Manitou Gear Box Serie PG 115 Repair Manual 647027EN - PDF DOWNLOAD

647027EN (27/07/2008)

GEAR BOX SERIE PG 115 Repair manual

MANITOU BF B.P 249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

1st Date of Issue : 23 / 07 / 2008

647027EN

DATE OF ISSUE 23 / 07 / 2008

OBSERVATION - 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED, EITHER PARTLY OR TOTALLY.

CONTENTS

– GEAR BOX AND CONVERTER ......................................................................

5

– GEAR BOX .....................................................................................................

6

(Details)

– GEAR BOX ....................................................................................................

8

(Mecanism details - gears)

– TRANSMISSION HYDRAULIC CIRCUIT ....................................................... 10 – TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT .................................. 11 – TRANSMISSION KINEMATICS ..................................................................... 12 – TRANSMISSION MAINTENANCE ................................................................. 14 – PRESSURE CHEKING ................................................................................... 16 – SPECIAL SERVICE TOOLS ........................................................................... 21 – TECHNICAL CHARACTERISTICS .................................................................. 22 – DIS-ASSEMBLY AND RE-ASSEMBLY ........................................................... 25 GENERAL INFORMATION ...............................................................................

26

1 - TRANSMISSION DISASSEMBLY .................................................................

28

2 - INPUT SHAFT DISASSEMBLY AND RE-ASSEMBLY ......................................

(Includes Forward High and Forward Low clutch packs)

34

3 - DISASSEMBLY AND RE-ASSEMBLY OF THE OUTPUT SHAFT ........................

40

(Includes Speed Clutch 2 and Speed Clutch 3 packs) 4 - DISASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT .......................

(Includes Speed Clutch 1 pack)

46

5 - REVERSE IDLER SHAFT ............................................................................

52

6 - PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY .............

58

10 - GEAR BOX RE-ASSEMBLY .......................................................................

60

– ELECTRICITY ................................................................................................. 68

3

4

GEAR BOX AND CONVERTER

9

8

2 3

6

1

7 5

4

1 – Complete gear box 2 – Converter 3 – Intermediate plate 4 – Screw 5 – Washer 6 – Converter reinforcement plate 7 – Screw 8 – Screw 9 – Washer

5

30 31 67 62

25

6

14

26

27

27

11

13

63

66

36

71

10

27 7 65

26

69

8

LP 6 bar

64

1

9

9

44 43 42 41 40

52

46

8 7

31 30

32

61

53

15

75 18

17

1

BP194

68

60

52

2

21

24

59

45 26 bar

47

48

8

37 7

3

LP 6 bar

39

12

38

55 27 56

PPO OC DIC HCEH J TT JUOHITNUNEETDTE E GS EJO D SEI GO TS DT AC DE ATZ INE S SE L H K RIE ITTU JUNT GU NGSAS AR A NIZ T Z ION E

51

2

16 16

73

19 15

16 16

23

R

FL

20

51

24

7

FH

74

8

7

7 8 28

58

22

74

72

8 7

34 7 8

29

54 8 7

8

70 33

6

74

BP195

49 50

35

73

5

4

74

3

74

57

GEAR BOX (Details)

GEAR BOX (Details) 1 – Transmission housing

39 – Seal kit

2 – Transmission rear case

40 – Screw

3 – Screw

41 – Cover

4 – Washer

42 – "O" ring

5 – "O" ring

43 – Washer

6 – Seal

44 – Suction strainer

7 – Plug

45 to 48 - Valve start cold 26 bar

8 – "O" ring

45 – Plug

9 – Plug

46 – Spring

10 – Complete pump

47 – Ball

11 – Seal

48 – "O" ring

12 – "O" ring

49 – Sensor

13 – Screw

50 – Seal

14 – Washer

51 – "O" ring

15 – Hollow screw

52 – Plug

16 – Seal

53 – Screw

17 – Solenoid - Clutch N°1 (1)

54 – Stud-bolt

18 – Pipe (3rd and 4th gear)

55 – Oil temperature sensor

19 – Pipe (1st gear)

56 – "O" ring

20 – Screw

57 – Brake assy

21 – Valve - Clutch N°2 (2) and N°3 (3)

58 – Plug

22 – Complete electrical valve control

59 – "O" ring

- Forward gear low (LH)and high (FH)

60 – Filter housing

speed

61 – Oil filter

23 – Control valve - Reverse gear (R)

62 – Adaptor

24 – Screw

63 – Pipe

25 – Pipe

64 – Gauge

26 – Hollow screw

65 – Connection

27 – Seal

66 – Fastening plate

28 – Screw

67 – Screw

29 – Screw

68 – Wiring harness (gear box)

30 – Drain plug

69 – "O" ring

31 – "O" ring

70 – Screw

32 – Plug

71 – Screw

33 – Spacer

72 – Kit (Brake lining + Spring)

34 – Air breather

73 – Kit (Screw + Nut)

35 – Coupling flange

74 – Kit brake lining

36 – Valve (pressure regulation)

75 – Plug

- (LP) converter 6 bar

90 – Seal kit

37 – Plug

91 – Valve Kit

38 – Over pressure valve

92 - Pumpe kit

- (LP) principal 15 bar

93 – Seal kit 7

8

4

7 7

72

48

10

75 74

9

49 50

5

3

9

69

45

20

80

77

44

75 85

91 76 91

46

11 8

16

19

17

78

14

6

94

93

89

88

58

92

53

90

92

26

24

104

T4 103

79

52

105

62 60

58

51 64 63

12

T6

13

T9

1

92

6 6

101

68

6

12

13

T7

102

99

100

T10 79

8

28

88

98

87

86

97

77

61 65 56 47 59

99

9

57

32

80

67 48

66

39

15

23

83

70

83 82 81 81

71

37

84

25

26

33

36

22

41

84

35 40

41

10

85

21 36

106 107

56

78

61

10

T8 27 30 31

29 34

54 90 55

38

89

38

14

11 19 17

20

16

2 21 18 9

96 73

43

42

95

GEAR BOX (mecanism details - gears)

GEAR BOX 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 51 52 53 54 55

(mecanism details - gears)

