JCB SS500 Transmission Service Repair Manual - PDF DOWNLOAD

Service Manual JCB Drivetrain Systems Ltd Wrexham Industrial Estate WREXHAM Untied Kingdom LL13 9UF Tel: (01978) 661140 Fax: (01978) 661863

General Information

1

Care & Safety

2

Routine Maintenance

3

Electrics

4

Transmission

5

Brakes

6 NOTE

All references in this manual to ‘Forward’ and ‘Reverse’ assume a front-mounted engine.

SS500 SERIES TRANSMISSION WITH TRANSFER GEARBOX - TG150 Publication No. 9803/9060 Issue 2

Introduction This publication is designed for the benefit of Service Engineers.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

General Information - includes torque settings and service tools.

Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

Routine Maintenance - includes service schedules and recommended lubricants etc.

The remaining sections deal with Dismantling, Overhaul etc. of specific components: 4 5 6

= = =

Electrics Transmission Brakes

The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference.

Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section containing the subject. For example: “2 Drain the transmission system (see Transmission - Dismantling, Section 5).”

Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.

Use the contents list at the beginning of each section to find the exact page number.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.

‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.

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General Information

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Contents

9803/9060

Page No.

Unit Identification

1-1

Torque Settings

2-1

Service Tools Numerical List

3-1

Service Tools

4-1

Sealing and Retaining Compounds

5-1

Issue 1

Section 1

General Information

1-1

Section 1 1-1

Unit Identification Synchro Shuttle Serial Plate The Synchro Shuttle serial number is stamped on a label which is mounted to the rear face of the unit.

1

When replacement parts are required, always ensure that the correct parts are obtained, e.g. in the case of gear replacements, always check the part number stamped on the gear, and the number of teeth.

2

When ordering replacement parts, quote the details on the serial plate shown.

3

It is essential that all gaskets and seals removed while dismantling, should be renewed on reassembly.

4

On reassembly care should be taken that all parts are correctly replaced since any component omitted or incorrectly assembled can lead to a complete failure.

5

Lubricants should comply with the recommended list as provided in this manual. It is important to adhere to the oil changing procedure.

6

It is advisable to lightly lubricate with a recommended lubricant, parts such as gears, shafts, thrust washers and oil seals during reassembly.

A317660

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General Information

Section 1

2-1

2-1

Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts Bolt Size in 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16

11/8 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m

lbf ft

1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

10 20 36 58 87 125 175 300 480 715 1430 2500

Torque Settings kgf m

lbf ft

Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55

Nm 7 12 28 56 98 244 476 822 1633 2854

0.7 1.2 3.0 5.7 10 25 48 84 166 291

5 9 21 42 72 180 352 607 1205 2105

Rivet Nut Bolts/Screws Bolt Size (mm) M3 M4 M5 M6 M8 M10 M12

(3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 1.2 3.0 6.0 10.0 24.0 48.0 82.0

0.12 0.3 0.6 1.0 2.5 4.9 8.4

0.9 2.0 4.5 7.5 18.0 35.5 60.5

Note: All bolts used on Synchro Shuttle gearboxes are high tensile and must not be replaced by bolts of a lesser tensile specification.

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3-1

Service Tools Numerical List 4101/0251 4101/0451 4101/0651 4101/0250 4102/0552 4102/1212 4102/1951 4104/0251 4104/0253 4104/1557 814/00417 816/15118 816/20008 816/20013 816/55038 816/55040 816/80061 892/00078 892/00179 892/00225 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00273 892/00275 892/00276 892/00277 892/00293 892/00294 892/00301 892/00302 892/00304 892/00333 892/00812 892/00817 892/00818 892/00819 892/00822 892/00916 892/00920 892/00922 892/00966 892/01064 892/01065 992/04000 992/07608 992/07609 992/07610 992/07611 9803/9060

Loctite 242 Loctite 932 Loctite 648 Loctite 243 Loctite 275 Loctite 574 or Permabond A136 Loctite 577 Activator (Aerosol) Activator (Bottle) Cleaner/Degreaser Valve Spring Pressure Test Adapter Adapter Adapter Pressure Test ‘T’ Adapter Pressure Test ‘T’ Adapter Valve Plug Connector Bearing Press Adapter - Impulse Extractor Pressure Test Kit Pressure Test Adapter Pressure Test Adapter Pressure Test Adapter Pressure Test Adapter Pressure Test Adapter Pressure Test Adapter Pressure Test Adapter Pressure Test ‘T’ Adapter Pressure Test ‘T’ Adapter Pressure Test ‘T’ Adapter Pressure Test ‘T’ Adapter Flow Monitoring Unit Sensor Head Load Valve Adapter Adapter Sensor Head 0 - 380 l/m Adapter Adapter Adapter Connector Pipe Connector Pipe Flow Test Adapter Flow Test Adapter Flow Test Adapter Heavy Duty Socket Drive Coupling Spanner Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Splined Bolt Socket Clutch Pack Spring Compressor Flow Test Adapter Torque Converter Alignment Tool Test Point (1/4” BSP) Adapter Spanner Holding Fixture Torque Multiplier Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter

Page No.

Page No. 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-4 4-3 4-3 4-3 4-3 4-3 4-4 4-3 4-1 4-1 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-1 4-2 4-3 4-4 4-4 4-2 4-1 4-1 4-1 4-1

992/07612 992/07613 993/59400 993/59401 993/59402 993/59403 993/59404 993/59405 993/59406 993/59500 993/70111

Bearing Adapter Bearing Adapter Endfloat Setting Tool for Gearbox Base Plate Setting Yoke Mainshaft Adapter (long) Mainshaft Adapter (short) Output Yoke Adapter Plate Setting Yoke Support Pillars Impulse Extractor Adapter Breakback Torque Wrench

4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-2 4-1 4-2

Issue 1

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General Information

Section 1

4-1

4-1

Service Tools

892/00224 S216290

892/00817 892/00818 892/00819 892/00333

17 mm A/F x 3/4in. square drive 22 mm A/F x 3/4in. square drive 15 mm A/F x 1/2in. square drive 19 mm A/F x 3/4in. square drive

Impulse Extractor Set

S197070

892/00179

Bearing Press (use with appropriate adapters)

S188200

992/07608 992/07609 992/07610 992/07611 992/07612 992/07613

Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter

892/00225

S188160

993/59500

892/00812

Drive Coupling Spanner for front and rear axle yoke couplings on Synchro Shuttle

A B C D

D S196720

9803/9060

892/00920 892/00301 892/00302 892/00304

Adapter - Impulse Extractor Small 17mm to 25mm Medium 25mm to 45mm Large 45mm to 80mm Adapter - Impulse Extractor (synchro shuttle transmission)

Flow Test Adapter Flow Test Adapter Flow Test Adapter Flow Test Adaptor

A277320

A

B

C

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General Information

Section 1

4-2

4-2

Service Tools (cont'd)

992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)

S197030

892/00922

12.2� Torque Converter Alignment Tool

993/59400 993/59401 993/59402 993/59403 993/59404 993/59405 993/59406

End Float Setting Tool for gearbox: Base Plate Setting Yoke Mainshaft Adapter (long) Mainshaft Adapter (short) Output Yoke Adapter Plate Setting Yoke Support Pillars

S267260

892/00822 Splined Bolt Socket for driveshafts S197060

S204180

892/00916 Clutch pack spring compressor 993/70111

Torque Wrench

A270850

S259320

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4-3

Service Tools (cont'd)

Hydraulic Circuit Pressure Test Kit 892/00253 892/00201 892/00202 892/00203 892/00254 993/69800 892/00706

Pressure Test Kit Replacement Gauge 0-20 bar (0-300 lbf/in2) Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 (0-6000 lbf/in2) Replacement Hoses Seal Kit for 892/00254 (can also be used with probe 892/00706) Test Probe

S188121

Pressure Test Adapters

Pressure Test ‘T’ Adapters S188131

892/00262 816/55038 816/55040 892/00263 892/00264 892/00265

1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSP x Test Point

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261 892/00966

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1/1/4 in BSP x Test Point 5/8 in UNF x Test Point 1/4” BSP x Test Point

S200141

Flow test Equipment 892/00268 892/00269 892/00293 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 892/00273 892/00294 1606/0015 892/00078 1604/0008 1606/0012 816/20013

9803/9060

Flow Monitoring Unit Sensor Head 0-100 l/min (0-22 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in M x 3/4 in M BSP Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Sensor Head 0-380 l/min Connector Pipe Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP

S188151

Issue 1

Section 1

General Information

Section 1

4-4

4-4

Service Tools (cont'd)

892/01064

Adaptor Spanner for reverser unit stake nut.

892/01065

Holding Fixture for reverser unit dismantling/assembly.

A388071 A388060

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5-1

Sealing and Retaining Compounds Loctite 574 or Permabond A136

A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

† 4102/1212

Loctite 275 or Permabond A140

For all size of flanges where the strength of the joint is important.

4102/0552

Loctite 932 or Permabond A137

For all retaining parts which are likely to be dismantled and for use on threads larger than 50 mm dia.

4101/0451

A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25 mm diameter.

†4101/0251

A medium strength locking fluid similar to Loctite 242 but with greater resistance to thread contamination.

4101/0250

Loctite 648 or Permabond A118

For retaining parts which are unlikely to be dismantled.

4101/0651

Loctite 577

A medium strength thread sealing compound.

4102/1951

Loctite Activator

A cleaning primer which speeds the curing rate of anaerobic products.

Loctite 242 or Permabond A113

Loctite 243

Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

† 4104/0251 † 4104/0253

Aerosol Bottle

† 4104/1557

Aerosol

Note: The above list is the range of sealants and retaining compounds available. Items marked † are those referred to within the sections.

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Care & Safety

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Page No.

Safety Notices

1-1

General Safety

2-1

Operating Safety

3-1

Maintenance Safety

4-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

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Care & Safety

Section 2

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2-1

All machinery, whether mobile or static, can be hazardous.

When equipment is correctly operated and properly maintained it can be safe to work with. But when it is carelessly operated or poorly maintained it can become a danger.

Do not work with any equipment until you are sure that it is serviceable, that you know how to control it and be aware of all relevant safety requirements.

If the equipment covered by this manual forms part of a larger product (eg. a vehicle) be sure to observe the safety requirements which relate to the product as a whole, as well as those given in this manual.

On this and the following pages and throughout this manual, you will find safety messages. Please read and understand these safety messages before using and working on the equipment covered in this manual.

Make sure you also read and understand all other safety messages contained in operator handbooks and service manuals concerned with the product of which this equipment forms part.

Remember BE CAREFUL BE ALERT BE SAFE

General Safety ! WARNING Decals This equipment may include safety decals You can be injured if you do not obey decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the equipment. Make sure replacement parts include warning decals where necessary.

! WARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.

INT-1-3-7

! WARNING Clothing You can be injured if you do not wear the proper clothing.

Loose clothing can get caught in the equipment. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

! WARNING Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness.

! WARNING Raised Attachments Raised attachments on certain kinds of equipment can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked.

INT-1-3-8

! WARNING Care and Alertness All the time you are working with or on the equipment, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-9

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3-1

Operating Safety ! WARNING

! WARNING

Equipment Condition Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts.

Make sure all maintenance procedures are completed before using the equipment.

Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

! WARNING Controls You or others can be killed or seriously injured if you operate machine control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

! WARNING Equipment Limits Operating equipment beyond its design limits can damage the equipment, it can also be dangerous. Do not operate the equipment outside its limits. Do not try to upgrade the equipment performance with unapproved modifications.

! WARNING Engine/Steering Failure If the engine or steering on the ‘parent’ machine fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

! WARNING Engine The engine on the ‘parent’ machine has rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.

! DANGER Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.

INT-2-2-10

! WARNING Exhaust Gases Breathing the ’parent’ machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air.

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Care & Safety

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4-1

Maintenance Safety ! WARNING

! DANGER

Repairs Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer.

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open.

GEN-1-5

! WARNING Modifications and Welding Non-approved modifications can cause injury and damage.

Welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your distributor for advice before modifying the equipment.

! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses.

INT-3-1-11/1

! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

INT-3-1-3

! WARNING ! WARNING

Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

INT-3-2-4

! WARNING

INT-3-1-4

! WARNING Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the vehicle battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter.

Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidently flying out.

GEN 6-2

! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-11

! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately.

INT-3-1-10/1

9803/9060

! CAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

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4-2

4-2

Maintenance Safety (cont'd) ! WARNING

! WARNING

Fires Do not use water to put out an equipment fire, you could spread an oil fire or get a shock from an elecrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible.

Firefighters should use self-contained breathing apparatus.

Fluoroelastomeric Materials Certain seals and gaskets (e.g. transmission oil seals) may contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

! WARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.

INT-3-2-8

! WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: - Damaged end fittings - Chafed outer covers - Ballooned outer covers - Kinked or crushed hoses - Embedded armouring in outer covers - Displaced end fittings.

New fluoroelastomeric components at ambient temperature require no special safety precautions.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA. Used fluoroelastomeric components subjected to temperatures greater than 300°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

Ensure that components have cooled then remove and place material into plastic bags.

2

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

3

Thoroughly wash contaminated area with detergent and water.

4

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

INT-3-3-2

! WARNING Make the machine safe before working underneath it. Park the machine on level ground. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN-1-2/IT

DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.

INT-3-3-5/1/IT

! WARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.

HYD 1-3

! WARNING Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.

GEN-1-12

! WARNING Some lubricants contain lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant.

Dispose of waste (rags etc.) in accordance with local regulations.

2-1-1-8/IT

! WARNING Before carrying out any servicing, park the machine on firm level ground and apply the parking brake. Make sure the transmission selector and gear lever are in the neutral position. Switch OFF the engine and remove the starter key.

Operate the control levers and remove the hydraulic filler cap to vent any residual pressure. Disconnect the battery.

GEN-1-13

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Lubricants & Capacities

1-1

Transmission Oil Fill Procedure

1-1

JCB Drivetrain Dipstick Details

1-1

Lubricants - Health and Safety

1-2

Service Schedules

2-1

Synchro Shuttle Transmission Check Oil Level Change Oil & Clean Strainer Renew Filter

3-1 3-1 3-1

Issue 2

Section 3

Routine Maintenance

Section 3

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1-1

Lubricants & Capacities ITEM

CAPACITY

FLUID/LUBRICANT

INTERNATIONAL SPECIFICATION

Kuwait EL4117 SAE 10w Kuwait EL4118 SAE 30 Mobil ATF 210

Cat TO-4 Cat TO-4 ESP-M2C 33G Mobil HP222

†SS500 Transmission

litres *17.5

UK gal 3.8

US gal 4.6

Grease Points

--

--

--

Mobil HP222

Electrical Connections

--

--

--

As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.

NB. Petroleum jelly must NOT be used on sealed-type connectors.

†

Capacities shown with an asterisk are approximate total system and dependent on vehicle circuit. Use the maximum and minimum marks on dipstick when filling.

Transmission Oil Fill Procedure Note: When installing a transmission in a machine, whether new or in service, it is extremely important to follow the correct oil fill procedure to prevent internal damage to the transmission.

1

With the engine stopped, fill the transmission with specified transmission fluid to dipstick maximum mark (see Synchro Shuttle Transmission - Check Oil Level).

2

Start the engine and run slowly for a period not exceeding five minutes. This allows the oil to fill filter, pump, torque converter, oil cooler and hoses.

3

Stop the engine, wait approximately one minute. Recheck the oil level and fill to dipstick level.

JCB Drivetrain Dipstick Details X

Tube size 1” O/D x 16 S.W.G. ERW 1

Y Locknut and seal required for securing and sealing dipstick/filler tube - Part No. 155/10600 Filler tube must sit fully home in transmission casing counterbore.

A Note: Figures given below are for transmissions installed horizontally. Allowance may be needed if installed at an angle (Front to Rear). JCB Drivetrain should be consulted if transmission is to be inclined in vehicle chassis.

B A234630

Transmission Figures Dimension A Dimension B

9803/9060

187 mm (max) 199 mm (min)

X Seal Ferrule Y Male nut fitting 11/2 in Hex. A/F

Issue 2

Section 3 1-2

Routine Maintenance

Section 3

Lubricants - Health and Safety

1-2

Hygiene Lubricants are not a health risk when used properly for their intended purposes.

2

Apply a barrier cream to the skin before handling used oil.

However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

3

Note the following when removing oil from skin:

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.

Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

a

Wash your skin thoroughly with soap and water.

b

Using a nail brush will help.

c

Use special hand cleansers to help clean dirty hands.

d

Never use petrol, diesel fuel, or paraffin for washing.

4

Avoid skin contact with oil soaked clothing.

5

Don't keep oily rags in pockets.

6

Wash dirty clothing before re-use.

7

Throw away oil-soaked shoes.

Storage Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

First Aid - Oil

Waste Disposal All waste products should be disposed of in accordance with all the relevant regulations.

Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.

The collection and disposal of used oil should be in accordance with any local regulations. Never pour used oil into sewers, drains or on the ground.

Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

Handling

Skin In the case of excessive skin contact, wash with soap and water.

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

Spillage

Used Oil

Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Used lubricants contain harmful contaminants.

Fires

Here are precautions to protect your health when handling used oil:

Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus.

1

Avoid prolonged, excessive or repeated skin contact with used oils.

9803/9060

Issue 1

Section 3

Routine Maintenance

Section 3

2-1

2-1

Service Schedules A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

Calendar equivalents: 10 Hours = Daily 50 Hours = Weekly 500 Hours = Six Months 1000 Hours = Yearly 2000 Hours = 2 Years Service checks should be carried out as in the table at whichever time occurs first.

Pre-start Cold Checks Service Points and Fluid Levels TRANSMISSION Transmission Oil Level Transmission Oil Transmission Filter Transmission Strainer Drive Shafts

Operation

- Check - Change - Change - Clean - Security/Grease

Functional Test and Final Inspection TRANSMISSION Forward/Reverse and Gear Change - Operation Transmission Main Line Pressure †† Clutch Disconnect Neutral Start Operation Clutch Pack Pressures ††

Operation

- Check - Check - Check - Check - Check

†

First 100 Hours Service only, to be completed by your Distributor.

