DOWNLOAD PDF: Manitou MLT 845, MLT-X 845 Repair manual

®

BP 249 Z. I. 44 158 ANCENIS CEDEX FRANCE TEL : 02 40 09 10 11

YOUR DEALER

REF : 547526 EN (13 / 01 / 1999)

MLA 627 REPAIR MANUAL

1st DATE OF ISSUE CATALOGUE INFORMATION

13 / 01 / 1999

DATE OF ISSUE

13 / 01 / 1999

OBSERVATIONS - 1st ISSUE

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

CONTENTS Groups

Chapters

0

General points

0-1-M27 EN

Characteristics

10

I.C. Engine

10-3-5 et 6 EN

Engine disassembly

20

Gear box / converter

20-3-8 EN

Gear box / converter disassembly “ POWER SHIFT “

30

Axle assembly

30-3-7 EN

Axle disassembly 172 - 177 - 272 - 277 - 279

70

Hydraulic

70-3-80-M27 EN

Cylinder disassembly

70-6-M27 EN

Hydraulic diagram

70-7-M27 EN

Hydraulic circuit

70-7-20-M27 EN

Plate of hydraulic details

70-8-30 EN

Operation - Adjustment : balancing valve

70-8-35 EN

Test stand “ Valve adjustment“

70-8-40-M20 EN

LS pump operation

80

Electricity

80-6-M27 EN

Electric diagram

80-8-14-M22 EN

Operation of the “ EGS “ shift lever

80-8-80-M27 FR

Safety system adjustment

GROUP 0

GENERAL POINTS

CHARACTERISTICS MLA 627 0-1-M27 EN

13 / 01 / 1999

3

CHARACTERISTICS ENGINE Type Cylinders Strokes Injection system Ignition order Rocker arm clearance (cold) - Aspiration - Exhaust Engine size Bore Stroke Volume ratio Rated speed Idle speed Max. speed under no load conditions Power DIN 70.020 Maximum torque

Perkins 1004-4T 4 4 direct 1.3.4.2.

0,20 mm 0,45 mm 3990 cm3 100 mm 127 mm 16,0:1 2300 rpm 775 rpm 2475 rpm 106 CV - 78 KW 349 Nm at 1800 rpm

COOLING CIRCUIT Type Suction fan - Bladess - Diameter Thermostat - Initial opening - Fully open

water 6 18 in 75°C/85°C 92°C/98°C

ELECTRIC SYSTEM Mass Battery Alternator Voltage regulator Start-up

Negative 12V - 120 Ah 12V - 55 A built into the alternator 12 V

TRANSMISSION Type Gearbox

Hydrodynamic Power shift with steering wheel electric control 4 3 Electric

- N° of forward gears - N° of reverse gears Reverser 4

BRAKES Type Service brake

oil-bath discs power pedal brake, that acts on front and rear wheels manual control, acts on front axle

Parking brake FRONT AXLE Type Wheel hub reducer Differential lock

rigid epicycloid limited slip

REAR AXLE Type Wheel hub reducer Differential lock

rigid epicycloid limited slip

FRONT AND REAR TYRES STANDARD Dimensions Inflation pressure

15,5/80 - 24 Suregrip 3,3 Bar

OPTIONAL Dimensions Inflation pressure

15,5/80 - 24 Suregrip 3,3 Bar

HYDRAULIC SYSTEM Movement circuit: Pump type Capacity at 2300 rpm Pressure

gears 100 l/min 230 bar

Steering circuit : Type Pressure

load-sensing 175 bar

Brake circuit : Pump type Capacity at 2300 rpm Pressure

gears 9 l/min 120 bar

5

SPECIFICATIONS Truck maximum running speed : I II III IV

FORWARD 5,9 Km/h 11,3 Km/h 23 Km/h 33 Km/h

REVERSE 5,9 Km/h 11,3 Km/h 23 Km/h

Standard lifting height

5450 mm

Rated capacity with STD equipment Forks

2700 Kg

Load centre

500 mm

Weight of truck with STD equipment Forks

6700 Kg

Distribution of the weights and axle with STD equipment Forks front axle rear axle

2930 Kg 3770 Kg

Dimensions of standard forks (length x width x thickness) :

Maximum gradeability unladen laden

1200 x 125 x 45 mm

> 100% > 100 %

Suspensions Oscillating rear axle

Tank capacity hydraulic oil fuel

120 l 120 l

6

DIMENSIONS AND LOAD CHART

MLA 627

7

A

1200 MM

B

2500 MM

C

1415 MM

C1

1430 MM

D

5350 MM

F

1760 MM

G

460 MM

G1

375 MM

G2

435 MM

H

2680 MM

I

1435 MM

K

1170 MM

L

45 MM

N

2015 MM

O

125 MM

P2

42 °

P3

27 °

R

4080 MM

U

45 °

V

4600 MM

V1

2125 MM

V2

4225 MM

W

2200 MM

Y

10 °

Z

156 °

MLA 627 T

MLA 627 T

7

7

6

6 5.45

5.45 5

1150kg

2

1

3

2

1

0.5m

0

2700kg

2000kg

4

1250kg 1500kg

3

1500kg 2000kg

4

2400kg

5

0.5m

3 2.70 3.42

2 1.89 2.15

1

0m

-1 4

SUIVANT NORME pr EN 1459 annexe B.

3 2 2.80 1.70 3.23 2.25

1

0m

SUIVANT NORME pr EN 1459 annexe B.

8

N°217948

-1 4

N°217425

0

FILTERS CARTRIDGES AND BELTS

2

5 1

3 4

7 6

8

PART NUMBER

DESIGNATION

▲

9

CLEAN

CHANGE

1 Engine oil filter

133755

2 Air filter cartridge ▲

185578

3 Transmission oil filter

550145

Every 400 H

4 Fuel filter cartridge

49660

Every 400 H

5 Hydraulic oil filter cartridge (exhaust)

485696

Every 400 H

6 Hydraulic oil filter cartridge (intake)

77402

Every 800 H

7 Air filter safety cartridge ▲

484952

Every 800 H

8 Engine belt

474948

Every 800 H

9 Cab air filter

527427

:In heavily dust laden atmosphere, reduce this servicing schedule.

9

Every 400 H Every 50 H

Every 800 H

Every 400 H

LUBRICANTS

LUBRICATED PART

CAPACITY

RECOMMENDED PRODUCT

- I.C. ENGINE

7,6 L

oil MANITOU SAE 15W/40

- HYDRAULIC OIL TANK

120 L

oil MANITOU HYDRAULIQUE ISO 46

- GEARBOX

15,5 L

oil SHELL DONAX TA

- FRONT AND REAR AXLE DIFFERENTIAL

8,5 L

oil MANITOU Special brakes immersed

- FRONT AXLE REDUCTION GEAR - FRONT AND REAR WHEEL FINAL DRIVES

5L 5L each

oil SHELL SPIRAX HD 80W/90

- GENERAL GREASING

Grease SHELL RETINAX HD

- TELESCOPIC BOOM LUBRICATION - PIVOTS

Grease SHELL RETINAX HDM

- COOLING SYSTEM

15 L

MANITOU ANTIFREEZE

- FUEL TANK

120 L

Diesel fuel

10

GROUP 10

I. C. ENGINE

GROUP 20

GEAR BOX / CONVERTER

GEAR BOX DISASSEMBLY GEAR BOX "POWER SHIFT" 20-3-8EN

13 / 01 / 1999

TABLE OF CONTENTS T12000 TRANSMISSION ASSEMBLY HOW THE UNITS OPERATE SECTIONAL VIEWS AND PARTS IDENTIFICATION Transmission Case and Plate Group

Fig. A

Converter Group

Fig. B

Transmission Case Group

Fig. C

Converter Group

Fig. D

Pump Gear Group

Fig. E

Pump and Filter Group

Fig. F

Reverse Gear Group

Fig. G

Forward and Reverse Group

Fig. H

Output Shaft and 3rd High Group

Fig. I

1st and 2nd Group

Fig. J

Output Shaft Group

Fig. K

Control Valve Group - Modulation

Fig. L

Assembly Instruction

Fig. M,N,O,P,Q

DISASSEMBLY OF TRANSMISSION

1

REASSEMBLY OF TRANSMISSION

65

CLUTCH ENGAGEMENT (POWER FLOW) 4 SPEED

90

CLUTCH ENGAGEMENT (POWER FLOW) 3 SPEED

91

SPECIFICATIONS AND SERVICE DATA

92

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL

94

PRESSURE CHECK POINTS

96

CLEANING AND INSPECTION

99

TROUBLESHOOTING GUIDE

100

CONVERTER STALL PROCEDURE

101

DESCRIPTION

103

T12000 TRANSMISSION ASSEMBLY The transmission and hydraulic torque converter portion of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first understand their function and how they operate.

The transmission and torque converter function together and operate through a common hydraulic system. It is necessary to consider both units in the study of their function and operation.

The electric shift control valve is located in the vehicle's operator compartment. The function of the control is to energize the selected solenoid valves thus directing the oil under pressure to the selected directional and range (gear) clutches. The purpose of the range or directional clutches is to direct the power flow through the gear train to provide the desired speed range and direction.

An axle disconnect is optional and is located on the output shaft. The drive to the front axle can be disconnected or connected by manual, pneumatic, or hydraulic shifting.

When either directional clutch is selected the opposite clutch is relieved of pressure and vents back through the direction selector solenoid. The same procedure is used in the speed selector.

The direction or speed clutch assembly consists of a drum with slots and a bore to receive a hydraulically actuated piston. The piston is "oil tight" by the use of sealing rings. A steel disc with external tangs is inserted into the drum and rests against the piston. Next, a friction disc with splines at the inner diameter is inserted. Discs are alternated until the required total is achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with O.D. splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch.

To engage the clutch, the electric shift control lever is placed in the desired position. This energizes the selected direction and range (gear) solenoids allowing the oil under pressure to flow through tubes and passages to the selected clutch shafts. Oil sealing rings are located on the clutch shaft. These rings direct oil under pressure through a drilled passageway in the shaft to a desired clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs with tangs on the outer diameter clamping against discs with teeth on the inner diameter enables the hub and clutch shaft to be locked together and allows them to drive as a unit.

There are bleed balls in the clutch piston or clutch drum which allow quick escape for oil when the pressure to the piston is released.

HOW THE UNITS OPERATE With the engine running, the transmission charging pump draws oil from the transmission sump through the oil suction tube and screen and directs it through the pressure regulating valve and oil filter.

The pressure regulating valve maintains pressure to the transmission solenoid valves for actuating the direction and speed clutches. This regulator valve consists of a hardened valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in the closed position. When a specific pressure is achieved, the valve spool works against the spring until an exhaust port is exposed along the side of the bore. This sequence of events provides the proper system pressure. This requires a small portion of the total volume of oil used in the system.

The remaining volume of oil is directed out through an external oil cooler and into the lube inlet port. From the lube inlet port oil goes through the forward-reverse shaft, lubricating the forward and reverse clutches, with the remainder going to the torque converter. After entering the converter, the oil is directed through the converter blade cavity and exits in the passage between the turbine shaft and impeller hub. The oil then lubes the impeller hub bearing with the remainder going to the 3rd-2nd clutch shaft and 1st-2nd clutch shaft to lubricate those clutches and shaft bearings. The oil then gravity drains to the transmission sump.

The hydraulic torque converter consists basically of three elements and their related parts to multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller element through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump in that it picks up fluid at its center and discharges at its outer diameter.

The torque converter turbine is mounted opposite the impeller and is connected to the output shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its center. Fluid directed by the impeller out into the particular design of blading in the turbine and reaction member is the means by which the hydraulic torque converter multiplies torque.

The reaction member of the torque converter is located between and at the center of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element.

The torque converter will multiply engine torque to its designed maximum multiplication ratio when the output shaft is at zero R.P.M. Therefore, we can say that as the output shaft is decreasing in speed the torque multiplication is increasing.

With the engine running and the electric shift control lever in neutral position, oil pressure from the regulating valve is blocked at the solenoid control valves, and the transmission is in neutral. Movement of the control lever will energize the forward or reverse solenoid valves and selected range (gear) solenoid, directing oil under pressure to the selected direction and range (gear) clutches.

10

MOUNTING LOCTITE 518

17 16 9

3

1

4

5

6

11 12 13

7

2

19

8

Figure A

18

14 15

TRANSMISION L.H. HOUSING T12000 (FIG. A) ITEM

DESCRIPTION

QUANTITY

1

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

End yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Front housing . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Bottle of airtightness product . . . . . . . . . . . . .1

11

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

12

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

15

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

16

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

17

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

18

Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1

2

17

17

3 17

1 17 4

11 12 9 5

10

7 8

17

17

6

6

Figure B

CONVERTER HOUSING T12000 (FIG. B) ITEM

DESCRIPTION

QUANTITY

1

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Converter housing . . . . . . . . . . . . . . . . . . . . . .1

6

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

7

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

8

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

9

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

10

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

11

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

12

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

17

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

14 11 11 14 15 9 8 40 16 7 16 5 10

1

2

6

4

18

28

20 19

29 30

19 20 39 26

36 3 37

22 21

36 33

35 34

31 32

25 24 23

Figure C

TRANSMISION HOUSING T12000 (FIG. C) ITEM

DESCRIPTION

QUANTITY

ITEM

DESCRIPTION

QUANTITY

1

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26

Drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Strut plate . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Oil converter temperature sensor . . . . . . . . . .1

31

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

6

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

7

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

8

Transmision housing . . . . . . . . . . . . . . . . . . . .1

34

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

9

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

37

Valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

38

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

15

Air breather . . . . . . . . . . . . . . . . . . . . . . . . . . .1

39

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

16

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

40

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

20

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

21

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

17 20 18

12 13 14 15

7

5

1

2

3

8

16

9 10 11

6

4

Figure D

CONVERTER T12000 (FIG. D) ITEM

DESCRIPTION

QUANTITY

1

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Gear (35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

1

2

3

4

5

8

Figure E

7

PUMP GEAR T12000 (FIG. E) ITEM

DESCRIPTION

QUANTITY

1

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Gear (31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

7

8

10

9

11 14 12 13 17

1 2

4

3

5

18 16 15 19

Figure F

PUMP AND FILTER T12000 (FIG. F) ITEM

DESIGNATION

QUANTITY

1

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

11

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

12

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Complete coupling . . . . . . . . . . . . . . . . . . . . .1

3

4

9

5

6

7

8

1

2

Figure G

REVERSE GEAR T12000 (FIG. G) ITEM

DESCRIPTION

QUANTITY

1

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14 13 12 REVERSE

11 10 9 8 7 6 22

5

24

43 42 41

23

4

37

3

36

21

44

20 45

2

16 35 19

34 48 47 46

18 17

33 32 31

15

30 29 40 28

FORWARD

27 26 25

39 38

Figure H

FORWARD AND REVERSE T12000 (FIG. H) ITEM

DESCRIPTION

QUANTITY

ITEM

DESCRIPTION

QUANTITY

2

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

27

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

5

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

30

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

34

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

35

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

37

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Spring washer . . . . . . . . . . . . . . . . . . . . . . . .1

38

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

15

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

39

Valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

40

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

41

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

42

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

43

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

44

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

45

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

46

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

47

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24

Spring washer . . . . . . . . . . . . . . . . . . . . . . . . .1

48

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

51 52 50 9 7 6 5

53

49 8

4 3 2

h 4t

1

18 17

15

16

14

24

13 12

23

11

22

10

3rd

20 19

33

21 32 31 30

27 29 28 25

48

54

26

42

39

47

41

37

46 45 44

40 38 36 35 34

Figure I

43

OUTPUT SHAFT AND 3rd HIGH T12000 (FIG. I) ITEM

DESCRIPTION

QUANTITY

ITEM

DESCRIPTION

QUANTITY

1

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29

Spring washer . . . . . . . . . . . . . . . . . . . . . . . .1

3

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

30

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .5

6

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .5

7

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

34

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

35

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

37

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

38

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

39

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

40

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

41

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

42

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .6

43

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

44

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

45

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Spring washer . . . . . . . . . . . . . . . . . . . . . . . . .1

46

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

47

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

48

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

49

Gear (29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

50

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

51

Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

52

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

53

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

54

Gear (43) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11 10 9

43 44 8

45

7 6

17

5 3

16

2

15

1

14

/ re 1è

13

/ te 1s

/ 1ro

t 1s

12 23

20 22 21

32

19 31 30

18

29 28

me 2è

/ do /2 te /2

d 2n

27 25

42

24

49

46 41 40 39

26 38 48 47 37 36 35 34 33

Figure J

1ST AND 2ND T12000 (FIG. J) ITEM

DESCRIPTION

QUANTITY

ITEM

DESCRIPTION

QUANTITY

1

Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

Valve bank . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

31

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .5

5

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .5

6

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

34

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

37

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

38

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

39

Roller bearing . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Lug disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

40

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Clutch disc . . . . . . . . . . . . . . . . . . . . . . . . . . .1

41

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

15

Friction disc . . . . . . . . . . . . . . . . . . . . . . . . . . .1

42

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

43

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Snap ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

44

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Spring washer . . . . . . . . . . . . . . . . . . . . . . . . .1

45

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

46

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

47

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

48

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

49

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23

Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28

Spring washer . . . . . . . . . . . . . . . . . . . . . . . . .1

15 16 17 11 12 13 14

9 10 18

5 3 1

6

7

8

4

2

Figure K

OUTPUT SHAFT T12000 (FIG. K) ITEM

DESCRIPTION

QUANTITY

1

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

End yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Circlips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

End yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Gear (43 teeths) . . . . . . . . . . . . . . . . . . . . . . .1

1

14

2

13

3

12

4

11

5

10 9 37

8 6

36 7

34

33

38

35

30 26 27 28 29

21 20 19 18

17 15 16 32

Figure L

ELECTRIC CONTROL WITH MODULATION T12000 (FIG. L) ITEM

DESIGNATION

QUANTITY

1

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6

Upper pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12

Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . .1

14

Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15

Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17

Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18

Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20

Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32

Complete electrovalve . . . . . . . . . . . . . . . . . .5

33

Upper pin . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

34

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35

"O" ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36

Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

37

Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

38

Complete sensor . . . . . . . . . . . . . . . . . . . . . . .1

3 SPEED ASSEMBLY INSTRUCTION

Oil filter

REVERSE IDLER VIEW H

View F

View T REV.

FWD.

View K View H

3rd

C

SECTION C-C

C

Expander

1st

2nd

SECTION A-A (See reference Figure Q)

Piston ring

VIEW T Figure M

4 - 6 SPEED ASSEMBLY INSTRUCTION

View K

Oil filter .13 (3,2)

View F View T View K

REV.

FWD.

View H

4th HI

1st

3rd

VIEW F Enlarged view of seal

2nd

SECTION A-A (See reference Figure Q) Figure N

1

Assemble oil filter and tighten to 27 à 34 N.m.

23 Use 3/8-16 x 5,00 screw.

2

Teflon seals must be sized prior to assembly.

10 outer steel plates - 10 inner plates. Alternately assembly, starting with outer steel plate.

24 Use 5/16-18 x 3,250 screw.

3

4

6 outer steel plates - 6 inner plates. Alternately assembly, starting with outer steel plate.

5

5 outer steel plates - 5 inner plates. Alternately assembly, starting with outer steel plate.

6 7

25 Use 5/16-18 x 2,00 screw.

26 Use 3/8-18 x 3,250 screw.

27 Use 5/16-24 nut.

28 Use 5/16-24 nut.

29 Use 3/8-24 nut.

30 Tighten all cartridge nuts to 5 à 7 N.m.

Shield bearing - assembly with shield as shown.

Fwd.Rev.2nd and 3rd, clutch return disc springs.

Concave side of first disc spring to be placed against clutch piston wear sleeve. Remaining four springs to be stacked alternately as shown.

ASSEMBLY NOTES : Use Permatex and Loctite only where specified.

All lead in chamfers for oil seals, piston rings, and "O" rings must be smooth and free from burrs.

Inspect before assembly.

Lubricate all piston ring grooves and "O" rings with oil before assembly.

Apply a thin coat of grease between seal lips on lip type seals prior to assembly.

8

Low clutch return disc springs concave side of first disc spring to be placed against clutch piston wear sleeve. Remaining six springs to be stacked alternately as shown.

Apply a thin coat of grease of Permatex No. 2 or Loctite Ref. 561176 to O.D. of all oil seals before assembly.

Apply a thin coat of Loctite Ref. 561176 or Dryseal No. 506 to all pipe plugs.

After assembly of parts using Loctite or Permatex, then must not be any free or excess material which might enter the oil circuit.

Clearance between clutch piston and steel separator 10 plate to be 1,22 - 2,74. If over 2,74 clearance, add

one steel outer disc under end plate.

Clearance between clutch piston and steel separator 11 plate to be 2,03 - 3,43. If over 3,43 clearance, add

one steel outer disc under end plate.

13 Tighten regulator sleeve to 61 - 68 N.m.

Use solenoid bore plug in middle position for 3 speed

14 version only.

Solenoid cartridge to be assembled and tightened to

15 22 - 27 N.m.

Assemble speed sensor adjusting bushing using 16 Loctite Ref. 4500 095 and stake threaded area three

places equally spaced and apply torque 61 to 68 N.m.

19 19

M10 x 1,17 - 1,20

20 20

M10 x 2,32 - 2,40

21 21

Use 5/16-18 x 5,00 screw.

22 22

Use 5/16-18 x 3,500 screw.

Figure O

19 & 20 Clean mounting surfaces and tapped holes with solvent. Dry thoroughly, being certain tapped holes are dry and clean. Install components and special self-locking screws. Tighten screws to proper torque perchart.

NOTE : Assembly of components must be completed within a 15 mn period from start of screw installation. The special screw is to be used for one installation only. The screw is removed for any reason, it must be replaced. The epoxy left in the tapped holes must be removed with the proper tap and cleaned with solvent. Dry holes thoroughly and use a new screw for reinstallation.

If special capscrews are not available, clean epoxy from threads and dry thoroughly. Apply Loctite ref. 561176 thread locker to threads.

Install capscrews in the proper locations and tighten to specified torque (See torque chart).

TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS NOMINALE SIZE

M10 M12

GRADE 8,8 or 9,8

GRADE 10,9

COARSE THREAD lbf·ft [n·m] 30-37 [40-50] 50-55 [65-75]

COARSE THREAD lbf·ft [n·m] 44-48 [60-65] 74-81 [110-110]

PIPE PLUG TORQUE CHART TORQUE THREAD NPTF

lbf·ft

[N·m]

1/16-27 1/8-27 1/4-18 3/8-18 1/2-14 3/4-10

5-7 7-10 15-20 25-30 30-35 40-45

[7-9] [9-14] [20-27] [34-41] [41-47] [54-61]

PERMANENT PLUG METRIC TORQUE THREAD SIZE

lbf·ft

[N·m]

M18 x 1.5 6H M26 x 1.5 6H

25-30 45-50

[34-41] [61-68]

Figure P

SECTION B - B

4T 0) 5 1 . ) (27 75 67 (26.

0 .

3 1 05 1.

for g n i sh bu t tpu Ou

r so en s d ee sp

n. tio p to hif s uto -A

Charging pump SAE-A

After curing of Loctite, speed sensor bushing must be secure with 54,2 N.m. torque.

Filler plug Imput sensor location for auto shift.

Breather

Solenoid bore plug

1,397 (35,48) 1,383 (35,13) 43T 1,067 (27,10) 46T 1,053 (26,75)

Charging pump SAE-B optional

Bushing for speedometer speed sensor - option

Stake 3 places approx. equally spaced

Charging pump SAE-C optional

VIEW REVERSE

TORQUE SPECIFICATION FOR LUBRICATED OR PLATED SCREWS AND NUTS NOMINALE SIZE

GRADE 5 FINE THREAD lbf·ft

.2500 .3125 .3750 .4375 .5000 .5625 .6250 .7500

9-11 16-20 26-29 41-45 64-70 91-100 128-141 223-245

[N·m] [12-15] [22-27] [35-39] [56-61] [87-95] [123-136] [174-191] [302-332]

GRADE 8 COARSE THREAD lbf·ft 8-10 12-16 23-25 37-41 57-63 82-90 113-124 200-220

[N·m] [11-14] [16-22] [31-34] [50-56] [77-85] [111-122] [153-168] [271-298]

Figure Q

FINE THREAD lbf·ft 11-13 28-32 37-41 58-64 90-99 128-141 180-198 315-347

[N·m] [15-18] [38-43] [50-56] [79-87] [122-134] [174-191] [224-268] [427-470]

COARSE THREAD lbf·ft 9-11 26-30 33-36 52-57 80-88 115-127 159-175 282-310

[N·m] [12-15] [35-41] [45-49] [71-77] [108-119] [156-172] [216-237] [382-420]

MAINTENANCE AND SERVICE The instructions contained herein cover the disassembly and reassembly of the transmission in a sequence that would normally be followed after the unit has been removed from the machine and is to be completely overhauled. It must also be understood that this is a basic T12000 intermediate drop output transmission with many options. The units are very similar to trouble-

shoot, disassemble, repair, and reassemble.

CAUTION : Cleanliness is of extreme importance and an absolute must in repair and overhaul of this unit.

Before attempting any repairs, the exterior of the unit must be thoroughly cleaned to prevent the possibility of dirt and foreign matter entering the mechanism.

DISASSEMBLY

Figure 1 Side view T12000 intermediate drop transmission.

Figure 2 Rear view showing disc brake and electric control.

-1-

Figure 4 Remove torque converter plug retainer ring.

Figure 6 Remove torque converter to turbine shaft retainer ring.

Figure 5 Remove plug and "O" ring.

Figure 7 Remove torque converter assembly.

-2-

Figure 11 Remove charging pump permanent pump hole cover.

(Not used when auxiliary pump is used.)

Figure 8 Remove torque converter to shaft locating ring.

Figure 9 Remove filter assembly.

Figure 12 Remove pump mounting bolts and washers. Remove pump and gasket.

Figure 10 Remove pressure regulator and regulator sleeve.

Note : Special tool can be fabricated. (See figure 407A).

Figure 13 Remove converter housing to transmission case bolts and washers.

-3-

Figure 17 Remove pump drive gear and bearing.

Figure 14 Remove converter housing and gasket

Figure 18 Remove solenoid valve cartridge retainer nut and "O" ring.

Figure 15 Remove impeller hub gear.

Figure 19 Remove solenoid coil and "O" ring.

Figure 16 Remove pump drive idler gear washer.

-4-

Figure 20 Remove valve cartridge and "O" ring.

Figure 23 Pry spacer plate away from transmission case at dowel pin holes.

Figure 21 Repeat procedures Figures 18 through 21 for remaining solenoid valves.

A 3 speed will have a bore plug in the center box.

Remove bore plug.

Figure 24 Remove spacer plate and gasket.

Figure 22 Remove spacer plate bolts and washers.

Figure 25 Remove 1st and 2nd clutch assembly.

-5-

Figure 29 Pry bore plug from housing.

Figure 26 Remove forward and reverse clutch assembly.

Figure 30 Note "O" ring on bore plug.

Figure 27 Remove high and 3rd clutch assembly.

NOTE : A 3 speed will only have 3rd clutch.

Figure 31 Remove 3rd clutch to bearing retainer ring.

Figure 28 Remove intermediate shaft bore plug retainer ring.

-6-

Figure 32 Tap 3rd clutch gear and hub from bearing.

Figure 35 Remove inner bearing locating ring.

Figure 33 Remove gear and hub.

Figure 36 Remove outer bearing locating ring.

Figure 34 Tap 3rd clutch rear bearing from housing.

Figure 37 Remove brake disc assembly bolts from brake and housing. NOTE : Brake is an option and will not be on all units.

-7-

Figure 38 Remove brake caliper assembly.

Figure 41 Remove bearing locating ring.

Figure 39 Turn front output flange as shown. Remove retainer ring from ring groove and pry output flange from housing.

NOTE : For units with front axle disconnect see Figure 416, page 76.

Figure 42 Remove output gear to shaft retainer ring.

Figure 40 Output flange, oil seal sleeve and front bearing removed.

Figure 43 Tap output shaft and flange from housing.

-8-

Figure 44 Flange removed. NOTE : Brake disc is optional and was removed with flange.

Figure 47 Remove sleeve and "O" ring.

Figure 45 Remove output gear.

Figure 48 Remove output shaft rear bearing.

Figure 46 Remove flange oil seal sleeve retainer ring.

Figure 49 Remove bearing locating ring.

-9-

Figure 50 Remove modulator valve housing. NOTE : For single modulation and mechanical inching, see Figure 458, page 83.

Figure 53 Remove supply tube clamp screw. NOTE : Clamp screw cannot be reused. For reassembly a new screw must be used.

Figure 51 Remove inner, middle and outer springs. Remove valve stop pin and accumulator spool. Remove regulator spool and sleeve assembly.

Figure 54 Remove supply tube "O" ring.

Figure 52 Remove diverter sleeve. NOTE : Diverter sleeve has a 5/16-24 threaded hole in end of it. A threaded rod screwed into end of it will facilitate removal of diverter sleeve.

Figure 55 Remove supply tube and screen assembly.

- 10 -

Figure 59 Pilot bearing and oil distributor sleeve removed.

Figure 56 Remove oil sleeve distributor lock screw plug.

Remove lock screw.

DISASSEMBLY AND REASSEMBLY OF LOW 1ST AND 2ND CLUTCH DISASSEMBLY LOW 1ST BEING DISASSEMBLED

Figure 57 Use a hammer puller as shown to remove distributor sleeve.

Figure 60 Remove clutch shaft oil sealing rings.

Figure 58 Sleeve being removed. Remove pilot bearing.

Figure 61 Remove front bearing retainer ring.

- 11 -

Figure 65 Clutch gear and pilot bearings removed.

Figure 62 Remove front bearing.

Figure 66 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 63 Remove outer thrust washer, bearing and inner thrust washer.

Figure 64 Remove clutch gear and disc hub.

Figure 67 Remove clutch disc end plate retainer ring.

- 12 -

Figure 68 Remove clutch disc end plate.

Figure 71 Remove retainer ring retainer.

Figure 69 Remove inner and outer clutch discs.

Figure 72 Remove disc springs.

Note : See page 104.

Figure 70 Compress disc springs and remove retainer ring.

Figure 73 Remove clutch piston wear plate.

- 13 -

Figure 77 Remove inner race from shaft.

Figure 74 Turn clutch over and tap clutch shaft on a block of wood to remove clutch piston.

2ND CLUTCH DISASSEMBLY

Figure 75 Remove clutch shaft rear bearing.

Figure 78 Remove gear from shaft.

Figure 76 Using a gear puller as shown, remove gear and rear bearing inner race.

Figure 79 Remove gear locating ring from shaft.

- 14 -

Figure 83 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 80 Remove thrust bearing and clutch gear retainer ring.

Figure 84 Remove clutch disc end plate retainer ring.

Figure 81 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 85

Figure 82 Remove clutch gear and hub and gear bearings.

Remove end plate.

- 15 -

Remove clutch discs.

Figure 86

Figure 89 Remove disc springs.

Note : See page 104.

Figure 87 Compress disc springs and remove retainer ring.

Figure 90 Remove clutch piston wear plate.

Figure 88 Remove retainer ring retainer.

Figure 91 Remove clutch piston.

- 16 -

REASSEMBLY OF LOW (1ST) CLUTCH (See cleaning and inspection page)

Figure 92 Two bleed valves in clutch drum must be clean and free of any foreign material.

Figure 94 Position piston in low clutch drum as shown. Use caution as not to damage inner and outer piston sealing rings.

Figure 92A Install clutch piston outer seal ring.

Figure 95 Position clutch piston wear plate on piston.

Figure 93 Install clutch piston inner seal ring. Note : Ring must be sized before installing in clutch drum. Sizing is best accomplished by rotating piston while holding a round object against the new seal ring as shown. Rotate piston until seal ring is flush with outer diameter of piston.

Figure 96 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate seven (7) springs.

Note : See page 104.

- 17 -

Figure 97 Position return spring retainer on clutch shaft.

Figure 100 Install first steel (outer) clutch disc.

Figure 98 Start ring on shaft with snap ring pliers.

Figure 101 Install first friction (inner) clutch disc. Alternate steel and friction until ten (10) steel and ten (10) friction discs are in position.

Figure 99 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring.

Be sure ring is in full position in groove.

Figure 102 Install clutch disc end plate.

- 18 -

Figure 104 Position thrust bearing inner washer on clutch shaft.

Figure 103 Install end plate retainer ring.

Figure 105 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 103 Note : Low (1st) clutch pack must be checked for clutch disc clearance.

Stand the clutch assembly on end. The clutch discs on the bottom will fall to the end plate.

Measure the distance between the clutch piston and the first steel disc by inserting a feeler gauge or taper gauge through the slots in the clutch drum.

The required clearance is 2,03 - 3,43.

If the clearance is greater than 3,43, add one steel disc under the end plate.

Figure 106 Install outer thrust bearing against bearing.

- 19 -

Figure 107 Press bearings in clutch gear and disc hub, being certain bearings are pressed flush with face of gear on both sides.

Figure 110 Position thrust bearing on shaft.

Figure 108 Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly.

Do not force this operation.

Figure 109 Position inner thrust washer on shaft.

Figure 111 Position outer thrust washer on shaft.

- 20 -

Figure 114 Install clutch shaft oil sealing rings. Grease rings to facilitate reassembly into front housing.

2ND CLUTCH REASSEMBLY

Figure 112 Install clutch shaft front bearing.

Note : Bearing has a shield in it. This shield must be up.

Figure 115 Install inner and outer clutch piston seal rings. Size inner ring as explained in figure 93.

Figure 116 Position piston in clutch drum, using caution as not to damage piston sealing rings.

Figure 113 Install front bearing retainer ring.

- 21 -

Figure 117 Install clutch piston wear plate.

Figure 120 Start ring on shaft with snap ring pliers.

Figure 118 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate five (5) springs.

Note : See page 104.

Figure 121 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be sure ring is in full position in groove.

Figure 119 Position return spring ring retainer on clutch shaft.

- 22 -

Figure 122 Install first steel (outer) clutch disc.

Figure 125 Install end plate retainer ring.

Figure 123 Install first friction (inner) clutch disc. Alternate steel and friction until five (5) and five (5) friction discs are in position.

Figure 126 Position thrust bearing inner washer on clutch shaft.

Figure 127 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 124 Install clutch disc end plate.

- 23 -

Figure 128 Install outer thrust bearing washer against thrust bearing.

Figure 131 Position thrust bearing inner washer on clutch shaft.

Figure 129 Press needle bearings in clutch gear and disc hub, being certain bearings are pressed flush with face of gear on both sides.

Figure 132 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 130 Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs.

Be sure the clutch hub is in full position in the clutch assembly. Do not force this operation.

Figure 133 Install outer thrust bearing washer against bearing.

- 24 -

Figure 134 Install thrust washer retainer ring.

Figure 137 Install rear bearing inner race on clutch shaft with bearing race shoulder down.

Figure 135 Install clutch shaft gear locating ring.

Figure 136 Install clutch shaft gear on clutch shaft with long hub of gear down.

Figure 138 Position rear bearing on bearing race.

- 25 -

DISASSEMBLY AND REASSEMBLY OF 3RD AND 4TH (HIGH) CLUTCH 4TH CLUTCH USED ON 4 AND 6 SPEED MODELS ONLY DISASSEMBLY

Figure 141 Remove clutch gear locating ring. For 3 speed models, proceed to figure 155.

Figure 139 Remove clutch shaft oil sealing rings.

Figure 142 Remove outer thrust washer retainer ring.

Figure 140 Using a gear puller as shown, remove clutch gear and front bearing.

Figure 143 Remove outer thrust washer, thrust bearing and inner thrust washer.

- 26 -

Figure 147 Remove end plate retainer ring.

Figure 144 Remove clutch gear and disc hub.

Figure 148 Remove end plate.

Figure 145 Remove bearings and spacer from clutch gear.

Figure 146 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 149 Remove clutch discs.

- 27 -

Figure 150 Compress disc springs and remove retainer ring.

Figure 153 Remove clutch piston wear plate.

Figure 151 Remove retainer ring retainer.

Figure 154 Remove clutch piston.

DISASSEMBLY OF 3RD CLUTCH

Figure 155 Remove thrust washer retainer ring. Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 152 Remove disc springs; Note : See page 104.

- 28 -

Figure 156 Remove end plate retainer ring.

Figure 159 Compress disc springs and remove retainer ring.

Figure 157

Figure 160 Remove retainer ring retainer.

Figure 158 Remove clutch discs.

Figure 161 Remove disc springs.

Note : See page 104.

Remove end plate.

- 29 -

Figure 162 Remove clutch piston wear plate.

Figure 165 Install inner and outer clutch piston seal rings. Size inner ring as explained in figure 93. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.

Figure 163 Remove clutch piston.

REASSEMBLY OF 4TH CLUTCH (See cleaning and inspection page)

Figure 166 Install clutch piston wear plate.

FOR 3 SPEED PROCEED TO FIGURE 183

Figure 167 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate five (5) springs.

Note : See page 104.

Figure 164 Clutch piston bleed ball must be clean and free of any foreign material.

- 30 -

Figure 168 Position return spring ring retainer on clutch shaft.

Figure 171 Install first steel (outer) clutch disc.

Figure 169 Start ring on shaft with snap ring pliers.

Figure 172 Install first friction (inner) clutch disc. Alternate steel and friction until six (6) steel and six (6) friction discs are in position.

Figure 170 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring.

Be sure ring is in full position in groove.

Figure 173 Install clutch disc end plate.

- 31 -

Figure 175 Position thrust bearing inner washer on clutch shaft.

Figure 174 Install end plate retainer ring.

3rd

4th

Figure 176 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Gauge

Figure 174a 4th (high) clutch pack must be checked for clutch disc clearance.

Stand the clutch assembly on end. The clutch discs on the bottom will fall to the end plate.

Measure the distance between the clutch piston and the first steel disc by inserting a feeler gauge or taper gauge through the slots in the clutch drum.

The required clearance is 1,22 et 2,74.

If the clearance is greater than 2,74, add one steel disc under the end plate.

Figure 177 Install outer thrust bearing washer against bearing.

- 32 -

Figure 180 Position thrust bearing on shaft.

Figure 178 Press one bearing in clutch gear. Install bearing spacer next to bearing. Press second bearing in gear, being certain bearings are pressed flush with face of gears one both sides. Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly. Do not force this operation.

Figure 181 Position outer thrust washer on shaft.

Figure 179 Position inner thrust washer on shaft.

Figure 182 Install thrust washer retainer ring.

- 33 -

Figure 183 Install clutch shaft gear locating ring.

Figure 185 Install clutch shaft front bearing.

Note : Bearing has a shield in it. This shield must be up.

Figure 184 Position gear on clutch shaft.

Figure 186 Install clutch shaft oil sealing rings. Grease rings to facilitate reassembly into front housing.

- 34 -

3RD CLUTCH REASSEMBLY

Figure 190 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate five (5) springs.

Note : See page 104.

Figure 187 Clutch piston bleed all must be clean and free of any foreign material.

Figure 188 Install inner and outer clutch piston seal rings. Size inner ring as explained in figure 93. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.

Figure 191 Position return spring ring retainer on clutch shaft

Figure 192 Start ring on shaft with snap ring pliers.

Figure 189 Install clutch piston wear plate.

- 35 -

Figure 195 Install first friction (inner) clutch disc. Alternate steel and friction uuntil five (5) steel and five (5) friction discs are in position.

Figure 193 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be sure ring is in full position in groove.

Figure 196 Install clutch disc end plate.

Figure 194 Install first steel (outer) clutch disc.

Figure 197 Install end plate retainer ring.

- 36 -

Figure 198 Position thrust bearing inner washer on clutch shaft.

Figure 201 Install 3rd clutch pilot bearing on clutch shaft. A coat of high quality grease will hold pilot bearing in position.

DISASSEMBLY AND REASSEMBLY OF FORWARD AND REVERSE CLUTCHES Note : A 3 speed transmission will not have external gear teeth on the forward and reverse clutch drum.

REVERSE CLUTCH BEING DISASSEMBLED Figure 199 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 200 Install outer thrust bearing washer against thrust bearing. Install thrust washer retainer ring.

Figure 202 Remove outer thrust washer, thrust bearing and inner thrust washer.

- 37 -

Figure 203 Remove clutch gear and disc hub.

Figure 206 Remove end plate retainer ring.

Figure 204 Remove bearings and spacer from clutch gear.

Remove end plate.

Figure 207

Figure 205 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 208 Remove clutch discs.

- 38 -

Figure 209 Compress disc springs and remove retainer ring.

Figure 212 Remove clutch piston wear plate.

Figure 213 Remove clutch piston.

Figure 210 Remove retainer ring retainer.

DISASSEMBLY OF FORWARD CLUTCH

Figure 211 Remove disc springs.

Note : See page 104.

Figure 214 Remove clutch shaft oil sealing rings.

- 39 -

Figure 215 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 218 Remove outer thrust washer, thrust bearing and inner thrust washer.

Figure 216 Remove clutch gear and disc hub.

Figure 219 Remove end plate retainer ring.

Figure 217 Remove bearings and spacer from clutch gear.

Remove end plate.

Figure 220

- 40 -

Figure 221 Remove clutch discs.

Figure 224 Remove disc springs.

Note : See page 104.

Figure 222 Compress disc springs and remove retainer ring.

Figure 225 Remove clutch piston wear plate.

Figure 223 Remove retainer ring retainer.

Figure 226 Remove clutch piston.

- 41 -

REASSEMBLY OF FORWARD CLUTCH (See cleaning and inspection page)

Figure 230 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate five (5) springs.

Note : See page 104.

Figure 227 Clutch piston bleed orifice must be clean and free of any foreign material.

Figure 231 Position return spring ring retainer on clutch shaft.

Figure 228 Install inner and outer clutch piston seal rings. Size inner ring as explained in figure 93. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.

Figure 232 Start ring on clutch with snap ring pliers.

Figure 229 Install clutch piston wear plate.

- 42 -

Figure 235 Install first friction (inner) clutch disc. Alternate steel and friction until six (6) steel and six (6) friction discs are in position.

Figure 233 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be sure ring is in full position in groove.

Figure 236 Install clutch disc end plate.

Figure 234 Install first steel (outer) clutch disc.

Figure 237 Install end plate retainer ring.

- 43 -

REV

FWD Gauge

Figure 239 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 237a NOTE : Forward cllutch pack must be checked for clutch disc clearance.

Stand the clutch assembly on end. The clutch discs on the bottom will fall to the end plate.

Measure the distance between the clutch piston and the first steel disc by inserting a feeler gauge or taper gauge through the slots in the clutch drum.

The required clearance is 1,22 - 2,74.

If the clearance is greater than 2,74, add one steel disc under the end plate.

Figure 240 Install outer thrust bearing washer against thrust bearing.

Figure 241 Press one bearing in clutch gear, flush with face of gear. Install bearing spacer next to bearing. Press second bearing in gear, flush with face of gear. Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly.

Do not force this operation.

Figure 238 Position thrust bearing inner washer on clutch shaft.

- 44 -

Figure 245 Install clutch shaft oil sealing rings. Grease rings to facilitate reassembly into front housing.

Figure 242 Position inner thrust washer on shaft.

REVERSE CLUTCH REASSEMBLY

Figure 246 Clutch piston bleed orifice must be clean and free of any foreign material.

Figure 243 Position thrust bearing on shaft.

Figure 247 Install inner and outer clutch piston seal rings. Size inner ring as explained in Figure 93. Install clutch piston in clutch drum. Use caution as not to damage sealing rings.

Figure 244 Position outer thrust washer on shaft.

- 45 -

Figure 248 Install clutch piston wear plate.

Figure 251 Start ring on shaft with snap ring pliers.

Figure 249 Install piston return disc springs. First spring with large diameter of bevel toward wear plate. Alternate five (5) springs.

Note : See page 104.

Figure 252 Use a sleeve with the proper inner diameter to fit over shaft and against retainer ring. A sharp blow with a soft hammer will compress springs and seat retainer ring. Be sure ring is in full position in groove.

Figure 250 Position return spring ring retainer on clutch shaft.

- 46 -

Figure 253 Install first steel (outer) clutch disc.