– Input shaft – Gear (24 teeth) – Gear (32 teeth) – Bearing – Thrustwasher – "O" ring – Roller bearing – Snap ring – Bearing – Washer – Circlips T7: Clutch forward gear low speed (FL) T9: Clutch forward gear high speed (FH) – Seal – Piston – "O" ring – Bearing – Plate – Spring retainer – Spacer – Clutch disc – Friction disc – Roller bearing – Shim – Spacer – Countershaft – Gear (24 teeth) – Bearing – Piston T8: Clutch reverse gear – Seal – "O" ring – Spring retainer – Clutch disc – Friction disc – Spacer – Circlips – Washer – Bearing – Thrustwasher – Seal – Plate – Snap ring – Roller bearing – Spacer – Shim – Countershaft – Gear (44 teeth) – Gear (38 teeth) – Gear 1st and 2nd gear – Bearing – Washer – Screw – Seal – Clutch disc – Friction disc – Snap ring – Plate

56 57 58 59 60 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 – 101 – 102 – 103 – 104 – 105 – 106 – 107 –

9

Bearing Washer Seal Washer Circlips Roller bearing Spring retainer "O" ring Piston T6: Clutch N°1 Spacer Spacer Shim Out put shaft Gear 4th gear (26 teeth) Gear 3rd gear (38 teeth) Gear (48 teeth) Bearing Bearing Washer Bearing Washer Clutch disc Friction disc Piston T4: Clutch N°3 T10: Clutch N°2 Plate Roller bearing Spacer Bearing Stop washer Snap ring Circlips Spring plate Spring "O" ring Seal Roller bearing Seal Spring plate Circlips Spacer Shim Out put shaft Gear Bearing Spacer Seal End yoke "O" ring Washer Screw Spacer Shim

TRANSMISSION HYDRAULIC CIRCUIT Clutch - CRAWLER Embrayage RAMPANTE(Option) (OPTION)

Clutch - 1st Embrayage 1ÈREGEAR

Clutch - FORWARD GEARBASSE LOW Embrayage MARCHE AVANT SPEED

Clutch - FORWARD GEARHAUTE Embrayage MARCHE AVANT HIGH SPEED

Clutch - REVERSE GEAR Embrayage MARCHE ARRIÈRE

Clutch - 2nd Embrayage 2ÈME GEAR

REGULATEUR PRESSURE REGULADE PRESSION TOR (14.5 bars) (14,5 bar)

PRISE DE PRESSION Pressure test point

Clutch - 3rd GEAR Embrayage 3ÈME

CONVERTER PRESSURE PRISE DE PRESSION TEST POINT CONVERTISSEUR

FILTRE OIL AFILTER HUILE

PUMP DE PRISE PRESSURE PRESSION TEST POINT POMPE

CONVERConverter TISSEUR

LIMITEUR DE CONVERTER PRESSION DU PRESSURE CONVERTISSEUR LUBRICATION PRISE DE LIMITER (6.5 PRESSURE TEST (6,5 bar) PRESSION bars) POINT LUBRIFICATION

SOUPAPE DE COLD STARTING DEMARRAGE VALVE A FROID (26 bars) (26 bar)

PRISE DE TEMPERATURE TEMPERATURE TEST POINT

POMPE Pump

LUBRICATION PRISE DE PRESSURE PRESSION TEST POINT LUBRIFICATION

Suction CREPINE strainer D'ASPIRATION

TRANSMIS-

LUBRIFICATION SION LUBRICATRANSMISSION

TION

SUMP CARTER

REFROIDISSEUR OIL COOLER D'HUILE

10

TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT

Clutch - CRAWLER (Option)

Clutch - 1st GEAR Clutch FORWARD GEAR LOW SPEED

Clutch FORWARD GEAR HIGH SPEED

Clutch - REVERSE GEAR

Clutch - 2nd GEAR

Clutch - 3rd GEAR Pressure limiter

14,5 bar

6,5 bar Oil filter Pressure regulator Cold starting valve

26 bar

Converter

Pump Cooler

Suction strainer

11

TRANSMISSION KINEMATICS Gear

FORWARD gear Clutch FL+1 FH+1 FL+2 FH+2 FL+3 FH+3

1st 2nd 3rd 4th 5th 6th

REVERSE gear Clutch R+1 R+2 R+3 (Not used)

R

R

24

24 42

42 FH

42

FH

FL

42

FL

24

24 32

32

46

44 38

46

44 38

1

1

19

19 3

37

32 2

48

3

28

37

32 2

48

28

26

26

25

25

1st GEAR FORWARDS

2nd GEAR FORWARDS

12

R

R

24

24

42 FH

42

42 FL

FH

42

FL

24 32

24 32

46

44 38

46

44 38

1

1

19 3

37

32 2

19

48 3

28

26

37

32 2

48

28

26

25

25

3rd GEAR FORWARDS

4th GEAR FORWARDS

R

R

24

24

42 FH

42

42 FL

FH

42

FL

24 32

24 32

46

44 38

46

44 38

1

1

19 3

37

32 2

19

48 3

28

26

37

32 2

48

28

26

25

25

5th GEAR FORWARDS (Not used)

6th GEAR FORWARDS

13

TRANSMISSION MAINTENANCE RECOMMANDED LUBRICANTS : Oils used in this transmission must all meet the following specifications : GRADE

SPECIFICATION

CLASSIFICATION

10W30

API GL 4 ALLISON C3

MIL-L-2105B

OPERATING TEMPERATURE : 85° - 90° C

OIL LEVEL

In order to ensure a good lubrication and a good operating temperature it is important to use the specified oil and to maintain the correct level.

The level must be checked always with the oil gauge dipstick, with the engine idling. * Do not pour oil over the upper mark as this could cause overheating due to oil splashing through the pinions (emulsion and deterioration of the oil). This could also cause external leaks.

OIL AND FILTER CHANGING It is recommanded to change the oil at the following intervals :

Oil changing is also necessary to eleminate the metal particles of the transmission components.

The particles result from a normal use.

After the first 50 hours of work.

Then every 800 hours maximum afterward.

Always clean the strainer when changing the oil.

Replace the filter after the first 50 hours of work and every 400 hours afterward.

PRECAUTION To prevent a lack of lubrication in the transmission when towing the machine on long distances, it is recommended to uncouple the gear box out put shaft.

Many factors having an influence on the oil changing require to increase the oil changing frequency.

CAPACITY (GEAR BOX only) : 15,5 L

OIL USED BY MANITOU : MANITOU oil automatic transmission shaft.

1 25 56 215

L L L L

-

Ref 62 Ref. 487 Ref. 545 Ref. 490

148 655 557 207

14

15

PRESSURE CHECKING PRESSURE CHECKING PROCEDURE -

Put fork lift truck on block.