††

Indicates jobs which should only be done by a specialist.

9803/9060

10 Hr

50 Hr

O

†100 Hr

500 Hr

1000 2000 Hr Hr

O O O

O

O

10 Hr

50 Hr

†100 Hr

O

500 Hr

O

O

O

O

O

O

O

1000 2000 Hr Hr

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

Issue 1

Section 3

Routine Maintenance

Section 3

Synchro Shuttle Transmission

3-1

3-1

Check Oil Level - for Interval see Service Schedule A A

- Dipstick/Filler

Oil level should be to the full mark on the dipstick when the oil is cold i.e. before starting machine operation.

A

If the engine has been running, wait approximately five minutes to allow oil to drain from the torque converter before checking the oil level.

DO NOT OVERFILL

Change Oil & Clean Strainer

F

- for Interval see Service Schedule

! CAUTION When the strainer is removed, oil will gush out. Keep to one side when you remove the strainer.

2-3-4-1

Drain oil by removing plug B. Clean strainer C using a suitable solvent.

When refitting strainer, renew gasket D and apply Loctite 242 to bolts E. Torque Settings Item E

Nm 10

kgf m 1.0

lbf ft 7.4

Renew Filter - for Interval see Service Schedule 1

Unscrew and discard element F.

2

Smear seal G with transmission oil, and fit new element. Note the element must be screwed on until it contacts the filter head and then tightened a minimum of 3/4 turn - equal to 15 Nm (11 lbf ft) torque.

3

D C

Fill system to dipstick mark with specified transmission fluid. (See Transmission Oil Fill Procedure.)

G E

B A317671

9803/9060

Issue 1

Section 4

Electrics

Section 4

i

i

Contents

9803/9060

Page No.

Technical Data Solenoid Valves Relay Requirements

1-1 1-3

Circuit Schematics Basic Machine Circuit Diagram

3-1

Column Control Lever Connections Deutsch Plug Kits

4-1 4-3

Issue 1

9803/9060

Vickers 02-172615

JFP GAV 648, Vickers 02-156793

Circuits and Functional Symbols

Solenoid Valves

2

1

-

1

3

A317760

4

2

-

P T

A B

A234580

1-1

3

4

+

+

Section 4 Electrics Section 4

Technical Data 1-1

Issue 1

9803/9060

4-way, 3-position, directional control

40 l/min (minimum)

10 bar

50 cc/min @ 40 °C, 10 bar

ATF 210

ISO 22/17

-

IP 67

+ 12V DC nominal (9V - 16V)

+ 10.5V (max) @ 25 °C air (after energised for 10 mins @ +16V and off for 10 secs)

+ 1.5V (min) @ 20 °C air

+ 26V DC for 5 mins @ 0 °C

4.9 ohms ± 5% @ 20 °C

- 40 °C to + 43 °C - 40 °C to + 100 °C

3 amps minimum, 50 ns maximum reverse recovery time

Operating Flow

Operating Pressure (nominal)

Leakage (maximum)

Fluid Type

Fluid Cleanliness

Seals

Waterproof Specification

Coil Operating Voltage

Pull-in Voltage

Drop-out Voltage

Peak Voltage

Coil Resistance

Operating Temperature Range Air Oil

Diode Protection

Solenoid Valve (Forward/Reverse) J.F.P GAV648 VICKERS: 02-156793

Type

Solenoid Valves

3 amps minimum, 50 ns maximum reverse recovery time

- 40 °C to + 43 °C - 40 °C to + 100 °C

8 ohms ± 5% @ 20 °C

+ 26V DC for 5 mins @ 0 °C

+ 0.5V (min) @ 20 °C air

+ 10.5V (max) @ 25 °C air (after energised for 10 mins @ +16V and off for 10 secs)

+12V Nominal (10.8V - 13.2V)

1-2

IP 67

70 Shore Nitrile

ISO 22/17

ATF 210

150 cc/min @ 40 °C, 10 bar

10 bar

10 l/min (maximum)

4-way, 2-position

Solenoid Valve (Internal Park Brake and PTO) VICKERS: 02-172615 (SV1-4720)

Section 4 Electrics Section 4

Technical Data 1-2

Issue 1

Section 4 1-3

Electrics Technical Data

Section 4 1-3

Relay Requirements Relays are used in electrical circuits for a variety of reasons. However, the more usual application is to protect components like switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this coil causes internal contacts to open (or close) and therefore controls a (larger) current in another circuit. Although relays look similar, internally they can be different, for example, they can be single contact or double contact; normally closed or normally open.

Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function properly.

Note: Relays are normally not supplied with the gearbox. It is the responsibility of the O.E.M. to provide relays for the protection of components.

Listed below are the gearbox components requiring relay protection.

Neutral Start Ignition Transmission Dump Forward Drive Buzzer (if fitted) Park Brake (if switch fitted) Reverse Drive Drive (Layshaft / Mainshaft) Power Take-off Solenoid Note : The above list does not include any relays that may be required for machine electrics such as indicators, lights etc.

9803/9060

Issue 1

Section 4 3-1

Electrics Circuit Schematics

Section 4 3-1

Basic Machine Circuit Diagram Note: Circuits shown with dashed lines indicate nonstandard equipment.

Main Components

Switches

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

Battery Thermostart Starter Motor Starter Solenoid Forward Solenoid Reverse Solenoid Reverse Alarm Parking Brake Solenoid PTO Solenoid { Compressor Temperature Sender { Compressor Temperature Gauge { Compressor Hourmeter { Stabiliser Leg Solenoid { Steer Mode Solenoids { Steer Mode Unit { Junction Box Hammer Solenoid { Flashier Unit Diode Trailer Indicator Warning Buzzer { Side Instrument Console Tachometer Water Temperature Gauge Fuel Gauge Hourmeter Water Temperature Sender Fuel Sender Buzzer Shut Down System (Compressor) { Engine Shut Off System Front Instrument Console Alternator Rear Horn { Rear Windscreen Washer Pump Rear Windscreen Wiper Motor Front Windscreen Washer Pump Front Windscreen Wiper Motor Front Horn Dipper Socket Face Level Fan { Beacon Motor Tracker { Radio { RH Speaker { LH Speaker { Heater Resistor { Heater Motor { Air Conditioning Motor { Heater Resistor Heater Motor

9803/9060

Starter Switch Forward/Reverse Switch Gear Lever Dump Switch Loader Lever Dump Switch Parking Brake Switch Compressor Switch { Front Proximity Switch { Rear Proximity Switch { Steer Mode Selector Switch { Brake Lights Switch { Hammer Switch Hazard Warning Light Switch Direction Indicator Switch Engine Coolant Temperature Switch Transmission Oil temperature Switch Engine Oil Low Pressure Warning Light Switch Transmission Oil Low Pressure Warning Light Switch Air Filter Blocked Switch Low Brake Pressure Warning Switch Compressor Air Filter Switch { Air Receiver Temperature Switch { Air/Oil Delivery Temperature Switch { Rear Horn Button Rear windscreen Wash/Wipe Switch Front Windscreen Wash/Wipe Switch Front Horn Button Road Lights Switch Headlamp Flasher Switch Headlight Dip Switch Front Working Lights Switch Rear Work Light Switch Beacon Switch Cab Interior Light Switch Heater Switch Air Conditioning Switch { Freeze Valve Low Pressure Switch { High Pressure Switch { Heater Switch Rear Fog Light Switch {

Note: { Indicates non standard equipment.

Issue 1

9803/9060

3-2

1

Section 4

2

2

4

61

170

171

3

62

173

174

64

172

63

5

175

6

7 154

177

176

8

65

11

66

178

9

10

12

13

67

69

68

184

185

14

70

110

16

113

111 112

179

71 17

116 115

114 118

72

73

19

119

117

18

20

22

23 24

26 27

25

75 76

77

78

79

79 29

81

21

130 132 121 123 125 127 120 122 124 126 128129 131 133

74

Circuit Schematics

Electrics

28

82

Issue 1

A300680

3-2

Section 4

9803/9060

3-3

Section 4

1

2

61

176

3

4

172

176

174

64 63

5

62

6

173

Circuit Schematics

Electrics

175

7

65

8

9

66

16

30

72

18

115

114

119

73

19

117 118 116

28

32

121 133

74

75 76

78 77

31

127 122 124 125 130 120 123 126 131

79

25

22

23

26

24

27

001 830Y 837C 200 160AH

600

Issue 1

A300690

3-3

Section 4

Section 4 3-4

Electrics

Section 4

Circuit Schematics

3-4

Basic Machine Circuit Diagram Lights

Relays

110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154

170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185

Left Hand Brake Light Left Hand Trailer Brake Light { Right Hand Trailer Brake Light { Right Hand Brake Light Left Hand Trailer Indicator Light { Left Hand Indicator Light - Front Left Hand Indicator Light - Rear Right Hand Trailer Indicator Light { Right Hand INdicator Light - Front Right Hand Indicator LIght - Rear Alternator No Charge Light Parking brake Warning LIght Engine coolant Temperature Warning LIght Transmission Oil Temperature Warning Light Engine Oil Low Pressure Warning Light Transmission Oil Low Pressure Warning Light Air Filter Blocked Warning Light Low Brake Pressure Warning Light 2 Wheel Steer Selected Warning Light 4 Wheel steer Selected Warning Light Hazard Warning Light Main Beam Warning Light Side Instrument Console Light Direction Indicator Light Front Instrument Console Warning Lights Side Lights Warning Light Rear Working Lights Warning Light Front working lIghts Warning Light Rear Fog Light Warning Light { Left Hand Main Beam Light Right Hand Main Beam Light Left Hand Dipped Beam Light Right Hand Dipped Beam Light Left Hand Trailer Light { Left Hand Number Plate Light Left Hand Tail Light Left Hand Side Light Right Hand Trailer Light { Right Hand Number Plate Light Right Hand Tail Light Right Hand Side Light Front Working Lights Rear Working Lights Rear Fog Light { Reverse Light

9803/9060

Neutral Start Relay Neutral Lock Relay ‘Ignition’ Relay 1 Transmission Dump Relay Forward Relay Reverse Relay Parking Brake Light Relay Parking brake Relay Compressor Neutral or Stabiliser Leg Lock Relay Hammer Relay { Shutdown Relay { ‘Ignition’ Relay 2 Road Lights Relay Air Conditioning Relay { 2 Wheel Steer Relay 4 Wheel Steer Relay

Fuses A1 - A9 B1 - B9 C1 - C9 Note: { Indicates non standard equipment.

Issue 1

Section 4

Electrics

Section 4

Column Control Lever Connections

4-1

4-1

A C

D

X

B

X

Z 7 8 9 10 11 12

3 2

3

4

2

4

5

1

5

6

6

1

2

3

2 R 1

8 6

4

N F

7

3

1

5

4

5 6

10 11 9

A281880

9803/9060

Issue 1

Section 4

Electrics

Section 4

Column Control Lever Connections

4-2

The diagrams opposite show both a gear switch A and a multi-function switch B. Item A incorporates a locating pin X which engages with a drilled hole in the column to ensure correct location and prevents rotation of the switch mounting. The two switches are clamped onto the shaft using two screws D. If item B is not required, mounting clamp C should be used instead.

The gear switch incorporates a rotary selector for forward and reverse and a horn button. Forward/Reverse selection is made by lifting the lever out of its neutral (detent) position and moving it forward (for forward direction) or back (for reverse direction).

4-2

Wiper Column Switch In order to prevent a wiper fuse failure, the wiper park circuit should not be grounded directly to earth.

The connection should be made through a relay as shown at Y or by installing a diode (5A minimum or suitable rated for the wiper motor amperage) as shown at X.

2

X

7

-

+

8

Gear Switch Connections X 1 2 3 4 5 6

6

Forward/Reverse feed Horn feed Horn load Reverse Neutral Forward

3

1

5

4

TO PARK SWITCH

10

Y

11 9

A406060

Multi-function Switch Connections Z 1 2 3 4 5 6 7 8 9 10 11 12

Flasher mode Washer feed High beam Headlamp feed Low beam Wiper park Wash/Wipe load Wiper feed Left turn Right turn Turn signal feed NC

Deutsch Mating Connector Requirements

Item

Housing (6 way) Terminal Socket Contact (female) Locking Wedge Seal Plug

Deutsch Part No. ITL Part No. Qty. Y DT06-6S 1062-16-0122 0462-201-16141 W6S -

460/34701

1

460/34702 460/34702 -

6 1 -

460/34901

1

460/34702 460/34902 460/34903

12 1 1

E

Z Housing (12 way) Terminal Socket Contact (female) Locking Wedge Seal Plug

DT06-12S 1062-16-0122 0462-201-16141 W12S 114017

E A302260

Connectors E must be protected by a suitable cover against damage and high pressure washers.

9803/9060

Issue 1

Section 4 4-3

Electrics

Section 4

Column Control Lever Connections

4-3

Deutsch Plug Kits

A282040

A281920

12-Pin Plug Kit Female Connector 460/34900

6-Pin Plug Kit Female Connector 460/38200

A281950

Sealing Plug (460/34903) Plugs are used to seal unused terminal holes

9803/9060

Issue 1

Section 5

Transmission

Section 5

i

i

Contents

Page No.

Technical Data

1-1

Towing Procedure Engine or Electrical Failure Condition (Gearboxes with internal parking brake only)

2-1 2-1

Descriptions of Operation Component Identification Hydraulic and Electrical Operation Syncromesh Reverser Clutch Power Take-Off Clutch

3-1 3-3 3-5 3-7 3-9

Propshafts Removal and Replacement

4-1

Synchro Shuttle Transmission Removal and Replacement - Gearbox - Torque Converter Pressure and Flow Tests Torque Converter Stall Test Sump Oil Strainer Procedure

5-1 5-3 6-1 6-4 6-5

(after transmission overhaul)

9803/9060

Gearbox (with internal parking brake) Dismantling and Assembly Shaft End Float Measurements

7-1 7-5

Gearbox (with external parking brake) Dismantling and Assembly Shaft End Float Measurements

7 - 10 7 - 14

Solenoid Valve Dismantling and Assembly

8-1

Reverser Unit Dismantling and Assembly Piston Ring Seals - Fitting Procedure

9-1 9-5

Power Take-Off Clutch Removal and Replacement Dismantling and Assembly

11 - 2 11 - 2

Transfer Gearbox TG150 Removal and Replacement Dismantling and Assembly

12 - 1 12 - 2

Fault Finding Synchro Shuttle Gearbox - Hydraulics Synchro Shuttle Gearbox - Mechanical Internal Parking Brake Power Take-Off Transmission Oil Contaminated with Water - Cooler Test Procedure - Flushing Procedure

14 - 1 14 - 3 14 - 6 14 - 7 14 - 8 14 - 9 14 - 9 Issue 1

Section 5

Transmission

Section 5

Technical Data

1-1

1-1

Synchro Shuttle Transmission Description

Combined reverser and gearbox unit with internal wet multi-plate parking brake or external brake disc/caliper type parking brake on output shaft as applicable.

Designation

SS500 (permanent 4 wheel drive, double yoke)

Weight (dry)

150 kg (330 lb)

Torque Converter Diameter

279 mm (11 in)

Torque Multiplication at Stall

2.40

No. of Teeth Transfer Gear Layshaft

Optional High Ratio 19 36

Standard Ratio 17 38

Gear Ratios 1st 2nd 3rd 4th

4.27 : 1 2.50 : 1 1.18 : 1 0.70 : 1

6.31 : 1 3.70 : 1 1.75 : 1 1.03 : 1

Torque Converter Colour Code Identification

2.40 : 1 Ratio 2.78 : 1 Ratio 2.80 : 1 Ratio

Colour Coded Dots

2 orange 1 green

Minimum Engine Rev/min at Converter Stall

Refer to Machine Performance Data

Converter Pressures (in Neutral)

2.78 : 1

1 pink 1 yellow

2.80

3 brown 1 black

bar

kgf/cm2

lbf/in2

Converter In at 50 deg. C

1000 rev/min 2000 rev/min

2.4 - 3.4 5.2 - 6.2

2.5 - 3.5 5.3 - 6.3

35 - 50 75 - 95

Converter In at 100 deg. C

1000 rev/min 2000 rev/min

1.3 - 2.0 5.2 - 5.9

1.4 - 2.1 5.3 - 6.0

20 - 30 75 - 95

Converter Out at 50 deg. C

1000 rev/min 2000 rev/min

1.0 - 1.7 0 - 2.1

1.1 - 1.8 0 - 2.1

15 - 25 0 - 30.5

Converter Out at 100 deg C.