Figure 256 Install end plate retainer ring.

Figure 254 Install first friction (inner) clutch disc. Alternate steel and friction until six (6) steel and six (6) friction discs are in position.

FWD

REV Gauge

Figure 256a Note : Reverse clutch pack must be checked for clutch disc clearance.

Stand the clutch assembly on end. The clutch disc on the bottom will fall to the end plate.

Measure the distance between the clutch piston and the first steel disc by inserting a feeler gauge or taper gauge through the slots in the clutch drum.

The required clearance is 1,22 - 2,74.

Figure 255 Install clutch disc end plate.

If the clearance is greater than 2,74 add one steel disc under the end plate.

- 47 -

Figure 260 Press one bearing in clutch gear, flush with face of gear. Install bearing spacer next to bearing. Press second bearing in gear, flush with face of gear. Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs. Be sure the clutch hub is in full position in the clutch assembly.

Do not force this operation.

Figure 257 Position thrust bearing inner washer on clutch shaft.

Figure 258 Position thrust bearing on clutch shaft against inner thrust bearing washer.

Figure 261 Position inner thrust washer on shaft.

Figure 259 Install outer thrust bearing washer against bearing.

Figure 262 Position thrust bearing on shaft.

- 48 -

Figure 263 Install outer thrust washer on shaft.

Figure 265 Remove regulator valve piston and pressure regulator valve spring.

REGULATOR VALVE DISASSEMBLY AND REASSEMBLY Figure 266 Spring and piston removed.

DISASSEMBLY

REASSEMBLY (See cleaning and inspection page)

Figure 264 Tap pin from regulator valve sleeve. Use caution as valve spool is under spring pressure.

Figure 267 Position pressure regulator valve spring into regulator valve piston.

- 49 -

Figure 268 Install pressure regulator valve spring and regulator valve piston as an assembly into regulator valve sleeve.

Figure 271 Remove accumulator spool.

Figure 269 Compress valve spring and valve and install pin into regulator valve sleeve.

DISASSEMBLY AND REASSEMBLY OF DUAL MODULATED VALVE ASSEMBLY DISASSEMBLY

Figure 272 Remove cross pin from sleeve.

NOTE : Some units will have two cross pins the same length. Some units will have two pins of different lengths. The longest pin goes in the bottom hole.

Figure 270 Remove inner, middle and outer spring and stop pin from modulation housing sleeve. Reference Figure 51.

- 50 -

Figure 273 Remove regulator spool, spring, retainer spring and spacer spring from housing sleeve.

Figure 276 Check orifice in regulator spool to be free and clear of any foreign material.

REASSEMBLY (See cleaning and inspection page)

Figure 274 Install spring spacer in spring retainer.

Figure 277 Install spring retainer, spring and regulator valve in sleeve against inner cross pin.

Figure 275 Install spring in spring retainer.

Figure 278 Compress regulator spool and spring in sleeve far enough to install cross pin.

- 51 -

Figure 279 Install cross pin.

NOTE : Some units will have two cross pins the same length. Some units have two pins of different lengths.

The longest pin goes in the bottom hole.

Figure 282 Install middle spring.

Figure 280 From opposite end, position accumulator spool in sleeve as shown.

Figure 283 Install inner spring.

Figure 281 Install outer accumulator spring.

- 52 -

Figure 285 If charging pump or pump drive gear are to be replaced, remove retainer ring and drive gear.

Figure 288 Remove revese idler gear.

REASSEMBLY (See cleaning and inspection page)

Figure 286 Remove reverse idler gear end plate capscrew and washer.

Figure 289 Remove reverse idler gear end plate capscrew and washer.

Figure 287 Remove end plate and dowel pin.

Figure 290 Remove idler gear tanged thrust washer.

- 53 -

Figure 291 If reverse idler shaft is to be replaced, support spacer plate around idler shaft opening and press idler shaft from spacer. Do not drive on idler shaft as doing so may cause damage to spacer plate.

Figure 294 Tap pump drive idler shaft from spacer plate.

Figure 295 Remove pump drive idler shaft and thrust washer.

Figure 292 Idler shaft and locating ring removed.

Figure 293 Remove locating ring from idler shaft.

Figure 296 Remove stator support oil sealing ring. Remove sealing ring expander ring.

- 54 -

Figure 297 Push support toward transmission side far enough to expose retainer ring. Remove retainer ring.

Figure 300 Remove sealing ring expander ring.

Figure 298 From converter end, remove stator support and thrust washer.

Figure 301 If support bushing or bearing is to be replaced, remove from stator support.

Figure 299 Remove stator support oil sealing ring.

Figure 302 Compress converter safety valve spring and remove retaining washer.

- 55 -

Figure 303 Remove safety valve spring.

Figure 306 Turn spacer over and position safety valve spring on poppet. Compress spring and install poppet retaining washer.

Note : End of spring must go in recessed side of washer.

Figure 304 Turn spacer plate over and remove safety valve poppet.

REASSEMBLY OF SPACER PLATE (See cleaning and inspection page)

Figure 307 If stator support bushing was removed, install bushing in support. Install needle bearing in stator support.

Figure 305 From transmission side of spacer plate, position converter safety valve poppet in bore in spacer.

Figure 308 Install stator support oil sealing ring expander ring.

- 56 -

Figure 309 Install oil sealing ring on expander ring.

NOTE : Expander spring gap to be 180 degrees from sealing ring hook joint.

Figure 312 Install stator support locating ring.

Figure 310 Position impeller hub gear washer on spacer plate.

Figure 313 Push support back through spacer until locating ring shoulders in support bore. Turn spacer plate over and install support retaining ring.

Figure 311 Install stator support through washer and spacer plate.

Figure 314 Position pump drive idler shaft washer on spacer plate.

- 57 -

Figure 315 Position pump drive shaft through washer and into spacer plate. Align roll pin in spacer plate.

Figure 318 Support spacer plate and press reverse idler shaft into position and tight against locating ring.

Figure 316 Tap shaft into place.

Figure 319 Turn spacer plate over and position tanged thrust washer on shaft, being certain tang in washer is in notch in spacer plate.

Figure 320 Position idler gear needle bearing on shaft. Lubricate bearing.

Figure 317 Install locating ring on reverse idler shaft.

- 58 -

Figure 324 Tighten capscrew to specified torque. (See torque chart.)

Figure 321 Position idler gear on bearing.

FRONT OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY (See Figure 443 page 80 for front disconnect flange) DISASSEMBLY (NOTE : Do not remove expansion plug unless it is being replaced)

Figure 325 Remove flange to bearing retainer ring.

Figure 322 Position idler gear end plate and roll pin on idler shaft, aligning roll pin with hole in idler shaft.

Figure 326 Using a bearing puller as shown, remove bearing.

- 59 -

Figure 330 Remove oil seal retainer ring from output flange.

Figure 327 Bearing removed.

REASSEMBLY (See cleaning and inspection page) NOTE: If the output flange expansion plug is being replaced, see Figure 452, page 82 for proper installation.

Figure 328 Oil seal sleeve and "O" ring removed.

Figure 331 Position bearing retainer ring on output flange.

Figure 332 Apply a very light coat of Permatex #2 to the outer diameter of the output flange oil seal. Press oil seal in oil seal sleeve. Oil seal must be flush with one side of face of oil seal sleeve and lip of seal must be in.

Figure 329 Remove oil seal from sleeve.

- 60 -

DISASSEMBLY AND REASSEMBLY OF CONVERTER HOUSING (See cleaning and inspection page)

Figure 333 Install new "O" ring on oil seal sleeve. Position oil seal sleeve assembly on output flange.

NOTE: Recessed portion of oil seal and sleeve must be up, with lip of seal up. This leaves a space between oil seal and output bearing.

Figure 336 Remove torque converter bearing.

Figure 334 Press bearing on output flange.

Figure 337 Remove oil distributor and "O" rings.

Figure 335 Install bearing to flange retainer ring.

Figure 338 Remove converter oil seal.

- 61 -

Figure 342 Sleeve removed.

Figure 339 Remove converter housing plug. (High and 3rd clutch shaft)

Figure 343 Remove converter housing plug. (1st and 2nd clutch shaft).

Figure 340 Remove oil distributor sleeve set screw.

Figure 341 Using a hammer puller as shown, remove oil distributor sleeve. (High and 3rd)

Figure 344 Remove oil distributor sleeve set screw.

- 62 -

Figure 347 Install new "O" rings on converter housing oil distributor.

Install oil distributor in converter housing with long hub toward oil seal.

Figure 345 Using a hammer puller as shown, remove oil distributor sleeve. (1st and 2nd)

REASSEMBLY OF CONVERTER HOUSING (See cleaning and inspection page)

Figure 348 Press converter bearing in housing against shoulder.

Figure 346 Apply a very light coat of Permatex 2 to the outer diameter of the converter housing oil seal. Press seal in housing with lip of seal in.

Figure 349 Tap lightly on the valve into place.

- 63 -

Figure 350 Apply Loctite 243 to threads of sleeve set screw.

Note : This screw has a hole in it. Use caution as not to allow any Loctite to plug hole. Install set screw in converter housing and in oil distributor.

Figure 353 Apply Loctite 243 to threads of sleeve set screw.

Note : This set screw has a hole in it. Use caution as not to allow any Loctite to plug hole. Install set screw in converter housing and in oil distributor.

Figure 351 Install set screw plug.

Figure 352 Install high 3rd clutch shaft oil distributor sleeve in converter housing with inside diameter chamfer up and the notch in the distributor aligned uyp with the retaining set screw hole in the converter housing.

Figure 354 Install set screw plug - 64 -

REASSEMBLY OF TRANSMISSION (See cleaning and inspection page)

Figure 358 Install reverse and forward clutch shaft rear bearing in transmission case. NOTE : For single modulation and mechanical inching see Figure 458, Page 83.

Figure 355 Install forward-reverse oil distributor sleeve in transmission case with inside diameter chamfer out, (toward front of transmission) and the notch in the distributor aligned up with the retaining set screw hole in the transmission case.

Figure 359 Install modulation diverter in transmission case.

Figure 356 Apply Loctite #243 et install set screw in transmission case and in oil distributor sleeve.

Figure 360 Position a new "O" ring on lower end of the modulation valve sleeve and spring assembly. Install "O" ring on other valve sleeve.

Figure 357 Install set screw plug.

- 65 -

Figure 361 Install valve or valves in transmission case.

Figure 364 Position supply tube and screen assembly and tube clamp in transmission case sump.

Figure 365 Push supply tube through opening in case and install "O" ring.

Figure 362 Position a new "O" ring on modulator valve housing.

Figure 366 Install supply tube clamp screw in case and tighten securely.

NOTE : Clamp screw has a locking adhesive on the threads and must be used one time only. See note in Figure 53.

Figure 363 Install housing over sleeve and spring assembly and tighten securely.

- 66 -

Figure 367 Install output shaft inner bearing locating ring in rear of transmission case.

Figure 370 Apply a very light coat of Permatex #2 to the outer diameter of the output flange oil seal. Press oil seal in oil seal sleeve. Oil seal must be flush with one side of face of oil seal sleeve and lip of seal must be in.

Position oil seal sleeve in transmission case with recessed portion of oil seal toward output bearing.

This leaves a space between oil seal and output bearing.

Figure 368 Install rear bearing in case against locating ring.

Figure 369 Install new "O" ring on rear oil seal sleeve.

Figure 371 Install oil seal sleeve retainer ring.

- 67 -

Figure 375 Install front output shaft bearing locating ring.

Figure 372 From front of transmission case, position output gear with long hub of gear toward front.

For front axle disconnect see Figure 416, page 76.

Figure 376 Position front output flange and bearing assembly on output shaft. Using snap ring pliers as shown, squeeze snap ring ends together and tap flange assembly into case until snap ring can seat in snap ring groove.

Figure 373 Install rear output flange and shaft through output oil seal. Align splines on shaft with splines on output gear. Install shaft through gear. Use caution as not to damage oil seal. Brake disc is an option and will not be on all units.

Figure 377 Install 3rd speed clutch gear bearing locating ring in transmission case..

Figure 374 Install output shaft to output gear retainer ring.

- 68 -

Figure 378 Position 3rd speed clutch gear in transmission case.

Figure 381 Install new "O" ring on bore plug. Install bore plug in case.

Figure 382 Install bore plug retainer ring.

Figure 379 Block gear and install inner retainer ring and rear bearing.

Figure 383 Install high and 3rd clutch assembly in 3rd clutch gear disc hub. Align splines oh 3rd gear disc hub with internal teeth of friction discs. Do not force this operation. Gear splines must be in full position with internal teeth of all friction discs.

Figure 380 Install clutch gear shaft to bearing retainer ring.

- 69 -

Figure 384 Install forward and reverse clutch assembly.

Figure 387 Install spacer plate assembly on transmission, aligning clutch shafts with openings in spacer plate. Use caution as not to damage oil sealing rings.

Figure 385 Install 1st and 2nd clutch assembly.

Figure 388 Spacer plate must be tight against transmission case.

Do not use bolts to pull spacer plate and case together. Tap spacer plate into position at dowel pins.

Install spacer plate to transmission case capscrews.

Figure 386 Position new tranmission case to converter housing gasket on transmission case.. A light coat of grease will hold gasket in position.

Figure 389 See NOTE on Figure J, for proper capscrew installation and torque.

- 70 -

ELECTRIC CONTROL VALVE REASSEMBLY

Figure 390 Position impeller hub gear on stator support.

Figure 393 Install bore plug and "O" rings in center hole on 3 speed transmission only.

Figure 391 Install pump idler gear bearing and idler gear on idler shaft.

Figure 392 Install idler gear thrust washer, aligning hole with roll pin.

Figure 394 With "O" rings in position, install solenoid cartridges.

- 71 -

Figure 395 Tighten cartridges to specified torque. See assembly instruction drawing.

Figure 398 Position spacer to converter housing gasket on spacer. A light coat of grease will hold gasket in place.

The use of aligning studs will facilitate converter housing to spacer installation. The transmission could be laid down to align the end of the clutch shafts into sealing ring sleeves in converter housing. Do not force this operation. converter housing must be tight against transmission spacer.

NOTE : Do not use bolts to pull converter housing in place.

Install converter housing to transmission case screws and lockwashers. See Figures J and K for proper screw location and installation.

Figure 396 With cartridge to coil "O" ring in place, position solenoid coil on cartridge.

Figure 397 With new "O" ring in position, install coil to cartridge nut. Tighten cartridge nut per assembly instruction drawing.

- 72 -

Figure 400 Tighten bolts to specified torque. See note in Figure 398. See Figures J and K for proper screw location and installation.

Figure 403 Install converter assembly retainer ring.

Figure 401 Install converter locating ring on turbine shaft.

Figure 404 With new "O" ring in place, install bore plug in converter assembly.

Figure 402 Position converter assembly on stator support and turbine shaft.

Figure 405 Install bore plug retainer ring.

- 73 -

1/8" FILLET WELD 1/2" DRIVE SOCKET

Figure 406 Install regulator sleeve assembly in converter housing.

Figure 407a

Figure 408 With new gasket in place, install charging pump in converter housing.

Figure 407 Using a special tool as shown in Figure 407a, tighten sleeve to 61,1 - 67,7 N.m.

- 74 -

Figure 409 Install charging pump to converter housing bolts and washers and tighten to specified torque. See torque chart.

Figure 411 Install oil filter on regulating valve.

Tighten filter to 27 - 34 nm. I

Figure 410 If auxiliary pump is used, it is not necessary to install the permanent pump hole cover. With new gasket in place, install pump hole cover on charging pump.

Install bolts and washers and tighten to specified torque. See torque chart.

- 75 -

FRONT DISCONNECT OUTPUT SHAFT REMOVAL (Not on MLA)

Figure 419 Remove flange assembly locating ring.

Figure 416 Remove front output flange retainer ring from ring groove.

Figure 417 Carrefully pry the output flange, seal and bearing from bearing bore.

Figure 420 Remove front disconnect shift rail detent spring plug and "O" ring. CAUTION : Plug is under spring pressure.

Figure 418 Remove flange assembly. NOTE : See page 80 for output flange service.

Figure 421 Remove detent spring, ball and overshift stop pin.

- 76 -

Figure 422 Remove shift fork to shift rail lockscrew.

Figure 425 Remove output gear to shaft retainer ring.

Figure 423 Remove disconnect shift fork and rail.

Figure 426 Remove rear output flange retainer ring from ring groove.

Figure 424 Remove disconnect shift hub.

- 77 -

Figure 427 From the front, tap output shaft from output gear and rear bearing.

Figure 430 If oil seal sleeve and bearing did not come out with shaft, tap from transmission case. Do not tap on rear bearing locating ring.

Figure 431 Remove rear bearing and oil seal sleeve.

Figure 428 Remove output shaft and flange. NOTE : Output oil seal sleeve and bearing may come out with shaft.

Figure 432 Remove rear bearing locating ring. Refer to Figure 430.

Figure 429 Remove output gear.

- 78 -

FRONT AXLE DISCONNECT OUTPUT SHAFT INSTALLATION (Not on MLA)

Figure 436 Install front output shaft bearing locating ring.

Figure 433 Install rear output flange and shaft through output oil seal. Align splines on shaft with splines on output gear. Install shaft through gear. Use caution as not to damage oil seal.

Figure 437 Position front output flange and bearing assembly on output shaft. Using snap ring pliers as shown, squeeze snap ring ends together and tap flange assembly into case until snap ring can seat in snap ring groove.

Figure 434 Install output shaft to output gear retainer ring.

Figure 438 Apply Permatex #2 to outer diameter of shift rail oil seal. Install seal in case with lip of seal in.

Figure 435 Position shift hub on output shaft.

- 79 -

Figure 442 Tighten plug securely. Refer to Figure 377 Figure 439 Position shift fork in shift hub on output shaft. Install shift rail through oil seal. Align fork and rail.

Figure 440 Install shift fork to rail lockscrew. Tighten securely and lockwire to prevent loosening.

DISCONNECT FLANGE SERVICE FRONT OUTPUT FLANGE DISASSEMBLY AND REASSEMBLY FLANGE USED WITH FRONT DISCONNECT

Figure 441 Position detent ball, spring, overshift pin and plug as shown.

Figure 443 Remove flange to bearing retainer ring.

- 80 -

Figure 444 Using a bearing puller as shown, remove bearing.

Figure 447 Remove oil seal from sleeve.

Figure 445 Bearing removed.

Figure 448 Remove oil seal retainer ring from output flange.

Figure 446 Oil seal sleeve and "O" ring removed.

Figure 449 Tap expansion plug from flange.

- 81 -

Figure 450 Remove output bushing.

Figure 452A

REASSEMBLY (See cleaning and inspection page)

Apply Loctite 577 to plug O. D. Prior to insertion. Remove excess material.

Must be secure and oil tight.

Figure 451 Install new inner and outer flange bushings to dimensions shown in Figure 452B. NOTE : Bushings used only with front disconnect.

Figure 452B

Figure 452 Apply a light coat of Loctite #577 to the outer edge of expansion plug. Install plug in flange with axial force equal to 28024 Nm. NOTE : See Figure 452A for expansion plug installation tool fabrication. It is imperative plug be installed properly to prevent oil leakage.

Figure 453 Position retainer ring on output flange.

- 82 -

Figure 454 Apply a very light coat of Permatex #2 to the outer diameter of the output flange oil seal. Press oil seal in oil seal sleeve. Oil seal must be flush with one side of face of oil seal sleeve and lip of seal must be in.

Figure 457 Install bearing to flange retainer ring.

SINGLE MODULATION AND MECHANICAL INCHING REMOVAL

Figure 455 Install new "O" ring on oil seal sleeve. Position oil seal sleeve assembly on output flange.

NOTE : Recessed portion of oil seal and sleeve must be up, with lip of seal up. This leaves a space between oil seal and output bearing.

Figure 458 Remove inching valve housing.

Figure 459 Remove inching return spring, actuator rod and regulator spring.

Figure 456 Press bearing on output flange.

- 83 -

Figure 460 Remove inching sleeve and "O" ring.

Figure 463 Remove modulator valve outer, middle and inner springs and spring stop.

Figure 461 Remove inching spool.

Figure 464 Remove modulation housing sleeve and accumulator spool.

Figure 462 Remove modulator valve housing and "O" ring.

Figure 465 Remove shuttle sleeve and spool.

- 84 -

DISASSEMBLY AND REASSEMBLY OF SINGLE MODULATOR VALVE ASSEMBLY DISASSEMBLY

Figure 469 Remove modulator sleeve pin.

Figure 466 Remove modulator valve body "O" ring.

Figure 470 Remove regulator spool assembly retainer ring.

Figure 467 Remove modulator valve outer, middle and inner springs and spring stop . Reference Figure 463

Figure 471 Remove regulator spool stop, spring and spring and sleeve assembly.

Figure 468 Remove accumulator spool. Reference Figure 464.

- 85 -

Figure 475 Figure 472 Remove regulator spool sleeve retainer ring.

Remove check ball.

REASSEMBLY (See cleaning and inspection page)

Figure 473 Remove regulator spool sleeve assembly. Remove "O" ring.

Figure 476 Install a new "O" ring on regulator spool sleeve.

Position check ball in sleeve.

Figure 474 Remove sleeve check ball retainer pin.

Figure 477 Install check ball retainer pin.

- 86 -

Figure 478 Position sleeve and ball assembly in regulator spool with check ball retainer pin up.

Figure 481 Install regulator spool stop, spring and regulator spool and sleeve assembly in housing sleeve.

Figure 479 Install sleeve retainer ring.

Figure 482 Compress regulator spool spring and install retainer ring.

Figure 483 Position new "O" ring on modulation sleeve.

Figure 480 Install housing sleeve pin.

- 87 -

SINGLE MODULATION AND MECHANICAL INCHING INSTALLATION

Figure 487 Install inching return spring.

Figure 484 Instal a new "O" ring on inching sleeve. Install inching spool in sleeve. Install spool and sleeve in inching control bore.

Figure 488 With new actuator rod oil seal in position and new "O" ring on inching housing, install housing over actuator rod and thread into inching bore.

Figure 485 Install inching regulator spool spring.

Figure 489 Tighten inching valve housing to specified torque.

See assembly instruction drawing.

Figure 486 Install inching actuator rod over spring.