Connect pressure gauges (40 bars) to various test points.

Engine running, allow the transmission temperature to warm up to 60 to 80 °C. With the engine at maximum speed, read the pressures for each gear engaged. Check the values obtained with the table below.

NOTA : The threads for the pump and converter pressure test points are 3/4" UNF. All others are 9/16" UNF. - Refer to the gauge box reference 547037 for the connections of the leads, valves and links.

PRESSURE TABLE IN BARS Clutch - forward Clutch - forward Clutch - reverse gear low speed gear high speed FORWARD GEAR gear FL FH (T8) (T7) (T9) 1st gear

Clutch 1

Clutch 2

Clutch 3

(T6)

(T10)

(T4)

14,25

0

0

14,75

0

0

nd

0

14,25

0

14,75

0

0

rd

3 gear

14,25

0

0

0

15,75

0

4th gear

0

14,25

0

0

15,75

0

5th gear

14,25

0

0

0

0

15,75

6th gear

0

14,25

0

0

0

15,75

Clutch 1

Clutch 2

Clutch 3

(T6)

(T10)

(T4)

2 gear

Clutch - forward Clutch - forward Clutch - reverse gear low speed gear high speed gear REVERSE GEAR FL FH (T8) (T7) (T9) 1st gear

0

0

14,25

14,75

0

0

2nd gear

0

0

14,25

0

15,75

0

0

0

14,25

0

0

15,75

rd

3 gear

Pump

(T3)

15 - 18

Converter (T1)

5-8

Lubrication (T5)

0,75 - 1,25

16

PRESSURE READING ON GEAR BOX "TURNER POWERSHIFT"

MACHINE TYPE and N° : .................................................. N° of HOURS : .........................................

GEAR BOX TYPE and N° : .................................................

Clutch - forward Clutch - forward Clutch - reverse gear low speed gear high speed FORWARD GEAR gear FL FH (T8) (T7) (T9)

Clutch 1

Clutch 2

Clutch 3

(T6)

(T10)

(T4)

Clutch 1

Clutch 2

Clutch 3

(T6)

(T10)

(T4)

1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear

Clutch - forward Clutch - forward Clutch - reverse gear low speed gear high speed REVERSE GEAR gear FH FL (T8) (T7) (T9) 1st gear 2nd gear 3rd gear Pump

(T3)

Converter

(T1)

Lubrication (T5)

COMMENTS : .................................................................................................................................... ......................................................................................................................................................... ......................................................................................................................................................... * BREAKDOWN AT THE ORIGIN : ....................................................................................................... ......................................................................................................................................................... ......................................................................................................................................................... * DETERMINED CAUSE OF THE BREAKDOWN : ................................................................................. ......................................................................................................................................................... ......................................................................................................................................................... ......................................................................................................................................................... ......................................................................................................................................................... .........................................................................................................................................................

17

T3

T1

T2

CONVERTER PRESSURE (T1) PUMP OUTLET PRESSURE NOT USED (T2) PUMP PRESSURE AFTER FILTER (T3)

CLUTCH 3rd GEAR PRESSURE (T4)

LUBRICATION PRESSURE (T5)

18

CLUTCH 1st GEAR PRESSURE (T6)

CLUTCH - FORWARD GEAR SLOW SPEED FL PRESSURE (T7)

CLUTCH - REVERSE GEAR PRESSURE (T8)

CLUTCH - FORWARD GEAR HIGH SPEED FH PRESSURE (T9)

CLUTCH 2nd GEAR PRESSURE (T10)

CONVERTER PRESSURE NOT USED (T11)

19

T5

T7

T9

T11

T10

T4

20

T2

T1

T3

T8

T6

SPECIAL SERVICE TOOLS TOOL NUMBER

DESCRIPTION

- 479307

Bearing Extractor, use with brg. removal collets.

- 600743

Piston seal sizing ring.

- 563390

4wd shaft front \ rear, Rev. Idler shaft front \ rear and Input shaft front brg. removal collet.

- 563392

Countershaft, Output shaft and Crawler shaft, front \ rear brg. removal collet.

- 600744

Input shaft rear brg. removal collet.

- 563394

Output shaft and Crawler shaft front, bearing removal collet.

- 600745

Clutch pack spring compresser (Fits all shafts except output).

- 600746

Clutch pack spring compresser (Fits all shafts).

- 600747

Shimming Tool Kit.

- 600748

Shimming Tool.

RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS. Ø INTERIOR

Ø EXTERIOR

C/shaft, 4wd, Output shaft rear & Co-axial input shaft front bearing.

41 mm

47 mm

Reverse idler,Output shaft front & input shaft bearing.

36 mm

41 mm

50,5 mm

58 mm

Output shaft 1st gear brg. sleeve and Co-axial input shaft rear bearing.

The dummy plug for re-fitting inner detent spring & ball can be made using a piece of bar 18mm dia. x 25 mm long.

21

TECHNICAL DATA SHAFT END FLOATS All shaft end floats should be 0,0254 to 0,0762 mm.

The following sized shims are available for each shaft : 0.06, 0.18, 0.07, and 0.05 mm.

GEAR END FLOATS All free rotating gear end floats should be - 0.42 to 0.080 mm.

BOLT TORQUE'S Strainer bolts Pump retaining bolts Output Yoke bolts O ring plugs 9/16" UNF O ring plugs 3/4" UNF Filler plug 1 5/16" UNF Main transmission case bolts Drain plug Converter relief valve Pressure regulator valve Cold start seating cap 4WD solenoid valve spool 4WD Solenoid coil retaining nut Control valve ret. capscrews Hydraulic pipe (internal) capscrews Hydraulic pipe (internal) banjo bolts Hydraulic pipe (external) banjo bolts Filter housing bolts Oil filter Temperature sender Countershaft front brg. ret. bolt Speed Probe lock nut Brake mounting bolt lock nuts Brake adjustment lock nut Dipstick bracket capscrews Dipstick tube capscrews

18 to 31 Nm. 18 to 31 Nm. 68 to 88 Nm. 20 to 27 Nm. 40 to 54 Nm. 68 to 80 Nm. 55 to 75 Nm. 34 to 54 Nm. 23 to 30 Nm. 45 to 64 Nm. 45 to 64 Nm. 16 to 22 Nm. 2.7 to 5.4 Nm. 7 to 9 Nm. 10 to 18 Nm. 20 to 27 Nm. 40 to 46 Nm. 45 to 64 Nm. 7 to 10 Nm. 20 to 27 Nm. 68 to 88 Nm. 25.5 Nm. 150 Nm. 61 to 75 Nm. 7 to 9 Nm. 45 to 64 Nm.