1000 rev/min 2000 rev/min

0.3 - 0.6 1.0 - 1.7

0.3 - 0.6 1.1 - 1.8

4.0 - 8.0 15 - 25

Converter Inlet Relief Valve Pressure (max)

6.5

6.7

95

Lubrication Pressures (in neutral) At 50 deg.C 1000 rev/min 2000 rev/min

bar 0.2 - 0.3 0.4 - 0.7

kgf/cm2 0.2 - 0.4 0.4 - 0.7

lbf/in2 3.0 - 5.0 6.0 - 10.0

At 100 deg.C

0.1 - 0.2 0.3 - 0.6

0.1 - 0.2 0.3 - 0.6

2.0 - 3.0 4.0 - 8.0

Main Line Pressure (in neutral) †At 50 deg. C 1000 rev/min 2000 rev/min Full engine revs

bar 9.3 - 10.3 10.7 - 11.7 11.0 - 12.4

kgf/cm2 9.5 - 10.5 10.9 - 12.0 11.2 - 12.6

lbf/in2 135 - 150 155 - 170 160 - 180

At 100 deg.C

9.3 - 10.3 9.3 - 10.3

9.5 - 10.5 9.5 - 10.5

135 - 150 135 - 150

9803/9060

1000 rev/min 2000 rev/min

1000 rev/min 2000 rev/min

Issue 1

Section 5

Transmission

Section 5

Technical Data

1-2

1-2

Synchro Shuttle Transmission (cont'd) Clutch Pressure (forward and reverse) At 50 deg. C 1000 rev/min 2000 rev/min

bar 5.5 - 6.2 7.6 - 9.6

kgf/cm2 5.6 - 6.3 7.7 - 9.8

lbf/in2 75 - 90 105 - 160

At 100 deg.C

5.5 - 6.3 6.2 - 6.9

5.6 - 6.3 6.3 - 7.0

75 - 90 85 - 100

L/min 10.4 - 13.6 14.5 - 20.0

US gal/min 2.8 - 3.6 3.8 - 5.3

UK gal/min 2.3 - 3.2 3.2 - 4.6

1000 rev/min 2000 rev/min

Flow Rates (in neutral) Torque Converter Housing - without PTO Cooler at 50 deg.C 1000 rev/min 2000 rev/min Cooler at 100 deg.C

1000 rev/min 2000 rev/min

10.2 - 12.5 22.7 - 26.1

2.7 - 3.3 6.0 - 6.9

2.3 - 3.0 5.0 - 5.7

Pump at 50 deg.C

1000 rev/min 2000 rev/min

11.0 - 15.0 22.5 - 29.5

2.9 - 4.0 6.0 - 7.8

2.5 - 3.3 5.0 - 6.5

L/min 12.38 - 16.19 17.26 - 23.80

US gal/min 3.33 - 4.28 4.52 - 6.31

UK gal/min 2.74 - 3.81 3.81 - 5.47

Flow Rates (in neutral) Torque Converter Housing - with PTO Cooler at 50 deg.C 1000 rev/min 2000 rev/min Cooler at 100 deg.C

1000 rev/min 2000 rev/min

12.14 - 14.88 27.02 - 31.07

3.21 - 3.93 7.14 - 8.21

2.74 - 3.57 5.95 - 6.78

Pump at 50 deg.C

1000 rev/min 2000 rev/min

13.09 - 17.85 26.78 - 35.12

3.45 - 4.76 7.14 - 9.28

2.97 - 3.93 5.95 - 7.74

Cooler at 50 deg.C

1000 rev/min 2000 rev/min

L/min 12.1 - 15.8 16.8 - 23.2

US gal/min 3.2 - 4.2 4.4 - 6.1

UK gal/min 2.7 - 3.5 3.7 - 5.1

Pump at 50 deg.C

1000 rev/min 2000 rev/min

12.8 - 17.4 26.1 - 34.2

3.4 - 4.6 7.0 - 9.0

2.9 - 3.8 5.8 - 7.5

PTO Pump Flow Rates

†Note: For new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will be slightly higher than those shown (approximately 0.7 - 1.0 bar, 10 - 15 lbf/in2).

IMPORTANT NOTE: Pre-delivery and inspection pressures must be measured and recorded.

9803/9060

Issue 1

Section 5 2-1

Transmission

Section 5

Towing Procedure

2-1

If there is no transmission damage, the machine may be towed for a distance of approximately 1.5 kilometres (1 mile). Always use a rigid tow bar, ensure that the gear lever is in neutral. Restrict towing speed to 25 k.p.h. (15 m.p.h.).

If it is necessary to tow the machine for a distance in excess of 1.5 kilometres (1 mile) the propshafts should be disconnected to prevent damage to the transmission system.

! WARNING Removal or disconnection of the propshafts(s) will disable the parking brake. It is essential that the following procedure be adopted.

Position the machine on firm level ground and block the wheels securely to prevent any movement. Select neutral and release the parking brake.

Disconnect the forward and rear propshaft(s) from the axle(s), and tie up the shaft securely well clear of the rotating axle yoke.

Alternatively remove the propshaft(s) completely.

Connect the towing vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the towing speed to 25 k.p.h. (15 m.p.h.).

When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshafts.

Important: In some countries neither of the above procedures may be legally acceptable for towing on public highways.

Engine or Electrical Failure Condition (Gearboxes with internal parking brake only) In the event of an engine or electrical failure, the internal parking brake will default to its ON position and must be released as follows: 1

Gain access to the gearbox parking brake housing A mounted on the rear face of the gearbox.

2

Remove brake housing centre bolt B and spacer C.

3

Remove spacer C from bolt B. Retain the spacer.

4

Screw bolt B back into the housing centre hole until the bolt head just touches the housing.

A

After repair, the spacer must be refitted. Apply sealant to bolt B and torque tighten to 56 Nm (42 lbf ft).

C

B

B S182550 S228500

9803/9060

Issue 1

Transmission

3-1

Section 5

Descriptions of Operation

H

F

9803/9060

N

P

D

E

Component Identification

L

G

M

A

J

K

B

C

R

3-1

A314521

Section 5

Issue 1

9803/9060

Gearboxes with external parking brake only: R Parking Brake Disc

Transmission

Note: The illustration shows a torque converter housing which incorporates a power take-off (PTO) M and oil filter N.

Gearboxes with external parking brake.

The gearbox has an external brake disc R and caliper type parking brake on the output shaft as shown, and does not feature the multi-plate brake L and solenoid valve P.

Gearboxes with internal parking brake only.

The gearbox incorporates an internal hydraulic wet multi-plate parking brake L operated by a solenoid control valve P as shown.

Drive is finally transmitted from the layshaft H via the output gear K to both axles.

Reverser Clutch Unit Oil Pump Torque Converter Pressure Maintaining Valve Solenoid Valve Mainshaft 3rd/4th Synchromesh Unit Layshaft 1st/2nd Synchromesh Unit Output Gear Power Take-Off (PTO) Oil Filter

Gearboxes with internal parking brake only: L Wet Multi-plate Parking Brake P Solenoid Valve

A B C D E F G H J K M N

Component Key:

3-2

Drive is transferred from the reverser unit by helical gears to the mainshaft F, which carries the 3rd/4th synchromesh unit G, and to the layshaft H, which carries the 1st/2nd synchromesh unit J. The synchromesh units are of the ‘blocking Pin’ type, a full description of which is given in Synchromesh Operation.

The reverser unit A consists of a pair of hydraulically operated clutches giving forwardneutral-reverse drive. Oil pressure is provided by a crescent-type pump B driven at engine speed by the drive lugs of the torque converter C. The oil pressure is controlled by a pressure maintaining valve D and clutch selection is achieved by means of an electric solenoid valve E.

The transmission consists of a torque converter, mounted on the engine, and a separately mounted drop gearbox. The gearbox comprises a hydraulic reverser unit and a manual 4-speed synchromesh gear system.

Component Identification

Section 5 Section 5

Descriptions of Operation 3-2

Issue 1

9803/9060

R

R1

K

J

A1 A A2

N

A3

B

L

A390890

S

Exhaust

Lubrication

Pressure

Full Pressure

Key to Oil Flow & Pressure

Transmission

Descriptions of Operation

M

E1

E2 E

P

C

H

3-3

K1

D

Hydraulic and Electrical Operation

Section 5 Section 5 3-3

Issue 1

9803/9060

Reverse: When the reverse is selected electrical solenoid E2 is energised and pressurised oil is diverted to the reverse clutch A2. At the same time oil from clutch A1 is diverted back to the sump

Forward: In the diagram, electrical solenoid E1 is energised by the forward/reverse control lever in the cab.

Pressurised oil is diverted to the forward clutch A1 and forward is selected. A restrictor orifice in the feed to the solenoid valve modulates the pressure to the clutch to smooth engagement. At the same time oil from reverse clutch A2 is diverted back to the sump via solenoid valve E. PTO Drive Deselected When the PTO drive is deselected via a switch in the cab, the electrical solenoid K1 is de-energised.

Pressurised oil is diverted to the brake piston forcing a brake disc R1 onto the output shaft assembly M. At the same time oil from the clutch J is diverted back to the sump, disengaging the clutch.

PTO Drive Selected When the PTO drive is selected via a switch in the cab, the electrical solenoid K1 is enegised.

Pressurised oil is diverted to the clutch J, engaging drive to the output shaft M. At the same time oil from the brake piston R is diverted back to the sump, releasing the brake.

Pressurised oil is fed directly to the PTO solenoid control valve K.

The PTO drive is controlled by a hydraulic clutch similar in design to the forward/reverse clutches. A hydraulic brake is also incorporated to prevent the drive shaft rotating when the PTO is deselected.

Power Take Off Operation

For a further detailed description refer also to Reverser Clutch.

Neutral: When neutral is selected (via the control lever or the transmission dump button), the flow of the pressurised oil is blocked at the solenoid valve. No solenoids are energised and no clutches engaged.

Power Take-Off Components: M Output Shaft Assembly J PTO Clutch K Solenoid Valve K1 Electrical Solenoid R Brake Piston R1 Brake Disc

A Reverser Clutch Unit A1 Forward Clutch A2 Reverse Clutch A3 Input Shaft B Oil Pump C Torque Converter D Pressure Maintaining Valve E Solenoid Valve E1 Electrical Solenoid - Forward E2 Electrical Solenoid - Reverse H Oil Cooler L Oil Strainer N Oil Filter P Pressure Relief Valve (Torque Converter)

Component Key:

3-4

Solenoid Valve Operation Pressurised oil at the solenoid valve E is used to control the forward/reverse clutches A1 and A2.

Oil is drawn from the gearbox sump via strainer L by pump B. Pressurised oil from the pump is fed through an internal passage via the filter N to the pressure maintaining valve D, which maintains pressure to the solenoid valve E for forward/reverse clutch selection. Excess oil from the maintaining valve flows back through casing cross drillings to the torque converter C. Oil enters the converter between the converter hub and the stator support, and leaves between the stator and the input shaft.

Pressure in the converter is controlled by a relief valve P which dumps excess oil from the converter line back to the sump.

Oil from the torque converter flows out of the transmission to the external oil cooler H, returning at the rear of the transmission unit to pass through the centre of the input shaft A3 for clutch lubrication. Oil then returns to the sump.

Hydraulic and Electrical Operation

Section 5 Transmission Section 5

Descriptions of Operation 3-4

Issue 1

Section 5 3-5

Transmission Descriptions of Operation

Section 5 3-5

Synchromesh The gearbox is fitted with 'Blocking Pin' synchromesh, comprising the following parts: Synchro Hub (A) controls the operation of the synchromesh unit and gear selection, the selector fork fitting into the outer groove. Internal dog teeth link the selected gear to the drive shaft. Through the synchro hub centre are two sets of holes for the blocker pins (C) and the split energiser pins (D), spaced alternately.

Synchro Rings (B) are rigidly joined by the blocker pins, with the split energiser pins held, in counterbores, between the two synchro rings.

Blocker Pins (C) have a narrow neck in the centre, against which the synchro hub transmits radial drive during gear changes. The edges of the blocker pin neck and their mating synchro hub holes are designed so that, as the radial loads are reduced, the synchro hub can slide over the shoulder of the blocker pin.

Split Energiser Pins (D) take the initial axial load of the synchro hub on the shoulder of the split energiser pin neck.

As the axial load reaches approximately 400 N (40.8 kg; 90 lb) the internal springs allow the split energiser pin to collapse and the synchro hub to move axially.

Synchro Cups (E) take the frictional drive from the synchro ring on their inner faces. The synchro cups are splined to drive their respective gears whilst synchronisation is taking place.

Diagram F shows the gearbox with first gear engaged.

Synchro ring B is in contact with synchro cup E and the synchro hub dog teeth are linking first gear to the shaft gear.

In this position the split energiser pins D are 'collapsed'.

5171

When selecting second gear the synchro hub A slides along the split energiser pins until the pin recess and the synchro hub flange are in line. At this point the split energiser pins open and the synchro rings are moved by the synchro hub pushing on the split energiser pin shoulder.

Initial contact between the synchro ring and the synchro cup starts to synchronise the speed of the shaft and second gear. The rotational force of the synchro ring is taken by the blocker pin against the edge of the synchro hub hole, as at G. As the axial load on the synchro hub increases, the split energiser pin 'collapses' and the conical faces of the blocking pin and synchro hub hole come into contact, as at H. Further increases in the axial loads increase the frictional grip of the synchro ring and the synchro cup, causing the shaft and gear speeds to synchronise.

As the speeds are synchronised the radial load on the blocker pin and the synchro hub is reduced. This allows the synchro hub to slide freely along the blocker pin and engage its dog teeth with second gear, see diagram J.

9803/9060

Issue 1

Section 5

Transmission

Section 5 3-6

Descriptions of Operation

3-6

Synchromesh (cont’d) A

B

C

E

D F

H

G

J S05154A

9803/9060

Issue 1

Section 5

Transmission

3-7

Section 5

Descriptions of Operation

9803/9060

A390970

9

4

3

8

1

Reverser Clutch

A3

G1

A1 6 5 6 10

A2

G2

7

E

E1

E2

3-7

Issue 1

9803/9060

Transmission

†The valve E is shown using symbols.

Actuation of the hydraulic pistons 10 and 5 is controlled via three position solenoid valve E†.

When neutral is selected, solenoids E1 and E2 are deactivated and the flow of pressurised oil to the clutches is blocked. Springs 8 and 9 move the pistons away from the clutch plates and oil from both pistons is vented to the sump.

When either forward or reverse is selected, the solenoid valve E diverts pressurised oil via cross drillings inside the input shaft A3 to the appropriate clutch (piston 10 or 5) in the unit. Pressure from the other clutch is vented to the sump via the solenoid valve spool. Oil is prevented from leaking by seals 6 on the pistons and ring seals 7 on the input shaft A3.

In the diagram, clutch A1 is engaged. The counter plates 3 and friction plates 4 are pressed together by hydraulically actuated piston 5. Drive is then transmitted from the input shaft to the gear G1.

Clutch A2 is disengaged and no drive is transmitted to gear/plate carrier G2. The gear is also free to rotate on the input shaft assembly.

1 Reverser Clutch Unit 3 Counter Plates 4 Friction Plates 5 Piston 6 Seal 7 Seal 8 Spring 9 Spring 10 Piston A1 Clutch Pack A2 Clutch Pack A3 Input Shaft E Solenoid Valve E1 Solenoid Coil E2 Solenoid Coil G1 Output Gear/Plate Carrier G2 Output Gear/Plate Carrier

Component Key:

3-8

The clutch housings and input shaft are a one piece assembly A3. The assembly is permanently driven by the engine via the torque converter. Clutch counter plates 3 are also permanenty driven via meshing teeth inside the clutch housings.

Clutch friction plates 4 are meshed with the gear/plate carriers (G1 and G2).

The clutches are of the wet, multi-plate type.

The reverser clutch unit 1 transfers drive from the input shaft A3 to either gear G1 or gear G2 depending on which of the two clutches (A1 or A2) is engaged, giving forward or reverse drive. When neither clutch is engaged, neutral is selected.

Reverser Clutch

Section 5 Section 5

Descriptions of Operation 3-8

Issue 1

Section 5 3-9

Transmission

Section 5 3-9

Descriptions of Operation

Power Take-Off Clutch The drive for the PTO is transmitted by constant mesh from gear A through idler gear B onto the power take off clutch gear C. Gear A is mounted on the input reverser shaft D and is driven via the torque converter. The converter has an additional integral splined spigot when compared to a 'standard' converter, this additional spline is used to directly drive gear assembly A via gear E.

When the solenoid is de-energised, the friction/counter plates are released by spring pressure and the constant meshing gears will once again freely rotate (with no drive being transmitted). At the same time pressurised oil is directed via the solenoid spool G to the back of the piston L, applying the PTO brake. This prevents the yoke and its drive shaft rotating as soon as the operator disengages the PTO.

The constant meshing gears will freely rotate until the PTO clutch solenoid F is energised. When the solenoid is energised, pressurised oil is diverted via a solenoid spool G to the power take off clutch pack assembly H. The clutch pack works on a similar principle to the standard 'reverser' clutch found in the standard syncro shuttle transmission, that is the pressurised oil enters the clutch and forces a piston against the friction/counter plate assembly J. Because the friction/counter plates are now compressed drive is transferred from the clutch gear C, through the friction/counter plate assembly to the PTO drive yoke K.

E D A

A212860

9803/9060

Issue 1

Section 5

Transmission

Section 5 3 - 10

Descriptions of Operation

3 - 10

A212880

F

G SECTION THROUGH A - A

H

K

J

C

B

A391030

9803/9060

Issue 1

Section 5

Transmission

Section 5

Propshafts

4-1

4-1

Removal and Replacement

X

Removal Before removing propshafts always mark both companion flanges and also mark the sliding joints prior to removal.

Replacement 1

2

On reassembly, after lubricating sliding joints with Mobil HP222 grease, align the shafts against identification marks previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings.

Y

Apply Loctite 242 to the threads of all bolts and torque tighten to values given below:

Note: The retaining straps D stretch with use, therefore these straps must always be replaced with new ones.

The propshaft must have both ends exactly on the same plane as shown at X. The yokes must not be at right angles as at Y or at an intermediate angle as at Z.

Z

The propshaft should not be installed with the joints exactly in line, but with joint ends at an inclination of 2° - 3°. The joint end angles should be identical at both ends of the propshaft to equalise joint velocity.

S189610

Bolt Torque Settings Position A B C

Nm 75 - 85 118 21

kgf m 7.7 - 8.7 12 2.1

lbf ft 55 - 63 87 15

D

C B A

A

B

A405890

9803/9060

Issue 1

Section 5

Transmission

Section 5 5-1

Synchro Shuttle Transmission

5-1

Removal and Replacement - Gearbox

Y

K

X

D

L E

F

P

Q R

B A A M

J N G

H A405900 S405910 A405900

9803/9060

Issue 1

Section 5

Transmission

Section 5 5-2

Synchro Shuttle Transmission

5-2

Removal and Replacement - Gearbox Park the machine on firm level ground.

12

Make sure that the weight of the transmission is supported by the trolley jack and remove the transmission mounting bolts K.

13

Using the trolley jack, lower the transmission and engine to gain access to the top flywheel housing to engine block retaining bolts J.

14

Disconnect the transmission oil cooler at the transmission unit, shown at B and N.

15

Disconnect the transmission solenoid valve flying lead connectors A and the pressure sender. Label the connectors for identification when refitting.

16

Remove the breather pipe from the pressure maintenance valve block to top of the dipstick tube as shown at M.

17

Put a support under the engine as shown at G to prevent it from dropping when the transmission is removed.

