OM Pimespo D25-D30-G25-G30 Transmission TXL 30S for Forklift Trucks Repair Manual

TRANSMISSION TXL 30/S FOR FORKLIFT TRUCKS

D 25 - D 30 - G 25 - G 30 1ª EDITION 06/2001

ST. N° 604.24.113

REPAIR INSTRUCTIONS

06/2001

FI AT O M CA R RE L L I E L E VATO R I S . P. A.

INTRODUCTION

This publication may contain information that is not up-to-date as a result of modifications made by the constructor, at any time, for technical or trade reasons or to comply with legal regulations in different countries.

Descriptions and photos may be of equipment that is not standard.

FIAT OM Carrelli Elevatori S.p.A. Technical Service Via De Gasperi, 7 20020 Lainate - Milano Copyright by FIAT OM Carrelli Elevatori S.p.A. Printed in Italy

Printed n. 604.24.113

Centrostampa s.n.c. - Brescia

TRANSMISSION TXL 30/S

FOREWORD

This manual has been prepared to provide the customer and the maintenance personnel with information and instructions on the maintenance and repair of TXL 30/S transmission.

In order to become familiar with the various parts of the transmission, its principle of operation, trouble shooting and adjustments, it is important for the mechanic to study the instructions in this manual carefully and use it as a reference when performing maintenance and repair operations.

Whenever repair or replacement of component parts is required, only spares parts as listed in the applicable spare catalogue should be used. Use of “will-fit” or non-approved parts may endanger proper operation and performance of the equipment.

FIAT OM CARRELLI ELEVATORI S.p.A. does not warrant repair or replacement parts; nor failures resulting from the use thereof.

Printed 604.24.113

UK - 3

06/2001

TRANSMISSION TXL 30/S

INDEX SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 7 TECHNICAL DATA - Transmission TXL 30/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 9 Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 10 Kinematic diagram of the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 11 Drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 11 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 12 General views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 16 TRANSMISSION HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 18 Hydraulic diagram description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 20 SCHEME A - Gear in neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 21 SCHEME B - Started lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 22 SCHEME C - Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 23 DISASSEMBLING AND REASSEMBLING OF TRANSMISSION - Specific tools . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 24 Converter case overhauling - A VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 31 Converter case overhauling - B VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 35 DISMANTLING AND REASSEMBLING OF DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 37 DISASSEMBLING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 46 Oil pump and transmission cover overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 48 DISASSEMBLY CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 51 Clutches overhauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 52 DEMI AXLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 59 AXLE CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK- 59 DIFFERENTIAL UNIT DISASSEMBLY AND OVERHAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 61 OIL FILTER CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 64 TRANSMISSION CASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 65 SHOES DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 67 WHEEL HUB DISMANTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 71 FRAME MOUNT SUPPORT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 72 BEARINGS ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 75 DIFFERENTIAL REASSEMBLY AND EBEVEL GEAR SET POSITIONING WITH RELEVANT ADJUSTMENT . . . . . . UK - 76 TRANSMISSION REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 80 DIFFERENTIAL REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 83 Bevel pinion-and-ring gear set inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 84 DISTRIBUTOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 86 WHEEL SHAFT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 87 CONVERTER CARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 88 TYPE AND QUANTITY OF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 89 DATA FOR COUPLING TO ENGINE - Engine gearbox coupling diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 90 TECHNICAL DATA - Distributor pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 92 RUNNING-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 93 PERIODIC SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 93 TROUBLE SHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UK - 94

Printed 604.24.113

UK - 5

06/2001

TRANSMISSION TXL 30/S

SAFETY RULES

WATCH FOR THIS SIGN This sign identify important messages devoted to your safety.

Read carefully safety rules reported here and follow with the greatest care all recommended suggestion to avoid potential dangers and protect your health and personal safety.

Avoid Causalities Most of all injuries and accidents that are encountered in workshops are caused by disregarding some simple and basic caution and safety rule.

For this reason most of these events can be avoided. To anticipate possible causes will suffice and acting accordingly with proper care and caution.

Each kind of operating machine, even if correctly planned and assembled, cannot be absolutely safe.

A cautious and careful operator is the best warrant against injuries.

Following scrupulously safety rule will be sufficient to prevent many dangerous injuries.