RECOMMENDED SEALANTS Transmission case joint Output shaft gear 4wd gear (Permanent 4wd assy) Countershaft gears Expansion plugs Speed probe lock nut Brake Calliper mounting lock nuts

Loctite Loctite Loctite Loctite Loctite Loctite Loctite

5203 638 spline lock.

638 spline lock.

638 spline lock.

574 or Omnifit FD10.

270.

542.

22

CLUTCH PACKS Clutch Pack Forward High Forward Low Clutch 1 Clutch 2 Clutch 3 Reverse 4wd Hydraulic

No. of Friction Plates 6 5 8 8 5 5 8

No. of Plain Steel Plates 6 5 8 8 5 5 8

Clutch plate thickness when new : • Friction Plate • Plain steel plate

Clutch Pack Thickness when new.

22.48 to 24.06 mm 18.75 to 20.05 mm 30 to 32.08 mm 30 to 32.08 mm 18.75 to 20.05 mm 18.75 to 20.05 mm 30 to 32.08 mm

1.97 to 2.13 mm 1.78 to 1.88 mm

23

24

DIS-ASSEMBLY RE-ASSEMBLY

25

GENERAL INFORMATION We recommend that the procedures as outlined in this manual be followed when performing maintenance work on this transmission.

BEARINGS When a transmission is removed at relativity low mileage, bearings should be removed with pullers designed for the purpose. Wrap the bearings to keep our dirt.

TOOLS This transmission can be repaired with ordinary mechanics hand tools however this procedure is not only slow but may damage otherwise serviceable parts. To reduce maintenance costs and vehicle downtime, we recommend that the special tools listed in this manual be procured from a tool manufacturer, as stated.

Clean, inspect and lubricate all bearings just prior to reassembly. If accumulated mileage is over 1500 hours we suggest that all bearings be replaced.

CLEANLINESS

The exploded views of sub-assemblies which are incorporated in this manuel are for the mechanic’s convenience and show the latest material.

The parts are arranged in their correct order and may also be used as a reference for assembly or disassembly of this unit.

REPLACEMENT PARTS

Transmission should be steam cleaned externally prior to disassembly. Seal all opening before cleaning to prevent entry of dirt and water which can damage serviceable parts. Dirt is abravise and will cause premature wear and failure of clutch plates, hydraulic valves and bearings.

SHIMS * Due to the nature of opération of the hydraulic system cleanliness is of prime importance and the following guidelines should be observed :

When inserting shim packs, it is essential that the thinnest shims are placed between the thicker shims to prevent any possible damage to the shims.

1 – Not lint or cotton rags should be used in order to prevent any possible clogging.

SEALS

2 – When fitting new clutch plates they should be soaked in clean new oil as recommended for 3 hours.

The seals which have been removed on the disassembly shall be replaced by new on reassembly.

3 – All parts should be thoroughly cleaned and lubricated with new oil prior to reassembly.

26

27

1 - TRANSMISSION DIS-ASSEMBLY

1-1

1-2

Remove the 4 plastic plugs, cap screws and spacers, (if fitted), and withdraw the forward direction control valve.

Invert the transmission on a suitable bench . For convenience the bench top should have a hole in it to accommodate the input shaft and pump.

1-3

1-4

Remove the 4 plastic plugs and cap screws and withdraw the Speed Clutch 2 and 3 control valve.

Remove the 4 plastic plugs and cap screws and withdraw the reverse direction control valve.

1-5

1-6

Remove the Speed Clutch 1 soleniod coil retaining nut and withdraw the coil.

Unscrew and remove the Speed Clutch 1 solenoid valve spool.

28

1-10

1-11

Remove the bolt, washer and O ring and withdraw the 4 wheel drive yoke and spacer. (Not fitted on 2 wheel drive models).

Remove the bolt, washer and O ring and withdraw the output yoke or flange.

1-12

1-13

Withdraw the 2 external hydraulic pipe banjo bolts and washers and remove the lubrication transfer pipe.

Undo the speed probe locknut and unscrew and withdraw the speed probe and sealing washer.

1-14

1-15

Remove 2 capscrews from the dipstick tube bracket.

Withdraw the 2 capscrews and remove the dipstick tube assembly.

29

1-16

1-17

Remove the 4 wheel drive shaft assembly (Not fitted on 2 wheel drive models).

Remove the 17 screws and using suitable lifting equipment take off the rear transmission case.

Lever slots are provided to assist removal.

NOTE : The bearing cones and shims may fall from the rear case during removal.

1-18

1-19

Tilt the countershaft and withdraw the input shaft assembly.

Lift the countershaft and input shaft assemblies together by approximately 30 mm and get an assistant to simultaneously lift and remove the output shaft assembly.

1-20

1-21

Remove the countershaft assembly.

Remove the reverse idler shaft assembly.

30

1-22

1-23

Remove the 2 capscrews and 2 banjo bolts and withdraw internal hydraulic pipe.

Remove the bearing shells from the front case.

1-24

1-25

Remove and discard the expansion plug from the upper shimming access hole.

Remove and discard the expansion plug from the left side shimming access hole.

1-26

1-27

Remove 2 screws and withdraw the strainer cover, O ring, spacer and strainer.

Using a strap wrench remove and discard the oil filter.

31

1-28

1-29

Remove the Converter Relief Valve.

Remove 2 bolts and take of the oil filter housing and 2 O rings.

1-30

1-31

Remove the cold start housing, spring and ball.

Remove the Pressure Regulator Valve.

1-32

1-33

Invert the case. Remove 4 screws and sealing washers then withdraw the pump assembly and sealing ring.

Remove the temperature sender.

32

33

2 - INPUT SHAFT DISASSEMBLY AND RE-ASSEMBLY (Includes Forward High and Forward Low clutch packs) 2-1

2-2

Remove and discard the 3 sealing rings.

Using the appropriate bearing puller remove the rear bearing.

(Tool No. 600744)

2-3

2-4

Remove the primary gear circlip.

Remove the thrust washer and needle bearing.

2-5

2-6

Remove the primary gear.

Remove the two bearings and spacer.

NOTE : There is no spacer fitted on the forward high side.