18

Remove the flywheel housing to engine bolts J.

19

Manoeuvre the transmission with the torque convertor clear of the engine housing.

20

Lower the trolley jack and pull the transmission and torque convertor clear of the machine.

! WARNING A raised and badly supported machine can fall on you.

Position the machine on a firm, level surface. Before raising one end ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being started while you are beneath the machine.

GEN 1-1

Removal 1

Stabilise and raise the machine to allow room for the transmission to be pulled clear. Block/support the machine.

2

Drain the transmission system, Dismantling and Assembly.

3

Remove the engine bonnet.

4

Remove when applicable, the engine fan retaining bolts P (4 off) and remove the fan, see note 1.

see

Gearbox

Note 1: At a later stage the transmission is tilted to give access to retaining bolts, if the fan is not removed at this stage it could foul.

5

Disconnect the gearshift lever from the top of the transmission as shown at D.

6

Remove the axle drive shaft bolts E and F as applicable.

7

On gearboxes with an internal parking brake, remove the parking brake solenoid flying lead connector L.

7

On gearboxes with an external parking brake, disengage the clevis at the caliper as shown at X, loosen locknuts Y and remove the cable from the bracket. Tie the cable up clear of the gearbox.

8

Remove PTO solenoid flying lead connector R.

9

Remove the transmission dipstick tube and filter.

10

Remove the access bung/plate at the bottom of the flywheel housing. Through the access hole, loosen and remove the torque convertor to engine flywheel retaining bolts Q.

11

Support the transmission with a trolley jack as shown at H, see note 2.

Replacement Replacement is the reverse of the removal sequence.

On gearboxes with an external parking brake, set the parking brake caliper and adjust the operating cable, see External Parking Brake Caliper - Setting Procedure, Section 6.

Set the torque converter as described in Torque Converter - Removal and Replacement.

Fill the transmission with specified transmission fluid (see Lubricants and Capacities and Transmission Oil Fill Procedure, Section 3). Leave hose N off until the filling operation is complete. After filling refit hose N. Torque Settings Item E F J K P Q

Nm 118 21 98 237 44 19

kgf m 12 2.1 10 24 4.5 2

lbf ft 87 15 72 175 33 14

Note 2: Attach a 'cradle' to the trolley jack that will partially embrace the transmission.

9803/9060

Issue 1

Section 5

Transmission Synchro Shuttle Transmission

5-3

Section 5 5-3

Removal and Replacement - Torque Converter Removal 1

Slacken and remove hexagon head screws 3 from drive plate 1.

2

Withdraw torque converter and drive plate from splined fly wheel mounting.

Before Replacing Ensure that flywheel face, drive plate, and hardware are clean and free from burrs or other surface imperfections.

Replacement 1

Offer drive plate 1 and drive plate annulus 2 to torque converter.

2

Place the torque converter alignment tool A over the torque converter spigot, make sure that the tool locates in two of the converter bolt holes as shown. It is important to note that the converter drive tube must be protected against damage or contamination at all times.

3

Fit four of the drive plate retaining bolts 3 and torque tighten to 40 Nm (30 lbf ft). Remove the alignment tool and fit the remaining two retaining bolts 3.

4

Offer the torque converter and drive plate/annulus assembly to the flywheel, bolt the drive plate annulus to the flywheel (use only 3 bolts). Check the converter runout as shown at B, which should not exceed 0.38 mm (0.015 in).

A

2

3

1

S228920

9803/9060

Issue 1

Section 5

Transmission

Section 5 5-4

Synchro Shuttle Transmission

5-4

Removal and Replacement - Torque Converter (cont’d) Replacement Note: In the unlikely event that the run-out exceeds 0.38 mm (0.015 in), remove the converter and check the spigot for burrs, remove the drive plate and rotate it 180° on the torque converter, repeat steps 2 to 4.

B

S161470

5

Remove the torque converter and drive plate/annulus assembly from the flywheel.

6

Install the converter transmission/engine:

assembly

to

the

a

Install the torque converter with its drive plate/annulus sub-assembly onto the transmission input shaft, make sure that the splines on the converter pump drive shaft engage with the splines in the pump, also take care not to damage the oil seal.

b

Rotate the engine flywheel so that one bolt hole is in a six o’clock position.

c

Rotate the torque converter and drive plate assembly so that one bolt hole is in a six o’clock position.

d

Install the pump housing/torque assembly to the engine.

e

Remove the access plate from the bottom of the engine flywheel housing and through the access hole fit and hand tighten one bolt 5 in the six o’clock position.

S218440

Torque Settings Item 3 5

Nm 40 19

kgf m 5 2

lbf ft 30 14

converter

Note: It is important to mount washers 4 with the outside diameter radius against the drive plate, i.e. facing toward the flywheel. f

Rotate the flywheel until the next bolt hole is accessible, fit and hand tighten the next bolt 5.

Repeat the operation until all bolts are fitted. Finally torque tighten bolts 5 to 19 Nm (14 lbf ft), rotating the flywheel each time to align bolts 5 with access hole. Refit access plate.

9803/9060

Issue 1

Section 5

Transmission

Section 5 6-1

Synchro Shuttle Transmission

6-1

Pressure and Flow Tests

E

D

B C

H

J

G

F

S205690

A S204870

W

S204890

9803/9060

X

Y

Z Issue 1

Section 5

Transmission

Section 5

Synchro Shuttle Transmission

6-2

6-2

Pressure and Flow Tests Before completing any of the transmission pressure/flow tests, make sure that the oil level is correct and at normal operating temperature.

All gauges etc used in the following pressure/flow tests are shown in Section 1.

If testing the complete transmission, the following procedures are listed in a logical sequence and should therefore be completed in the same sequence. Also, refer to the fault finding procedures at the end of the transmission section for reference to specific tests.

Mainline Pressure

Test points have been introduced which can be left in place after testing. Remove blanking plugs as required and fit the test points (see Section 1). If the test points are to be left in place use Loctite 242 on the threads when fitting. Torque tighten to 28 Nm (21 lbf ft).

1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector A.

2

Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show the Mainline Pressure which should be as shown in Technical Data.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

4

Stop engine and remove test gauge.

! WARNING Fine jets of hydraulic oil at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic oil leaks. Do not put your face close to suspected leaks.

Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic oil. If hydraulic oil penetrates your skin, get medical help immediately.

HYD 1-1

! WARNING Take care when disconnecting hydraulic hoses and fittings as the oil will be HOT.

If the mainline pressure is low, refer to the fault 'Low Mainline Pressure' for a list of possible reasons. A high reading could indicate a faulty pressure maintenance valve.

Clutch Pressure (Forward Clutch Given in Example) 1

Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure gauge to test connector B (item C for reverse clutch).

2

Start engine and run at 1000 rev/min. With parking brake and footbrake firmly applied, select Forward, the pressure gauge will show the Clutch Pressure which should be as shown in Technical Data.

Trans 1-2

! WARNING DO NOT go underneath the machine with the engine running. Switch off the engine, apply the parking brake and chock both sides of all wheels before going underneath the machine.

Trans 2-1

TEST POINTS

Note: If the mainline pressure is in the lower part of the tolerance band (see Technical Data), then the forward and reverse clutch pressures should also be in the lower part of the tolerance band and vice versa.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

B - Forward clutch pressure

4

Stop engine and remove test gauge.

C - Reverse clutch pressure

If the clutch pressure is low, the clutch could be leaking. A leaking clutch is easier to detect when the engine is running at idle. With the engine at idling speed, check the mainline pressure and then check the clutch pressure as described above, if the clutch pressure is 1.7 bar (25 lbf/in2) less than the mainline pressure, then the clutch is probably leaking.

Refer to the fault 'Low Clutch Pressure' before dismantling the clutch.

A - Mainline pressure

D - Converter inlet/converter relief valve pressure E - Converter outlet pressure F - Pump flow (remove filter and fit adapters) G - Lubrication pressure H - Cooler flow (flowmeter in line from transmission to cooler)

A high reading could indicate a faulty pressure maintaining valve.

J - Load Valve

9803/9060

Issue 1

Section 5 6-3

Transmission

Section 5

Synchro Shuttle Transmission

6-3

Pressure and Flow Tests (cont’d) Pump Flow

Converter Relief (Safety) Valve Pressure

1

Stop engine, remove transmission filter F, and screw adapter X (892/00304) on to the threaded spigot. Fit test adapter Y (892/00301) and secure with adapter Z (892/00302). Connect flowmeter W (892/00229).

1

Connect a 0-10 bar (0-145 lbf/in2) pressure gauge to test point D.

2

Fit a load valve J into the converter out line.

2

Start engine and run at 1000 rev/min. With the transmission in neutral the flowmeter will show the Pump Flow which should be as shown in Technical Data.

CAUTION: Make sure the load valve is in the OPEN position (the adjusting knob screwed fully out) before starting the following pressure test. If the load valve is not fully open, damage to the converter seals will be incurred.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

CAUTION: DO NOT allow the pressure to exceed 7.6 bar (110 lbf/in2) or damage to the converter seals will be caused.

4

Stop engine and remove test adapters, refit filter.

3

Start the engine and run at 1000 rev/min. With the transmission in neutral, slowly screw down the load valve J whilst observing the gauge reading which should rise to the Converter Relief (Safety) Valve setting as specified in Technical Data.

Stop engine, connect a 0-10 bar (0-145 lbf/in2) pressure gauge and flowmeter (see note) into the converter out line as shown at E and H respectively.

4

If the reading is higher than specified then the converter relief valve is faulty. A low reading indicates a leaking pump seal or a faulty converter relief valve.

Note: The flowmeter must have a low back pressure, otherwise an incorrect reading will be obtained.

5

Stop engine, remove test gauges and refit hoses to original position.

If the pump flow is low, refer to the fault Low Pump Flow.

Converter Out Pressure/Oil Cooler Flow Rate 1

2

3

4

Run the engine at 1000 rev/min with transmission in neutral. The pressure gauge indicates the Converter Out Pressure and the flowmeter indicates the Oil Cooler Flow Rate, both readings should be as specified in Technical Data.

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

Lubrication Pressure 1

Stop engine, connect a suitable pressure gauge into the return line from the oil cooler to the transmission as shown at G.

2

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will indicate the Lubrication Pressure which should be as specified in Technical Data.

3

Repeat step 2 and note gauge readings with engine running at 2000 rev/min.

4

Stop engine and remove pressure gauge.

Stop engine, remove test gauges and refit hoses to original position.

If the pressure is low, refer to the fault Low Converter Out Pressure for a list of possible reasons. A high pressure together with low flow could be caused by a blocked oil cooler.

Converter In Pressure 1

Stop engine, connect a 0-10 bar (0-145 lbf/in2) pressure gauge to test point D.

2

Start the engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show Converter In Pressure which should be as shown in Technical Data. A high or low reading could indicate a faulty converter relief valve, or a problem with the pump.

3

Remove pressure test gauge.

9803/9060

Issue 1

Section 5

Transmission Synchro Shuttle Transmission

6-4

Section 5 6-4

Torque Converter Stall Test Note: Before completing the torque converter stall test, make sure that the mainline and clutch pressures are correct. If the pressures are incorrect, the clutches could slip, causing premature wear of the clutch friction plates.

Also, make sure that the machine neutral circuit pressure (including steer circuit) is correct (14 bar; 200 lbf/in2 maximum).

1

Ensure that the engine and transmission are at normal working temperature. Run engine at maximum speed and check the No Load Speed (High Idle Speed U.S.A). See Engine Technical Data for correct figure; adjust if necessary.

2

Apply parking brake A and footbrake firmly B, select 4th Speed Forward and open throttle C fully. Engine speed should be as specified at Torque Converter Stall in Transmission Technical Data. Select Reverse and repeat test.

DO NOT stall the converter for longer than 30 seconds or the transmission fluid will overheat.

3

If engine speeds are higher than the stated figures check the transmission for clutch slippage or internal leakage.

If engine speeds are below the stated figures either the engine is losing power and should be serviced/overhauled or the torque converter reaction member clutch is slipping.

To check the engine, make sure the main relief valve is set correctly, select Neutral, open throttle fully and operate an excavator service to 'blow off' the main relief valve. Engine speed should fall to slightly above the Maximum Governed Speed (see Engine Technical Data). If engine speed is correct the torque converter is faulty.

Note 1: The engine can also be checked by doing a stall test and 'blowing off' the main relief valve simultaneously. The speed should be as stated in Technical Data ('Engine Rev/Min at Converter Stall + MRV Operating').

Note 2: Maximum Governed Speed is a datum figure only.

It cannot be adjusted or checked with the engine installed in the machine.

A

B

C

S181851

9803/9060

Issue 1

Section 5

Section 5

Transmission Synchro Shuttle Transmission

6-5

6-5

Sump Oil Strainer Procedure (after Transmission Overhaul) Component Key: A B C D E F G

Suction strainer (892/00970) Gasket Pressure Filter Hot Oil Oil Cooler Feed Pipe Bolt (2 off) Cold Water

C F A

B

C D E G

X

Y

X Y

9803/9060

Solid Adapter with Magnet Threaded Adapter with 1 in BSP plug and magnet

A405920

Issue 1

Section 5 6-6

Transmission Synchro Shuttle Transmission

Section 5 6-6

Sump Oil Strainer Procedure (after Transmission Overhaul) If the transmission is not thoroughly cleaned during overhaul, any particles below 200 micron (0.2 mm) can pass through the existing suction strainer and into the transmission pump before being caught in the pressure filter.

This can result in transmission pump failure and the transmission may have contamination related problems (scoring of bearings and clutch housing).

It is recommended that a special 75 micron (0.075 mm) service suction filter is temporarily fitted after a transmission overhaul to clean the system and prevent further damage.

The following procedure should be adopted:1

During the overhaul, the transmission should be cleaned as thoroughly as possible.

2

If a significant amount of particles and oil debris is present, then it is recommended that the oil cooler and pipework are cleaned or replaced.

3

Fill the transmission with clean, correct specification oil (see Lubricants and Capacities, Section 3).

4

The transmission should be overfilled for initial start-up.

5

Disconnect the oil cooler feeder pipe at E and run the engine at idle.

6

Drain the excess oil into a suitable container which will prevent contaminated oil being pumped into the oil cooler or transmission. The transmission must be kept full at all times.

7

Reconnect the oil cooler at E. Run the machine to working temperature and carry out functional tests.

8

Remove the connection or plug from the suction strainer and drain the system.

Note: Drain through the strainer, not the drain plug and DO NOT re-use this oil as it will be contaminated.

9

Remove and clean the service suction strainer with its magnet. Retain for future use.

10

Fit the production suction strainer, tightening bolts F to 7 - 10 Nm (5.2 - 7.3 lbf ft).

11

Fit a new pressure filter C.

Note: The pressure filter should be changed again after 100 hours running.

12 Refill the system with clean and correct specification oil (see Lubricants and Capacities, Section 3).

9803/9060

Issue 1

Section 5 7-1

Transmission Gearbox (with internal parking brake)

Section 5 7-1

M

9803/9060

Issue 1

Section 5 7-2

Transmission Gearbox (with internal parking brake)

Section 5 7-2

Dismantling 1

Drain the oil from the casing into a suitable container by removing the drain plug 1 and sealing washer 2.

Discard the sealing washer.

2

Remove suction strainer retaining bolts 3 and remove the strainer 4. Remove and discard the strainer cap gasket 5.

3

Remove and discard the oil filter.

11

Press out brake operating piston 26 from the end cover 24 by removing the piston housing centre bolt 28 and spacer 29 and screwing in an M10 x 30 bolt to press out the piston. Remove and discard the piston 'O' ring 27. Remove the M10 x 30 bolt and refit the original bolt and spacer.

12

30 k.p.h. Gearbox Remove counter plates 31 (10 off), friction plates 32 (9 off), annular pressure plate 33, reaction pins 34 (3 off) and the disc spring assembly 35 from the brake casing.

12A 20 k.p.h. Gearbox Remove brake pressure plate 30, counter plates 31 (7 off), friction plates 32 (6 off), annular pressure plate 33, reaction pins 34 (3 off) and the disc spring assembly 35 from the brake casing.

S203970

4

Position the gearbox with the rear casing 37 uppermost.

5

Unscrew capscrews 6 (4 off). Remove the solenoid valve assembly 8 and discard the 'O' rings 9 (4 off).

6

Remove output yoke stake nuts 13 using service tool 892/00812. Discard the stake nuts. Remove washers 14 and yokes 15 from the output shaft 16. Note that some gearbox variants may have a flange headed bolt fitted instead of items 13 and 14.

7

Remove and discard the output shaft oil seals 17.

8

Remove the gear change turret retaining bolts 18 (4 off).

Remove the turret 19 and gasket 20. Discard the gasket.

9

Remove the brake feed pipe 21.

10

30 k.p.h. Gearbox Remove the brake end cover retaining bolts 22 (4 off) and 23 (2 off) and remove the end cover 24. Remove and discard the end cover gaskets 25 and spacer M. 20 k.p.h. Gearbox Remove the brake end cover retaining bolts 22 (4 off) and 23 (2 off) and remove the end cover 24. Remove and discard the end cover gasket 25.

9803/9060

13

Remove the adaptor block assembly retaining setscrews 10 (4 off) and remove the block 11. Remove and discard the gasket 12. Remove pressure maintaining valve spool and spring 68.

14

Remove the casing retaining bolts 36.

15

Screw a lifting eye into a brake housing bolt hole. Using a suitable hoist, lift the rear casing 37 away from the front casing 38. Prise bars may be used at the points provided to assist in 'cracking' the joint. Remove and discard the face 'O' rings 39 and 40.

S203991

Issue 1

Section 5 7-3

9803/9060

Transmission Gearbox (with internal parking brake)

Section 5 7-3

Issue 1

Section 5 7-4

Transmission

Section 5

Gearbox (with internal parking brake)

7-4

Dismantling (cont'd) 16

Remove the output shaft assembly 41.

29

17

Remove locking screws 42 (2 off) from selector forks 44 and 45 and selector blocks 43.

Assembly

18

Remove the detent plugs 46, springs 47 and balls 48 (2 off each).

