumstances
Quick wearing
Change tine, use shorter one
Use solids first before hollow to
break the soil
Adjust working depth
Use thinner/ shorter tines
If dry, irrigate first
Use solids first to break the soil
Adjust tine angle setting
Front roller is not stable
On the ground
Wrong tines, too much resistance
Tough circumstances
Change tine size
Adjust working depth
Use other size tines
Adjust working depth
Irrigate first
Do job not in one pass
PTO breakages Slip clutches slips often
Tubes are cracking
Check setting
Replace lining plates
Clean clutch internally
PTO angles too wide
PTO angles not the same
Damage to draw rods Bending/ breaking Machine not at 90 degrees
Central bar bent
Bearing bushes worn
Tines hit the ground with reversing.
Lift height not correct
Damage to the turf Oval holes
Turf damage
Soil too wet
Change tine angle setting
Reduce forward speed
Adjust working depth
Use thinner tines
Tine not tight in tine
holder
Tough circumstances Use other tines
Grind flat area to tines
Adjust the tine angle setting

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Crankshaft problems Big end nuts slacken Solve vibration, see vibration
Crankshaft bearing collapsed
Incorrect assembled after repair.
Remove, clean, use loctite
Rear roller shaking Rear roller locked
Rear roller moves upwards with
hollow coring
Tough circumstances
Unlock
Change speed and PTO rev’s
Put roller free on the ground
Change machine settings.
13.0 MAINTENANCE.
Pre-Delivery-Inspection Check bolts/ nuts
Connect the unit to a tractor
Run unit for 5 min
See instructions in this
manual
Look and listen
After first 20 hours
(new or repaired)
Grease PTO and rollers
Check bolts/nuts
Look closely at machine
4 shots each EP 2
After every 100 hours Grease PTO and rollers
Check bolts/ nuts
Look closely at machine
Grease spindles front roller
4 shots each EP 2
After every 500 operating
hours.
Replace the oil in the
gearbox.
Use 80W90 (3 liters).
14.0 EU-Declaration
We, Redexim Utrechtseweg 127 3702 AC Zeist Holland, hereby declare fully on our
authority that the product:
VERTI-DRAIN 7117, WITH MACHINE NUMBER AS INDICATED ON THE MACHINE
AND IN THIS MANUAL,
to which this declaration relates is according to the stipulation of the 2006/42/EC directive
for machines as well as the following standards: NEN-EN-ISO 12100 : 2010 and NEN-EN-
ISO 13857 : 2008.
Zeist, 01/10/09
A.C. Bos
Manager Operations & Logistics
Redexim Holland

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15.0 TECHNICAL INFORMATION.
Generally speaking, this Verti-Drain is not a complicated machine. A couple of technical items will
be explained. If you still have questions, please contact your dealer, who is willing to assist you.
Fig. 8
In the above fig.8. the torque setting for the several bolts/nuts is given and the timing of the
crankshaft.
The angle of both handles on the gearbox should be 33.75 degrees.
The gearbox position should be parallel with the machine.
If the head of a tine holder bolt is damaged by a tine, remove the leftover bolt by drilling from the rear
of the machine. Replace the bolt after that.
The draw rod length should be 290 (±1) mm (11.440 0±0.004”). This can be set with the additional
shims F.
The rubber stop in the draw rod is accessible via removing head G.
Use the self lock nuts only once.
The machine has three different kind of cranks: one for the gearbox, one for the big end pin and one
for the big end nut.
Carefully time the crankshaft after parts are replaced. Damage/ vibrations may occur when not
properly done. Use only genuine parts.
 remove spring tension of draw rod first by extracting and blocking the draw rod.
 Place the machine on sturdy studs, before starting any repair.