34

2-7

2-8

Remove the needle bearing and thrust washer.

Remove the clutch pack spirol retaining ring.

2-9

2-10

Remove the clutch pack retaining plate.

Remove the clutch pack.

2-11

2-12

Remove the circlip and spring pack assembly.

Using the appropriate tool compress the piston spring pack and release the circlip.

(Tool No. 600746)

35

2-13

2-14

Invert the shaft and remove the sealing ring.

Using pliers, as shown, pull the piston out of the drum.

2-15

2-16

Remove and discard the piston sealing rings and O rings.

Re-assembly of the Input Shaft.

Using the appropriate bearing puller remove the front bearing.

(Tool No. 563390) Repeat steps 2:4 to 2:13 to dismantle the forward high clutch pack.

2-17

2-18

Using transmission fluid to lubricate the seals push the pistons into the sizing ring and leave for approximately 30 minutes.

(Tool No. 600743)

Re-new the piston sealing rings, to assist assembly the seals may be warmed in lukewarm water prior to assembly.

NOTE : The outer seal must be fitted with the open edge facing away from the clutch pack.

36

2-19

2-20

Replace the spring pack assembly and circlip as shown.

Using transmission fluid to lubricate the seals push the piston into the drum.

2-21

2-22

Replace an externally splined ( plain ) disc and then an internally splined (friction) disc alternately until six of each have been replaced.

Using the appropriate tool compress the spring pack and locate the circlip into its groove.

(Tool No. 600746)

2-23

2-24

Replace the clutch pack retaining plate and re-fit the spirol retaining clip.

Replace the thrust washer and bearing.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

37

2-25

2-26

Replace the bearing , spacer and bearing.

NOTE : There is no spacer fitted on the forward high side.

Line up the clutch plate splines and replace the primary gear (see tips).

2-27

2-28

Replace the needle bearing and thrust washer as shown. Check gear end float.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

Re-fit the primary gear circlip.

2-29

2-30

Using an appropriately sized tube replace the bearing as shown.

Fit 3 new sealing rings to the rear of the shaft as shown.

38

2-31

Invert the shaft and repeat steps 2:17 to 2:27 and step 2:29 .Then fit a new sealing ring to the front of the shaft.

NOTE : The Forward low clutch pack uses 5 friction and 5 plain plates.

(To avoid damage the sealing rings may be left off until all shimming operations have been completed).

39

3 - DISASSEMBLY AND RE-ASSEMBLY OF THE OUTPUT SHAFT (Includes Speed Clutch 2 and Speed Clutch 3 packs) 3-1

3-2

Position the shaft in a soft jawed vice as shown and remove and discard the 3 sealing rings.

Using the appropriate bearing puller remove the front bearing.

(Tool No. 563394)

3-3

3-4

Remove the thrust washer and needle bearing.

Remove the primary gear.

3-5

3-6

Remove the two bearings.

NOTE : There is a spacer fitted between the bearings on the Speed Clutch 2 side.

Remove the needle bearing and thrust washer.

40

3-7

3-8

Remove the clutch pack spirol retaining ring.

Remove the clutch pack retaining plate.

3-9

3-10

Using the appropriate tool compress the piston spring pack and release the circlip.

(Tool No. 600746)

Remove the clutch pack.

3-11

3-12

Using pliers, as shown, pull the piston out of the drum.

Remove the circlip, retainer and spring.

41

3-13

3-14

Invert the shaft and using the appropriate bearing puller remove the rear bearing.

(Tool No. 563392)

Remove the drive gear using suitable pullers.

Then repeat steps 3:3 to 3:12.

NOTE : The Speed Clutch 2 assembly uses a multi spring pack instead of a single spring and retainer.

3-15

3-16

Remove and discard the piston sealing rings and O rings.

Re-assembly of the Output Shaft.

Re-new the piston sealing rings.To assist assembly the seals may be warmed in lukewarm water prior to assembly.

NOTE : The outer seal must be fitted with the open edge facing away from the clutch pack.

3-17

3-18

Using transmission fluid to lubricate the seals push the piston into the drum.

Using transmission fluid to lubricate the seals push the piston into the sizing ring and leave for approximately 30 minutes.

(Tool No. 600743)

42

3-19

3-20

Replace the spring and retainer and position circlip as shown.

NOTE : The Speed Clutch 2 assembly uses a multi spring pack instead of a single spring and retainer.

Using the appropriate tool compress the spring and locate the circlip into its groove.

(Tool No. 600746)

3-21

3-22

Replace an externally splined (plain) disc and then an internally splined (friction) disc alternately until eight of each have been replaced.

NOTE : The Speed Clutch 3 pack uses 5 friction and 5 plain plates.

Replace the clutch pack retaining plate and refit the spirol retaining clip.

3-23

3-24

Replace the thrust washer and bearing.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

Replace the 2 needle bearings.

NOTE : There is a spacer fitted between the bearings on the Speed Clutch 2 side.

43

3-25

3-26

Replace the needle bearing and thrust washer as shown. Check gear end float.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

Line up the clutch plate splines and replace the primary gear (see tips).

3-27

3-28

Invert the shaft and repeat steps 3:16 to 3:26.

Then refit the drive gear using Loctite 638, or equivalent on the shaft splines.

Using an appropriately sized tube replace the bearing as shown.

3-29

3-30

Using an appropriately sized tube replace the rear bearing as shown.

Finally fit 3 new sealing rings to the front of the shaft as shown.

44

45

4 - DISASSEMBLY AND RE-ASSEMBLY OF THE COUNTERSHAFT (Includes Speed Clutch 1 pack) 4-1

4-2

Using the appropriate bearing puller remove the rear bearing.

(Tool No. 563392)

Position the shaft in a soft jawed vice as shown and remove and discard the 2 sealing rings.

4-3

4-4

Remove the Speed Clutch 1 primary gear.

Remove the thrust washer and needle bearing.

4-5

4-6

Remove the two bearings and spacer.

Remove the needle bearing and thrust washer.

46

4-7

4-8

Remove the clutch pack spirol retaining ring.

Remove the clutch pack retaining plate.

4-9

4-10

Remove the clutch pack.

Using the appropriate tool compress the piston spring pack and release the circlip.

(Tool No. 600746)

4-11

4-12

Remove the circlip and spring pack assembly.

Using pliers, as shown, pull the piston out of the drum.

47

4-13

4-14

Remove and discard the piston sealing rings and O rings.