19

Slide selector shafts 49 from selector forks 44 and 45.

20

Remove taper plug 50 from the casing. Thread a piece of thin looped wire to the bottom of the RH selector shaft locating hole. Using a small diameter screwdriver through the taper plug hole, push the baulk roller 51 into the wire loop. Carefully withdraw the baulk roller.

21

Remove the layshaft assembly 52.

22

Remove the main shaft assembly 53.

23

Remove the reverser unit 54. For dismantling and assembly instructions, refer to Reverser Unit Dismantling and Assembly.

24

25

Remove idler gear spacer 55, thrust washers 56, thrust bearing 57, idler gear 58, needle roller bearings 59, bearing spacer 59A, thrust washers 56 and thrust bearing 57 from idler shaft 60.

Remove the idler shaft 60 using a slide hammer if necessary.

26

Remove the bearing cups located in the front casing using a slide hammer.

27

Turn the gearbox into the horizontal position.

28

Remove the pump assembly retaining bolts 61 (4 off) and withdraw the pump assembly 63 from the front casing. Discard the washers 62 (4 off) and 'O' ring 64.

Remove the bearing cups located in the rear casing using a slide hammer.

Note: All bearings must be lightly oiled before assembly.

Make sure all components are thoroughly clean and renew all 'O' rings.

1

Clean the mating faces of front casing 38 and rear casing 37.

2

Fit new bearing cups into front and rear casings using a bearing dolly.

3

Fit the idler shaft 60 using a soft faced hammer.

4

Fit the idler gear assembly (thrust washers 56, thrust bearing 57, needle roller bearings 59, bearing spacer 59A, idler gear 58, thrust washers 56, thrust bearing 57 and idler gear spacer 55).

5

Fit the reverser unit 54.

6

Fit the main shaft assembly 53.

7

Fit the layshaft assembly 52.

8

Fit the output shaft assembly 41.

9

Thread the RH gear selector rod 49 through selector fork 45 and into the casing. Secure with locking screw 42. Torque tighten to 35 Nm (25.8 lbf ft).

10

Using a piece of looped wire, lower the baulk roller 51 down the LH selector rod channel in the casing. When in position at the bottom, push the roller into position using a small screwdriver through the taper plug hole (item 50). Remove the wire and screwdriver. Fit the taper plug 50 and torque tighten to 28 Nm (20.7 lbf ft).

11

Thread the LH selector rod 49 through selector fork 44 and into the casing. Secure with locking screw 42.

Torque tighten to 35 Nm (25.8 lbf ft).

12

Fit detent balls 48, springs 47 and plugs 46 (2 off each).

Torque tighten plugs to 35 Nm (25.8 lbf ft).

13

Screw a lifting eye into a brake housing bolt hole of the rear casing 37. Using a suitable hoist, lift the rear casing into position over the front casing 38. Carefully lower the rear casing onto the front casing, ensuring that the locating pegs are fully engaged. Secure the casings with six equally spaced bolts 36. Torque tighten to 56 Nm (41.3 lbf ft). Remove the lifting eye.

S203980

9803/9060

Issue 1

Section 5

Transmission

Section 5 7-5

Gearbox (with internal parking brake)

7-5

Assembly (cont'd) 20

Shaft End Float Measurements

Calculate the required shim thickness.

Example: 14

Clean the parking brake mating face.

15

Using service tool kit Pt No. 993/59400, fit base plate A onto the parking brake mating face and secure with socket head set screws B. Torque tighten to 56 Nm (41.3 lbf ft).

a

End Float Tolerance : 0.03 to 0.08 mm. (Identical clearance for all shafts.)

b

Measured End Float : 0.20 mm

c

To give an end float within the tolerance, subtract 0.05mm from dimension at para. b for the required shim thickness, e.g., 0.20 - 0.05 = 0.15 mm.

16

Pass the adaptor C through the large diameter hole in the base plate and screw into the end of the layshaft.

17

Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E on the base plate and secure with bolts F. Tighten the bolts.

21

Remove the bolts F securing the lever unit mounting blocks E and remove the lever unit. Unscrew and remove the adaptor C.

Fit a magnetic base dial test indicator (DTI) G onto the base plate with the pin resting on the top of the adaptor.

22

Remove taper plug 67.

23

Fit the short extension H to the adaptor C.

24

Using a lever, put the gearbox in gear.

25

Screw the adaptor into the end of the main shaft. Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E in the appropriate position on the base plate A and secure with bolts F. Tighten the bolts.

26

Fit a magnetic base DTI G onto the base plate with the pin resting on the top of the adaptor.

27

Measure main shaft end float and determine shim thickness by repeating steps 19 and 20. Refer to view X.

18

19

Measure layshaft end float as follows (refer to view W): a

b

Using a torque spanner on the nut of the lever unit as shown, apply a torque of 30 Nm (22.1 lbf ft) clockwise while turning the output shaft backwards and forwards using a turning handle. Zero the DTI. Apply a torque of 30 Nm (22.1 lbf ft) anti-clockwise while turning the output shaft backwards and forwards using a turning handle. Take the layshaft end float reading from the DTI.

W 9803/9060

S204020

X

S204030

Issue 1

Section 5

Transmission

Section 5

Gearbox (with internal parking brake)

7-6

7-6

Assembly (cont'd) 28

Temporarily refit taper plug 67.

29

Remove short extension from adaptor.

30

Fit the rear output yoke 15, washer 14 and stake nut 13. Torque tighten to 350 Nm (258.2 lbf ft).

31

Fit the output yoke adaptor J and secure with bolts K. Torque tighten to 22 Nm (16.2 lbf ft). Screw the adaptor C into the yoke adaptor extension L until tight.

32

Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E in the appropriate position on the base plate A and secure with bolts F. Tighten the bolts.

33

Fit a magnetic base DTI G onto the base plate with the pin resting on the top of the adaptor.

34

Measure the output shaft end float and determine shim thickness by repeating steps 19 and 20. Refer to view Y.

39

Clean the mounting face of the flywheel housing. Mount the DTI on the face with the probe resting on the end of the reverser unit shaft. Firmly press the reverser unit shaft in to take up any shaft end float. Zero the DTI. Refer to view Z.

40

Screw a threaded bolt or rod into the threads exposed when oil inlet adaptor 65 was removed, until it touches the end of the reverser unit shaft.

Z

S204050

S204010

41

Screw bolt or rod in further (approx. 10 Nm; 7.4 lbf ft) whilst turning output shaft. Stop when increasing resistance is felt. DO NOT overtighten. Take the DTI reading.

42

Calculate the required shim thickness as detailed in step 20.

Remove the lever unit, adaptor, base plate and output yoke adaptor.

43

Remove bolt or rod and the DTI. Temporarily refit oil inlet adaptor 65 and sealing washer 66.

Remove the rear stake nut 13, washer 14 and output yoke 15.

44

Turn the gearbox into the vertical position, with the rear casing upwards.

Remove oil inlet adaptor 65 and sealing washer 66 from the rear casing.

45

Screw a lifting eye into a brake housing bolt hole. Using a suitable hoist, lift the rear casing 37 away from the front casing 38. Prise bars may be used at the points provided to assist in 'cracking' the joint. Turn the rear casing over.

Y 35

36

37

38

Turn the gearbox into the horizontal position.

9803/9060

Issue 1

Section 5 7-7

Transmission Gearbox (with internal parking brake)

Section 5 7-7

Assembly (cont'd) 46

Using a bearing puller, remove the layshaft bearing cup from the rear casing. Referring to the shim thickness calculation for the layshaft 52, fit the required shims into the rear casing. Using a bearing dolly, refit the layshaft bearing cup.

47

Repeat step 46 for the main shaft 53, output shaft 41 and reverser unit 54.

48

Turn the rear casing over.

49

Fit the face 'O' rings 39 and 40 into the front case mating face recesses.

50

Apply a bead of sealant to the front case mating face, smoothing the sealant around the 'O' ring areas.

51

53

If any measurement is outside the tolerance, remove rear casing, see step 45. Using a bearing puller, remove the bearing cap(s) of the shaft(s) outside the tolerance.

Add or remove shim(s) to bring the measurement(s) within the tolerance. Using a bearing dolly, refit the bearing cup(s) into the rear casing.

54

Remove the front case 'O' rings 39 and 40 and clean the sealant from the front case mating face.

55

Repeat steps 49 to 52 inclusive. The end float measurements should now be within the tolerance for all shafts. If any measurement is still outside the tolerance, repeat step 53.

56

Turn the gearbox into the horizontal position. Fit new 'O' ring 64 to the oil pump assembly. Refit the oil pump assembly and secure with new washers 62 and bolts 61. Torque tighten to 28 Nm (20.7 lbf ft). Make sure that the pump rotors rotate.

Screw a lifting eye into a brake housing bolt hole of the rear casing 37. Using a suitable hoist, lift the rear casing into position over the front casing 38. Carefully lower the rear case onto the front case, ensuring that the locating pegs are fully engaged. Secure the casings with bolts 36. Torque tighten to 56 Nm (41.3 lbf ft).

Remove the lifting eye.

S203980

57

Pack the cavity between the lips of both front and rear output shaft oil seals 17 with grease and fit the seals.

58

Fit the front and rear output yokes 15 and secure with washers 14 and new stake nuts 13. Do not fully tighten at this stage. Align the front and rear output yokes ensuring that the staking slot can be reached when the stake nut is fully tightened. Note that some gearbox variants may have a flange headed bolt fitted instead of items 13 and 14.

59

Fit the gear change turret 19 with a new gasket 20 and secure with setscrews 18. Torque tighten to 56 Nm (41.3 lbf ft).

60

Fit oil inlet adaptor 65 with new sealing washer 66 into the rear casing. Torque tighten to 102 Nm (75.2 lbf ft).

61

Fit taper plug 67. Torque tighten to 56 Nm (41.3 lbf ft).

S203991

52

Repeat end float measurements, as detailed in steps 15 to 36 inclusive, to check that end float on all shafts remains within the tolerance of 0.03 to 0.08 mm (0.001 - 0.003 in).

9803/9060

Issue 1

Section 5 7-8

Transmission Gearbox (with internal parking brake)

Section 5 7-8

Assembly (Cont'd) Note: Before assembling the parking brake, ensure the housing has been thoroughly cleaned.

62

30 k.p.h. Gearbox Position the output yokes so that the staking slots are accessible. Assemble the parking brake in the following order: disc springs 35 (see note), annular pressure plate 33, reaction pins 34 (3 off), and, alternately, counter plate 31 (10 off) and friction plates 32 (9 off).

62A 20 k.p.h. Gearbox Position the output yokes so that the staking slots are accessible. Assemble parking brake in the following order: disc springs 35 (see note), annular pressure plate 33, reaction pins 34 (3 off), alternately, counter plates 31 (7 off) friction plate 32 (6 off), and pressure plate 30.

63

Note: Two sizes of spacer M are available. The reaction pin 34 must protrude above the spacer by 2.1 to 3.7 mm (0.082 to 0.146 in.) as shown. Select the appropriate size spacer M that will achieve this dimension when assembled. To measure the amount of protrusion of the pin, use the short setscrews 22 to bolt down the spacer M and compress the brake pack.

62B 20 k.p.h. Gearbox - Optional Uprated Parking Brake An optional 7 friction plate brake is available which utilises parts of the 30 k.p.h. version, together with new items detailed below.

Assemble the parking brake in the following order: Heavy duty disc springs 35 (new part no. 814/10105) (see Note), annular pressure plate 33, reaction pins 34 (3 off), now install counter plate 31 (1 off) followed by alternate friction plate 32 (7 off) with counter plates 31 (6 off), next fit counter plates 31 (6 off) followed by spacer M with gasket 25 (2 off) and end cover 24.

2.1 to 3.7 mm (0.082 to 0.146 in)

M

34 A221441

63A 20 k.p.h. Gearbox Fit new 'O' ring 27 to brake piston 26. Fit piston into brake end cover 24. Fit a new gasket 25 onto the brake end cover mounting face. Fit the cover and loosely secure with setscrews 23 (2 off) and 22 (4 off).

M

A343980

64

Assemble the brake feed pipe 21 between the brake housing and the rear cover.

65

Torque tighten the brake end cover retaining setscrews 23 and 22 to 56 Nm (41.3 lbf ft) and the brake feed pipe 21 nuts to 22 Nm (16.2 lbf ft).

66

To check that the brake releases, remove brake cover centre setscrew 28 and spacer 29. Refit the setscrew without spacer. Screw in setscrew whilst attempting to turn one of the gearbox output yokes. When the yoke begins to turn the brake has released. Unscrew the setscrew whilst turning an output yoke until the yoke cannot be turned. This confirms that the brake is on.

Refit spacer 29 onto the setscrew. Apply Loctite 242 to the threads of the setscrew and refit to the brake cover.

Torque tighten to 56 Nm (41.3 lbf ft).

67

Fit adaptor block assembly 11 and new gasket 12 to the rear casing. Secure with setscrews 10 and torque tighten to 10 Nm (7.4 lbf ft).

68

Fit new 'O' rings 9 to the underside of solenoid valve 8.

Fit solenoid onto the adaptor block assembly 11, ensuring that 'O' rings remain in position in solenoid base. Secure solenoid valve using cap screws 6 (4 off).

Torque tighten to 5.8 Nm (4.3 lbf ft).

The brake also utilises a high pressure solenoid adapter block (part no. 445/75600).

Note: Make sure that the disc springs 35 are installed the correct way, as shown below. Inspect disc springs for damage or excessive wear. If necessary renew the springs.

35

A204620

9803/9060

30 k.p.h. Gearbox Fit new 'O' ring 27 to brake piston 26. Fit piston into brake end cover 24. Fit new gaskets 25 and spacer M (see Note). Fit the cover and loosely secure with setscrews 23 (2 off) and 22 (4 off).

Issue 1

Section 5 7-9

Transmission Gearbox (with internal parking brake)

Section 5 7-9

Assembly (cont'd) 69

Assemble the pressure maintaining valve spool and spring 68 into adapter block 11. Apply Loctite 242 to the threads of the plug and tighten. Do not overtighten as damage to the aluminium housing could result.

70

Fit a new gasket 5 to a clean suction strainer 4 and insert into the casing. Apply Loctite 242 to the threads of setscrews 3 (2 off) and torque tighten to 10 Nm (7.4 lbf ft).

S203970

71

Torque tighten the output yoke stake nuts 13 to 350 Nm (258.2 lbf ft). Stake the nuts using a square ended staking tool. Note that some gearbox variants may have a flange headed bolt fitted instead of item 13.

72

Fit drain plug 1 with new sealing washer 2. Torque tighten to 102 Nm (75.2 lbf ft).

73

Fit a new oil filter.

9803/9060

Issue 1

Section 5 7 - 10

9803/9060

Transmission Gearbox (with external parking brake)

Section 5 7 - 10

Issue 1

Section 5 7 - 11

Transmission Gearbox (with external parking brake)

Section 5 7 - 11

Dismantling 1

Drain the oil from the casing into a suitable container by removing the drain plug 1 and sealing washer 2. Discard the sealing washer.

2

Remove suction strainer retaining bolts 3 and remove the strainer 4. Remove and discard the strainer cap gasket 5.

3

Remove and discard the oil filter.

10

Remove the adaptor block assembly retaining setscrews 10 (4 off) and remove the block 11. Remove and discard the gasket 12. Remove pressure maintaining valve spool and spring 68.

11

Remove the casing retaining bolts 36.

12

Screw a lifting eye into a layshaft end cover bolt hole.

Using a suitable hoist, lift the rear casing 37 away from the front casing 38. Pry bars may be used at the points provided to assist in 'cracking' the joint. Remove and discard the face 'O' rings 39 and 40.

S203970

4

Position the gearbox with the rear casing 37 uppermost.

5

Unscrew capscrews 6 (4 off). Remove the solenoid valve assembly 8 and discard the 'O' rings 9 (4 off).

6

Remove output yoke 15 and brake disc 15A attachment bolts 13 using service tool 892/00812. Remove yoke 15 and brake disc 15A from the output shaft 16. Note that some gearbox variants may have stake nuts and washers fitted instead of item 13. Discard the stake nuts if fitted.

7

Remove and discard the output shaft oil seals 17.

8

Remove the gear change turret retaining bolts 18 (4 off).

Remove the turret 19 and gasket 20. Discard the gasket.

9

Remove layshaft cover plate retaining bolts 22 (6 off), remove cover plate 24, discard gasket 25.

9803/9060

S203991

Issue 1

Section 5 7 - 12

9803/9060

Transmission Gearbox (with external parking brake)

Section 5 7 - 12

Issue 1

Section 5 7 - 13

Transmission

Section 5

Gearbox (with external parking brake)

7 - 13

Dismantling (cont'd) 13

Remove the output shaft assembly 41.

26

14

Remove locking screws 42 (2 off) from selector forks 44 and 45.

Remove the bearing cups located in the rear casing using a slide hammer.

Assembly

15

Remove the detent plugs 46, springs 47 and balls 48 (2 off each).

16

Slide selector shafts 49 from selector forks 44 and 45.

17

Remove taper plug 50 from the casing. Thread a piece of thin looped wire to the bottom of the RH selector shaft locating hole. Using a small diameter screwdriver through the taper plug hole, push the baulk roller 51 into the wire loop. Carefully withdraw the baulk roller.

1

Clean the mating faces of front casing 38 and rear casing 37.

2

Fit new bearing cups into front and rear casings using a bearing dolly.

18

Remove the layshaft assembly 52.

3

Fit the idler shaft 60 using a soft faced hammer.

19

Remove the main shaft assembly 53.

4

20

Remove the reverser unit 54. For dismantling and assembly instructions, refer to Reverser Unit Dismantling and Assembly.

Fit the idler gear assembly (thrust washers 56, thrust bearing 57, needle roller bearings 59, bearing spacer 59A, idler gear 58, thrust washers 56, thrust bearing 57 and idler gear spacer 55).

5

Fit the reverser unit 54.

6

Fit the main shaft assembly 53.

7

Fit the layshaft assembly 52.

8

Fit the output shaft assembly 41.