- 88 -

Figure 490 Position shuttle spool in shuttle sleeve. Install spool and sleeve in modulator valve bore.

Figure 493 Install stop pin, inner, middle and outer springs in accumulator and housing sleeve.

Figure 491 With new "O" ring in position, install modulation housing sleeve assembly in bore.

Figure 494 Position a new "O" ring on modulator valve housing.

Thread housing into valve bore.

Figure 492 Install accumulator spool in housing sleeve as shown.

Figure 495 TIghten modulator valve housing to specified torque.

See assembly instruction drawing. Refer to Figure 364.

- 89 -

CLUTCH ENGAGEMENT

CLUTCH ENGAGEMENT FOR 4 SPEED T12000 POWER SHIFT TRANSMISSION

FORWARD shift speed

direction clutch

speed clutch

1st

A

C

2nd

A

D

3rd

A

E

4th

F

E

shift speed

direction clutch

speed clutch

REVERSE

1st

B

C

2nd

B

D

3rd

B

E

- 90 -

CLUTCH ENGAGEMENT

CLUTCH ENGAGEMENT FOR 3 SPEED T12000 POWER SHIFT TRANSMISSION

FORWARD Shift speed

direction clutch

speed clutch

1st

A

C

2nd

A

D

3rd

A

E

shift speed

direction clutch

speed clutch

REVERSE

1st

B

C

2nd

B

D

3rd

B

E

- 91 -

SPECIFICATIONS AND SERVICE DATA POWER SHIFT TRANSMISSION AND TORQUE CONVERTER

TRANSMISSION OUT PRESSURE

With transmission outlet oil temperature 82,3 - 93,3°C and transmission in NEUTRAL. Operating specifications : 4 Bar minimum pressure at 2000 R.P.M. engine speed AND a maximum of 8 Bar outlet pressure with engine operating at no-load governed speed.

CONTROLS

Forward and reverse - Electric Speed selection - Electric

CLUTCH TYPE

Multiple discs, hydraulically actuated, spring released, automatic wear compensation, and no adjustment, all clutches oil cooled and lubricated.

CLUTCH INNER DISC

Friction

CLUTCH OUTER DISC

Steel

OIL FILTRATION

Full flow oil filter safety by-pass, also strainer screen in sump at bottom of transmission case.

CLUTCH PRESSURE

13 Bar minimum - With parking brake set (see note), oil temperature 82,2 - 93,3 °C, engine at idle (775 R.P.M.), shift thru direction and speed clutches. All clutch pressure must be equal within 0,35 bar. If clutch pressure varies in any one clutch more than 0,35 bar repair clutch.

Normal operating pressure 16 - 19 Bar at 2000 R.P.M. Note : ALWAYS USE PARKING BRAKE WHEN MAKING CLUTCH PRESSURE CHECKS.

Filling hole Max. level Mini level

Drain plug - 92 -

LUBRICATION TYPE OF OIL

See Lube Chart.

CAPACITY

Consult Operator's Manual on applicable machine model for system capacity.

Torque Converter, Transmission, and allied hydraulic system must be considered as a whole to determine capacity.

CHECK PERIOD

Check oil level DAILY with engine running at 775 R.P.M.and oil at 82,2 93,3 °C. Maintain oil level to FULL port.

***NORMAL DRAIN PERIOD

Every 400 hours, change oil filter.

Every 800 hours, drain and refill system as follows : drain with oil at 65,5 to 93,3 °C. a) Drain transmission. b) Oil filter, remove and discard.

Install new oil filter. c) Refill transmission to low port. d) Run engine at 775 R.P.M. to prime converter and lines. e) Recheck level with engine running at 775 R.P.M. and add oil to bring level to low port. When oil temperature is hot (82,2 - 93,3 °C) make final oil level check. BRING OIL LEVEL TO FULL PORT Note : It is recomended that oil filter be changed after 50 and 100 hours of operation on new and rebuilt or repaired units.

RECOMMENDED LUBRICANTS FOR POWER SHIFTED TRANSMISSION AND TORQUE CONVERTERS Prevailing ambient temperature : (a) C-2 Grade 30 (b) C-3 Grade 30 Temperature (c) Engine oil : Grade 30 APIrange "1" CD/SE or CD/SF (d) MIL-L-2104CGrade 30 (e) MIL-L-2104DGrade 30 Temperature range "2"

SHELL DONAX TA

Temperature range "3"

(a) Dexron (b) Dexron II D See caution below.

Temperature range "4"

(a) MIL-L-46167 (b) MIL-L-46167 A

Temperature range "5"

(a) Conoco Highperformance synthetic motor Spec. N° 6718

* Dexron is a registered trademark of General Motors Corporation. preferred oil viscosity : Select highest oil viscosity compatible with prevailing ambient temperatures and oil application chart.

Temperature ranges "2" and "3" may be used to lower ambient temperatures when sump preheaters are used.

Temperature ranges "4" should be used only in ambient temperature range shown.

***Normal drain periods and oil filter change intervals are for aver-age environmental and duty-cycle conditions.

Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination. For extreme conditions judgment must be used to determine the required change intervals.

modulated shift transmissions : T12000, 18000, 24000, 28000 & 32000 series transmissions with modulated shift use only C-3 or temperature range "3" item (a) & (b) *Dexron or *Dexron II D. See caution below. 3000, 4000, 5000, 6000, 8000, 16000 & 34000 series transmission with modulated shift use only C-3 or temperature range "3" item (a) only *Dexron. Do NOT use *Dexron II D. See caution below.

CAUTION : *Dexron II D is not compatible with graphitic clutch plate friction material UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS. *Dexron II cannot be used in the 3000, 4000, 5000, 6000, 8000, 16000 and 34000 series power shift transmissions, or the HR28000 & HR32000 series having converter lock-up, or the C270 series converter having lock-up UNLESS IT MEETS THE APPROVED C-3 SPECIFICATIONS.

- 93 -

SERVICING MACHINE AFTER TRANSMISSION OVERHAUL The transmission, torque converter and its allied hydraulic system are important links in the driveline between the engine and the whells. The proper operation of either unit depends greatly on the condition and operation of the other. Therefore, whenever repair or overhaul of one unit is performed, the balance of the system must be considered before the job can be considered complete.

5. Reassemble all components and use only type oil recommended for lubrication section. Fill transmission through filler opening until fluid comes up to LOW port on transmission.

After the overhauled or repaired transmission has been installed in the machine, the oil cooler and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in several manners and a degree of judgment must be exercised as to the method employed.

Run engine two minutes at 775 R.P.M. to prime torque converter and hydraulic lines. Recheck level of fluid in transmission with engine running at idle (775 R.P.M.

Remove LOWER check plug, fill until oil runs from LOWER oil hole. Replace filler and level plug.

Add quantity necessary to bring fluid level to run freely from LOWER oil level check plug hole.

Install oil level plug. Recheck with hot oil (82,2 93,3°C).

The following are considered the minimum steps to be taken : 1. Drain entire system thoroughly.

Bring oil level to FULL port to run freely from UPPER oil level plug hole.

2. Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed from machine for cleaning.

6. Recheck all drain plugs, lines, connections, etc..., for leaks and tighten where necessary.

3. Replace oil filter elements, cleaning out filter cases thoroughly.

4. The oil cooler must be thoroughly cleaned.

The cooler should be "back flushed" with oil and compressed air until all foreign material has been removed. Flushing in direction of normal oil flow will not adequately clean the cooler. If necessary, cooler assembly should be removed from machine for cleaning, using oil, compressed air and steam cleaner for that purpose. DO NOT use flushing compounds for cleaning purposes.

- 94 -

- 95 -

PRESSURE CHECK 1) Regulated clutch pressure : (main pressure)

Adap. mark.64

2) Pressure towards cooler : (converter pressure)

Adap. mark.64

3) Forward gear clutch pressure :

Adap. mark.65

4) Reverse gear clutch pressure :

Adap. mark.65

5) 1st gear clutch pressure :

Adap. mark.65

6) 2nd gear clutch pressure :

Adap. mark.65

7) 3rd gear clutch pressure :

Adap. mark.66

8) 4th gear clutch pressure :

Adap. mark.65

2

1

TOP VIEW 5

3

6 4

7 8

RIGHT SIDE VIEW

LEFT SIDE VIEW

62 63

63

63

63

63

63

63

63

Mark.62 : Ref. 218 101 - CLARK box kit T12000 speed short drop Mark.63 : Ref. 561 031 - Pressure gauge connection 1/4" Mark.64 : Ref. 561 032 - Adapte`r MB 1/8" N PTF

64

64

65

65

65

65

65

66

Mark.65 : Ref. 561 033 - Adapter M.SAE 3/8" UNF Mark.66 : Ref. 561 079 - Adapter M.SAE 3/8" UNF x MJ 7/16

67

67

67

67

67

67

Mark.67 : Ref. 25 011 - "O" ring

- 96 -

Procedure Before carrying out the pressure check, lift up and wedge the lift truck, making sure the main wheels are not in contact with the ground.

- Fix the adapters and the pressure gauge connection onto the check ports : • The adapters Mark.64 of the kit are to be fixed onto the points 1 and 2.

• The adapters Mark.65 of the kit are to be fixed onto the points 3-4-5-6 and 8.

• The adapters Mark.66 of the kit is to be fixed onto the point 7.

- Bring the box oil to a temperature : 82 to 104°C. - Check the pressure with an engine speed of 2000 R.P.M. - Transmission in neutral for the pressures 1 and 2.

1) Main pressure : 16 to 19 bar • Minimum pressure of 13 bar 2) Converter pressure : 4 to 8 bar 3) Forward gear pressure 4) Reverse gear pressure 5) 1st gear Same pressure as main pressure 6) 2nd gear A 7) 3rd gear 8) 4th gear

}

1

- The pressure of the reverser and gear clutches must be equal to the main pressure. If this pressure in one of these clutches differs from more than 0,35 bar, repair the corresponding clutch.

B

2

D

C

8

3 7

5 4 6

- 97 -

CONVERTER TIMING

Engine 1004-4T

Box T12000 Speed Intermediate Drop

The engine R.P.M. on timing represents 2090 R.P.M. whatever the ratio.

- 98 -

CLEANING AND INSPECTION INSPECTION The importance of careful and thoroughinspection of all parts cannot be overstressed. Replacement of all parts showing indication of wear or stress will eliminate costly and avoiable failures at a later date.

CLEANING Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and parts are thoroughly cleaned.

CAUTION : Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors when using solvent type cleaners.

BEARINGS Carefully inspect all rollers : cages and cups for wear, chipping, or nicks. to determine fitness of bearings for futher use. Do not replace a bearing cone or cup individually without replacing the mating cup or cone at the same time. After inspection, dip bearings in Automatic Tranmission Fluid and wrap in clean lintless cloth or paper to protect them until installed.

BEARINGS Remove bearings from cleaning fluid and strike flat against a block of wood to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles. Repeat above operation until bearings are thoroughly clean. Dry bearings using moisturefree compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.

OIL SEALS, GASKET, ECT. Replacement of spring load oil seals, "O" rings, metal sealing rings, gaskets and snap rings is more economical when unit is disassembled than premature overhaul to replace these parts at a future time.

Further loss of lubricant through a worn seal may result in failure of other more expensive parts of the assembly. Sealing members should be handled carefully, particularly when being installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply a thin coat of Permatex n° 2 on the outer diameter of the oil seal to assure an oil tight fit into the retainer. When assembling new metal type sealing rings, same should be lubricated with coat of chassis grease to stabilize rings in their grooves for ease of assembly of mating members. Lubricate all "O" rings and seals with recommended type Automatic Transmission Fluid before assembly.

HOUSINGS Clean interior and exterior of housings, bearing caps, ect., thoroughly. Cast parts may be cleaned in hot solution tanks with mild alkali solutions providing these parts do not have ground or polished surfaces.

Parts should remain in solution long enough to be thoroughly cleaned and heated. This will aid the evaporation of the cleaning solution and rinse water.

Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali.

Cast parts may also be cleaned with steam cleaner.

CAUTION : Care should be exercised to avoid inhalation of vapors and skin rashes when using alkali cleaners.

All parts cleaned must be thoroughly dried immediately by using moisture-free compressed air or soft , lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated oil, or lapping compound.

GEARS AND SHAFTS If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening is worn through or cracked, replace with new gear. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted and that shafts are true.

HOUSING, COVER, ECT, Inspect housings, covers and bearing caps to be certain they are thoroughly clean and that mating surfaces, bearing bores, ect., are free from nicks or burrs. Check all parts carefully for evidence of cracks or condition which would cause subsequent oil leaks or failures.

- 99 -

TROUBLESHOOTING GUIDE FOR THE T12000 TRANSMISSION The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly.

to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines and controls, including the engine, as a complete system.

When troubleshooting a transmission problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components.

Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary,

By analyzing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system.

T12000 TRANSMISSION most important. Transmission fluid is the "life blood" of the transmission. It must be supplied in a adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from splipping and to cool and lubricate the working components.

T12000 (powershift with torque converter transmission troubles fall into two general categories : mechanical problems and hydraulic problems).

In addition to the mechanical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is

TROUBLESHOOTING PROCEDURES Stall test : Use a stall test to identify transmission, converter, or engine problems.

Hydraulic check : Also, before checking the transmission clutches, torque converter, charging pump and hydraulic circuit for pressure and rate of oil flow , it is important to make the following transmission fluid check :

Transmission pressure checks : Transmission problems can be isolated by the use of pressure test. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure may also be measured.

Check oil level in the transmission. The transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times. See NOTE below.

Note : The transmission fluid must be at operating temperature of 82 - 93°C to obtain correct fluid level and pressure readings. DO NOT ATTEMPT TO MAKE THESE CHANGES WITH COLD OIL.

Mechanical checks : Prior to checking any parts of the system for hydraulic function (pressure testing), the following mechanical checks should be made : There are only two mechanical linkages available on the transmission.

1. Mechanical inching from brake pedal to inching valve on transmission.

2. Linkage from axle disconnect to disconnect actuator.

The raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at "stall".

CAUTION : Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall R.P.M.

Check the parking brake and inching pedal for correct adjustment and travel. Be sure the pedal moves freely and returns fully.

Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points.

The controls are actuated electrically. Check the wiring and electrical components.

Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary.

The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no-load governed speed specifications.

- 100 -

CONVERTER STALL PROCEDURE 1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels.

2. Put the directional control lever in FORWARD (or REVERSE, as applicable).

3. Put the speed control lever in 3rd (3 speed) (HIGH) or 6th (6 speed).

With the engine running, slowly increase speed to approximately one-half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range.

CAUTION : Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excessive temperature. Excessive temperature (120°C maximum) will cause damage to transmission clutches, fluid, converter and seals.

TROUBLESHOOTING GUIDE Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles.

LOW CLUTCH PRESSURE 1.

2.

3.

4.

5.

CAUSE Low oil level.

Clutch pressure regulating valve stuck open.

Faulty charging pump.

Broken or worn clutch shaft or piston sealing rings.

Clutch piston bleed valve stuck open.

REMEDY 1. Fill to proper level.

2. Clean valve spool and housing.

3. Replace pump.

4. Replace sealing rings.

5. Clean bleed valves thoroughly.

LOW CHARGING PUMP OUTPUT 1. Low oil level.

2. Suction screen plugged.

3. Defective charging pump.

1. Fill to proper level.

2. Clean suction pump.

3. Replace pump.

OVERHEATING 1. Worn oil sealing rings.

2. Worn charging pump.

3. Low oil level.

4. Dirty oil cooler.

5. Restriction in cooler lines.

1. Remove, disassemble and rebuild converter assembly.

2. Replace.

3. Fill to proper level.

4. Clean cooler.

5. Change cooler lines.

NOISY CONVERTER 1. Worn charging pump.

2. Worn or damaged bearings.

1. Replace.

2. A complete disassembly will be necessary to determine what bearing is faulty.

LACK OF POWER 1. Low engine R.P.M. at converter shall.

2. See "Overheating" and make same checks.

1. Tune engine check governor.

2. Make corrections as explained in "Overheating".

- 101 -

- 102 -

GEAR TRANSMISSION T12000 Speed intermediate drop

- 103 -

MODEL DESCRIPTION

1101 T12 4 XX - XX OUTPUT LOCATION AND RATIO

NUMBER OF SPEEDS

T12000 TRANSMISSION CONVERTER 1106 F

F = FREE WHEEL

MANITOU MODEL : 1106 F : MLT

- 104 -

STANDARD SPECIAL 10 - 19 50 - 59 20 - 29 40 - 49 60 - 69 90 - 99 T = HR MODEL MT = MHR MODEL

S. D. L. D. I. D.

BOOST PUMP EXTERNAL, LOCATED AT REAR SIDE OF TRANSMISSION

CHARGING PUMP

BOOST PUMP ON TRANSMISSION

FILTER : SPIN-ON

46,2 L / MIN AT 1800 R.P.M.

- 105 -

CONTROLS

SOLENOIDS ENERGIZED FWD.

REV.

1

A, D, E

B, D, E

2

A, E

B, E

3

A

B

4

A, C

—

3

B A C D E

- ELECTRONIC SENSORS 3 - TURBINE SPEED SENSOR

- 106 -

MODULATION

A. MODULATION ON FWD. AND REV

MODULATION

- 107 -

DUAL VALVE MODULATION

vent

REV - CLUTCH FWD - CLUCTH

- 108 -

T12000 MODULATOR VALVE LONG MODULATION

BAR 21 20

CLUTCH PRESSURE - BAR

19 17 15,5

15

14 12 10

10

9

8

7 5 3,5 2

1,75

1

CYCLE TIME - SECONDS

- 109 -

HYDRAULIC CIRCUIT DUAL MODULATION

CLUTCH PRESSURE REGULATOR VALVE

FILTER

COOLER

SAFETY

B

PUMP

A

C

D

CONVERT.

E

- 110 -

MODULATION

MODULATION

VALVE

HYDRAULIC DIAGRAM DUAL MODULATION

MODULATION

MODULATION

OPERATOR COMPARTMENT TEMP. PRESSURE GAUGE GAUGE

CLUTCH

PRESSURE REGULATOR VALVE

REV

HOSE

FWD slow

SAFETY VALVE

FWD high 4th speed

COOLER

3rd speed

FILTER

TORQUE CONVERTER

PUMP

2nd speed HOSE

LUBRIFICATION

FILTRE AIR BREATHER

1st speed OIL SUMP 4 SPEED SHIFT DIAGRAM FORWARD

REVERSE NEUTRAL

X = SOLENOID ENGAGED

- 111 -

REGULATOR AND SAFETY VALVE PRESSURE REGULATOR VALVE

SAFETY TORQUE CONVERTER

CONTROL VALVE VIBRATION FREQUENCY

- 112 -

SPEED

INPUT

REV

FWD

FWD - HI

1

ST

2

INPUT

3

1

ND

FWD

FWD - HI

FORWARD 3TH

FWD - HI

OUTPUT

ST

2

3

RD

3

RD

OUTPUT

ND

FORWARD 2ND

REV

1

FWD

RD

FORWARD 1ST

INPUT

REV

ST

2

INPUT

3

REV

FWD

RD

FWD - HI

OUTPUT

ND

1

FORWARD 4TH

- 113 -

ST

2

ND

OUTPUT

INPUT

REV

FWD

FWD - HI

1

ST

2

INPUT

3

1

ND

FWD

FWD - HI

1

FWD - HI

OUTPUT

REVERSE 2ND

REV

ST

2

3

FWD

RD

REVERSE 1ST

INPUT

REV

RD

OUTPUT

ND

REVERSE 3TH

- 114 -

ST

2

ND

3

RD

OUTPUT

- 115 -

TO STARTER SOLENOID

START

PREHEAT

DRIVE

DECLUTCH REQUEST ON/OFF (ON PEDAL)

g/n

r

REVERSE RELAY

TURBINE SPEED

g/n

o

o

2x21w

j/vt

j/vt

bl

n/s

o

ro

g/n

COILS

ELECTRIC DIAGRAM : BRANCHEMENT EGS

o

bl

g/n n/s

j ro

n

r jvt jvt

GROUP 30

AXLE ASSEMBLY

DISMANTLING AXLE 172 - 177 - 272 - 277 - 279 30-3-7 EN

25 / 09 / 1998

INDEX

Introduction .............................................................................................

5

Maintenance and lubrication - Symbols..................................................

7

Brakes.....................................................................................................

8

Brakes / External adjustment..................................................................

10

Parking brakes / External adjustment .....................................................

14

Planetary - 4,25 - 5,25 ............................................................................

16

Planetary wheel hub - 4,25 - 5,25...........................................................

17

Epicycloidal reduction - 4,25 - 5,25.........................................................

18

Axle 177 - Epicycloidal reduction - 6,23..................................................

19

Disassembly articulation 272 - 277 - 279................................................

22

Assembly articulation 272 - 277 - 279 ....................................................

23

Assembly articulation 272 - 277 - 279 ....................................................

26

Disassembly steering cylinder 277 - 279 ................................................

27

Steering cylinder assembly 277 - 279.....................................................

29

Bevel pinion support ...............................................................................

31

Axle bevel pinion support 277 - 279 .......................................................

35

Bevel pinion support ...............................................................................

36

Axle bevel pinion support 277 - 279 .......................................................

37

Axle adjustments of bevel gear set 172 - 177 - 272 ...............................

38

Taper roller bearings of differential .........................................................

39

Adjusting bevel gear set 172 without brake ............................................

42

Disassembly of differential......................................................................

44

Assembly of the differential.....................................................................

45

Self locking differential............................................................................

46

Conversion tables ..................................................................................

47

Tightening torques ..................................................................................

47

Trouble shooting .....................................................................................

48

Special tools ...........................................................................................

52

-3-

-4-

INTRODUCTION

The efficienty and continued operation of mechanical units depends on constant and correct maintenance and also on efficient repair work should there be a break-down or malfunction.

The instructions in this manual have been made based on a complete overhaul of the unit. However the mechanic must decide whether or not it is necessary to dismantle the individual components when only partial repair work is needed.

The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the operations, allows accurate work to take place. Therefore all the information needed for correct disassembly, the relative checks and assembly of each individual component, has been written down.

In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle.