Invert the shaft and remove the retaining bolt and washer.

4-15

4-16

Using the appropriate bearing puller remove the front bearing.

(Tool No. 563392)

Remove the 2 drive gears using suitable pullers or a press.

48

RE-ASSEMBLY OF THE COUNTERSHAFT 4-17

4-18

Replace the 2 drive gears using Loctite 638, or equivalent, on the shaft splines.

Using an appropriately sized tube replace the front bearing as shown.

4-19

4-20

Replace the retaining washer and bolt then torque to 68-88 Nm.

Re-new the piston sealing rings to assist assembly the seals may be warmed in lukewarm water prior to assembly.

NOTE : The outer seal must be fitted with the open edge facing away from the clutch pack.

4-21

4-22

Using transmission fluid to lubricate the seals push the piston into the drum.

Using transmission fluid to lubricate the seals push the pistons into the sizing ring and leave for approximately 30 minutes.

(Tool No. 600743)

49

4-23

4-24

Using the appropriate tool compress the spring pack and locate the circlip into its groove.

(Tool No. 600746)

Replace the spring pack assembly and circlip as shown.

4-25

4-26

Replace the bearing, spacer and bearing.

Replace the thrust washer and bearing.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

4-27

4-28

Replace the Speed Clutch 1 gear.

Replace the needle bearing and thrust washer as shown. Check gear end float.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

50

4-29

4-30

Using an appropriately sized tube replace the bearing as shown.

Replace an externally splined (plain) disc and then an internally splined (friction) disc alternately until eight of each have been replaced.

4-31

4-32

Replace the clutch pack retaining plate and re-fit the spirol retaining clip.

Fit 2 new sealing rings.

51

5 - REVERSE IDLER SHAFT

5-1

5-2

Remove and discard the 2 sealing rings.

Using the appropriate bearing puller remove the rear bearing.

(Tool No. 563390)

5-3

5-4

Remove the thrust washer and needle bearing.

Remove the reverse primary gear.

5-5

5-6

Remove the two bearings and spacer.

Remove the needle bearing and thrust washer.

52

5-7

5-8

Remove the clutch pack spirol retaining ring.

Remove the clutch pack retaining plate.

5-9

5-10

Using the appropriate tool compress the piston spring pack and release the circlip.

(Tool No. 600746)

Remove the clutch pack.

5-11

5-12

Using pliers, as shown, pull the piston out of the drum.

Remove the circlip and spring pack assembly.

53

5-13

5-14

Remove and discard the piston sealing rings and O rings.

Invert the shaft and using the appropriate bearing puller remove the front bearing.

(Tool No. 563390)

RE-ASSEMBLY OF THE REVERSE SHAFT

5-15

5-16

Using an appropriately sized tube replace the front bearing as shown.

Re-new the piston sealing rings to assist assembly the seals may be warmed in lukewarm water prior to assembly.

NOTE : The outer seal must be fitted with the open edge facing away from the clutch pack.

5-17

5-18

Using transmission fluid to lubricate the seals push the pistons into the sizing ring and leave for approximately 30 minutes.

(Tool No. 600743)

Using transmission fluid to lubricate the seals push the piston into the drum.

54

5-19

5-20

Replace the spring pack assembly and circlip as shown.

Using the appropriate tool compress the spring pack and locate the circlip into its groove.

(Tool No. 600746)

5-21

5-22

Replace an externally splined (plain) disc and then an internally splined (friction) disc alternately until five of each have been replaced.

Replace the retaining plate and re-fit the spirol retaining clip.

5-23

5-24

Replace the thrust washer and bearing.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

Replace the bearing, spacer and bearing.

55

5-25

5-26

Line up the clutch plate splines and replace the reverse primary gear (see tips).

Replace the needle bearing and thrust washer as shown. Check gear end float.

NOTE : The needle bearing should be fitted with the closed side of its cage against the gear.

5-27

5-28

Using an appropriately sized tube replace the front bearing as shown.

Fit 2 new sealing rings.

(To avoid damage the sealing rings should be left off until all shimming operations have been completed).

56

57

6 - PERMANENT 4 WHEEL SHAFT DISASSEMBLY 6-1

6-2

The permanent 4 wheel drive shaft.

Using the appropriate bearing puller remove the front and rear bearings.

(Tool No. 563390)

6-3

Remove the 4 wheel drive gear using suitable pullers or a press.

58

RE-ASSEMBLY 6-5

6-4

Replace the 4 wheel drive gear using Loctite (ref.: 548110), on the shaft splines.

Then using a suitably sized tube re-fit the front and rear bearings.

Using a suitably sized tube re-fit the front and rear bearings.

59

10 - TRANSMISSION RE-ASSEMBLY General Re-assembly Notes : • All nylon patch bolts may be re-used 5 to 6 times provided a prevailing thread torque of 15 to 18 Nm. is recorded.

• All shafts and bearings should be lubricated with transmission fluid prior to assembly.

• To prevent possible contamination of hydraulic parts lint or cotton rags should not be used.

10-1

10-2

Invert the front case and fit the internal pipe using 4 new sealing washers, one either side of each banjo connection. Tighten the 2 banjo bolts to 20 -27 Nm. and the two capscrews to 10 - 18 Nm.

Fit two new O rings to the internal hydraulic pipe.

10-3

10-4

Re-fit the reverse shaft assembly.

Re-fit the bearing shells to the front case.

10-5

10-6

Re-fit the input shaft assembly.

Lift the input shaft approximately 30mm and refit the countershaft assembly.

60

10-7

10-8

Re-fit the 4wd shaft assembly (Not used on 2wd models).

Lift the input and countershaft assemblies together approximately 30mm and get an assistant to simultaneously fit the output shaft assembly.

Take care not to damage the shaft sealing rings.

10-9

10-10

Fit a new O ring to the transmission case.

Using a suitably sized tube fit new rear output and 4wd oil seals into the front and rear cases.

The rear output seal should be fitted to a depth of 6mm. Fill the seal lips with light grease.

10-11

10-12

Invert the rear case and replace the shim packs and bearing cups. The 2mm thick spacer shim should be fitted into the case first , then fit the remaining shims followed by the bearing cup. A light grease may be used to help hold the cups in the case.

Re-fit the internal pipe using 4 new sealing washers, one either side of each banjo connection. Tighten the 2 banjo bolts to 40 - 46 Nm.