9

Thread the RH gear selector rod 49 through selector fork 45 and into the casing. Secure with locking screw 42. Torque tighten to 35 Nm (25.8 lbf ft).

10

Using a piece of looped wire, lower the baulk roller 51 down the LH selector rod channel in the casing. When in position at the bottom, push the roller into position using a small screwdriver through the taper plug hole (item 50). Remove the wire and screwdriver. Fit the taper plug 50 and torque tighten to 28 Nm (20.7 lbf ft).

11

Thread the LH selector rod 49 through selector fork 44 and into the casing. Secure with locking screw 42.

Torque tighten to 35 Nm (25.8 lbf ft).

12

Fit detent balls 48, springs 47 and plugs 46 (2 off each).

Torque tighten plugs to 35 Nm (25.8 lbf ft).

13

Screw a lifting eye into a layshaft housing bolt hole of the rear casing 37. Using a suitable hoist, lift the rear casing into position over the front casing 38. Carefully lower the rear casing onto the front casing, ensuring that the locating pegs are fully engaged. Secure the casings with six equally spaced bolts 36. Torque tighten to 56 Nm (41.3 lbf ft). Remove the lifting eye.

21

Remove idler gear spacer 55, thrust washers 56, thrust bearing 57, idler gear 58, needle roller bearings 59, bearing spacer 59A, thrust washers 56 and thrust bearing 57 from idler shaft 60.

22

Remove the idler shaft 60 using a slide hammer if necessary.

23

Remove the bearing cups located in the front casing using a slide hammer.

24

Turn the gearbox into the horizontal position.

25

Remove the pump assembly retaining bolts 61 (4 off) and withdraw the pump assembly 63 from the front casing. Discard the washers 62 (4 off) and 'O' ring 64.

Note: All bearings must be lightly oiled before assembly.

Make sure all components are thoroughly clean and renew all 'O' rings.

S203980

9803/9060

Issue 1

Section 5

Transmission

Section 5 7 - 14

Gearbox (with external parking brake)

7 - 14

Assembly (cont'd) 20

Shaft End Float Measurements

Calculate the required shim thickness.

Example: 14

Clean the layshaft end cover mating face.

15

Using service tool kit 993/59400, fit base plate A onto the layshaft end cover mating face and secure with socket head set screws B. Torque tighten to 56 Nm (41.3 lbf ft).

a

End Float Tolerance : 0.03 to 0.08 mm. (Identical clearance for all shafts.)

b

Measured End Float : 0.20 mm

c

To give an end float within the tolerance, subtract 0.05mm from dimension at para. b for the required shim thickness, e.g., 0.20 - 0.05 = 0.15 mm.

16

Pass the adaptor C through the large diameter hole in the base plate and screw into the end of the layshaft.

17

Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E on the base plate and secure with bolts F. Tighten the bolts.

21

Remove the bolts F securing the lever unit mounting blocks E and remove the lever unit. Unscrew and remove the adaptor C.

Fit a magnetic base dial test indicator (DTI) G onto the base plate with the pin resting on the top of the adaptor.

22

Remove taper plug 67.

23

Fit the short extension H to the adaptor C.

24

Using a lever, put the gearbox in gear.

25

Screw the adaptor into the end of the main shaft. Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E in the appropriate position on the base plate A and secure with bolts F. Tighten the bolts.

26

Fit a magnetic base DTI G onto the base plate with the pin resting on the top of the adaptor.

27

Measure main shaft end float and determine shim thickness by repeating steps 19 and 20. Refer to view X.

18

19

Measure layshaft end float as follows (refer to view W): a

b

Using a torque spanner on the nut of the lever unit as shown, apply a torque of 30 Nm (22.1 lbf ft) clockwise while turning the output shaft backwards and forwards using a turning handle. Zero the DTI. Apply a torque of 30 Nm (22.1 lbf ft) anti-clockwise while turning the output shaft backwards and forwards using a turning handle. Take the layshaft end float reading from the DTI.

S204020

W 9803/9060

X

S204030

Issue 1

Section 5

Transmission

Section 5

Gearbox (with external parking brake)

7 - 15

7 - 15

Assembly (cont'd) 28

Temporarily refit taper plug 67.

29

Remove short extension from adaptor.

30

Fit the rear output yoke 15 and attachment bolt 13.

Torque tighten to 350 Nm (258.2 lbf ft).

31

Fit the output yoke adaptor J and secure with bolts K. Torque tighten to 22 Nm (16.2 lbf ft). Screw the adaptor C into the yoke adaptor extension L until tight.

32

Fit the lever arm pegs D into the adaptor annular space.

Position the lever unit mounting blocks E in the appropriate position on the base plate A and secure with bolts F. Tighten the bolts.

33

Fit a magnetic base DTI G onto the base plate with the pin resting on the top of the adaptor.

34

Measure the output shaft end float and determine shim thickness by repeating steps 19 and 20. Refer to view Y.

39

Clean the mounting face of the flywheel housing. Mount the DTI on the face with the probe resting on the end of the reverser unit shaft. Firmly press the reverser unit shaft in to take up any shaft end float. Zero the DTI. Refer to view Z.

40

Screw a threaded bolt or rod into the threads exposed when oil inlet adaptor 65 was removed, until it touches the end of the reverser unit shaft.

Z

S204050

41

Screw bolt or rod in further (approx. 10 Nm; 7.4 lbf ft) whilst turning output shaft. Stop when increasing resistance is felt. DO NOT overtighten. Take the DTI reading.

Y

42

Calculate the required shim thickness as detailed in step 20.

35

Remove the lever unit, adaptor, base plate and output yoke adaptor.

43

Remove bolt or rod and the DTI. Temporarily refit oil inlet adaptor 65 and sealing washer 66.

36

Remove the attachment bolt 13 and output yoke 15.

44

37

Remove oil inlet adaptor 65 and sealing washer 66 from the rear casing.

Turn the gearbox into the vertical position, with the rear casing upwards.

45

Screw a lifting eye into a layshaft end cover bolt hole.

Using a suitable hoist, lift the rear casing 37 away from the front casing 38. Pry bars may be used at the points provided to assist in 'cracking' the joint. Turn the rear casing over.

S204010

38

Turn the gearbox into the horizontal position.

9803/9060

Issue 1

Section 5 7 - 16

Transmission Gearbox (with external parking brake)

Section 5 7 - 16

Assembly (cont'd) 46

Using a bearing puller, remove the layshaft bearing cup from the rear casing. Referring to the shim thickness calculation for the layshaft 52, fit the required shims into the rear casing. Using a bearing dolly, refit the layshaft bearing cup.

47

Repeat step 46 for the main shaft 53, output shaft 41 and reverser unit 54.

48

Turn the rear casing over.

49

Fit the face 'O' rings 39 and 40 into the front case mating face recesses.

50

Apply a bead of sealant to the front case mating face, smoothing the sealant around the 'O' ring areas.

51

53

If any measurement is outside the tolerance, remove rear casing, see step 45. Using a bearing puller, remove the bearing cap(s) of the shaft(s) that is outside the tolerance. Add or remove shim(s) to bring the measurement(s) within the tolerance. Using a bearing dolly, refit the bearing cup(s) into the rear casing.

54

Remove the front case 'O' rings 39 and 40 and clean the sealant from the front case mating face.

55

Repeat steps 49 to 52 inclusive. The end float measurements should now be within the tolerance for all shafts. If any measurement is still outside the tolerance, repeat step 53.

56

Turn the gearbox into the horizontal position. Fit new 'O' ring 64 to the oil pump assembly. Refit the oil pump assembly and secure with new washers 62 and bolts 61. Torque tighten to 28 Nm (20.7 lbf ft). Make sure that the pump rotors rotate.

Screw a lifting eye into the layshaft end cover bolt hole of the rear casing 37. Using a suitable hoist, lift the rear casing into position over the front casing 38. Carefully lower the rear case onto the front case, ensuring that the locating pegs are fully engaged. Secure the casings with bolts 36. Torque tighten to 56 Nm (41.3 lbf ft).

Remove the lifting eye.

S203980

S203991

52

Repeat end float measurements, as detailed in steps 15 to 36 inclusive, to check that end float on all shafts remains within the tolerance of 0.03 to 0.08 mm (0.001 0.003).

9803/9060

57

Pack the cavity between the lips of both front and rear output shaft oil seals 17 with grease and fit the seals.

58

Fit the rear output yoke 15 and front output brake disc 15A and secure with attachment bolts 13. Do not fully tighten at this stage. Note that some gearbox variants may have stake nuts and washers fitted instead of item 13. Use new stake nuts if fitted.

59

Fit the gear change turret 19 with a new gasket 20 and secure with setscrews 18. Torque tighten to 56 Nm (41.3 lbf ft).

60

Fit oil inlet adaptor 65 with new sealing washer 66 into the rear casing. Torque tighten to 102 Nm (75.2 lbf ft).

61

Fit taper plug 67. Torque tighten to 56 Nm (41.3 lbf ft).

Issue 1

Section 5 7 - 17

Transmission Gearbox (with external parking brake)

Section 5 7 - 17

Assembly (cont'd) 62

Fit a new gasket 25. Fit the layshaft end cover 24 and secure with setscrews 23 (2 off) and 22 (4 off). Torque tighten to 56 Nm (41.3 lbf ft).

63

Fit adaptor block assembly 11 and new gasket 12 to the rear casing. Secure with setscrews 10 and torque tighten to 10 Nm (7.4 lbf ft).

64

Fit new 'O' rings 9 to the underside of solenoid valve 8.

Fit solenoid onto the adaptor block assembly 11, ensuring that 'O' rings remain in position in solenoid base. Secure solenoid valve using cap screws 6 (4 off).

Torque tighten to 5.8 Nm (4.3 lbf ft).

65

Assemble the pressure maintaining valve spool and spring 68 into adapter block 11. Apply Loctite 242 to the threads of the plug and tighten. Do not overtighten as damage to the aluminium housing could result.

66

Fit a new gasket 5 to a clean suction strainer 4 and insert into the casing. Apply Loctite 242 to the threads of setscrews 3 (2 off) and torque tighten to 10 Nm (7.4 lbf ft).

S203970

67

Torque tighten the output yoke and brake disc attachment bolts 13 to 350 Nm (258.2 lbf ft). Note that some gearbox variants may have stake nuts and washers fitted instead of item 13. If fitted, stake the nuts using a square ended staking tool.

68

Fit drain plug 1 with new sealing washer 2. Torque tighten to 102 Nm (75.2 lbf ft).

69

Fit a new oil filter.

9803/9060

Issue 1

Section 5

Transmission Solenoid Valve

8-1

Section 5 8-1

Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling.

Note: It is not normally recommended to remove the spool 12 from the valve body. None of the component parts of the CETOPS valve assembly can be renewed individualy. The extent of permissible servicing is cleaning and the consequential renewal of ‘O’ rings seals. If damage to any component or distortion of the spool is evident the complete valve assembly must be renewed.

Great care should be taken when dismantling and assembling the valve to avoid the following:

• Contamination • Damage to spools • Damage to seal grooves Any of the above may result in possible problems with the operation of the valve.

For assembly the sequence should be reversed.

For clarity, only one solenoid has been numbered in the dismantling sequence.

Dismantling 1

Remove the surface mounted ‘O’ rings 1.

2

Unscrew the knurled nut 2 and remove O-ring 3, withdraw the solenoid 4 and O-ring 5.

3

Hold the solenoid valve body 6 in a vice, using the spanner flats A, remove spindle 7 and O-ring 8.

4

Pull out actuating pin 9, spring 10, spring retainer 11 and spool 12.

5

Dismantle the opposite solenoid in the same sequence as described above.

6

Inspect the spool and spool bore for signs of wear, nicks scratches etc.

161590

Assembly 1

Renew all O-rings.

2

Lightly lubricate all parts with clean transmission fluid before assembling.

3

Check that the flying leads are secure and that the connectors are intact.

4

Apply a small quantity of Loctite 242 to the threads in the knurled nut 2 before fitting.

Torque Settings Item 2

Nm 10-15

9803/9060

kgf m 1-1.5

lbf ft 8-10 Issue 1

Section 5

Transmission

Section 5 9-1

Reverser Unit

9-1

Dismantling 1

Carefully remove the piston ring seals 1 (3 off).

Note: If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.

2

Remove the stake nut 1A as follows. a

Carefully prise away the staked area of the nut.

b

Clamp the holding fixture (service tool 892/01065) in the jaws of a vice as shown at A.

c

Locate the clutch assembly into the holding fixture.

d

Undo the nut using the adaptor spanner (service tool 892/01064) and a 1/2� square drive socket wrench as shown at B.

Note: The nut must be discarded - DO NOT re-use.

3

Turn the assembly over and knock the clutch shaft on a wooden block to loosen the clutch end bearing 2.

Remove the bearing using pullers.

4

Remove the thick thrust washer 3, thrust bearing 4 and thin thrust washer 5.

5

Withdraw the gear and splined hub assembly 6 and the needle roller bearing 7.

6

Remove the thin thrust washer 8, thrust bearing 9 and thick thrust washer 10.

A

B

A388080

9803/9060

Issue 1

Section 5

Transmission Reverser Unit

9-2

Section 5 9-2

Dismantling (cont'd) 7

Remove the clutch friction/counter plate retaining circlip 11.

8

Remove the thick pressure end plate (6mm thick) 13.

Note: There may also be shims fitted item 12.

9

Remove clutch friction plates 14 (4 off) and counter plates 15 (4 off). Keep plates together in sets, DO NOT mix with those from other clutches.

10

Remove the thin pressure plate (4mm thick) 13A.

11

Remove the disc springs 16. Note that some units may have only one disc spring fitted as shown A.

A Single spring type

Double spring type

A407530

9803/9060

Issue 1

Section 5 9-3

Transmission Reverser Unit

Section 5 9-3

Dismantling (cont'd) 12

Position clutch assembly in a suitable press to compress the piston spring then remove circlip 17.

S145000

13

Lift off spring retaining plate 18.

14

Remove spring 19 and oil baffle plate 20.

15

Turn the assembly over and knock the clutch shaft on a wooden block to loosen the piston 21.

Note: If the piston does not loosen, hand pump air down the shaft oil inlet hole.

16

Remove the piston 21. Remove and discard the piston 'O' ring 22 and shaft 'O' ring 23.

17

Dismantle the opposite clutch assembly (torque converter end) by repeating steps 1 to 16. Note that the clutch shaft has only one piston ring seal 1 fitted at the torque converter end.

9803/9060

Issue 1

Section 5

Transmission

Section 5 9-4

Reverser Unit

9-4

Assembly The assembly procedure is the reverse of the dismantling procedure.

8

Fit thrust washers 10 and 8 and thrust bearing 9.

9

Carefully align teeth of clutch plates using a thin rod or screwdriver. Fit gear and splined hub assembly 6.

10

Fit needle roller bearing 7, thrust washers 5 and 3 and thrust bearing 4.

11

Pack the clutch end bearing with Mobil HP222 Grease and press the bearing onto clutch shaft.

12

Fit a new stake nut 1A and torque tighten to 200 Nm (147.5 lbf ft).

Make sure all components are thoroughly clean prior to assembly. Renew all 'O' rings.

1

Fit new ‘O’ rings 22 and 23 to the piston and shaft.

Lubricate the piston 21 with hydraulic oil and press fully into bore of clutch housing.

2

Fit oil baffle 20, spring 19 and spring retaining plate 18.

3

Compress spring and fit circlip 17.

4

Fit the disc spring assembly 16 and the thin pressure plate (4mm thick) 13A.

5

Fit counter plates 15 and friction plates 14 alternately, starting with a counter plate.

6

Fit the thick pressure end plate (6mm thick) 13 and clutch friction/counter plate retaining circlip 11. Using an air line blow air down the shaft oil inlet hole and check the piston and clutch pack is free to operate smoothly.

7

Note: To tighten the nut locate the clutch assembly into the holding fixture (service tool 892/01065) as shown in dismantling and use the adaptor spanner (service tool 892/01064) and a 1/2” square drive torque wrench.

13

Re-stake the nut using a square ended staking tool as shown at B.

14

Fit piston ring seals.

15

Assemble the opposite clutch assembly (torque converter end) by repeating steps 1 to 14.

Using a dial test indicator as shown at A, measure the end float of the pressure end plate 13, which should be 2.0 to 3.3 mm (0.079 to 0.130 in). If the float is above 3.3mm (0.130 in), fit shim 12 between the retaining circlip and pressure end plate to bring end float within tolerance. If the float is below 2.0 mm (0.079 in), remove the thin pressure plate (4mm thick) 17 at piston end and replace with a counter plate 13, then shim as necessary to bring end float within tolerance.

B

A

A388110

S191420

9803/9060

Issue 1

Section 5 9-5

Transmission Reverser Unit

Section 5 9-5

Piston Ring Seals - Fitting Procedure 1

Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a 'coil'.

157250

2

Smear the seal with grease and then fit the seal to the shaft.

Make sure that the seal sits below or flush with the outer diameter of the shaft. If necessary, use finger pressure as shown to make the seal flush with the shaft.

CAUTION: If the seal is not set below or flush with the outer diameter of the shaft, then the seal will 'cut' when the shaft is fitted to its mating component.

9803/9060

Issue 1

Section 5

Transmission

Section 5 11 - 1

Power Take-Off Clutch

11 - 1

Dismantling and Assembly

20

21

27 19 28

18 26 17

24

25

23

16

22 29A 32 31 30

29 34

35

33

36

38 3

7

37

2

8 9 10

1 15 14

11 12

13 6 5 4

39 9803/9060

S407280

Issue 1

Section 5

Transmission Power Take-Off Clutch

11 - 2

Section 5 11 - 2

Removal and Replacement

Dismantling and Assembly

Removal

Idler Assembly

Note: If the PTO clutch is to be dismantled, the coupling nut 4 should be loosened before the clutch is removed from the gearbox.

The idler assembly (items 33 - 37) can be dismantled after the PTO clutch has been removed and must be assembled before the PTO is replaced. Withdraw shaft 33 using an impulse extractor screwed into the M12 tapped hole in the end of the shaft, then remove the remaining components via the PTO cavity. Assembly is the reverse of the dismantling sequence.