IMPORTANT : Throughout the phases of repair or maintenance work it is advisable to use proper equipment such as : trestles, or supporting benches, plastic or copper hammers, appropriate levers, extractors and specific spanners or wrenches. So that the work is facilitated and the working surfaces and the operators themselves are protected.

Before going on to disassemble the parts it is best to thoroughly clean the unit, removing any encrusted or accumulated greases and then drain the oil through the oil-draining plugs.

INTRODUCTORY STATEMENT All the disassembled mechanical units should be thoroughly cleaned with appropriate products and then restored or replaced if damage, wear, craking or seizing have occured.

In particular, thoroughly check the state of all moving parts (bearing, gears, crown wheel and pinion, shafts) and sealing parts, (O-ring, oil shield) which are subject to major stress and wear. In any case it is advisable to replace the seals every time a component is overhauled or repaired.

During assembly the sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion, replacement of one reguires the replacement of the other.

During assembly the prescribed pre-loading and backlash of the parts must be maintained.

MAINTENANCE AND REPAIR We have compiled these instructions for maintenance and repair in order to facilitate any such work on the CLARK-HURTH Components differential units and gear change units. Drawings necessary in order to carry out maintenance and repair work can be bought directly from us.

Spare parts can be ordered either through the manufacturer of the vehicle or directly from us.

-5-

-6-

MAINTENANCE AND LUBRICATION - SYMBOLS

PARTS TO BE LUBRICATED

SYMBOLS

SEE OPERATOR'S MANUAL OF LIFT TRUCK. Removal of subassemblies

FREQUENCY Fitting of subassemblies

SEE OPERATOR'S MANUAL OF LIFT TRUCK. Removal of cumbersome parts

Fitting of cumbersome parts

Caution - important notice

Check/adjust eg. torques, measurements, pressure etc.

T = Special tools

P = 38

Fit the right way round

Check, examine, visual inspection

May be re-used (replace if necessary)

Replace on every fitting

Remove - apply safety device

Apply safety device, fix with adhesive (liquid mastic)

Avoid damage to materials, damage to parts

Mark before removal (for assembly)

Load/fill (oil, lubricant)

Drain, lubricant

Tighten

Pressurize hydraulic circuit

-7-

BRAKES WEAR CHECK AND REPLACEMENT OF BRAKE DISCS : Use discs till minimum thickness of S = 4,5mm.

T. 23

Loosen lock nuts and remove the axle housing horizontally.

Remove brake discs.

NOTE : If the brake discs must not been replaced, remove the complete pack without changing the position of the discs.

For assembly proceed in reverse order, align lubrication holes.

Use compressed air to eject the brake pistons.

This operation should only be carried out if necessary.

-8-

BRAKES Disassembly of piston ponts. bar

ASSEMBLY Even if the brake pistons have not been removed, seat them to the bore botton.

bar

-9-

Check for leakage using 0,51 bar compressed air for 10 minutes per side.

BRAKES / EXTERNAL ADJUSTMENT

bar

WEAR CHECK OF BRAKE DISCS : Brake the axle and check the tickness of the disks through the oil fill hole.

Use discs till minimum thickness of S = 4,5 mm.

T. 23

REMOVE BRAKE DISCS Loosen lock nuts and remove the axle housing horizontally.

Loosen the 3 adjuster screws : remove the pressure plate.

NOTE : If the brake discs must not been replaced, remove the complete pack without changing the position of the discs.

Ckeck that the springs are efficient.

Remove the brake plunger.

MOUNTING THE BRAKE PLUNGERS Mount the antiextrusion ring on the outside followed by the o-ring.

- 10 -

BRAKES / EXTERNAL ADJUSTMENT Tighten the 2 mobile stud bolts, lubricate the retention zones before mounting the plungers.

ASSEMBLING THE BRAKE DISK PACK Align the oil holes of the individual disks.

Mount the pressure plate with the vertical rods. Partially tighten the 3 adjuster screws.

Mount with loctite 242.

M12 8.8 bolt driving torque = 86 Nm on axle with bracket fixing.

M12 10.9 bolt driving torque = 120 Nm on axle with pendulum fixing.

BRAKE DISC PLAY ADJUSTMENT Gradually and fully turn (Driving torque ~ 50 Nm) the 3 adjuster screws in an anticlockwise direction, then turn them 3/4 of a turn in a clockwise direction to achieve a 0.75 mm play between the discs. Lastly, lock in place with the check nut.

- 11 -

BRAKES / EXTERNAL ADJUSTMENT

- 12 -

- 13 -

PARKING BRAKES / EXTERNAL ADJUSTMENT Mounting the internal lever.

Mount the bush and stop plate using Loctite 573.

M6 bolt driving torque = 10Nm. Mount the lever so thet in the relase position, it forms A ≈ 11° angle in the opposite direction to that of pulling.

Adjusting the parking brake with mechanical stops The play between the brake disks and parking brake levers on these axles will not need adjusting during the first assembly operations (this will have already been carried out in the factory).

Adjustment procedure for maintenance operations 1° Brake disk play adjustment.

2° Free both transmission levers from the control cable and from any other restraints.

3° Apply a ~ 8 ÷ 10 N load to the levers so that the lever itself rests on the pressure plate (without deforming the levers or internal springs (photo 5).

4° Having set this position, allow the stop adjuster screws to touch the levers and lock in place with the check nut (photo 5-6).

5° Position the plate (photo 7) and couple the external spring, locking it with a 75-77 mm pull (photo 8).

6° Re-connect the brake control cables to the levers.

7° Check that during the brake disengaging phase, the levers both return to the position in which they rest on the stop screws.

- 14 -

- 15 -

PLANETARY - 4,25 - 5,25 DISASSEMBLY THE PLANET SUPPORT Remove all 3 pins before removing the planets from the central hole of the cover.

ASSEMBLY Take care to center the thrust washer.

T. 15

Proceed in reverse order when mounting the support.

Champfer after having mounted the circlip as indicated.

- 16 -

PLANETARY WHEEL HUB - 4,25 - 5,25 DISASSEMBLY Before removing the axle shaft, lock the brake to keep the disks in place.

Use the partly tightened original screws and a plate for the puller.

Remove the bearing and spacer with a puller if necessary.

T.10

- 17 -

ASSEMBLY Check the rotation torque, allowing the taper bearing a slight end play.

The tangential force must be 20-30 N.

EPYCICLOIDAL REDUCTION - 4,25 - 5,25 ADJUSTMENT Measure the difference to establish the required shim size, EG. 0,9 mm.

Shim pack from 0,88 to 0,92 mm.

Insert the pin and thighten the bolts to 250 Nm using Loctite 270.

The tangential force must be max 40 ÷ 50 N. If corrections are required, add or remove shims considering that 0,02 mm cause a variation of ~ 10 N.

T.31

- 18 -

AXLE 177 - PLANETARY REDUCTION - 6,23 DISASSEMBLY

ASSEMBLY

Check the reference numbers.

Torque the screws at 315-320 Nm.

- 19 -

AXLE 177 - PLANETARY REDUCTION - 6,23 DISASSEMBLY T 32

Follow the operations on page 17.

ASSEMBLY

Use arexon adhesive (Liquid gasket material).

T. 38

ADJUSTMENT Follow the operation on page 17.

Use loctite 242 on the thread and grease around the pin diameter to prevent lock up.

Torque to 220 ÷ 230 Nm with a torque wrench + stop threaded MANITOU : 62079.

- 20 -

- 21 -

DISASSEMBLY ARTICULATION 272 - 277 - 279 Disassembly of steering joint.

Use the threaded holes in the pin as a puller.

Check the bearing races for possible damage.

Remove the double cardan joint.

Remove the nut and the stop screw.

Before removing the double cardan joint lock the differential and the brake to ensure that the disks remain in position.

- 22 -

ASSEMBLY ARTICULATION 272 - 277 - 279 Insert the external bearing race of the taper roller bearing.

Insert the double cardan joint.

277 T. 21 - 24

272 - 279 T. 08

Tighten the lock nut at 86 Nm using a torque wrench.

Assembly of a acla ring type 279.

Assembly of ring type 277.

T. 05

- 23 -

ASSEMBLY ARTICULATION 272 - 277 - 279

- 24 -

- 25 -

ASSEMBLY ARTICULATION 272 - 277 - 279 Taper roller bearing preload calculation.

Check the rotation torque.

Type 279 15-17 Nm. Type 277 21-23 Nm.

Tighten the screws with a torque wrench.

Type 279 120-123 Nm. Type 277 190-193 Nm.

- 26 -

DISASSEMBLY STEERING CYLINDER 277 - 279 Removing the steering cylinder from the axle.

ASSEMBLY Carry out the above operations in reverse order.

Use silicone.

Caulk.

- 27 -

DISASSEMBLY STEERING CYLINDER 277 - 279

HOW TO USE THE CYLINDER SERVICING TOOLS DRWG 279.24.620.01.

45x53x8 piston rod seals ; 45x52,9x1,5 anti-extrusion ring ; 82x4 O-ring, can be mounted without the aid of tools.

Proceed in the following way to mount the 90x74, 5x6,3 piston seal : Insert tool n° 400437 along the piston rod and allow it to fit on the piston. The 90x74,5x6,3 piston seal consists of two parts : an O-Ring in nitrile rubber and a retention pad.

Allow the nitrile rubber O-Ring to slide along the tapered part of tool n° 400437 until it fits into its housing.

Proceed in the same way with the retention pad. The 30x74x6,3 piston seal will mounted in its housing, but its original shape will have expanded. It must be recalibrated with tool n° 400436 in the following way.

Remove tool n° 400437, mount the two 5,5x2,5x270 guide rings in their seats. Mount tool n° 400436 on the piston with the chamfer pointing forwards and leave it mounted on the piston for 10-15 minutes. After this, assemble the piston rod on the cylinder body in the following way.

After having mounted the 45x52,9x1,5 anti-extrusion ring seals 45x53x8 piston rod seal and 45/53x4,7 scraper, insert tool n° 400438 on the end of the piston rod after having spread it with a light film of grease on the contact area between the piston rod and the tool itself. This will improve the adhesion a between the two parts.

Insert the piston rod + tool n° 400438 n° 400436 into the cylinder body. Part n° 400436 will be pushed out immeditely after the piston rod slides in the cylinder.

The piston rod must be mounted so that the piston comes out from part n° 400436 on the side opposite the chamfer.

Now remove assembly cone n° 400438 from the piston rod and insert it into the opposite end in the same way. After having mounted all the seals on to the head, fit this on to the piston rod, allow it to slide inside the cylinder, remove tool n° 400438 and apply the circlips 87x4 and A80x2,5L. NOTE : All the seal seats must be thoroughly cleaned before assembly and lubricated with a light film of oil.

Seal assembly will be facilitated if the seals are preheated to a temperature of 40-60 colsius degrees by immersing them in oil or exposing them to an infrared lamp.

- 28 -

STEERING CYLINDER ASSEMBLY 277 - 279 T. 45

T. 45

T. 45

T. 45 T. 45

T. 45

- 29 -

REPLACING THE LIP SEALS To remove, carry out the assembly operations in reverse order without using special tools.

Heat the seals in oil to ~ 80 ÷ 90°C (See page before).

Assemble the cylinder after having changed all the lip seals.

STEERING CYLINDER ASSEMBLY 277 - 279 Check that the steering cylinder piston rod is at half travel by measuring from both sides with a gauge or equivalent template.

Check parallelism between both wheel hubs at approx. 500 mm from the hub centre (front and rear).

T. 37

Adjusting the parallelism tightenings of safety clamps.

Adjusting the steering angle with the relative template.

T. 39÷44

Adjust the steering angle with end of travel screws.

279 L1 ß° 22mm 40° 17mm 50°

- 30 -

277 L1 ß° 18mm 50° 22mm 40° 32mm 36° 46mm 30°

BEVEL PINION SUPPORT Removal of bevel pinion support.

T. 07

T. 03-04

T. 19

- 31 -

Assemble the external races taper roller bearings.

Check cover measurement "A".

BEVEL PINION SUPPORT Determination of shim pack S1 for the preload of the taper roller bearings S1 = B - C + X X = Value to add in order to obtain the correct preload of the taper roller bearings.

Valeur X = See page 34.

T. 26

T. 26

Assembly of bevel pinion support and seal.

Assembly with Loctite 242.

T. 03-04

- 32 -

Tighten the ring nut with a torque wrench ; see solution on page 34.

BEVEL PINION SUPPORT Checking the rotation torque.

A 150÷200 Ncm B 150÷200 Ncm C 120÷170 Ncm D 120÷170 Ncm

Assembly of the lip seal and tightening of flange nut with a torque wrench.

part. X T. 14

- 33 -

- 34 -

AXLE BEVEL PINION SUPPORT 277 - 279 Disassembly : Take care to prevent damage to the retention areas of the «OR» rings when removing the differential gear from the central box.

T. 03-04

- 35 -

BEVEL PINION SUPPORT Determination of shim pack S2 for adjustment of bevel pinion position. Assembling of outer races without shims. Insert tool and verify after having set to zero the gauge on a surface plate. The difference is S2. Remove outer race of taper roller bearing, insert shims and reassemble the outer race definitively.

T. 27

A 60

Assembly of outer races of taper roller bearings.

T. 12

- 36 -

AXLE BEVEL PINION SUPPORT 277 - 279

T. 26

Determination of shim pack S1 for the preload of taper roller bearings : S1 = B - C + X X = Value to add in order to obtain the correct preload of the taper roller bearings (see exploded view drawing on page 34 -Solution D).

T. 26

T. 26

Assembly of bevel pinion support and tightening of flange nut (see exploded view drawing on page 34 -Solution D).

T. 13

T. 14

T. 03-04

For checking of torque (see page 33 -Solution D).

- 37 -

AXLE ADJUSTEMENT OF BEVEL GEAR SET 172 - 177 - 272 Determination of shim pack S2 for adjustement of bevel pinion position : S2 = (I + A) - (D + r) (See schema page 40).

D

Assembly of bevel pinion support with shim pack S2. Tighten the screws by about 86 / 89 with a torque wrench and using «Loctite 270».

Assembling central axle housing.

NOTE : Be careful not to damage the tight surfaces of the O-rings while inserting the differential case into the central axle housing.

- 38 -

TAPER ROLLER BEARINGS OF DIFFERENTIAL

T.06

Screw in the adjusting nuts to obtain approx.0.15 - 0.18 mm backlash between the teeth of the bevel gear set, without preloading the taper roller bearings.

Check the rotating torque of pinion and differential. Tighten nut on opposite site to the crown wheel to obtain a 35 - 45 Ncm higher rotating torque on the pinion.

T.06

Mark both ring nuts. To adjust the backlash move ring nuts only.

Loosen the one on bevel crown wheel side and tighten the opposite one for the equal measure if the backlash is too low ; viceversa if the backlash is too high.

Mount locking tabs in the best position and punch in place.

- 39 -

- 40 -

- 41 -

ADJUSTING BEVEL GEAR SET 172 WITHOUT BRAKE Disassembly.

ASSEMBLY AND ADJUSTMENT Insert an initial shim thickness of 0,8 mm on the crown wheel side and 0,85 mm on the opposite side.

Mount the differential with the lateral axle housings, leaving the bevel gear side nuts loose.

Check rotational torque of bevel pinion.

Tighten all nuts of the lateral axle housing.

Seat the taper roller bearings of the differential by tapping on both sides bon the axle shafts while turning the pinion.

- 42 -

ADJUSTING BEVEL GEAR SET 172 WITHOUT BRAKE Check the rotation torque of the pinion which must be increased by 35÷45 Ncm. If corrections are required, remove or add shims to respectively decrease or increase the rotation torque.

Check the backlash between the teeth of the bevel gear pair gap = 0,18 ÷ 0,25 mm.

If corrections are required, move the shims from one side to the other until the correct play is obtained. EG. : Excessive play : remove the shims from the side opposite the ring bevel gear and insert them on the ring bevel gear side.

Check lateral axle housing levelness after assemble.

- 43 -

DISASSEMBLY OF DIFFERENTIAL Removal of the differential from the axle.

NOTE : Replace the fitting bolts of the crown wheel every time that they have to be removed.

- 44 -

ASSEMBLY OF THE DIFFERENTIAL Insert the spring pins half way up the pin.

Torque all bolts M10x1,25x25, with a torque wrench clamping torque 73 Nm. M 12x30 bolts clamping torque 89 Nm. Use loctite 270.

- 45 -

SELF LOCKING DIFFERENTIAL Check the disc pack to determine the shims.

The total thickness of the disc pack with eventual shims must be 16,2 ± 0,1 mm.

Torque the bolts with a torque wrench.

M10x40-10 K tightening torque 69 à 72 Nm ; use loctite 242.

- 46 -

CONVERSION TABLES

5

1 Atm ≅ 1 bar ≅ 10 Pa ≅ 14.4 Psi Pa

N

da N

KN

Kg

Lbs

1N

1

0,1

0,001

0,102

0,225

1 da N

10

1

0,01

1,02

2,25

1 KN

1000

100

1

102

225

1 Kg

9,81

0,981

0,00981

1

2,205

1 Lbs

4,44

0,444

0,00444 0,4536

1

Nm

da Nm

KNm

Kgm

Lb-in

1 Nm

1

0,1

0,001

0,102

8,854

1 da Nm

10

1

0,01

1,02

88,54

1 KNm

1000

100

1

102

8854

1 Kgm

9,81

0,981

0,00981

1

86,8

1 Lb-in

0,1129 0,01129 0,0001129 0,01152

1 Kg cm 0,0981 0,00981 0,0000981

0,01

TIGHTENING TORQUES

Size of bolt

8.8

10.9

12.9

M4

2,9

4,1

-

M6

10,0

14,0

-

M8

25,0

35,0

-

M 10

49,0

69,0

-

M 10x1,25

52,0

73,0

88,0

M 12

86,0

120,0

-

M 14

135,0

190,0

-

M 14x1,5

150,0

210,0

250,0

M 16

210,0

295,0

-

M 18x1,5

325,0

460,0

550,0

550

-

-

A 22

- 47 -

1 0,868

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

Insufficient braking

1. Incorrect adjustment

Inspect disc thickness (see page 6) and if discs are usable readjust brakes to the specifications in the vehicle's manual.

2. Brake discs worn out

Inspectdisc thickness (see page 6) and replace if necessary.

3. Incorrect brake fluid

Replace all seals in axle and master cylinder that have made contact with the incorrect fluid and all brake hoses.

If incorrect fluid leaked into axle oil, seals and o-rings in axle must be replaced.

4. Loss of brake fluid

Inspect for and repair any leaks in outside circuit or master cylinder.

If caused by incorrect brake fluid see correction N° 3.

If leak is to the outside replace the orings between the center and intermediate housings.

If leak is to the inside replace above o-rings and brake piston o-rings.

5. Overheated axle causing brake fluid to vaporize (brake return when axle cools).

See "overheating" problem.

6. Air in brake circuit

Bleed brakes as described in the vehicle's service manual.

Soft brake pedal

- 48 -

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

Overheating

10. Oil level wrong

Drain, flush and refill oil to proper level.

11. Too small of a brake gap

Readjust brakes to the specifications in the vehicle's service manual.

12. Park brake dragging

Unlock the brake and adjust tre correct gap.

13. Incorrect brake fluid in system

See correction N° 3.

14. No free-pedal at master cylinder

Readjust brake pedal as described in the vehicle's service manual.

15. Restriction in brake lines

Inspect for and replace damage lines.

16. Restriction in return line of brake Servo system

Inspect for and replace damaged return line.

Inspect for and remove any filter, tee'd in line or any other source of back pressure from the return line.

17. Incorrect lubricant

Change the retaining rings of the brake circuit and brake pump.

Noise during coast and under power the same

26. Wheel bearings damaged

Replace and adjust as described on page 17.

Noise under power greater than during coast

27. Low oil level

Refill oil to proper level.

28. Incorrect lubricant

See correction N° 17.

29. Ring and pinion worn

Inspect throught rear cover.

Replace and adjust as described from page 31 to 39.

30. Worn ring and pinion bearings

Replace and adjust as described from page 31 to 39.

- 49 -

TROUBLE SHOOTING

PROBLEM

CAUSE

CORRECTION

31. Worn planetary gears or bearings

Replace as described on page 16.

32. Loose pinion nut

Inspect ring, pinion and pinion bearings. If undamaged retighten nut as described on page 32 and 33.

33. Only one pinion bearing is damaged

See correction N° 30.

Noise during turn (without NoSpin)

34. Worn spider and/or side gears

Replace as described from page 44.

A «Stick slip» noise when going from forward to reverse

38. Spider pins loose in diff-carrier

Inspect and replace as described from page 44.

39. Damaged or missing spider and/or side gear washers

See coorection N° 34.

Noise during coast greater than under power

- 50 -

- 51 -

SPECIAL TOOLS

- 52 -

SPECIAL TOOLS

- 53 -

SPECIAL TOOLS

- 54 -

SPECIAL TOOLS

- 55 -

SPECIAL TOOLS

- 56 -

SPECIAL TOOLS

- 57 -

SPECIAL TOOLS

- 58 -

SPECIAL TOOLS

- 59 -

SPECIAL TOOLS

- 60 -

GROUP 70

HYDRAULIC

CYLINDER DISASSEMBLY MLA 627 70-3-80-M27 EN

13 / 01 / 1999

CONTENTS

A - REMOVAL AND REASSEMBLY OF THE COMPLETE STEM ...........

4

B - REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING ................................................................................................

6

C - REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING ...........................................................................................

8

D - REMOVAL AND REASSEMBLY OF THE LOCKING RING SEALS AND RING ...........................................................................................

9

E - APPLICATION OF THE THREAD LOCKING MATERIAL .................... 10 F - CYLINDER DIAGRAMS.................................................................................. 11

3

A - REMOVAL AND REASSEMBLY OF THE COMPLETE STEM A1

REMOVAL - Place the cylinder in a vice fitted with false jaws - Tighten the vice, ensuring that the body does not get distorted.

- Free locking ring 2 (Fig. A1) using a spanner wrench.

- If you find it difficult to free the ring, see subsection "REMOVAL" in section E. - Completely unscrew locking ring 2 (Fig. A1).

- Extract the complete stem from the cylinder body.

NOTE : VERY LONG CYLINDERS - Take out the stem over 200 mm maximum.

- Give a half turn to the locking ring to loosen it (very slowly and evenly).