61

10-13

10-14

Using suitable lifting equipment re-fit the rear case, (without sealant at this stage), and secure with at least 6 equally spaced bolts. When fitting the rear case be careful to avoid damaging any of the shaft sealing rings.

Refit the flange retaining bolt and washer into the end of the output shaft. Then position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

NOTE : All shaft assemblies should be rotated several times to seat the bearings prior to measuring the end float.

10-15

10-16

Attach a suitable shimming tool, (with a 12mm thread), to the end of the 4 wheel drive shaft. Position a D.T.I. as shown. Use a pry bar lift the shaft, then measure and note the end float.

(Tool No. 563395) (Not fitted on 2 wheel drive models).

Fit tool (600747) into the countershaft shimming hole and position a D.T.I. on the end of the tool as shown. Then using a suitable pry bar through the side access hole, measure and note the shaft end float.

10-17

10-18

Fit tool (600747) into the input shaft shimming hole and position a D.T.I. on the end of the tool as shown. Then using a suitable pry bar through the upper access hole , measure and note the shaft end float.

Fit tool (600747) into the reverse shaft shimming hole and position a D.T.I. on the end of the tool as shown. Then using a suitable pry bar through the upper access hole, measure and note the shaft end float.

Remove the rear case and add or remove shims as necessary to give .0,025mm to .0,076mm inches end float on all shafts Repeat steps 10:13 to 10:18 until all shaft end floats are correct. Then fit new sealing rings to the shafts.

62

10-19

10-20

Refit the rear case, using an approved liquid gasket (Loctite 5203), taking care not to damage the shaft sealing rings. Tighten the 17 bolts to a torque of 55 to 75 Nm. Then replace the shaft end plug and O ring assemblies.

Fit new expansion plugs to the shimming access holes using an approved sealant (Loctite 649).

10-21

10-22

Lubricate the seals with transmission fluid then re-fit the pressure regulator valve and tighten to a torque of 45 to 64 Nm.

Lubricate the seals with transmission fluid then re-fit the converter regulator valve and tighten to a torque of 23 to 30 Nm.

10-23

10-24

Re-fit the cold start housing, spring and ball.

Then tighten to a torque of 45 to 64 Nm.

Refit the filter housing using 2 new O rings.

Tighten the two bolts to a torque of 45 to 64 Nm.

63

10-25

10-26

Lubricate the seal with a light grease and screw on a new oil filter. Tighten to a torque of 7 to 10 Nm.

Refit the strainer, spacer, O ring and cover plate.

Then tighten the two screws to a torque of 18 to 31 Nm.

10-27

10-28

Refit the speed probe, sealing washer and locknut. Adjust. then tighten the locknut to a torque of 25,5 Nm and seal with Loctite 542 (see notes for correct adjustment).

Re-fit the temperature sender. Then tighten to a torque of 20 to 27 Nm.

10-29

10-30

Lubricate the seals with a light grease and re-fit the Speed Clutch 1 solenoid spool. Tighten to a torque of 26 to 39 Nm. Then refit the solenoid coil and nut. Tighten to a torque of 2,7 to 5,4 Nm.

Refit the external transfer pipe using 4 new copper washers . Then tighten the 2 banjo bolts to a torque of 40 to 46 Nm.

64

10-31

10-32

Refit the dipstick tube bracket and tighten the 2 capscrews to a torque of 7 to 9 Nm.

Fit a new O ring to the dipstick tube assembly.

10-33

10-34

Insert the dipstick tube assembly through the bracket and fit to the case. Tighten the 2 capscrews to a torque of 45 to 64 Nm.

Re-fit the 4wd spacer and Yoke.

10-35

10-36

Replace the 4wd O ring , washer and bolt. Then tighten to a torque of 68 to 88 Nm.

Replace the output flange, O ring , washer and bolt. Then tighten to a torque of 68 to 88 Nm.

65

10-37

10-38

Ensure the 4 O rings are in place then re-fit the Speed Clutch 2 and 3 control valve assembly and tighten the 4 cap screws to a torque of 7 to 9 Nm. Then re-fit the 4 plastic caps to the capscrew holes.

NOTE : The valve can only be fitted one way round as it is located by a small dowel pin.

Ensure the 4 O rings are in place then re-fit the Reverse control valve assembly and tighten the 4 cap screws to a torque of 7 to 9 Nm. Then refit the 4 plastic caps to the capscrew holes.

NOTE : The valve can only be fitted one way round as it is located by a small dowel pin.

10-39

Ensure the 4 O rings are in place then re-fit the Forward control valve assembly using 4 capscrews, and spacers if fitted. Then tighten the 4 cap screws to a torque of 7 to 9 Nm. Then re-fit the 4 plastic caps to the capscrew holes.

NOTE : The valve can only be fitted one way round as it is located by a small dowel pin.

66

67

ELECTRICITY A - E.C.U. The E.C.U (Electronic Control Unit) controls the transmission.

It controls several gearbox functions: • gear changes • kickdown function (according to model) • diagnostics on the harness to the solenoid valves • diagnostics of inputs.

Situated in the cab at the front right of the driver.

E.C.U operating process :

Information from inverter lever

Output to display on control panel

Information from speed sensor

Information originating from handbrake / transmission cut-off

E.C.U.

Information originating from the switch crawling speed (5th gear speed)

Solenoid valve supply

68

+12V AC

F9:5A

F8:15A

1

25

24

69

BAT 12V

-

HANDBRAKE SWITCH

+

HANDBRAKE ON LED

AMP 1

PREHEATING

IGNITION KEY

+ IGNITION ON

2

DISTRIBUTOR LEVER

TRANSMISSION CUT-OFF SWITCH

12

13

36

3

1

10

9

4

8

2

7

5

1

0

STARTER MOTOR CONTROL

BRAKE PEDAL

6

+

5 1

HR

D±

Alt

B+

W

+

CT

SPEED SENSOR

TRNASMISSION CUT-OFF DIAGNOSTIC CATCHER

SWF MANIPULATOR BATTERY CHARGING LED

1

2

4

TRANSMISSION CUT-OFF

K18

3

5TH GEAR LOCK

CRAWLER SWITCH

GEAR N°4

GEAR N°3

GEAR N°2

GEAR N°1

R

F

FORWARD GEAR F. REVERSE GEAR R

K

KICK DOWN

E.C.U. SUPPLY

19

7

20

21

22

6

3

26

23

2

24

1

25

36

16

18

9

ELECTRONIC CONTROL UNIT 10

SPEEDOMETER

17

8

35

11

14

15

34

33

32

31

30

29

28

12

13

INPUT

BRAKE ON INFO

RELAY K8 : 30A

OUTPUT

+ FUS.F8

REVERSING ALARM OUTPUT

G

F

E

D

C

B

A

RELAY CONTROL

SERIAL COMM.