1

Disconnect the hydraulic pipe connection from the PTO housing. Plug the exposed connections to prevent ingress of dirt. Remove the power take off solenoid flying leads.

2

Loosen and remove the bolts 1 which secure the PTO housing 2 to the gearbox.

Dismantling

3

Carefully lift the PTO clutch from the gearbox. Remove and discard gasket 3.

Replacement Replacement is the reverse of the removal procedure.

Renew all seals and gaskets.

Torque tighten bolts 1.

When fitting nut 4, torque tighten as indicated then split the nut sleeve axially using a square ended staking tool. (This operation may be easier performed after the clutch has been replaced in the gearbox.)

Torque Settings Item 1 4

Nm 56 350

Ibf ft 41 258

kgf m 5.7 35.7

Follow the numerical sequence on the illustration to dismantle the unit, noting the points listed below.

Use suitable screws, inserted into the threaded holes provided, to remove the brake piston 10. Remove and discard the ‘O’ rings.

Bearing 18 is in two parts. The inner of bearing 18 will always remain on the clutch shaft when the clutch is removed.

Dismantling of the clutch assembly 7 will be easier if it is secured in a soft-jawed vice, coupling end lowermost.

Remove the gear 19 with spacer 20 and bearing 18 using a puller.

Thrust washer 28 and ring 27 should be removed using a bearing puller applied to thrust washer 28. Discard ring 27.

Take care not to damage the clutch housing and the oil holes in the end of the shaft when using the puller. Remove and retain spring 29 and plastic washer 29A. Note: Do not attempt to lever off these components. Always use the correct tool.

The clutch pack comprises alternate friction plates 24 and counter plates 25, beginning and ending with a friction plate.

The pack is sandwiched between two spacers 23 and 26, and secured by circlip 22. Retain these items as a set for assembly.

Note that the clutch housing cannot be removed from the shaft.

Discard all seals and ‘O’ rings.

9803/9060

Issue 1

Section 5

Transmission

Section 5 11 - 3

Power Take-Off Clutch

11 - 3

Dismantling and Assembly

B

20

21

27 19 28

18 26 17

A406091

24

25

23

16

22 29A 32 31 30

29 34

35

33

36

38 3

7

37

2

8 9 10

1 15 14

11 12

13 6 5 4

39 9803/9060

S407280

Issue 1

Section 5

Transmission Power Take-Off Clutch

11 - 4

Section 5 11 - 4

Dismantling and Assembly (cont’d) Inspection

Brake Operation

Thoroughly clean all components. Ensure that all oil ways are clear.

With the assembly mounted on the gearbox, check the operation of the clutch brake as follows:

Inspect generally for damage. Check for scoring inside the piston housing and at the oil feed end of the shaft. Polish out if necessary.

With no electrical power or pressure connected, check that the coupling 6 is free to rotate.

Check the operation of the non-return valve located in piston 30.

With air pressure connected to the solenoid valve 39 and the solenoid de-energised, check that the coupling cannot be rotated (i.e. brake on).

Check the clutch pack for damage and excessive wear.

Renew the complete set of friction and counter plates if necessary. Do not mix plates from different clutch packs.

With air pressure connected and the solenoid energised, check that the coupling can be rotated back and forth as far as the gear backlash allows (i.e. brake off).

Check the condition of brake disc 8. Renew if necessary.

Note: The solenoid can be damaged if it is connected the wrong way round. Ensure correct polarity before applying power.

Assembly Assembly is the reverse of the dismantling sequence, but please note the following: Use new seals and ‘O’ rings. Lightly oil components before installing them.

Pack the cavity between the lips of seal 13 with grease before assembly.

Thrust washer 28 should be installed using a bearing press, ensuring that the plate is pressed squarely onto its shoulder on the shaft. Ring 27 should similarly be installed using a bearing press.

When installing the clutch pack, ensure that the friction/counter plates are installed in the correct sequence, see Dismantling. Note that there are seven friction plates 24, and six counter plates 25. Use the gear assembly 19 to align the inner teeth of the friction plates.

Lightly oil bearings 15, 18 and 21 before installing and rotate them during setting.

After assembly, and using an airline, check that the clutch operates smoothly and that there is endfloat.

Using a dial test indicator as shown at B, measure the clutch pack endfloat. The clutch pack endfloat should be 1.3 - 3.6 mm. If incorrect, check for damage, correct assembly and that the correct number of clutch plates have been installed.

Note that shims are not necessary.

Fitting nut 4 may be easier performed after the clutch has been replaced in the gearbox, see Removal and Replacement.

Torque Settings Item 39

Nm Ibf ft kgf m 47 - 54 35 - 40 4.8 - 5.5

9803/9060

Issue 1

Section 5

Transmission

Section 5 12 - 1

Transfer Gearbox - TG150

12 - 1

Removal and Replacement Removal

Replacement

1

Remove plug A and drain the oil into a container.

Replacement is the reverse of the removal procedure.

2

Support the gearbox and remove the top 2 bolts C, remove propshaft guard, not shown.

1

Clean and grease the gearbox drive splines and driveshafts.

3

Remove lower bolt C and lift the gearbox clear of the machine.

2

Align the power take off gearbox driveshaft.

3

Make sure the WARNING label on the PTO guard is in good condition and is legible.

4

Fit drain plug A, use a new seal.

5

Fill the gearbox with the recommended oil through the fill/level plug B.

Item A B

Nm 102 102

lbf ft 75 75

kgf m 10.4 10.4

C B A C C 9803/9060

Issue 1

Section 5 12 - 2

Transmission

Section 5 12 - 2

Transfer Gearbox - TG150

Dismantling and Assembly Dismantling

Assembly

1

Remove bolts 11 (9 off) and separate casing 1 and 2.

Assembly is the reverse of the dismantling sequence, but note the following.

2

Remove circlip 9 and remove gear 3. Driveshaft 5 can now be removed.

1

Use new seals and ‘O’ rings. Lightly oil components before installing them.

2

Fit seals flush with the outer edge of casing, pack the cavity between the lips of seals 10 and 6 with grease before assembly.

3

Clean mating faces of casing 1 and 2, use Loctite 574 to reseal.

Torque Settings Item 11

Nm 56

lbf ft 41

kgf m 5.7`

A303950

9803/9060

Issue 1

Section 5

Transmission

14 - 1

Section 5

Fault Finding

14 - 1

Synchro Shuttle Gearbox - Hydraulics Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used.

LACK OF POWER Possible Cause 1 Poor engine condition.

2 Low oil level.

3 Worn pump.

4 Torque converter damage.

5 Low mainline pressure.

6 Clutches slipping.

7 Internal leakage.

8 9 10

High stall speeds.

Low stall speeds.

Overheating.

LOW MAINLINE PRESSURE (in neutral) Possible Cause 1 Worn pump.

2 Blocked suction strainer.

3 Pressure maintaining valve sticking/leaking.

4 Oil aerated (foaming).

5

Oil leak through parking brake on/off circuit.

(Gearboxes with internal parking brake only)

HIGH STALL SPEEDS (Forward & Reverse Clutches) Possible Cause 1 Damaged converter blades.

2 Clutches slipping.

3 Internal leakage.

Remedy 1 Check and if necessary repair engine.

2 Top up system.

3 Check flow and if necessary repair or renew pump.

4 Check and if necessary repair or renew torque converter.

5 See fault 'Low Mainline Pressure'.

6 See fault 'Low Clutch Pressure'.

7 a) Check internal cored galleries and casting for porosity. b) Check condition of seals.

8 See fault 'High Stall Speeds'.

9 See fault 'Low Stall Speeds'.

10 See fault 'Overheating'.

Remedy 1 Check flow and if necessary repair or renew pump.

2 Clean suction strainer.

3 Free off or renew valve.

4 a) Internal leakage (cored galleries) - inspect/repair transmission. b) Dirty suction strainer - clean strainer. c) High oil level - drain to proper level. d) Incorrect grade of oil - drain then refill with correct oil.

5 a) Check external pipework for parking brake circuit. b) Check parking brake (pressure) circuit - refer to Fault Finding - Internal Parking Brake. c) Disconnect parking brake and re-check.

Remedy 1 Check and if necessary renew converter.

2 See fault 'Low Clutch Pressure'.

3 a) Check internal cored galleries and casting for porosity. b) Check condition of seals.

LOW STALL SPEEDS (Forward & Reverse Clutches) Possible Cause 1 Poor engine condition.

2 Torque converter reaction member clutch slipping.

Remedy 1 Check and if necessary repair engine.

2 Check and if necessary renew torque converter.

LOW CONVERTER OUT PRESSURE Possible Cause 1 Low mainline pressure.

2 Converter internal leakage.

3 Converter relief valve faulty.

4 Restriction in converter feed.

Remedy 1 See fault heading 'Low Mainline Pressure'.

2 Check and if necessary renew converter.

3 Check and if necessary repair relief valve.

4 See item 10 in fault 'Overheating'

LOW PUMP FLOW Possible Cause 1 Low oil level.

2 Blocked suction strainer.

3 Worn pump.

Remedy 1 Top up system.

2 Clean suction strainer.

3 Repair or renew pump.

9803/9060

Issue 1

Section 5 14 - 2

Transmission Fault Finding

Section 5 14 - 2

Synchro Shuttle Gearbox - Hydraulics (cont'd) HIGH CONVERTER OUT PRESSURE Possible Cause 1 Oil cooler/lines blocked.

2 Converter in pressure incorrect 3 Converter relief valve faulty.

Remedy 1 Clean cooler, free blockage.

2 Check converter in pressure correct 3 Check and if necessary repair relief valve.

LOW LUBRICATION PRESSURE Possible Cause 1 Low mainline pressure.

2 Oil cooler/lines blocked.

3 Ruptured lubrication line.

4 Converter internal leakage.

5 Converter relief valve faulty.

6 Leak at pump to case joint (indicated by low cooler flow) 7 Restriction in converter feed

Remedy 1 See fault heading 'Low Mainline Pressure'.

2 Clean cooler, free blockage.

3 Repair line.

4 Check and if necessary renew converter.

5 Check and if necessary repair or renew relief valve.

6 Check and if necessary repair or replace as necessary.

7 See item10 in fault 'Overheating'

LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING Possible Cause 1 Low mainline pressure.

2 Worn pump.

3 Blocked restrictor orifice in F/R solenoid valve block.

(Both F/R clutches will indicate low pressure).

4 Clutch seals worn.

5 6

Clutch piston rings worn.

Mechanical failure.

LOW COOLER FLOW Possible Cause 1 Converter relief valve faulty.

2 Leak at pump to case joint .

3 Worn pump.

4 Internal leakage.

5

Restriction in converter feed.

OVERHEATING Possible Cause 1 Low oil level.

2 High oil level.

3 Trapped or kinked hoses in cooler system.

4 Low converter out pressure and flow rate.

5 Oil cooler blocked.

6 Operating in wrong gear range.

7 Water system overheating.

8 9 10

11

Oil aerated (foaming).

Clutch piston(s) sticking on return stroke.

Cored galleries on front housing pump mounting face wrong depth (indicated by excessively low pressure and flow on converter out cooling line).

Leakage across pump mounting face and front case.

9803/9060

Remedy 1 See fault heading 'Low Mainline Pressure'.

2 Check flow and if necessary repair or renew pump.

3 Remove F/R solenoid and clear restriction in solenoid valve block.

4 Confirm with a clutch leak test, if required renew clutch seals.

5 Confirm with a clutch leak test, renew piston rings.

6 Strip and rebuild clutch, renew parts as required.

Remedy 1 Check and if necessary repair or renew relief valve.

2 Check and if necessary repair or replace as necessary.

3 Check flow and if necessary repair or renew pump.

4 a) Check internal cored galleries and casting for porosity. b) Check condition of seals.

5 See item 10 in fault 'Overheating'.

Remedy 1 Top up system.

2 Drain oil to correct level.

3 Renew or repair hoses.

4 Repair or renew the converter relief valve.

5 Clean cooler.

6 Select correct gears to suit working conditions.

7 Rectify water system problems, eg radiator, cooler lines, low water level etc.

8 See fault 'Low Mainline Pressure', item 4.

9 Check and repair clutch piston(s) and seal(s).

10 Replace front housing (or rectify existing housing).

11

Check for damaged surface on both components and loose pump mounting bolts.

Issue 1

Section 5

Transmission

14 - 3

Section 5

Fault Finding

14 - 3

Synchro Shuttle Gearbox - Mechanical Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.

A

If the transmission is noisy, start at check 1.

B

If the transmission is overheating, start at check 4.

C

If the transmission will not pull, start at check 12.

D

If there is no drive in one or both directions, start at check 17.

E

If the transmission is jumping out of gear, start at check 29.

F

If the transmission is sticking in gear, start at check 39.

G

If ratios are 'crash changing', start at check 41.

CHECK

ACTION

1

Is there noise when selecting direction?

YES: Check 3 NO: Check 2

2

Is there noise when running with direction selector in neutral and ratio selector in a gear?

YES: Check 9 NO: Check 19

3

Is there air in the hydraulic system?

YES: Continue running to expel air.

NO: Check 4

4

Is the fluid level correct?

YES: Check 5 NO: Check level only when machine is cold and top-up as required.

5

Are the oil passages restricted?

YES: Clear the restriction.

NO: Check 6

6

Is the suction strainer restricted?

YES: Remove and clean strainer.

NO: Check 7

7

Is pump pressure as specified?

YES: Check 9 NO: Check clutch pressure maintenance valve is free to operate.

8

When flow testing pump, is output low?

YES: Renew pump.

NO: Check converter sprag clutch for wear or slip.

9

Does the noise continue when direction selector is in forward or reverse?

YES: Check 10 NO: Check 11

10

Is transmission misaligned?

YES: Renew mountings and check position.

NO: Check 'converter out' pressure and flow.

11

Are the pump bushes worn?

YES: Renew NO: Check converter for wear or cooler for restriction to flow.

12

Is the transmission not pulling in one direction only?

YES: Check 16 NO: Check 13

13

Is the transmission not pulling in both Forward and Reverse?

YES: Stall test machine, Check 14.

NO: Check 16

9803/9060

Issue 1

Section 5 14 - 4

Transmission

Section 5

Fault Finding

14 - 4

Synchro Shuttle Gearbox - Mechanical (cont'd) CHECK

ACTION

14

Is 'converter in' pressure as specified?

YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass relief valve pressure setting.

15

Is pump being driven by converter?

YES: Check pump pressure.

NO: Renew damaged parts.

16

Are clutch sealing rings damaged?

YES: Tap pressure gauge into clutch feed lines to monitor pressure.

NO: Check clutch plates for damage.

17

Is there drive in one direction only?

YES: Check 19 NO: Check 18

18

Is the start switch in the run position and supplying current to the neutral start relay?

YES: Check 19 NO: Rectify.

19

Is the fault only when the transmission is hot?

YES: Dismantle solenoid and check components.

NO: Check microswitches, relay and wiring loom.

20

Is the noise a growl, hum or grinding?

YES: Check gears for damage or wear.

NO: Check 21

21

Is the noise a hiss, thump or bumping?

YES: Check bearings for damage or wear.

NO: Check 22

22

Is the noise a squeal?

YES: Check free running gears for seizure.

NO: Check 23

23

Is the noise present when in neutral or when in gear? NEUTRAL: Check 24 IN GEAR: Check 27

24

Is the countershaft or its bearings worn or damaged?

YES: Renew damaged parts.

NO: Check 25

25

Is there excessive backlash in the gears?

YES: Adjust by checking shaft end float.

NO: Check 26

26

Is the mainshaft pilot bearing worn?

YES: Renew.

NO: Check gear teeth for scuffing.

27

Is the mainshaft rear bearing worn?

YES: Renew.

NO: Check 28

28

Are the sliding gear teeth worn or damaged?

YES: Renew gears.

NO: Check 29

29

Are the selector forks loose?

YES: Tighten screws.

NO: Check 30

30

Are the selector fork pads or grooves in gears worn?

YES: Renew worn parts.

NO: Check 31

31

Are the dog gear teeth worn?

YES: Renew.

NO: Check 32

32

Are the selector rod detent springs broken?

YES: Renew.

NO: Check 33

9803/9060

Issue 1

Section 5 14 - 5

Transmission

Section 5

Fault Finding

14 - 5

Synchro Shuttle Gearbox - Mechanical (cont'd) CHECK

ACTION

33

Are the selector rods worn or damaged?

YES: Renew.

NO: Check 34

34

Are the selector fork pads out of position?

YES: Reposition or renew (check interlock).

NO: Check 35

35

Is there excessive end float in gears or shafts?

YES: Adjust.

NO: Check thrust washers and mating faces.

36

Is the synchroniser bronze worn?

YES: Renew synchro pack.

NO: Check 37

37

Are steel chips embedded in the bronze?

YES: Continue using, chips will either embed below bronze or be rejected.

NO: Check 38

38

Are the synchroniser components damaged?

YES: Renew.

NO: Check free running gears for seizure or damage.

39

Are the sliding gears tight on the splines?

YES: Free or renew.

NO: Check 40

40

Are chips wedged between splines of shaft or gear?

YES: Remove chips.

NO: Ensure that clutch is disengaged when dump pedal is pressed.

41

Are steel chips embedded in the bronze?

YES: Continue using, chips will either embed below bronze or be rejected.

NO: Check 42

42

Are the synchroniser spring pins damaged?

YES: Renew synchro.

NO: Check 43

43

Is the synchroniser bronze worn?

YES: Renew synchro.

NO: Check blocker pins.

9803/9060

Issue 1

Section 5

Transmission

14 - 6

Section 5

Fault Finding

14 - 6

Internal Parking Brake BRAKE INOPERATIVE BUT TRANSMISSION FUNCTIONS IN FORWARD AND REVERSE CHECK

ACTION

1

Is distance spacer C fitted to centre bolt? (See Towing Procedure - Engine or Electrical Failure Condition)

YES: Check 2.

NO: Fit spacer.

2

Is the parking brake solenoid spool sticking?

YES: Free off or renew valve.

NO: Check 3.

3

Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire?

YES: Dismantle parking brake and check condition.

NO: Check 4.