- Take out the stem by about 2500 mm.

- Support the stem end to prevent it from weighing on the locking ring (Fig. A2).

- Carry on unscrewing the locking ring. If the effort is excessive, lift and lower the stem to reduce the friction.

Never force the ring when unscrewing it as this could cause it to seize.

INSPECTION - Degrease and clean the cylinder chamber.

- Visually inspect the cylinder chamber, there should be no scratches, burrs, oxidisation, etc…

4

Locking 2 Bague dering fermeture 2 Stem11 Tige

A2

Body 33 Corps

Piston44 Piston

A3

- Apply hydraulic oil on the piston seals and ring, using a brush.

- Reassemble the complete stem inside the cylinder body 3 (Fig. A1).

- Ensure that the seals are not damaged while passing through the inside thread in the cylinder body.

- Apply hydraulic oil to the outside seals on the locking ring.

- Apply Loctite 222 (See section E) on the locking ring (Fig. A3).

- Screw the ring in.

- Block using a spanner wrench and a torque wrench, see table for the tightening torque (Fig. A4).

- Give one turn to the screw to ensure that the seals are correctly positoned.

REMARK

Locking ring Bague de fermeture Loctite Stem Frein filet Tige

Seal Joint

A4 LOCKING RING COUPLE DE SERRAGE TIGHTENING TORQUE BAGUE DE FERMETURE 450 400 350

Torque CoupleinenN.m N.m

REASSEMBLY

300 250 200 150 100

- We advise completing a hydraulic test of the cylinder before reasembling it on the machine.

- Operate the stem several times in both directions.

5

50 0

M40

M50

M60

M70

Filetage Thread

M80

M90

M100

B - REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING REMOVAL

B1

- Place the stem in a vice fitted with false jaws.

- Tighten so as to stop it turning.

- Loosen nut 5 (Fig. B1) and sunscrew it completely using a box wrench. Or depending on the version, remove locking screw 6 (Fig. 1) using a hexagonal wrench.

NOTE : Locking ring 6 (Fig. B1) is fitted using Loctite, then blocked by striking it with a chisel - Remove piston 4 (Fig. B2) by pulling it out manually or, depending on the version, by unscrewing piston 7 (Fig. B1) using a hook wrench.

- Remove locking ring 2 (Fig. B3) by sliding it along the stem.

Lockingde ring 2 Bague fermeture 2 Stem 1 Tige 1

Piston 44 Piston Piston Piston 77 Nut 5 Screw Ecrou 5 Vis 66

B2 Locking ring 2 Bague de fermeture 2 Piston 4 Piston 4

Stem Tige1 1

INSPECTION - Check that the stem is straight over its whole length, using a comparator (Fig. B4).

- Check that the stem is not scaling, corroded or scratched.

B3 Locking ring 2 Bague de fermeture 2 Stem Tige 11

REASSEMBLY - Reassemble locking ring 2 (Fig. B5) on stem 1 (Fig. B5).

- Reassemble piston 4 (Fig. B1) on the stem.

- Screw and lock nut 5 (Fig. B1) using a box wrench and a torque wrench. See the table for the tightening torque (Fig. B6). Or, depending on the version, screw piston 7 (Fig. B1) using a spanner wrench (see tightening torque Fig. B6) and block it with locking screw 6 (Fig. B1).

NOTE : • The locking screw should be fitted using Loctite 243, see section E. • Tightening torque for the screw = 20 Nm. • Strike with a chisel to drive the screw into the metal.

6

B4 Comparator Comparateur Stem11 Tige

B5 Locking ring 2 Bague de fermeture 2 Stem Tige 1 1

B6 PISTON TIGHTENING TORQUE COUPLE DE SERRAGE PISTON 1400 1200

TorqueCouple in N.m en N.m

1000 800 600 400 200 0

7

M20

M30

M40 M50 Filetage Thread

M60

M70

C - REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING NOTE : Never use cutting or sharp tools (screw drivers, blades, etc.) when assembling and removing seals.

Ensure that there are no chippings on the work bench.

C1 Seals Joints d'étanchéité

REMOVAL - Remove the piston seals and ring (Fig. C1 or C2).

- Take care not to damage the edges or the bottom of the grooves.

O-ring Joint torique

INSPECTION - Degrease and clean the piston.

- Check that the grooves bottoms and sides are smooth and without scratches.

- There should be no extraneous bodies in the grooves.

C2 Seals Joint d'étanchéité

REASSEMBLY - Fit the seals and ring as in Fig. C1 or C2).

- When fitting the outside seals, open them sufficiently to slip them into the grooves while ensuring that they do not break.

- The inside ring should be fitted by hand.

8

O-ring Joint torique

D - REMOVAL AND REASSEMBLY OF THE SEALS AND RINGS ON THE LOCKING NOTE : Never use cutting or sharp tools (screw drivers, blades, etc.) when assembling and removing seals.

Ensure that there are no chippings on the work bench.

D1 Extrusion proof ring 2 Joint anti-extrusion 2 Seals 1 Seals 3 Joint torique 3 Joint torique 1

REMOVAL - Remove the locking ring seals and rings.

- Take care not to damage the edges or the bottom of the grooves.

Racleurring 4 4 Scraper

INSPECTION

Stem Joint tigeseal 5 5

- Degrease and clean the locking ring.

- Check that the groove bottoms and sides are smooth and without scratches.

- There should be no extraneous bodies in the grooves.

- Thread the bare ring on the stem and slide it over its whole length.

- The gap should not be excessive, but it should not grip either.

D2 Seal Joint

REASSEMBLY Embout Bit 1 1

- Fit the seals and rings as in Fig. D1. The lips of the stem seal should face the pressure side.

- When fitting the stem seal, first introduce it in the groove, holding it back either with your thumb or a bit (item 1) with no sharp edges (Fig. D2).

- Push it into the groove with the other hand or a smooth die (item 2) (Fig. D3). If the seal is too tight, dip it into hydraulic oil heated to 50°C. Fit scraper ring 4 (Fig. D1) using a plug and a mallet.

O-rings 1 and 3 (Fig. D1) and extrusion proof ring 2 (Fig. D1) will be fitted by hand.

D3 Plug 22 Poinçon

Seal Joint

Bit 1 1 Embout

9

E - APPLICATION OF THE THREAD LOCKING MATERIAL CHARACTERISTICS Light thread locking material (Loctite 222) Application on the locking ring threads.

Without activation agent Handling time Use time

10 - 30 minutes 3 - 6 hours

(Placing of the cylinder under pressure)

With N Loctite activation agent Handling time Use time

10 - 20 minutes 2 - 4 hours

(Placing of the cylinder under pressure)

Shearing strength

1,5 - 4

N/mm2

Medium thread locking material (Loctite 243) Application on the M8 screws to lock the pistons.

Without activation agent Handling time Use time

10 - 20 minutes 3 - 6 hours

(Placing of the cylinder under pressure)

With N Loctite activation agent Handling time Use time

5 - 15 minutes 2 - 4 hours

(Placing of the cylinder under pressure)

Shearing strength

5 - 7,5 N/mm2

REMOVAL If the parts fitted with locking material cannot be removed using standard tools, we recommend heating the glued area to T = 250°C, preferably using a hot air pistol rather than a blowpipe.

REMARK If the temperature is near 0°C, we recommend using a Loctite activation agent for the assembly, in addition, this will limit the polymerisation time.

10

LIFTING CYLINDER 1ST MOUNTING

LIFTING CYLINDER 2ND MOUNTING

11

COMPENSATION CYLINDER 1ST MOUNTING

COMPENSATION CYLINDER 2ND MOUNTING

12

TELESCOPE CYLINDER

13

TILTING CYLINDER

14

STEERING CYLINDER 1ST MOUNTING

STEERING CYLINDER 2ST MOUNTING

15

LOCKING CYLINDER OF ATTACHMENT

16

HYDRAULIC DIAGRAMS MLA 627 70-6-M27 EN

13 / 01 / 1999

CONTENTS

– HYDRAULIC DIAGRAM ...................................................................................

4

– HYDRAULIC CONTROL VALVE ....................................................................

5

3

FDAV

FDAV

4

M

PF

R

4,8cm3/tr

41 cm3 /tr

LS

LS

T N

CS

DD

50b P

P

P

T

P

400 cm 3/tr

200b

P

L

P

T1

FA

M

SHF

100 L/min 100 MICRONS

EF

140b

R

T

B

R

BA

45b

10 MICRONS

2b

FR

40b

T

P1

AF

U

0,7 LITRE 70 BAR

0,7 LITRE 13 BAR

VDG

VDD

90 BAR F

FDAR

FDAR

D

P

PP

EE

230b

R1/4

VV UNIQUEMENT POUR FLECHE AVEC T.I.

a1

EA

b1 B1

PA

CSP

A1

a2

ET

200b

b2 B2

V1

C1

VT

A2

V2

a3

EI

250b

200b

b3 B3

C2 300b

A3

a4

EL

b4 B4

270b

A4

T

VC

a5

EH

b5 B5

150b

A5

T

T

V1

C1

VI

A2

B2

V2

M2

M4

SA P

CSP

PP

C2 300b

M1

T M3

V1

C1

VL

B1 A1

V2

C2 300b

P

T

CSP

SB

HA

B A

1

M4

M2

3

P

M3

M1

2

T

MA

COMMANDES ELECTRIQUES AU MANIPULATEUR

4

HYDRAULIC DIAGRAM

HYDRAULIC DIAGRAM AF

Brake accumulator

BA

Feed block + Accumulator

CS CSP

Safety valve Piloted Safety valve

D

DD

5- port control valve EA Attachment EE Intake EH Rear Attachment EI Tilting EL Lifting ET Telescope Steering pump manual

HA

Rear hydraulic

FA Suction filter FDAV Front disc brake FDAR Rear disc brake FR Return filter M

MA

PERKINS 1004-4 T heat engine Idling speed Rated speed under load Maximum speed empty Controller

P PA PF PP

Hydraulic pump Attachment fitting Brake pump Pressure fitting

R R1/4

Hydraulic tank Tap 1/4

SA SB SHF

Electrovalve Electrovalve Brake hydraulic system

VC VDD VDG VI VL VT VV

60x40 C1175 compensation cylinder 65x40 C387 right steering cylinder 65x40 C387 left steering cylinder 130x85 C413 tilting cylinder 110x60 C1140 lifting cylinder 70x50 C1600 telescope cylinder 40x30 C60 locking cylinder

825 rpm 2300 rpm 2480 rpm

5

6

HYDRAULIC CONTROL VALVE

D

EE

230 b.

ET

200 b.

EE

EI

EA

EI

200 b.

ET

250 b.

EI EL EH

D

5- port control valve EA EE EH EI EL ET

Attachment Intake Rear Attachment Tilting Lifting Telescope

7

8

HYDRAULIC CIRCUIT MLA 627 70-7-M27 EN

13 / 01/ 1999

2

CONTENTS

– Hydraulic braking circuit .......................................................................................................... 5 – Main hydraulic circuit ................................................................................................................ 6 – Lifting - telescope - compensation circuit ............................................................................ 7 – Telescope - inclination circuit .................................................................................................. 9 – Servo controls circuit ................................................................................................................. 10 – Rear optionnal circuit ................................................................................................................ 11 – Steering circuit ........................................................................................................................... 12

3

4

BRAKE HYDRAULIC CIRCUIT

5

MAIN HYDRAULIC CIRCUIT

6

LIFTING - TELESCOPE - COMPENSATION CIRCUIT 1ST MOUNTING

7

LIFTING - TELESCOPE - COMPENSATION CIRCUIT 2ND MOUNTING

8

TELESCOPE - TILTING CIRCUIT

9

SERVO CONTROLS CIRCUIT

10

REAR OPTIONNAL CIRCUIT

11

STEERING CIRCUIT

12

PLATE OF HYDRAULIC DETAILS MLA 627 70-7-20-M27 EN

13 / 01 / 1999

CONTENTS

– STEERING PUMP

..........................................................................

3

4

STEERING PUMP.

3

FLAP VALVES (200bar +20 0 ) PRESSURE RELIEF VALVE + 10 140bar 0

29

28

4

3 – Steering post 29 – Steering pump case 28 – Seal kit

5

6

OPERATION - ADJUSTMENTS : BALANCING VALVE 70-8-30 EN

25 / 09 / 1998

BALANCING VALVE

1) DESCRIPTION :

This is a single acting balancing valve designed to maintain and monitor the lowering of a load in one single direction.

The valve is fitted into the bore of a steel block. It consists in a differential surface flap valve (Item 1) (maximum pressure valve), one annular and co-axial unidirectional valve (Item 2) and two adjusting screws : screw 3 (delay time) and screw 4 (maximum pressure).

4

2

1

3

3

2) OPERATING PRINCIPLE

Connection :

Load lifting : During the lifting phase, the oil travels freely (V2 - C2) through the unidirectional valve (2).

Load holding : When the control valve is on neutral, the pressure generated by the load is blocked by the valve thus ensuring that the load is held up.

Load lowering : The pressure generated by the load and the actuating pressure on arm V1 - C1 cause the valve to open progressively thereby authorising the controlled lowering of the load (C2 - V2).

4

3) EXCESS PRESSURE Whenever the pression generated by the load exceeds the calibration value of valve 1, it discharges the possible pressure peak towards the flap valves within the control valve.

Indeed, the valve is designed to be compensated for pressures corresponding to the maximum pressure calibration.

CAUTION : The valve must shut even if subjected to the maximum pressure for the device on which it is fitted.

To that effect, the valve must be calibrated to a higher value than that value so as to compensate the hysteresis resulting from the rubbing of the moving parts against the internal wall.

The calibration value must be at least 30 % higher than the maximum pressure generated by the load : Pt > 1.3 Pc max.

Adjustment of the calibration pressure : remove the blind nut (Item 5) and operate the adjusting screw (Item 4); calibration per turn of the screw : 110 bar.

4) ACTUATING PRESSURE The actuating pressure required to lower a load is conditioned by the calibration pressure of the valve and that generated by the load, as defined by the formula below : Ppil : Pt - Pc R where Pt = calibration pressure Pc = pressure generated by the load R = actuating ratio, that is, ratio between the section of the actuating piston and the differential section of the flap valve subjected to the pressure generated by the load.

4) FUNCTIONS AND OPERATING LIMITS CAUTION : The valve is designed so that it is it is compensated to back pressure both on the maximum pressure section and on the actuating pressure. It is therefore necessary to ensure that a pressure exceeding the minimum actuating pressure does not occur on opening V1, or that it occurs only during the lowering phase controlled by the operator.

The valve should only be used with control valves on which openings A and B are closed when on neutral and fitted with flap valves. Indeed, back pressure occurring on the actuating piston could actuate the valve.

The valve is designed for the functions below : - Holding of the load with the control valve on neutral, - Limiting of the maximum pressure generated by shocks on the load or excess load, hammer blows due to sudden stopping or thermal expansion of oil if the control valve is fitted with flap valves.

- Protection against hose burst, since the valve is flanged directly on the cylinder.

5

OVERCENTER VALVE SERIES 33/42 CCAP

LOAD LIFTING

ANTISHOCK FUNCTION

6

OVERCENTER VALVE SERIES 33/42 CCAP

LOAD HOLDING

LOAD LOWERING

7

7) REMOVAL - REASSEMBLY - CALIBRATION CHECK Removal : a) Remove the blind nut and decalibrate the adjusting screw. b) Unscrew the spring guide plug and extract the internal components by hitting the valve body onto a wooden surface. c) Replace the retaining rings and seals, if worn. d) Thoroughly wash all parts and blow dry.

Reassembly : a) Carefully oil the parts before reassembly. Relocate the seals. b) Insert spring and unidirectional valve, ensuring that it slides freely into its housing. c) Insert the flap valve and check that it slides freely. d) Insert the spring plug together with the spring, spring driver and adjustment screw.

Calibration check : a) Connect opening C2 to the test bench pressure outlet. b) Increase the test pressure until the valve opens (seeping of oil through opening V2). Repeat the test 4 to 5 times. c) Set the calibration value by acting on the adjusting screw to achieve a value of 300 / 315 bar with a flowrate of 4.5 / 5 dm3 / minute. d) Reduce the test pressure to 70 % of the calibration value, check that the valve does not let through more than 5 drops per minute. e) Fit the blind nut using an O-ring and a new copper ring. f) Remove the test bench valve and protect it from damp and pollution.

8) MARKING Mark openings V1 - V2 - C1 - C2.

9) SEALING The valve is supplied complete and sealed.

8

10) CLEANING The valve should be cleaned prior to removing.

Blow dry all parts.

This operation should be completed in a well ventilated room.

11) HANDLING Check and replace all joints if necessary every two years of operation and, in all cases, every 1000 hours.

12) TROUBLE SHOOTING What follows is a list of possible breakdowns : Malfunction

Cause

Remedial action

Inadequate holding of the load

Holding seat

Replace unidirectional valve and stop valve

Worn holding seal

Replace holding seals

Inadequate calibration

Check calibration

Noisy valve, especially during the first few operations

Presence of air on the spring side

Bleed valve

Delayed opening of valve Loss of oil through the outside O-ring on the blind nut (this does not affect the load holding)

Excessively limited actuation Worn seals on the spring holder plug

Adjust actuation screw Replace seals

9

10

TEST STAND "VALVE ADJUSTMENT" 70-8-35 EN

®

N° 609

CODE : 4510

PAGE : 2/18

TECHNICAL DATA

TEST BENCH FOR CHECKING AND ADJUSTING PRESSURE VALVES FITTED ON THE MANISCOPIC AND MLT RANGE CYLINDERS

CONTENTS Page

- DESCRIPTION............................................................................................................... 3 - SETTING UP.................................................................................................................. 4 - CHECKING AND ADJUSTMENT A - Single valve unit ............................................................................................. 6 B - Two-valve unit ................................................................................................. 7 C - Balancing valve............................................................................................... 10 D - Pressure relief valve....................................................................................... 11 - VALVE REFERENCE AND PRESSURE TABLE A1 - Single valve unit ........................................................................................... 12 B2 - Two-valve unit ............................................................................................... 14 B2 - Two-valve unit (fitted on hydraulic flange)................................................. 15 B3 - Two-valve unit (fitted on hydraulic flange)................................................. 16 C1 - Balancing valve............................................................................................. 17 D1 - Pressure relief valve..................................................................................... 18

®

N° 609

CODE : 4510

PAGE : 3/18

TECHNICAL DATA

DESCRIPTION Prior to checking and adjusting the valves, it is necessary to dismantle them and to fit them on the test bench.

The hydraulic supply of the bench is via a hand pump, the calibration readings are taken from a pressure gauge connected to the supply circuit (see Fig. A).

A 6 5

1

Item 1 Item 2 Item 3 Item 4 Item 5 Item 6

Test bench Hand pump Pressure gauge Stand Hydraulic flange (needed for certain valves) Valve undergoing checks (example)

3

2

The test bench is supplied as a kit.

Complete kit

4

Ref

216 741 B

Contents of kit 216 741 : 1 2 3 4 5

Test bench Hand pump Stand Supply hose Fitting (x5) (M20x150 - 1/4 BSP) Copper rings (x5) 6 Elbow fitting (M20x150) 7 Pressure fitting 8 Fitting (MA 12S / MA 1/4 BSP JE) 9 Fitting (FE 12S / MA 12S modified) 10 Hydraulic flange Zinc plated hexagonal M8 - 50 screw (x2) Zinc plated hexagonal M10 - 30 screw (x2) Zinc plated M8 N washer (x4) Zinc plated M10 N washer (x2) Zinc plated W10 washer (x2) Zinc plated hexagonal M8 nut (x4) Zinc plated M8 - 30 Chc screw (x4) Seal (flange)

Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref. Ref.

552 407 195 186 195 188 195 187 35 348 35 348 405 955 58 181 191 728 194 771 214 360 58 531 63 544 61 674 29 437 42 232 58 528 60 845 189 960

4 3

1

2

5

7

10

6 8

9

CAUTION : In order to precisely check the pressures, it is indispensable to have a pressure gauge in working order, with a range from 0 to 400 bar minimum, and graduated from ten to ten bar.

NOTE : The pressure gauge is not supplied with the kit.

®

N° 609

CODE : 4510

PAGE : 4/18

TECHNICAL DATA

SETTING UP - Fix the stand on a work table (there are fixation holes for that purpose).

- Fit the pump on the stand * 4 hexagonal M8 bolts + 4 M8 N washers - Fit the test bench on the stand * 2 hexagonal M10 x 30 screws, 2 M10 N washers + 2 W10 washers - Fit all five fittings 1 (Fig. A) on the test bench.

- Connect the elbow fitting 2 (Fig. A) and supply hose 3 (Fig. A).

A 1

1

1

NOTE : The connection of the supply hose varies depending on the type of valve to check (see fig. D and E).

1

1

2

3

- Connect fittings 4 and 5 (Fig. B) to the hand pump.

B - Connect hose 3 (Fig. B) on the fittings.

3

- Fit pressure fitting 6 (Fig. B).

5

- Connect pressure gauge 7 (Fig. B).

4

7

- Fill the hand pump tank with Tellus 46 hydraulic oil.

6

CAUTION : The oil should only serve once.

- Flange 8 (Fig. C) should only be fitted on the bench to check certain valves - refer to tables B2 and B3 (Pages 15 and 16).

C NOTE : The flange is fitted to the bench by means of 4 zinc plated Chc M8 - 30 screws.

8

®

N° 609

CODE : 4510

PAGE : 5/18

TECHNICAL DATA

The test bench was designed for three types of valves (see Fig. D and E).

D

➀

➁

➀ - Valve A and B unit flanged onto the cylinders (fitted with one or two valves).

➁ - Balancing valves fitted on the cylinders. ➂ - Pressure relief valves fitted on the inclination -

compensation circuits (MLT Series 1 and MT 222 CP to MT 425 CP Turbo).

A

B

FITTING OF THE VALVES ON THE BENCH E

Supply Test bench

Hydraulic flange

➂

®

N° 609

CODE : 4510

PAGE : 6/18

TECHNICAL DATA

CHECKS AND ADJUSTMENT A - Single valve unit

A1 2

In order to check and adjust the valve units, bench supply should be via opening 1 in the middle (Fig. A1).