3

K2

shint 5

RELAY CONTROL

D

RELAY K3 : 20A

REVERSING LIGHTS

STARTER MOTOR

OUPUT

B

BUZZER

EV C

EV 3

EV 2

EV 1

EV R

EV H

EV L

B - Wiring diagram (MLT --- 120 LSU POWERSHIFT Série B-E2)

R1

+12V AC

F9:5A

F8:15A

70

-

BAT 12V

+

contacteur frein à main (serré)

8

2

R

3

2

4

7

5

1

6

9

10

8

up

CLEF DE CONTACT

+ APRES CONTACT

inter de selection coupure transm.

MODULE INTERFACE

14

1

F N

lampe témoin frein serré

INFO NEUTRE

JSM

2

2

R1

3

7

3

2

1

pédale de frein

6

10

1

down

4

5

CDE DEMARREUR

0 1

PRECHAUFFAGE

1

1

0

+

1

7

HR

5

D±

Alt

B+

W

inter suppr.5ème vitesse AV

lampe témoin de charge batterie

10

9

+

coupure transmission

CT

capteur de vitesse

inter crawler

(+) pour 5eme vitesse AV

vitesse AV n∞ 3 vitesse AR n∞ 2 vitesse AV n∞ 4 vitesse AR n∞ 3

vitesse AV n∞ 1 vitesse AR n∞ 1 vitesse AV n∞ 2

R

marche AR

coupure transmission

11

13

9

12

6

5

4

F

K

marche AV

kick_down

ALIM. E.C.U.

17

16

8

9

1

25 24

10

18

AFFICHEUR VITESSE

19

7

20

21

6

22

3

26

23

2

24

1

25

36

35

11

14

15

34

33

32

31

30

29

28

12

13

SERIAL COMM.

ELECTRONIQUE CONTROL UNIT

Prise test

AMP 1

option

option

12

13

36

sortie alarme recul

G

F

E

D

C

B

A

K2 5

sécurité démarrage RELAIS K8:30A

RELAIS K3:20A

3

shunt

D

B

Buzzer

DEMARREUR

feux de recul

EV C

EV 3

EV 2

EV 1

EV R

EV H

EV L

B - Wiring diagram (MLT 735 120 LSU POWERSHIFT Série 2-E2)

C - E.C.U. checking procedure As soon as the ignition is switched on, the E.C.U checks the output harnesses (E.C.U to solenoid valves) and input harnesses (from the inverter lever to E.C.U) in order to detect short circuits and breaks in the harness.

The E.C.U starts by checking the output harnesses and, if the test is correct, the input harnesses can be checked.

ECU output harness When the ignition is switched on, if no problems are detected on the harnesses, the letter "n" is shown on the display corresponding to the neutral position of the inverter lever.

If there is a fault on the outputs, the display shows lever "E" (error) for two seconds then reverts to the letter "n".

The faulty harness can be identified.

1st case: assembly with SWF manipulator (Fig. 1): Cross then restore the contact of the machine all while maintaining supported the button Kick Down (Fig. 2).

Fig. 1

Fig. 2

2nd case: assembly with JSM manipulator (Fig. 3): Cut the contact of the machine, schunt the diagnostic socket (fig. 4) then restore the contact.

Fig. 3

Fig. 4

X

+

Schunt

71

X

The display then shows the letter "E" followed by a number corresponding to the faulty harness.

Example : then

Errors codes on the output harness

- Fault on forward gear low FL solenoid valve

- Fault on forward gear high FH solenoid valve

- Fault on reverse gear solenoid valve

- Fault on 1st gear solenoid valve

- Fault on 2nd gear solenoid valve

- Fault on 3rd gear solenoid valve

- Fault on crawler solenoid valve

- Fault on microprocessor

72

E.C.U input harness The input harnesses are only checked if there are no faults on the outputs and after having switched the ignition off and then back on again whilst pressing the kick down button.

The control panel display is used for the checking procedure. Each display segment corresponds to an E.C.U input pin.

- Transmission cut-off pin

- Reverse gear on inverter pin

- Forward gear on inverter pin

- 4th gear on inverter pin

- 3rd gear on inverter pin

- 1st gear on inverter pin

- 2nd gear on inverter pin

- Neutral on inverter pin

- 5th gear locking switch

73

E.C.U connections

+ 12V ignition on

0V

36

13

Forward gear input

1

Reverse gear input

24

28

Kick down input

25

29

E.C.U.

12

0 V common Forward gear low solenoid valve Forward gear high solenoid valve Reverse gear solenoid valve 1st gear solenoid valve

1st gear input

2

2nd gear input

23

3rd gear input

26

32

4th gear input

3

33

2nd gear solenoid valve 3rd gear solenoid valve

5th gear cut-off input (trailer switch)

22

34

Crawler solenoid valve

Not used

27

35

OK to start in neutral output

Not used

4 21

15

Reversing alarm output

5

11

Not used

20

14

Not used

6

16

5 V - display

19

10

0V display

Cut-off by handbrake Not used Cut-off by brake pedal or control valve Crawler input Speed sensor earth

30 31

9 Speed sensor return F<10KHz

7

18

8

Communication port

74

17

Clock - display Data - display

D - Additional information about the forward speed sensor mounted on the PG 115 TURNER powershift gearbox - The speed sensor analyses the rotational speed of the transmission output shaft.

- It informs the E.C.U in order to authorise the automatic gear change from 4th to 5th gear (1112 Hz, approximately 16.5 kph).

- It also protects the gearbox when changing down gears and changing the direction of travel in accordance with the following values:

Gear change down 2 1 3 2 4 3 5 4

Max frequency in Hz 578 933 1230 1986 1032

Change of direction 5 4 Forward Then 3 Reverse 3 2 Forward Then 2 Reverse

Speed in kph Approx. 8,5 Approx. 14 Approx. 18.4 Approx. 29,5 for kick down Approx. 15,4 Auto

Speed in kph If V < 29,5 If V < 18,4 If V < 14

Sensor assembly :

Speed gear sensor

Gearbox output

0.4 mm or tighten fully then undo by 3/4 of a turn

75

76