4

Put the starter switch in 'IGN' position. Is there a voltage reading at the parking brake solenoid feed wire?

YES: Renew parking brake relay.

NO: Check switch and wiring.

BRAKE PERMANENTLY ENGAGED CHECK

ACTION

1

Is the parking brake solenoid spool sticking?

YES: Free off or renew valve.

NO: Check 2.

2

Put the starter switch in 'IGN' position. Disengage the parking brake, is there a voltage reading at the parking brake feed wire?

YES: Check 4.

NO: Check 3.

3

Put the starter switch in 'IGN' position. Is there a voltage reading at the parking brake solenoid feed wire?

YES: Check 4.

NO: Check switch and wiring.

4

Has the parking brake been dismantled recently?

YES: Dismantle and check for correct build.

NO: Check 5.

5

Is the transmission main line pressure correct?

YES: Check 6.

NO: See Fault Finding, Synchro Shuttle Gearbox Hydraulics.

6

Is the main line pressure correct with the parking brake circuit isolated?

YES: Dismantle parking brake and check condition.

NO: See Fault Finding, Synchro Shuttle Gearbox Hydraulics.

9803/9060

Issue 1

Section 5

Transmission

Section 5

Fault Finding

14 - 7

14 - 7

Power Take-Off Clutch FAULT

POSSIBLE CAUSE

ACTION

A

1

Solenoid valve faulty.

1

Dismantle solenoid valve and check component parts, renew valve if necessary.

2

Solenoid not energising.

2

Check electrical connections, switch, relay and wiring loom.

3

Insufficient hydraulic pressure.

3

Check hydraulic pressure at test point.

4

PTO brake not releasing/siezed.

4

Check.

1

Friction/counter plates in poor 1 condition/distortion.

B

PTO shaft does not turn.

Excessive PTO noise in operation.

9803/9060

Renew friction/counter plates.

Issue 1

Section 5

Transmission

Section 5

Fault Finding

14 - 8

14 - 8

Transmission Oil Contaminated with Water Carefully inspect the gearbox oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum permissible water content of the oil is 0.10%.

If the transmission oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before remedying, thoroughly investigate and rectify the cause of the water contamination.

Note: The recommended transmission oil is given in Lubricants and Capacities, Section 3.

Possible Cause

Remedy

1

Water ingress during filling/topping up.

Carry out flushing procedure.

Refill with the recommended grade of oil.

2

Missing/incorrect dipstick, damaged filler tube.

Renew missing/incorrect/damaged components.

Carry out flushing procedure.

Refill with the recommended grade of oil.

3

Machine operated in deep water.

Carry out flushing procedure.

Refill with the recommended grade of oil.

4

Gearbox casings damaged.

Inspect, renew damaged components.

Carry out flushing procedure.

Refill with the recommended grade of oil.

5

Gearbox oil circuit pipes/hoses damaged.

Inspect, renew damaged components.

Carry out flushing procedure.

Refill with the recommended grade of oil.

6

Oil cooler failure.

(Water cooled machine installations)

Inspect, renew damaged components.

Carry out cooler test procedure.

Carry out flushing procedure.

Refill with the recommended grade of oil.

Gearbox faults caused typically by water contamination and other factors related to the transmission oil:

1

2

3

Fault

Possible Cause

Remedy

Pressurisation of gearbox casing - Dipstick blows out/oil leaking from dipstick tube.

Water in oil combined with heat from torque converter causes steam.

Replace/renew dipstick.

Carry out flushing procedure.

Refill with the recommended grade of oil.

Gearbox over filled with oil.

Drain the oil level to the correct level, see Check Oil Level, Section 3.

Water ingress.

Renew friction plates.

Carry out flushing procedure.

Refill with the recommended grade of oil.

Overheating transmission oil.

See Fault Finding - Synchro Shuttle Gearbox - Hydraulics.

Water ingress.

Fit new bearings.

Carry out flushing procedure.

Refill with the recommended grade of oil.

Clutch Failure - Friction Lining Separation.

Badly worn/noisy bearings.

Insufficient lubrication.

9803/9060

Issue 1

Section 5 14 - 9

Transmission

Section 5

Fault Finding

14 - 9

Transmission Oil Contaminated with Water (cont’d) If the transmission cooler circuit becomes contaminated due to the ingress of water, stop the engine immediately. Drain the oil from the transmission sump and external cooler circuit into a suitable container.

Flushing Procedure 1

Reconnect the hoses to the cooler. Ensure the joints are clean and leakproof.

CAUTION: The oil could be hot, avoid contact with the skin to prevent scalds.

2

Renew the oil filter.

Inspection

3

Refill the transmission circuit with the recommended grade of oil.

Inspect the transmission generally for visible means of water entry into the system.

4

Start the engine and continue running for several minutes to reach normal operating temperature.

5

Stall the torque converter for 5 seconds.

6

Continue running the engine for 5 minutes.

Cooler Test Procedure

7

Repeat the torque converter stall for 5 seconds.

1

Remove the cooler from its mounting.

8

Continue this procedure for a period for up to 30 minutes, if possible during machine operation.

2

Drain remaining oil/water from the cooler.

9

3

Connect an air supply to the transmission oil inlet connection and plug and seal the outlet.

Drain the oil and fit a new filter. Test the oil for contamination.

10

Refill the transmission circuit with the recommended grade of oil.

Disconnect the transmission cooler circuit and clean thoroughly. The transmission cooler is a possible source of water contamination and should be tested for possible failure as follows:

4

Submerge the cooler in a tank of water and apply air pressure to test for leakage. If bubbles are visible the integrity of the cooler has broken down and the cooler should be scrapped.

Note: Air test pressure should not exceed 6 bar (90 lbf/in2).

5

If the cooler is not damaged, it should be cleaned and dried ready for reassembly onto the transmission.

After refilling the transmission with new oil, and the engine and transmission have returned to normal working temperature, the operator should periodically stall the torque converter for up to 5 second intervals to remove trapped water. To stall the torque converter, carry out the following procedure:

Note: If the oil drained at step 9 is clean and free from water contamination - return the transmission to service. If not, repeat flush and fill procedure.

General Procedure Between 50 and 100 hours operating time after cooler failure, drain the transmission cooler circuit and refill with the recommended grade of oil and renew the oil filter.

Oil should no longer show evidence of water contamination.

Further sampling should be carried out if in doubt.

Stalling the Torque Converter 1

Apply the foot brake firmly. If necessary, set the machine against a fixed obstruction.

2

Select 4th speed forward and open the throttle fully.

CAUTION: DO NOT stall the converter for more than 10 seconds maximum. If contamination is severe (oil still visibly emulsified) repeat the drain/fill procedure before returning the machine to service.

9803/9060

Issue 1

Section 6

Brakes

Section 6

i

i

Contents

9803/9060

Page No.

Technical Data

1-1

External Parking Brake Caliper Torque Figures Removal and Replacement Dismantling and Assembly Setting Procedure Renewing the Brake Pads

2-1 2-2 2-3 2-5 2-7

Issue 1

Section 6 1-1

Brakes Technical Data

Section 6 1-1

Internal Parking Brake Note: Because the internal parking brake is housed inside the gearbox, instructions for dismantling and assembly are detailed in Gearbox (with internal parking brake) - Dismantling and Assembly, Section 5.

See also Fault Finding - Internal Parking Brake, Section 5.

External Parking Brake Type

Disc brake with manually adjusted caliper.

Actuation

Cable operated.

Location

Mounted on transmission output shaft.

Disc Diameter

279.4 mm (11 in)

9803/9060

Issue 1

Section 6

Brakes

Section 6 2-1

External Parking Brake Caliper

2-1

Torque Figures The illustration shows a typical installation.

Where appropriate, the grade of bolt is indicated in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.

Torque Settings Item A B C

Nm 166 13-15 255

lbf ft 122 9-12 188

(12.9) (10.9 Tuflok)

C

A

B A388460

9803/9060

Issue 1

Section 6

Brakes

Section 6 2-2

External Parking Brake Caliper

2-2

Removal and Replacement Removal

! WARNING This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.

Installation and mounting of the parking brake calliper requires tightening of the mounting bolts to a specific torque figure. Do not attempt to do this job unless you have the correct tools available.

0010

1

Make sure precautions listed in the warnngs are completed.

2

Release the parking brake lever.

3

Disconnect cable clevis A from operating lever E, note which of the three holes on the lever is used.

4

Undo locknuts B and disconnect the cable from the braket D.

5

Support the caliper and remove the two mounting bolts and hardened washers C. Lift the caliper and bracket D clear of the brake disc.

! CAUTION The parking brake must not be used to slow the machine from travelling speed, except in an emergency, otherwise the efficiency of the brake will be reduced.

Whenever the parking brake has been used in an emergency, always renew both brake pads.

4-2-1-1/2

! WARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the caliper assemblies before commencing work. Clean hands thoroughly after work.

13-3-1-3

! WARNING Before working on the parking brake, park on level ground and put chocks on each side of all four wheels.

Stop the engine and disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

BRAK 8-8

Note: Do NOT remove transmission mounting bracket F unless it needs to be renewed.

Inspection Check the thickness of the friction material on the two brake pads. If either pad is worn below 2 mm (0.079 in.) fit a new pair of pads. For reference, the thickness of friction material on new pads is 3.18 mm (0.125 in.).

Check also the surface condition of the brake disc. Replace the disc if it is badly warped, pitted or out of tolerance: Minimum thickness Maximum thickness

-

8.89 mm (0.350 in).

9.65 mm (0.380 in).

Replacement Replacement is a reversal of the removal procedure.

B

B

1

Locate the caliper on the brake disc and fit new mounting bolts C with hardened washers, torque tighten to 255 Nm (188 lbf ft).

2

Insert cable into bracket D, do not tighten locknuts B at this stage as the brake will need adjusting.

3

Refit the clevis to the top hole in the operating lever E.

4

Make sure there is adequate freedom of movement of operating lever E to ensure a positive brake application, and that the lever returns to the rest position when the parking brake is released.

5

Adjust the parking brake, see Setting Procedure.

Never unscrew the clevis A to adjust the cable.

A

F C

E

Torque Settings Item C

D C 9803/9060

Nm 255

lbf ft 188

A390690

Issue 1

Section 6

Brakes

Section 6 2-3

External Parking Brake Caliper

2-3

2

9

1

Dismantling and Assembly

Y

A348331

15

13 13

12

13

13

12

11

10

X

6 5 3

4

Carrier Side Pad Lever Side Pad Bolt Anti-rotation Clip Washer Washer Lever Spring Rotor Ball Spacer Ball Bearings Mounting Bush O-ring Shaft Seal Housing

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

8

14

Component Key:

A228362

9803/9060

Issue 1

Section 6

Brakes

Section 6 2-4

External Parking Brake Caliper

2-4

Dismantling and Assembly Dismantling

Assembly

The numerical sequence shown on the illustration on the adjacent page is intended as a guide to dismantling.

Before assembly make sure all parts are clean and serviceable.

! WARNING

1

Fit a new shaft seal 14 if removed. Install the seal as shown. Press the seal into the housing using a suitable spacer block and bench press.

2

Coat the the shaft and ball pockets of rotor 9 and the ball pockets of housing 15 with silicone grease.

Remove the caliper brake pads, refer to Renewing the Brake Pads.

3

Insert the three ball bearings 11 into the pockets in the housing 15. Insert ball spacer 10.

Bend the tabs on anti-rotation clip 4. Remove bolt 3, anti-rotation clip 4 and washers 5 and 6. Hold lever 7 against the tension of the spring as the bolt is removed.

4

Slide rotor 9 through the casting and seat the ball pockets against the bearings.

Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

1

2

3

Note the position of lever 7 and the splines of the shaft.

Mark the end of the shaft and lever 7 to aid assembly.

Remove lever 7 and spring 8.

5

Position spring 8 over the shaft of rotor 9. Insert the large diameter end of the spring into hole X in the face of the housing.

4

Push out rotor 9 and remove ball spacer 10 and ball bearings 11. Take care not to lose the ball bearings.

6

Locate the small diameter end of spring 8 around the outside edge of lever 7 as shown at Y.

5

Push out mounting bushes 12 and remove O-rings 13.

7

Fit lever 7. Align the lever to the mark made during dismantling.

8

Hold the lever against the tension of the spring and fit washers 6 and 5, and new anti-rotation clip 4. Fit bolt 3 and tighten to 13-16 Nm (9-12 lbf ft).

9

Bend up a tab of the anti-rotation clip that aligns with one of the flats on the bolt.

Note: Shaft seal 14 will not need to be renewed unless excessively worn or damaged. If removal is necessary, press the seal out from inside the housing using a suitable spacer block and bench press. Clean out any remains of the seal after removal.

Inspection 1

2

Clean and dry all parts. Check all parts are free from excessive wear, damage or corrosion. Light scores or stains should be removed. Renew corroded or deeply scored parts.

Check rotor 9 for damage or distortion. Renew if necessary.

Always renew both brake pads if the parking brake has been used in an emergency.

3

Check the ball pockets in housing 15 for signs of scoring, pitting, damage or corrosion. Renew the housing if damaged.

4

Check spring 8 is not broken or distorted.

10 Fit the new brake pads, refer to Renewing the Brake Pads.

11 Lubricate the O-rings 13 and bushes 12 with silicone grease. Fit O-rings into the housing and insert mounting bushes. Wipe off any excess grease.

12 Before fitting the calliper, ensure the lever rotates smoothly and that the lever side pad 2 returns to the off position when the lever is released.

13

Refit the brake Replacement.

caliper,

see

Removal

and

14

Adjust the parking brake, see Setting Procedure.

Torque Settings 5

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

9803/9060

Item 3

Nm 13-16

lbf ft 9-12

Issue 1

Section 6

Brakes

Section 6 2-5

External Parking Brake Caliper

2-5

Setting Procedure

G

B

H

F

A C E

C

A311940

9803/9060

Issue 1

Section 6

Brakes

Section 6 2-6

External Parking Brake Caliper

2-6

Setting Procedure If the parking brake caliper assembly has been dismantled or the brake pads renewed, then the caliper must be set as follows:

! WARNING Before adjusting the parking brake, make sure that the machine is on level ground. Put chocks each side of all four wheels. Disconnect the battery so that the engine cannot be started. If you do not take these precautions the machine could run over you.

! WARNING If the machine starts to move during the following test, immediately apply the foot brakes and reduce the engine speed.

2-2-5-1

c

Slowly release the brake pedals, if the machine has not moved use the accelerator to gradually increase the engine speed to 1500 RPM - the machine should not move. DO NOT test for longer than 20 seconds.

d

If the machine moved inspect the caliper/pads, reset as described above.

BRAK - 008

1

Disengage the parking brake (lever horizontal). Turn handle grip A to bring pin B central to the slot.

2

Adjust the cable’s effective length so that the park brake is fully engaged when the park brake lever is vertical:

3

a

Release and adjust the two locknuts C.

b

Further adjustment, if required, is available at the clevis and cable mounting position at the park brake lever, shown at E.

In the event that there is insufficient adjustment in the cable, remove screw F, anti-rotation clip G and take operation lever H off its mounting spline.

4

Rotate the lever clockwise, one notch of the spline.

Refit anti-rotation clip G and screw F. Torque tighten the screw to 12.5 - 15.5 Nm; (1.3 - 1.6 kgf m; 9.2 - 11.5 lbf ft).

5

After the screw has been torque tightened bend the tabs of clip G to secure the screw.

6

Test the parking brake.

If you have any queries concerning this test procedure or parking brake adjustment, consult your local distributor.

! WARNING Do not use a machine with a faulty parking brake.

3-2-3-10

! CAUTION Non approved modifications to axle ratios, machine weight or wheel and tyre sizes may adversely affect the performance of the parking brake.

3-2-3-11

Note: On machines where the parking brake, when fully engaged, electrically disconnects the transmission drive; the machine is prevented from being driven with the park brake ON. Therefore, so that we can complete the test, move the park brake lever fractionally forward until the warning light is just extinguished; hold the lever in this position for the duration of the test. DO NOT move the lever too far forward, otherwise the park brake will not be fully operational. a

Make sure the parking brake is fully engaged (lever vertical - also see Note above). Select third gear.

b

Make sure the brake pedals are locked together, push down hard on the brake pedals and select forward drive.

9803/9060

Issue 1

Section 6

Brakes

Section 6 2-7

External Parking Brake Caliper

2-7

Renewing the Brake Pads ! WARNING Brake pads generate dust which if inhaled, may endanger health. Wash off the calliper before commencing work. Clean hands thoroughly after work.

13-3-1-3

Pad Removal 1

Remove the parking brake caliper from the transmission mounting bracket, refer to Removal and Replacement.

The brake pads 1 and 2 are removed through the brake disc slot in the caliper housing 15.

2

Press carrier side pad 1 into housing 15 and remove.

Ensure any residual silicone used for pad retention during assembly is removed.

3

Carefully lever pad 2 from the rotor inside the housing using a flat blade screwdriver. Take care to prevent damage to the plastic clip in the centre of the rotor 9 (there is no need to remove the rotor from the caliper).

Pad Inspection

15

! WARNING Oil on the brake disc will reduce brake effectiveness.

Keep oil away from the brake disc. Remove any oil from the disc with a suitable solvent. Read and understand the solvent manufacturer’s safety instructions. If the pads are oily, new ones must be fitted.

X

2-3-2-3/3

1

2

The minimum thickness of the friction material on either pad is 1mm (0.04 in), but it is recommended new pads are fitted as pads worn to this limit may not be able to be adjusted.

Check the condition of the disc surface. Renew the disc if badly warped, pitted or worn.

1 2 9

A390680

Pad Replacement 1

Fit the pad 2 to the lever side of the calliper. Position the pad inside housing 15. Locate the plastic clip in the centre of the rotor 9 into the hole X, and press the pad into place.

2

Fit the pad 1 to the carrier side of the calliper. Add a small amount of silicon sealant to the back outer edge of the backing plate to hold the pad in place within the housing.

3

Replace the Replacement.

caliper,

refer

to

Removal

and

Note: If there is insufficient adjustment after fitting new pads change the brake cable.

9803/9060

Issue 1