DANGER! Don't clean, lubricate or service with engine running.

General

Follow strictly directions reported for servicing and repair operations.

Don't wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves, unbuttoned jackets or overall with open zip that could be entangled in moving parts. It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes, gloves, goggles hel mets, etc.

Don't start any servicing operation on machine with anyone on driver seat, except for authorized operator that cooperate for the work to be done.

Don't operate machine or use relevant equipment from position other than driver's seat.

Don't service machine with engine running, if not specified by repair instructions.

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers, valves, etc.

All servicing operations must be performed with best attention and care.

Disconnect batteries and mark all controls to point out that servicing operations are on course. Block machine, all equipment must be lifted up, and mechanically secured accordingly, with the appropriate device Printed 604.24.113

UK - 7

06/2001

TRANSMISSION TXL 30/S

Brakes are inoperative when hand released for servicing operations: in such a condition machine control should be provided by proper blocks or similar equipment.

Should heavy components be displaced or moved, use proper hoist or similar equipment.

Care for people near operation areas.

Never pour gasoline or diesel fuel into open, wide, shallow containers to avoid creating dangerous flammable vapors.

Never use gasoline, diesel fuel or other inflammable fluids as detergent. Use only commercial non toxic, uninflammable cleaning compounds.

When using compressed air for cleaning purposes wear goggles with side shields.

Pressure must be limited to 2.1 bar max., according current safety rules.

Never use free flame for illumination when operations are devoted to repair or locate leaks.

Caution when repair shall be carried out working under machine, wear safety equipment: helmets, goggles and safety shoes.

Area where servicing operations are carried out must be always kept CLEAN and DRY. Clean and dry immediately any oil or water puddle.

Make sure that all the protective devices are in place before starting the machine .

Printed 604.24.113

UK - 8

06/2001

TRANSMISSION TXL 30/S

TECHNICAL DATA

Transmission TXL 30/S

Powershift transmission clutches:

operational pressure min. 8.5 bar, max. 9.5 bar

Converter:

■ input pressure min. 4 bar, max. 5 bar ■ output pressure min. 2 bar, max. 3 bar

Lubrication: Note:

pressure 0.8 ÷1 bar

the above mentioned data refer to an operative temperature of 100° C and a engine speed of about 2000 r.p.m.

Temperature:

■ normal operation: 80 - 100° C ■ peak: 120° C

Oil type and quality: Oil filter:

see page 89 ■ nominal filtration ratio = 25 µm ■ by-pass setting pressure 1.6 ÷ 1.8 bar ■ burst pressure ≥ 30 bar

Electrical installation

■ voltage: 12V d.c. (24V d.c.)

■ power: 26W

Printed 604.24.113

UK - 9

06/2001

TRANSMISSION TXL 30/S

Circuitry

2

+

-

1 Forward Gear

Reverse Gear

4

Reverse Gear

Forward Gear

3

1. Commutator 2. Fuse 3. Valves body 4. Solenoid valve Voltage 12/24 V CC/DC Power 26 W

Printed 604.24.113

UK - 10

06/2001

TRANSMISSION TXL 30/S

Kinematic diagram of the transmission

Power take off

M.A

Brake Input

Pump

R.M.

Drive ratio

Gearbox

Bevel drive

Total

8045 I 05.00

25 1 = 49 1.96

7 1 = 40 5.714

1 11.20

TM 27

25 1 = 49 1.96

6 1 = 43 7.167

1 14.05

8045 I 05.00

57 25 1 x = 57 49 1.96

7 1 = 40 5.714

1 11.20

TM 27

57 25 1 x = 57 49 1.96

6 1 = 43 7.167

1 14.05

Converter

Type

Mpa 2000

Gearing

8045 I 05.00

W 280

224 Nm

2.87

TM 27

W 280

165 Nm

3.06

Forward Gear (MA)

Reverse Gear (RM)

Printed 604.24.113

UK - 11

Free wheel

06/2001

TRANSMISSION TXL 30/S

General description The transmission is equipped with a single-stage converter with free wheel. Thus a high efficiency over the whole range of operation is achieved. It has two hydraulic clutches (one for forward gear and one for reverse gear) with multiple wet disks, while the constant mesh gears have the same ratio in forward and reverse gear. The selection of direction is effected by hydraulic selectors, which are controlled electrically.