- Fit the unit on the test bench using two M8 x 50 2 hexagonal screws (Fig. A1).

NOTE : Ensure that the O-ring is correctly positioned between the unit and the test bench.

1

Refer to Table A1 (Pages 12 and 13) for the calibration value for the valve.

- The parts reference is stamped on the top of the unit.

CHECK - Place the valve under pressure by operating the hand pump lever. The pumping movements should be slow and continuous.

- The applicable pressure is the maximum pressure displayed by the pressure gauge before the beginning of the opening of the valve.

ADJUSTMENT If the pressure displayed on the pressure gauge does not correspond to the value in the table, follow the procedure below :

A2

3

- Remove the valve plug (size 17 or 24 key).

- Using a hexagonal wrench (size 5 or 8, depending on the models), act on adjusting screw 3 (Fig. A2).

NOTE : Start by giving quarter turns then more progressively to achieve the correct adjustment.

- Replace the plug.

- Complete a final test.

A3 CAUTION : Prior to removing the valve unit, it is necessary to remove the pressure in the test bench supply circuit, by opening cock 4 (Fig. A3) on the hand pump.

- Remove the valve unit.

- Shut cock 4 (Fig. A3).

4

®

N° 609

CODE : 4510

PAGE : 7/18

TECHNICAL DATA

CHECKS AND ADJUSTMENT B - Two-valve unit First of all, you should check the reference of your valve unit on tables B1, B2 and B3 (Pages 14, 15 and 16) to find out whether it is necessary to fit the hydraulic flange on the test bench.

- Table B1 - No hydraulic flange - Table B2-B3 - With hydraulic flange

VALVE UNIT FITTED DIRECTLY ONTO THE TEST BENCH (TABLE B1)

B1 2

Checking of the valve on side C1 / V1 In order to check and adjust the valve units, bench supply should be via opening 1 in the middle (Fig. B1).

- Fit the unit on the test bench using two M8 x 50 2 hexagonal screws (Fig. B1).

1

NOTE : Ensure that the O-ring is correctly positioned between the unit and the test bench.

- Refer to Table B1 (Page 14) for the calibration value for the valve.

- Place the valve under pressure by operating the hand pump lever. The pumping movements should be slow and continuous.

- The applicable pressure is the maximum pressure displayed by the pressure gauge before the beginning of the opening of the valve.

Adjustment of the valve on side C1 / V1 If the pressure displayed on the pressure gauge does not correspond to the value in the table, follow the procedure below : - Remove the valve plug (14 key).

- Using a size 4 hexagonal wrench, act on adjusting screw 3 (Fig. B2).

NOTE : Start by giving quarter turns then more progressively to achieve the correct adjustment.

- Replace the plug.

- Complete a final test.

B2

3

®

N° 609

CODE : 4510

PAGE : 8/18

TECHNICAL DATA

CAUTION : Prior to removing the valve unit, it is necessary to remove the pressure in the test bench supply circuit, by opening cock 4 (Fig. B3) on the hand pump.

B3

- Remove the valve unit.

- Shut cock 4 (Fig. B3).

4

Checking of the valve on side C2 / V2

B4

- Fit the valve unit as shown in Fig. B4.

- Proceed as in "CHECKING OF THE VALVE ON SIDE C1 / V1".

VALVE UNIT FITTED ON THE HYDRAULIC FLANGE (TABLES B2 AND B3)

B5 1

- Fit hydraulic flange 1 (Fig. B5) on the test bench, using 4 Chc, M8 - 30 screws.

- Fit the valve unit to be checked on the hydraulic flange.

NOTE : The assembly varies according to the type of valve unit (see Fig. B6, B7, B8 and B9).

- For these valves the checking and adjustment procedure is the same as that described at the beginning of this chapter.

®

N° 609

CODE : 4510

PAGE : 9/18

TECHNICAL DATA

Fig. B6 : Valve unit ref. 195 636 fitted for the checking of the valve on side C1 / V1, see table B2 (page 15).

- The valve unit is fitted using three hexagonal M6 - 40 screws.

B6 2

NOTE : Use a size 13 wrench to remove the valve counternut and a size 4 hexagonal wrench to act on adjusting screw 2 (Fig. B6).

B7 Fig. B7 : Valve unit ref. 195 636 fitted for the checking of the valve on side C2 / V2, see table B2 (page 15).

3

NOTE : Use a size 13 wrench to remove the valve counternut and a size 4 hexagonal wrench to act on adjusting screw 3 (Fig. B7).

Fig. B8 : Valve unit ref. 199 263 fitted for the checking of the valve on side C1 / V1, see table B3 (page 16).

- The valve unit is fitted using four hexagonal M10 - 50 screws.

B8

NOTE : Use a size 24 wrench to remove the valve plug and a size 8 hexagonal wrench to act on adjusting screw 4 (Fig. B8).

4

B9 Fig. B9 : Valve unit ref. 199 263 fitted for the checking of the valve on side C2 / V2, see table B3 (page 16).

NOTE : Use a size 24 wrench to remove the valve plug and a size 8 hexagonal wrench to act on adjusting screw 5 (Fig. B9).

5

®

N° 609

CODE : 4510

PAGE : 10/18

TECHNICAL DATA

CHECKS AND ADJUSTMENT C - Balancing valve

C1 3

In order to check and adjust the valves, bench supply should be via opening 1 to the left (Fig. C1).

2

- Fit valve 2 to be checked (Fig. C1) in position.

Refer to Table C1 (Page 17) for the calibration value for the valve.

1

CHECK - Place the valve under pressure by operating the hand pump lever.

The pumping movements should be slow and continuous.

The applicable pressure is the maximum pressure displayed by the pressure gauge before the beginning of the opening of the valve.

C2 5

ADJUSTMENT

4

If the pressure displayed on the pressure gauge does not correspond to the value in the table, follow the procedure below : - Remove protection cap 3 (Fig. C1) using an adjustable spanner (do not hold the top of the cap, it might crush).

- Loosen counternut 4 (Fig. ) using a size 14 wrench.

- Using a size 4 hexagonal wrench, act on adjusting screw 5 (Fig. C2).

NOTE : Start by giving quarter turns then more progressively to achieve the correct adjustment.

C3

- Tighten counternut 4 (Fig. C2).

- Complete a final test.

- Replace cap 3 (Fig. C1).

CAUTION : Prior to removing the valve, it is necessary to remove the pressure in the test bench supply circuit, by opening cock 6 (Fig. C3) on the hand pump.

- Remove valve 2 (Fig. C1).

- Shut cock 6 (Fig. C3).

4

®

N° 609

CODE : 4510

PAGE : 11/18

TECHNICAL DATA

CHECKS AND ADJUSTMENT D - Pressure relief valve

D1 3

In order to check and adjust the valves, bench supply should be via opening 1 to the right (Fig. D1).

2

- Fit the valve 2 to be checked (Fig. D1) in position.

Refer to Table D1 (Page 18) for the calibration value for the valve.

1

CHECK - Place the valve under pressure by operating the hand pump lever.

The pumping movements should be slow and continuous.

The applicable pressure is the maximum pressure displayed by the pressure gauge before the beginning of the opening of the valve.

D2

ADJUSTMENT

5

4

If the pressure displayed on the pressure gauge does not correspond to the value in the table, follow the procedure below : - Remove protection cap 3 (Fig. D1) using a size 22 wrench.

- Loosen counternut 4 (Fig. D2).

- Using a screwdriver, act on adjusting screw 5 (Fig. D2).

NOTE : Start by giving quarter turns then more progressively to achieve the correct adjustment.

D3

- Tighten counternut 4 (Fig. D2).

- Complete a final test.

- Replace cap 3 (Fig. D1).

CAUTION : Prior to removing the valve, it is necessary to remove the pressure in the test bench supply circuit, by opening cock 6 (Fig. D3) on the hand pump.

- Remove valve 2 (Fig. D1).

- Shut cock 6 (Fig. D3).

6

®

N° 609

CODE : 4510

PAGE : 12/18

TECHNICAL DATA

A1

SINGLE VALVE UNIT

NUMBER

PRESSURE

484 514

350 bar 0

484 951

300 bar 0

+15

+15

LOCATION

189 197

484 542 MT 430 CPDS (1st assembly) 484 543 MT 430 CPDS (2nd assembly) 485 411 MT 430 CPDS 485 434 MT 430 CPDS 486 021 MT 430 CPDS - Interior telescope 486 028 MT 430 CPDS - Intermediary telescope

Telescope cylinder

Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder

484 402 MT 1230 S / 1230 SCP / ULTRA - Intermediary telescope (1st assembly) MT 1235 SCP 10/10 - Intermediary telescope(1st assembly) 484 409 MT 1230 S/1230 SCP / ULTRA Interior telescope (1st assembly) MT 1235 SCP 10/10 - Interior telescope (1st assembly) 486 900 BUGGISCOPIC Série 1 - Série 2 (1st assembly) 488 285 MT 1530 SCP - Telescope I (1st assembly) 485 471 MT 1530 SCP - Telescope II (1st assembly) 509 435 MT 1530 SCP - Telescope I (2nd assembly) 509 436 MT 1530 SCP - Telescope II (2nd assembly)

Tilt cylinder Tilt cylinder Tilt cylinder Tilt cylinder

484 398 MT 1230 S 486 895 BUGGISCOPIC Série 1 - Série 2 (1st assembly) 199 725 BUGGISCOPIC Série 2 (2nd assembly) 488 059 MT 1530 SCP

Tilt cylinder Tilt cylinder Tilt cylinder Tilt cylinder

484 398 MT 1230 SCP / ULTRA (1st assembly) 195 569 MT 1230 SCP / ULTRA (2nd assembly) 198 889 MT 1230 SCP (Simultaneous extension) 191 468 MT 626 / 725 Série 2 / ULTRA MLT 626 / 630 / 725 Série 3 / ULTRA (1st assembly) 202 142 MLT 626 / 630 / 725 Série 3 / ULTRA (2nd assembly) 199 639 MLT 523 / 526 Série 1 (1st assembly) 202 143 MLT 523 / 526 Série 1 (2nd assembly)/ Série 2 ML 320 205 532 MT 727 / 927 Série C 208 923 MT 1232 - 1240 - 1337 Série 1 MT 845 Série 1 202 143 MLT 628 / 632 / 728 205 532 MT 728-2 / 728-4 / 928-4

+15

300 bar 0

+15

300 bar 0

Tilt cylinder Tilt cylinder Tilt cylinder

191 614

Tilt cylinder Tilt cylinder

or

193 916 or

193 917

TYPE OF MACHINE

Stabiliser cylinder Stabiliser cylinder Lifting cylinder Tilt cylinder Telescope cylinder Telescope cylinder

Telescope cylinder

485 873

1/2

+15

300 bar 0

Tilt cylinder Tilt cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder

189 041 MLT 626 / 725 Série 2 / ULTRA (1st assembly) 191 466 MLT 626 / 725 Série 2 / ULTRA (2nd assembly) 192 413 MLT 626 / 725 Série 2 / ULTRA (3rd assembly) MLT 626 / 630 / 725 Série 3 / ULTRA (1er montage) 202 141 MLT 626 / 725 Série 2 / ULTRA (4th assembly) MLT 626 / 630 / 725 Série 3 / ULTRA (2nd assembly) 200 169 MLT 523 / 526 Série 1 - Série 2 (1st assembly) MT 727 / 927 Série C (1st assembly)

This table may be modified without notice, do not use it to order parts.

®

N° 609

CODE : 4510

PAGE : 13/18

TECHNICAL DATA

A1

SINGLE VALVE UNIT

NUMBER

PRESSURE

LOCATION Lifting cylinder

Lifting cylinder Lifting cylinder Lifting cylinder Telescope cylinder

191 614 or

193 916 or

+15

300 bar 0

Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder

193 917 Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder Telescope cylinder

TYPE OF MACHINE 211 000 MLT 523 / 526 Série 2 (2nd assembly) MT 727 / 927 Série C (2nd assembly) MLT 628 / 632 / 728 MT 728-2 / 728-4 / 928-4 205 985 ML 320 486 897 Buggiscopic Série 2 188 897 MT 1530 ULTRA 191 469 MLT 626 Série 2 / ULTRA MLT 626 / 630 Série 3 / ULTRA 191 470 MLT 725 Série 2 - Série 3 / ULTRA 486 900 BUGGISCOPIC Série 2 (2nd assembly) 199 640 MLT 523 / 526 Série 1 - Série 2 194 494 MT 1230 SCP / 1235 SCP 10/10 - Interior telescope Simultaneous extension (1st assembly) 199 295 MT 1230 SCP / 1235 SCP 10/10 Interior telescope Simultaneous extension (2nd assembly) 202 746 MT 727 Série C 205 530 MT 927 Série C - Interior telescope (1st assembly) 211 483 MT 927 Série C - Interior telescope (2nd assembly) MT 928-4 - Interior telescope 208 919 MT 1232 - 1240 Série 1 - Interior telescope 208 921 MT 1337 Série 1 - Interior telescope 212 995 MT 845 Série 1 207 205 MLT 628/632 207 230 MT 728-2 / 728-4 MLT 728

This table may be modified without notice, do not use it to order parts.

2/2

®

N° 609

CODE : 4510

PAGE : 14/18

TECHNICAL DATA

B1

TWO-VALVE UNIT C1/V1

C2/V2

PRESSURE NUMBER

LOCATION

TYPE OF MACHINE

C1/V1 C2/V2 Lifting cylinder

188 894 MT 830 / 830 CP / ULTRA (2nd assembly)

Lifting cylinder

188 895 MT 840 / 840 CP / ULTRA (2nd assembly)

Lifting cylinder

188 896 MT 930 / 930 S / 930 SCP / ULTRA (2nd assembly) MT 930 CP 10/10

+15

189 077

200 0 bar

ML 630 CP

+15

300 0 bar

Lifting cylinder

486 897 BUGGISCOPIC - Série 1

Telescope cylinder

189 299 MT 840 CP / ULTRA

Telescope cylinder

189 300 MT 930 / 930 S (3rd assembly) MT 930 CP / 930 SCP / ULTRA 10/10

Telescope cylinder

189 301 MT 830 (3rd assembly) MT 830 CP / ULTRA

Lifting cylinder

189 196

MT 1230 SCP / ULTRA

200 +15 300 +15 0 0 bar bar

+15

193 306

200 0 bar

487 912

205 0 bar

+10

+15

300 0 bar

+10

305 0 bar

188 897 MT 1230 S (2nd assembly) MT 1235 SCP 10/10

Lifting cylinder

208 924 MT 1232 / 1240 / 1337 Série 1

Lifting cylinder

212 996 MT 845 Série 1

Lifting cylinder

188 897 MT 1230 SCP Nacelle ORH MT 1530 SCP Nacelle ORH

Telescope cylinder Telescope cylinder

488 290 MT 1530 SCP - Telescope III (1st assembly) 509 437 MT 1530 SCP - Telescope III (2nd assembly)

This table may be modified without notice, do not use it to order parts.

1/1

®

N° 609

CODE : 4510

PAGE : 15/18

TECHNICAL DATA

B2

TWO-VALVE UNIT C1/V1

C2/V2

PRESSURE NUMBER

LOCATION

TYPE OF MACHINE

C1/V1 C2/V2 +15

195 636

325 0 bar

+15

325 0 bar

Slant compensation cylinder 195 635 MT 930 - 1235 10/10 ULTRA Slant compensation cylinder 211 320 MT 1240 Série 1 Slant compensation cylinder 212 426 MT 1337 Série 1

This table may be modified without notice, do not use it to order parts.

1/1

®

N° 609

CODE : 4510

PAGE : 16/18

TECHNICAL DATA

B3

TWO-VALVE UNIT C1/V1

1/1

C2/V2

PRESSURE NUMBER

LOCATION

TYPE OF MACHINE

C1/V1 C2/V2

199 263

300 bar

+15 0

300 bar

+15 0

Telescope cylinder

194 493 MT 1230 SCP / 1235 SCP 10/10 - Intermediary telescope Simultaneous extension (1st assembly)

Telescope cylinder

199 296 MT 1230 SCP / 1235 SCP 10/10 - Intermediary telescope Simultaneous extension (2nd assembly)

Telescope cylinder

205 531 MT 927 Série C - Intermediary telescope (1st assembly)

Telescope cylinder

MT 928-4 - Intermediary telescope (1st assembly) 211 260 MT 927 Série C - Intermediary telescope (2nd assembly)

Telescope cylinder Telescope cylinder

MT 928-4 - Intermediary telescope (2nd assembly) 208 920 MT 1232 / 1240 Série 1 - Intermediary telescope 208 922 MT 1337 Série 1 - Intermediary telescope

This table may be modified without notice, do not use it to order parts.

®

N° 609

CODE : 4510

PAGE : 17/18

TECHNICAL DATA

C1 NUMBER

182 917 (sun : CBEA CAN)

182 918 (sun : CBEA CAN)

184 334 (sun : CBEH CCN)

BALANCING VALVE

PRESSURE

240 bar ±5 %

280 bar ±5 %

290 bar ±5 %

LOCATION

75 825 MT . . H / CP (Jib 5.80m) 177 625 MT . . H / CP (Jib 6.75m) 78 773 MLT Série 1 75 526 MT . . H / CP (1st assembly) 183 965 MT . . H / CP (2nd assembly)

Telescope cylinder Telescope cylinder Telescope cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder Stabiliser cylinder Stabiliser cylinder

181 977 MT 930 (2nd assembly) 181 980 MT 840 (2nd assembly) 185 240 MT 830 (2nd assembly) 75 425 MT . . H / CP (Jib 5.80m - 1st assembly) 183 969 MT . . H / CP (Jib 5.80m - 2nd assembly) 75 426 MT . . H / CP (Jib 6.75m - 1st assembly) 183 966 MT . . H / CP (Jib 6.75m - 2nd assembly) 183 968 MT . . CP (Jib 5.80m floating position) 183 967 MT . . CP (Jib 6.75m floating position) 76 355 MT 231 / 431 CP (Jib 5.80m) 76 354 MT 231 / 431 CP (Jib 6.75m) 76 691 MT 231 / 431 CP (Jib 5.80m floating position) 76 690 MT 231 / 431 CP (Jib 6.75m floating position) 78 774 MLT Série 1 185 168 MT 930 S / SCP - MT 1230 S / SCP (1st assembly) 190 315 MT 930 S / SCP - MT 1230 S / SCP (2nd assembly) MT 930 S / SCP - MT 1230 S / SCP / ULTRA (1st assembly)

Lifting cylinder Lifting cylinder Lifting cylinder Lifting cylinder

182 985 MT 930 (1st assembly) 183 784 MT 840 (1st assembly) 185 071 MT 830 (1st assembly) 185 174 MT 1230 S (1st assembly)

Tilt cylinder

188 898 MT 830 / 930 (2nd assembly) MT 830 / 930 CP (1st assembly) 188 899 MT 840 (2nd assembly) MT 840 CP (1st assembly) 190 211 MT 830 / 930 CP (2nd assembly) MT 830 / 930 CP ULTRA (1st assembly) 190 212 MT 840 CP (2nd assembly) MT 840 CP ULTRA (1st assembly) 197 532 MT 830 CP / 930 CP (3rd assembly) MT 830 CP / 930 CP ULTRA (2nd assembly) MT 930 CP 10/10 197 533 MT 840 CP (3rd assembly) MT 840 CP ULTRA (2nd assembly) 189 310 MLT Série 1 (1st assembly) 189 311 MLT Série 1 (2nd assembly)

Tilt cylinder

(sun : CAEG CGN)

Tilt cylinder 290 bar ±5 % Tilt cylinder

Tilt cylinder Tilt cylinder Tilt cylinder

476 781 (sun : CBEH CDN)

476 783 (sun : CBEH CCN)

100 bar ±5 % 280 bar ±5 %

TYPE OF MACHINE

Telescope cylinder Telescope cylinder Telescope cylinder Tilt cylinder Tilt cylinder

Tilt cylinder

189 434

1/1

Stabiliser cylinder

190 857 MT 1230 SCP Nacelle ORH MT 1530 SCP

Stabiliser cylinder

190 857 MT 1230 SCP Nacelle ORH MT 1530 SCP

This table may be modified without notice, do not use it to order parts.

®

N° 609

CODE : 4510

PAGE : 18/18

TECHNICAL DATA

D1 NUMBER

73 746 ( HPI )

79 658 ( HPI )

PRESSURE RELIEF VALVE

PRESSURE +5

229 bar 0

+5

150 bar 0

LOCATION

TYPE OF MACHINE

Tilt compensation circuit

MLT Série 1

Tilt compensation circuit

MT 222 CP to MT 425 CP Turbo

Tilt compensation circuit

MT 222 CP to MT 425 CP Turbo

This table may be modified without notice, do not use it to order parts.

1/1

LS PUMP OPERATION 70-8-40-M.20EN

ULTRA LOAD SENSING FLOW DIVIDER

OPERATION AND MAINTENANCE INSTRUCTIONS

1

Overriding opening (P)

Secondary opening (EF)

Orifice load sensing

2

3

OPERATION GENERAL Pump / Ultra 520 machines Ultra Gear Pump, type 2PR 036 with integral Load Sensing Priority Valve is mounted on the left hand side power take off on the engine beneath the injector pump.

The pump supplies fluid to the main services circuit and on demand to the steering circuit.

Before removing and dismantling the pump it is necessary to determine if the problem is within the main service circuit or steering circuit.

To check main service circuit, fit flow meter to valve port marked EF and pressure gauge to the test point in the flow valve body.

At an engine speed of 2200 rev/min and with a maximum pressure 240 bar in the service circuit and with steering in neutral i.e. no demand, a flow of 71.25 l/min or greater should be achieved.

If the flow is less than this the pump should be replaced as renewal of gears and housing will not effect a permanent cure. If the pump output is satisfactory but there is external leakage the pump should be removed and re-sealed as indicated below.

To check Load Sensing Priority Valve remove the hose from Load Sense connection and fit suitable hose to enable a small amount of leakage to be collected in a container, fit pressure gauge to priority port P. With an engine speed of 1000 r.p.m. and with the steering in neutral a pressure of 10.1/10.7 bar should be evident at port P and a small amount of leakage occur from the Load Sense connection.