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15.1 TORQUE SETTINGS.
In fig.8., the torque settings of the most important bolts/nuts are given. For the ones the torque setting
is not mentioned, please be sure that they are tightened as a similar size bolt/nut would be tightened. If
bolts/nuts are working themselves loose, loctite may be applied.
15.2 THE CRANKSHAFT.
In fig.9. the assembly of the crankshaft is given. Also look at the spare part page for a more clear view
and setup. On a Verti-Drain 7117 the angle between the handles on the gearbox should be 33,75
degrees.
15.2.1 REPLACING A TRANSMISSION OIL SEAL.
In fig.9. a top view of the crankshaft is given. To replace an oil seal at the transmission, handle as
follows:
1. Loosen nuts II and IV, which may be tight through the loctite. Some heat may help.
2. Remove nuts III, remove crank handles VI.
3. Remove big end IX.
4. Slacken nut VIII, remove handle X.
5. Pull oil seal out, clean area, insert new seal..
6. Assemble (new) handle X, watch the timing.
7. Fill outside area between handle and splines with silicon paste.
8. Attach new locking plate and nut VIII.
9. Tighten and lock the nut according specifications (fig.8).
10. Assemble all other parts the way they were removed.
11. If the crankshaft seems lumpish, continue “removing crankshaft tension”, 15.2.3
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

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15.2.2. REPLACEMENT OF A CRANK WITH BEARING.
Replacing a crank is necessary when it is cracked or when the big end nuts start to come loose on a
regular bases. Either the crank bearing, the crank bearing fitting or the big end pin holes in the crank
are damaged. Replace the crank / bearing as soon as possible, to avoid any more damage to other
parts, as follows:
1. Remove the big end V.
2. Remove the handles IV.
3. Take the splined shaft with bearing out.
4. Remove bearing from splined shaft.
5. Replace the parts and assemble the other way round.
@ Use loctite for nut II, III and VIII.
15.2.3 REMOVING THE CRANKSHAFT TENSION.
If parts have been replaced on the crankshaft, the crankshaft may seem running tight. This is because
of possible tension in the crankshaft parts. It is necessary to resolve the tension, see fig.9.:
1. Tap the center of the crank adjacent to the gearbox, alternately left and right.
2. Feel whether the crank moves and continue till the crank has nested.
3. Repeat this operation with the adjacent crank and continue this way till the crankshaft will operate
more smoothly.
@ After any repair on the crankshaft, the crankshaft nuts should be checked regularly, see 12.0
@ Don’t assemble the cranks at the wrong side of the machine. See the spare part for the right part
numbers.
15.3 ALIGNMENT OF AN ELEMENT.
In the event that an element is no longer in line with the adjacent elements, the alignment can be
corrected as follows (see fig.8.):
- Slacken the four bolts/nuts A, that connect the crankshaft to the element.
- Slacken the two bolts B, that fix the element to the main frame.
- Try to align the element by moving it side wards, till it aligns with the adjacent ones.
- Start to tighten all bolts/nuts.
@ The element may be pushed out of line due to overload to the machine
@ When a crank is replaced, always realign the element, so that no additional tension is created in the
total element assembly.
@ Any pre-tension in the element assembly will shorten the bearing life and may damage other parts as
well, so check regularly.

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15.4 ASSEMBLY OF THE CROWN WHEEL AND PIGNON
1. Assemble the pignon wheel H, making sure to have the roller bearings unit positioned on the
cir-clip side. (see fig. 10)
2. Mount both bearings B into the bearing Houses C.
3. Mount the bearing assembly BC on side A of the gearbox.
4. Mount the shaft D without the bush E .
5. Mount the crown wheel F.
6. Measure the distance T1 of the bearing assembly BC.
- T1 should reach 22.7mm if not adjust with shims on point X to get the required distance of
22.7mm.
7. Mount the bearing assembly BC on side G of the gearbox and tighten well.
8. Check the play between the crown wheel F and pignon wheel H; this should have a slight play.
- If the play is correct proceed with point 9.
- If the play is too small replace the shim on point X for a thinner one and re-check the play.
- If the play is too big replace the shim on point X for a thicker one and re-check the play.
9. Remove the bearing assembly BC on side A.
10. Mount bush E.
11. Measure distance T1 of the removed bearing assembly BC.
12. Measure distance T.
13. Calculate T-T1+0.1mm; this is the required thickness of the shim to place at point Y.
14. Mount the required shim and the bearing assembly BC and tighten well.
15. Final Check:
- Check again the play between the crown wheel F and pignon-wheel H, this should have a
slight play.
- If there is still too much play disassemble side G, side A and add a thicker shim. After this
go back to point 11 and re-measure and re-check the play.

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Fig. 10