Connection engine - converter The converter is connected to the engine flywheel via flexible drive plate (see page 91).

Torque converter The single-stage converter has been designed to obtain maximum flexibility when being connected to different engines with different performances. It is able to transmit considerable power and guarantees maximum reliability. The converter-pump, integral with the converter housing, rotates generating sufficient fluid flow inside the converter to drive the turbine and transmit drive to the transmission gears as shown in the diagrams.

Applying the clutches

Forward Gear

Reverse Gear

M.A.

M.A.

R.M.

R.M.

M.A. = Forward Gear R.M. = Reverse Gear Printed 604.24.113

UK - 12

06/2001

TRANSMISSION TXL 30/S

General views

M L E

H

D

U

A. Filler plug, gear box oil B. Forward gear solenoid valve C. Reverse gear solenoid valve D. Oil drain plugs E. Drive axle oil breather F. Drive axle oil level plug G. Inching control H. Converter L. Dipstick with breather M. Exchanger return N. Exchanger delivery P. By-pass filter R. Additional oil level rod S. Modulating valve T. Pressure switch U. Temp. switch 115° ± 3°C V. Power take-off

Printed 604.24.113

UK - 13

06/2001

TRANSMISSION TXL 30/S

General views

P

S

G

F T

V

R

D A

N

Z

G

Printed 604.24.113

C

UK - 14

B

06/2001

TRANSMISSION TXL 30/S

General section

1. Converter 2. Gear driven by power take-off 3. Power take-off shaft 4. Pump 5. Forward clutch 6. Forward drive gear 7. Pinion drive gear 8. Gear 9. Driving gear, for power take-off 10. Turbine shaft 11. Silent chain 12. Brake Assembly 13. Differential Unit Printed 604.24.113

UK - 15

06/2001

TRANSMISSION TXL 30/S

Section A - A

13

Operation 1) Change of gear: an electrically actuated solenoid controls the corresponding valve for releasing oil pressure on the clutch piston, while a modulating valve regulate the pressure increase to the clutch gradually, allowing direction changes and soft gear shifts.

2) Inching control: the Inching valve, which is actuated mechanically, allows truck movement at a very low speed with constant speed of the engine. Inching control works on all gears.

3) Capacity: the dynamic torque transmissible by the clutches is higher than the transmission input torque after the converter. Thus a long service life of the clutches is guaranteed.

Printed 604.24.113

UK - 16

06/2001

TRANSMISSION TXL 30/S

Clutches These are hydraulically operated. The drive is transmitted via force-lubricated, force-cooled plates (12 active friction surfaces). In addition to high static and dynamic transmissible torque capacity, they also have a high kinetic energy absorption capacity during gearchanges. Clutch engagement is through piston displaced axially under fluid pressure. A spring pushes the piston back and the plates are then released.

Power take-off It is driven by the thermic motor and by a silent chain. The rotating direction as well as the speed correspond to that of the engine. The hydraulic pump for the lifting and steering system is flanged to the PTO.

Pump A gear oil pump that rotates at the same speed as the engine, is mounted coaxially with the direct drive shaft. Oil is sucked from the sump via a tube in the transmission case casting, and passes through a mesh filter.

Control Distributor The distributor is situated on the outside of the transmission case. It receives the oil delivered by the pump and incorporates devices that control the flow and pressure of the oil to ensure that the converter, the clutches and the lubrication system all operate correctly. It is provided with a modulator valve, which ensure gradual, shockfree gear changes and start-ups.

Printed 604.24.113

UK - 17

06/2001

TRANSMISSION TXL 30/S

TRANSMISSION HYDRAULIC SYSTEM

The whole transmission system relies for its trouble-free operation on the various components of the hydraulic system which perform the following functions: -

Ensure a given pressure inside the converter.

-

Ensure a continuous exchange of converter oil and cooling through heat exchanger.

-

Provide oil pressure to forward and reverse clutch pack

-

Lubricate clutch plates.