It pressure is higher or lower than indicated remove the Load Sense connection (30) spring (28) and main spool (27). Ensure that the spool slides freely in the bore with no stiction and also that the 0.7 mm dia orifice is in both the load sense connection and in the spool spring recess are clear and not blocked.

Re-Assemble valve and re-test as above, if the steering does not still function correctly then the other sterring components require investigation.

4

MAINTENANCE REMOVAL 1. Drain Hydraulic System.

2. Disconnect and plug inlet hose and pressure hoses fitted to Load Sense Valve.

3. Remove bold (1) and support bracket from rear of pump unit and the 5 bolts securing the pump to the engine.

REMPLACEMENT Replacement is reversal of removal.

Note : It is important to ensure that no contaminant enters the valve load sense connection as this has a 0.7 mm orifice that must remain clear.

DISMANTLING AND ASSEMBLY Prior to dismantling ensure that the exterior of the pump and working area are thoroughly cleaned and free of possible sources of contamination.

1. Remove drive gear (19) and key (14) using a suitable puller, do not lever or hammer off as this will result in internal damage to the pump. Check the shaft for any burrs or sharp edges which may cause seal damage and remove as necessary.

2. Mark body (8) and flange (16) to ensure correct re-assembly.

3. Remove load sensing valve by un-screwing 3 bolts (26) and washers (2).

4. Remove 4 nuts (23) and washers (24) separate flange and body using a soft faced hammer.

5. Drift out outer shaft seal (18) then remove retaining circlip (22) and inner shaft seal (18) from flange ensuring that shaft seal recess is not damaged.

6. Grasp driveshaft (12) and remove with balance plate (11) finally remove driven gear (13) and lower balance plate (11). Note position of these for correct re-assembly.

5

7. Remove spool (27) from valve by unscrewing the load sense connector (30), spring (27) and spool plug (4).

8. Remove and discard all seals and clean off all sealant from the flange/body interface.

INSPECTION Pump Inspect "0" ring groove and shaft seal recess in mounting flange, these should be undamaged and free from burrs.

The pump must be renewed if : a) The PTFE coated bearings in body and flange are worn through revealing the bronze backing. b) The gear side faces are scored, often operation on contaminated fluid results in a disinct wear step coincident with the gear tooth root diameter with corresponding wear on the balance plates. c) There is a noticeable wear groove on the driveshaft where the shaft seal lips run. d) The bronze balance plates are scored.

Valve Inspect valve body bore this must be free from scoring and damage to metering edges, the spool should slide freely in the bore and also be free of scroring and damage.

Ensure that the 0.7 mm dia. orifices in the load sense connection and spool spring recess are clear and free from contamination.

ASSEMBLY Prior to assembly all parts must be perfectly clean and lubricated with Hydraulic Fluid.

Renew all seals using Hydraulic Fluid as a lubricant.

Pump 1. Fit inner shaft seal (18) into mounting flange (16) with the garter spring facing into the pump, refit circlip (17) and outer shaft seal (18), with garter spring uppermost, coat seal lips with high melting point grease.

6

2. Stand pump body on the rear face, fit seal (10) and back up (9) to groove in balance plate and feed plate into bore. Ensure that the seals remain in their groove and that the two small holes in the balance plate are to the low pressure side of the pump i.e. the side with the threaded port.

3. Insert driveshaft (12) and driven gear (11) into their original bores.

4. Replace 2nd balance plate (11) into its original position, small holes to low pressure side, fit seal (10) and back up (9).

5. Fit "0" ring (15) into its groove in the mounting flange and also apply a small amount of loctite 574 sealant to body lower front face, i.e. outboard of oval location. This sealant is to prevent moisture entering this area and causing corrosion.

6. Fit protective sleeve and driveshaft (included in seal kit) and carefully fit mounting flange in its original position, the 4 mm diameter drain hole in rear face must be to low pressure side i.e. side with threaded port.

7. Fit washers (24) and nuts (23) to studs and torque tighten to 95 Nm ± 5 Nm. 8. For a small amount of clean hydraulic fluid into the port and check that the shaft can be turned without undue force.

Valve 9. Renew "0" rings on spool cap (4) and load sense connector (30).

10. Replace spool (27) into its bore with the spring recess upper most i.e. end of valve with "P" port.

11. Fit spool cap spring (plus any shims if fitted) and load sense connector.

Torque tighten spool cap to 78 Nm ± 5 Nm and load sense connector to 103 Nm ± Nm. 12. Fit "0" ring (7) to rear of pump face and fit valve in its original position. Secure with bolts (26 + 1), washer (2) and ensuring spacer (3) is fitted to the correct bolt as shown, torque tighten to 95 Nm ± 5 Nm. 13. Fit key and drive gear (19) with new tab washer (20). Torque tighten securing nut (21) to 100 Nm ± 5 Nm then bend up tabs.

7

GROUP 80

ELECTRICITY

ELECTRIC DIAGRAM MLA 627 80-6-M27 EN

13 / 01 / 1999

CONTENTS

– ELECTRIC DIAGRAM ........................................................................................

3

4

1

n

n

J

2

4

R1

n

Y8

41

40

S13a

3

Y7

vt

bl

S24

KO

L

v

H

H

v bc bc n

L

r

G

M1

F4

G1

j j

D

E7

I

E8

bl

E

S13b

E

D

F7

r

A

E9

bl

bl

r

A

Y1

5

j

r

A

o

E10

bl

E

6

E11

J

E

F20

F22

R2

F15

E12

J

E

F18

8

bl

E

B

bl

B

H1

E14

B

H9

bc

o

F

E18

S18

53 54

E17

m

C

m

vt

F10

12

P

G

S4

F

V1

V1

H3

P

11

J

H

r

B

S3

H2

g

B

S19

F8

A

V1

E19

g

C

g

9 10

V1

bl

jvt

G

V1

P1

bc

M7

E13

bc

E

bc

P2

7

m r

G

r

42 43 44 45 46 47 48 49 50 51 52

H7

bl

bl

bl

E

F6

J

I

I

E

bl

I

4

G2

bc bl

30 30 17 17 50 19 19 54 15 58

3210P

S1

P

M10

F11 H

V1

V1

F12

S5

13

J

H

55 56

j

C

F

V1

V1

H4

n

B

K7

57

r

H

jvt

S17

T

H8

H

15

H

r

B

S22 n/s

r

H

V1

V1

F14

S6

14

J

H

T

H5

vt

B

S8

V1

V1

K5

K8

H12

H13

jvt

j

S7

n/s

B

G

jvt

G

j

j

V2

K4

S14

n/s

K0

n

K

K

K3

g

n ro

J

vt

o

m

D

I

24

I

Y4

o

K

F19

E D

S13c

25

Y2

ro

K

I

jvt

K

G

F5

K

E

H

K3

H

E15

bc

C

bc

E16

S15

S11

m

r

H10

o

26 27 28

M7

o

V3

bc

m

j

F21

29

G

F1

r

N

N

S29

bl

vt J

58

M2

J

59

M3

n

S10

H6

J B

E1

g

E

E2

g

E3

n

E

n

n

E4

n

g

n

60 61 62 63 64 65

K6 jvt

g

g

66

67

E22

C

Y9

ro

N

F16

30

jvt

S23

N

S27

N

S28

31

Y10

bl

S20

32

Y13

m

r

C

vt

68

M8

F23

ro

Y11

33

j

69

34

Y12

n

H11

M9

35

S9

F3

70

M4

o

36

M5

vt

H

vt

I

vt

N

r

S26

S21 G

S25

F2

F

ro

23

Y5

bl

K

S2

F9

ro

22

Y6

n/s

K

K

K

F

G

21

Y3

g

K

vt

ro

F13

ro

J

F17

16 17 18 19 20

H

B

S12

o

A

G

E5

S16

71

C

F24

E6

D

37 38

r

vt

K4

39

j

ELECTRIC DIAGRAM

ELECTRIC DIAGRAM COLOUR CODING MAIN ELECTRIC CIRCUIT 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 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

bc : white j : yellow n : black ro : pink

- Battery - Starter - Preheating - Alternator - Motor stop solenoid - Fuel level sensor - Fuel level - Machine fault warning - Clock - Charge indicator - Motor oil pressure - Brake fluid - Air filter blocking - Motor water temperature - Transmission oil temperature - Free - Hand brake - Transmission cut-off - Starting safety - Forward/reverse relay - Reverse solenoid - 1st +2nd speed solenoid - 1st speed solenoid - 4th speed solenoid - Forward solenoid - Reverse alarm - R.H. working tail light - L.H. working tail light - Free - Extend telescope electrovalve - Retract telescope electrovalve - Jib head electrovalve - Retract attachment electrovalve - Extend attachement electrovalve - Unloking attachment light - Sound alarm - L.H. stoplight - R.H. stoplight - Control panel lighting - R.H. rear sidelight - R.H. front sidelight - L.H. rear sidelight - L.H. front sidelight - L.H. front dipped headlight - R.H.front dipped headlight - L.H. front headlight - R.H. front headlight - Headlight indicator light - Rotating beacon - L.H. front working headlight - R.H. front working headlight - Free - Free - Safety system - Front windscreen wiper - Front windscreen washer - Flasher unit/warning - Flashing unit indicator light/warning - R.H. rear indicator - R.H. front indicator - L.H. rear indicator - L.H. front indicator - Warning switch/indicator light - Roof light - Rear windscreen wiper - Roof windscreen wiper - Rear windscreen washer - Free

bl : blue jvt : yellow/green o : orange vt : green

g : grey m : brown r : red v : purple

CONNECTOR A B C D E F G H I J K L N

- Fuse board/relays (4 pin connection + 1 pin connection) - Indicator light module - Cabin - Rear lighting - Fuse box / relay (13 pin connection) - Fuse box / relay (7 pin connection) - Fuse box / relay (11 pin connection) - Fuse box / relay (21 pin connection) - Light switch - Front windscreen wiper - EGS (15 pin connection) - Hoock switch - Mono-ultra optional switch

ELECTRICAL COMPONENTS E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E22

- Rear right blinker - Front right blinker - Rear left blinker - Front left blinker - Left stop light - Right stop light - Rear right position light - Front right position light - Rear left position light - Front left position light - Front left low beam headlight - Front right low beam headlight - Front left headlight - Front right headlight - Rear right work headlight - Rear left work headlight - Front left work headlight - Front right work headlight - Rotating light - Roof light

FUSES F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24

5

- Free (15A) - Mono-Ultra (5A) - Warning / stop (10A) - Hoock (10A) - Left indicator (7,5A) - R.H. sidelight / Instrument panel (7,5A) - L.H sidelight (7,5A) - Rotating beacon (7.5A) - Working tail light (10A) - Front working headlight (10A) - Cigarette lighter (7,5A) - Free (7,5A) - Transmission (15A) - Overload safety system (10A) - Indicator light / fault alarm (5A) - Indicator (10A) - Front windscreen wiper / Front windscreen washer (10A) - Headlight (15A) - R.H. indicator (7,5A) - Dipped headlights (15A) - Warning / Roof light (15A) - Lighting switch(15A) - Rear windscreen wiper (7,5A) - Free (15A)

ELECTRIC DIAGRAM

G1 G2

- 12V 105Ah battery - 55A Alternator

H1 - Load indicator light H2 - Motor oil pressure indicator light H3 - Brake fluid H4 - Air filter blocking indicator light H5 - Motor water temperature indicator light H6 - Blinker light H7 - Lighting for the clock / gauge H8 - Transmission oil temperature H9 - Headlight indicator light H10 - Warning light H11 - Locking attachment safety light H12 - Free H13 - Brake indicator light K0 K2 K3 K4 K5 K6 K7 K8

- Starter safety relay - Free - Reverse realy - Transmission cut-off - Free - Flasher unit / warning - Load safety module - Electronic delay unit 2,5 s / free

M1 - Starter M2 - Front windscreen wiper M3 - Front windscreen washer M4 - Rear windscreen washer M5 - Roof windscreen washer M6 - Sound alarm M7 - Reverse sound alarm M8 - L.H. rear windscreen wiper M9 - R.H. rear windscreen wiper M10 - Cigarette lighter P1 P2

- Clock - Fuel level

R1 R2

- Preheating resistance - Fuel sensor

S1 - Key switch S2 - EGS S3 - Motor oil pressure sensitive switch S4 - Brake fluid S5 - Air filter blocking S6 - Motor water temperature S7 - Brake switch S8 - Front windscreen wiper S9 - Sound alarm control S10 - Front windscreen washer switch S11 - Warning light switch S12 - Speed switch S13a - Lighting switch (sidelight) S13b - Lighting switch (dipped headlight/headlight) S13c - Lighting switch (indicator) S14 - Transmission cut-off switch S15 - Working tail light switch S16 - Stop switch S17 - Transmission oil temperature S18 - Working headlight switch S19 - Rotating beacon switch S20 - Rear windscreen wiper switch / Windscreen washer

6

S21 S22 S23 S24 S25 S26 S27 S28 S29

- Loking attachment safety - Load safety switch - Roof light switch - Hoock switch - Extend telescope switch - Retract telescope switch - Retract attachment switch - Extend attachment switch - Jib head switch

V1 V2 V3

- Fault test diode - Transmission cut-off diode - Reversing light diode

Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13

- Engine stop solenoid - Forward solenoid - Reverse solenoid - 4th speed solenoid - 1st speed solenoid - 1st + 2nd speed solenoid - Extend electrovalve hook - Retract electrovalve hook - Extend telescope electrovalve - Retract telescope electrovalve - Retract attachment electrovalve - Extend attachment electrovalve - Jib head electrovalve

OPERATION OF THE “EGS” SHIFT LEVER 80-8-14-M.22EN

TABLE OF CONTENTS

A - Descriptions - Characteristics ......................................................

2

B - Driving ............................................................................................................

3

C - Test ....................................................................................................................

6

D - Test of connections ..............................................................................

7

E – Speed sensor test .................................................................................

7

1

A - Descriptions - Characteristics – 4 forward running speeds (Fwd).

– 3 reversing speeds (Rev.).

LED

Forward running

Colors

Inverting lever

RED GREEN YELLOW

NEUTRAL FWD REV.

LED (green) for fwd

LED lights up in "test" mode (see paragraphs C,D,E)

Neutral

reversing

1

2

N

T

3

4

5

6

7

8

F

N

R

LED "N" Neutral (red) (lights up when the “egs” shift lever is in neutral)

2

LED (green) lights up when the machine is immobile LED "T" lights up in "test" mode (yellow)

B - Driving – “Egs” shift lever in neutral.

– Turn on the ignition.

The following indicators light up on the EGS : - LED N (red) - LED 2 red - LED 8 (green) (immobile machine).

1

2

N

T

3

4

1

2

6

7

8

N

T

F

N

R

6

7

8

F

N

R

5

3

4

5

– Start up the thermal motor

B1 – FORWARD RUNNING – Place the “egs” shift lever in Fwd. On the EGS : - LED 2 lights up, green.

- LED N turns off.

- LED 8 stays lighted green while the machine is immobile.

– Accelerate the thermal motor, the machine starts to move forward.

On the EGS : - LED 2 stays lighted green.

- LED 8 turns off.

1

2

N

T

1

2

N

T

3

3

4

4

1

2

6

7

8

N

T

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

5

5

3

4

5

B1.1 - To change speed (shifting from 2nd to 3rd gear) – Give the “egs” shift lever a forward rotational impulse.

- LED 3 lights up green.

- LED 2 turns off.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

– To shift from 3rd to 4th gear, accelerate the machine.

- Forward impulsion : • Shifting from 3rd to 4th gear.

- LED 4 lights up green.

- LED 3 turns off.

Note 1 : It is possible to shift gear automatically (every 1.5 seconds) by maintaining the “egs” shift lever turned forward while increasing motor speed.

1

2

N

T

1

2

N

T

3

3

4

4

5

5

B1.2 - To shift down – Decrease the machine speed.

– Give the “egs” shift lever a rotational impulse towards the rear.

3

1

2

N

T

3

4

5

6

7

8

F

N

R

• Shifting from 4th to 3rd gear.

- LED 3 lights up green.

- LED 4 turns off.

1

2

N

T

1

2

N

T

1

2

N

T

1

2

N

T

3

4

5

6

7

8

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

- Rotational impulse towards the rear : • Shifting from 3rd to 2nd gear.

- LED 2 lights up green.

- LED 3 turns off.

3

4

5

- Rotational impulse towards the rear : • Shifting from 2nd to 1st gear.

- LED 1 lights up green.

- LED 2 turns off.

3

4

5

Note 2 : – When shifting down, always decrease the machine’s speed.

(When you give an impulse to shift down without slowing down the machine, for example, shifting from 4th to 3rd gear, - LED 3 lights up green, - LED 4 blinks,

3

4

5

the machine stays in 4th gear).

B2 – REVERSING – Place the “egs” shift lever in Rev.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

On the EGS : - LED 2 lights up yellow.

- LED 8 lights up green (immobile machine).

- LED N turns off.

1

2

N

T

1

2

N

T

3

4

5

– Accelerate the thermal motor, the machine starts to reverse.

On the EGS : - LED 2 stays lighted yellow.

- LED 8 turns off.

3

4

5

B2.1 - To change gears (shifting from 2nd to 3rd gear) – Give the “egs” shift lever a forward rotational impulse.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

- LED 3 lights up yellow.

- LED 2 turns off.

Note : It is possible to automatically change to higher gears (the same as for forward running, see note 1).

4

1

2

N

T

3

4

5

B2.2 - To shift down – Decrease the machine speed.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

– Give the “egs” shift lever a rotational impulse towards the rear.

• Shifting from 3rd to 2nd gear.

- LED 2 lights up yellow.

- LED 3 turns off.

– Rotational impulse towards the rear : • Shifting from 2nd to 1st gear.

- LED 1 lights up yellow.

- LED 2 turns off.

Note : To shift down, always decrease the machine speed (same as for forward running, see note 2).

1

2

N

T

1

2

N

T

3

3

4

4

5

5

B3 – SAFETY B3.1 - When turning on the ignition, if the inverted lever is either in Fwd or in Rev.

It is advised to put the “egs” shift lever in neutral before starting up.

• Start up will occur normally but the trolley will not be able to move. The “egs” shift lever must be placed in neutral before the desired direction is selected.

B3.2 - When for example, the machine is in 3rd gear, and the “egs” shift lever is directly placed from Fwd to Rev. without decreasing motor speed : On the EGS : - LED 3 blinks green and yellow.

The machine stays in Fwd.

5

1

2

N

T

3

4

5

1

2

N

T

1

2

N

T

3

3

4

4

5

5

6

7

8

F

N

R

6

7

8

F

N

R

6

7

8

F

N

R

C - Test Lever operation.

– Motor turned off.

– Place the lever in Fwd and maintain the handle turned forward.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

– Turn on the ignition then release the handle.

LED T lights up in Test mode (yellow).

LED 4 is lighted green.

1

2

N

T

3

4

5

• Verify the gear change information (from the smallest to the largest).

- Turn the handle backwards and maintain it in this position.

LED 5 lights up green (correct operation).

1

2

N

T

3

4

1

2

6

7

8

N

T

F

N

R

6

7

8

F

N

R

5

3

4

5

• Verify the gear change information ( from the largest to the smallest).

- Turn the handle backwards and maintain it in this position.

LED 3 lights up green (correct operation).

- Release the handle, LED 4 lights up again, green.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

– Place the “egs” shift lever in Rev. LED 4 lights up yellow.

- Turn the handle forward and maintain it in this position.

LED 5 lights up yellow.

- Turn the handle towards the rear and maintain it in this position.

LED 3 lights up yellow.

Correct operation has been validated.

6

1

2

N

T

3

4

5

D - Test of connections – Motor turned off.

1

2

6

7

8

N

T

3

4

5

F

N

R

6

7

8

F

N

R

– Place the lever in Fwd and maintain the handle turned towards the rear (towards the bottom).

– Turn on the ignition and release the handle.

1

2

N

T

3

4

5

– LED T lights up in test mode (yellow).

LEDs 1 to 8 light up one after the other.

LEDs 1,2,3,4,6,8 are green (wires correctly connected).

If one of these LEDs lights up yellow : A wire is disconnected or cut.

If one of these LEDs lights up red : Short-circuit.

LED 5,7 are yellow ( not used).

E - Speed sensor test Warning : the trolley moves forward during this operation.

1

2

N

T

3

4

5

6

7

8

F

N

R

– Motor turned off.

– Place the lever in Rev. and maintain the handle turned forwards (turned up).

– Turn on the ignition and release the handle.

1

2

N

T

3

4

5

6

7

8

F

N

R

LED T lights up in test mode (yellow).

– Place the lever in neutral.

LED 1 blinks, the sensor reads "zero" speed.

1

2

N

T

3

4

5

6

7

8

F

N

R

– Start up the motor.

– Place the lever in Fwd and accelerate the thermal motor.

LEDs 1 to 8 light up one after the other (correct operation).

LED 1 Speed 1 to 249.

LED 8 Speed 1999 to 2000, above 2000, LED 8 blinks.

1

2

N

T

3

4

5

6

7

8

F

N

R

If only LEDs 1 to 4 light up, the speed has not been reached: verify the brakes and the sensor.

7

1

2

N

T

3

4

5

6

7

8

F

N

R

SAFETY SYSTEM ADJUSTMENT 80-8-80-M27 EN

13 / 01 / 1999

SAFETY SYSTEME ADJUSTMENT MLA 627 Fig. G

PRESSURE ADJUSTMENT FOR THE SPRING WASHERS (with telescope retracted and the load on the ground, unladen).

- Loosen the lock nut (3) and unscrew the nut (4) sufficiently so that it is not in contact with the spring washers (2).

- Then, tighten this nut (4) bringing it into contact with the spring washers (2), then tighten it 3/4 of a turn.

- Tighten the lock nut (3).

ADJUSTING THE CONTACTOR (with a nominal load) - The trolley must be on a horizontal floor with a nominal load 2450 kg.

- Position the load on the forks, with the horizontal telescope extended 200 mm +0 -50mm.

- Loosen the lock nut (8).

- Turn the screw (7) clockwise until the audio alarm goes off.

- Tighten the lock nut (8).

- Retract the telescope, the audio and visual alarms should turn off.

- Then extend and retract the telescope several times in order to verify that the safety system works. The alarm should go off when the telescope is extended by 200 mm (horizontal telescope).

3

4