The main components of the hydraulic system are: a. Transmission oil pump An internal-tooth oil pump is fitted inside the transmission and has the same speed as the engine. Oil suction from the sump is through a line incorporating a gauze filter. b. Oil Filter One 25-micron filter, fitted between pump and control valve, filters the oil for the various components. c. Hydraulic torque converter Fitted between engine and reverser the converter uses the dynamic action of the oil to multiply engine output torque in line with truck work requirements. d. Heat exchanger Located on circuit in exit at the converter the exchanger dissipates the heat produced during gearbox operation. e. Reverser The reverser unit consists of two oil bath, multiplate clutch packs controlled hydraulically through the electrovalves. f. Supermodulating valve block This unit is fitted on the gearbox and incorporates: Max pressure valve (regulator) This valve regulates clutch pressure.

Modulating valve Located on the clutch supply circuit, this valve controls the increase in clutch pressure so that the clutch in question is fed gradually regardless of speed of manoeuvre.

Inching valve It cloke clutch pack pressure and gradually disengages the engaged clutch. Running speed is constantly reduced without changing engine speed so that the vehicle can be moved forward very slowly.

Printed 604.24.113

UK - 18

06/2001

TRANSMISSION TXL 30/S

Selector solenoid valves Situated on the feeding ducts of the clutch units, allows to convey oil to gears and to let it flow to exhaust.

Converter safety valve Located on converter inlet line, this valve settles the input pressure and protects the converter from accidental over pressure.

Lubrication safety valve Located on the lubrication circuit this valve checks increases in pressure in this circuit.

Printed 604.24.113

UK - 19

06/2001

TRANSMISSION TXL 30/S

Hydraulic diagram description

PRESSURE DROP 1.5 bar max.

LUBRICATION

FORWARD GEAR

REVERSE GEAR

CONTROL VALVE BLOCK

1. Suction Filter

7. Torque converter

2. Pump

8. Heat exchanger (cooler)

3. Oil filter with by-pass

9. Converter safety valve

4. Shift ressure valve

10. Mechanical inching valve

5. Pressure control valve

11. Forward and reverse speed valve

6. Throttle valve

12. Lubrication safety valve

Printed 604.24.113

UK - 20

06/2001

TRANSMISSION TXL 30/S

SCHEME A - Gear in neutral position

PRESSURE DROP 1.5 bar max.

LUBRICATION

FORWARD GEAR

REVERSE GEAR

Exhaust Clutch pressure

Converter inlet Converter outlet CONTROL VALVE BLOCK

Lubrication

Neutral position The oil suction by the pump, after filtration, is conducted to the pressure control valve and the, by way of the throttle valve (6), to the converter. From there, after having passed through cooler, the oil reaches the clutch for forward and reverse gear through the lubrification circuit and then oil sump.

The oil flow, regulated by the main valve, is conveyed to exhaust by the selection valve.

The exceeding oil reaching the main valve feeds the converter. The converter pressure is regulated by the converter pressure control valve that diverts the exceeding flow to the lubrication circuit.

Printed 604.24.113

UK - 21

06/2001

TRANSMISSION TXL 30/S

SCHEME B - Started Lift truck

PRESSURE DROP 1.5 bar max.

LUBRICATION

FORWARD GEAR

REVERSE GEAR

Exhaust Clutch pressure

Converter inlet Converter outlet CONTROL VALVE BLOCK

Lubrication

Running During this stage, the clutches are applied at maximum pressure, which is regulated by valve 4, while an increase in pressure is regulated by the modulator valve 5.

Printed 604.24.113

UK - 22

06/2001

TRANSMISSION TXL 30/S

SCHEME C - Inching

PRESSURE DROP 1,5 bar max.

LUBRICATION

FORWARD GEAR

REVERSE GEAR

Exhaust Clutch pressure

Converter inlet Converter outlet CONTROL VALVE

Lubrication Inching

Inching manoeuver The Inching control allows precise movement of the vehicle, irrespective of engine speed. The oil feed to the clutch is controlled, lowering the operating pressure, allowing slipping to occur according to pedal position.

Printed 604.24.113

UK - 23

06/2001

TRANSMISSION TXL 30/S

DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION

1

Specific tools

3

4

Printed 604.24.113

2

5

6

7

UK - 24

8

06/2001

TRANSMISSION TXL 30/S

1. Fixture for diassembling of clutch plates

1

Thread rod

Printed 604.24.113

UK - 25

06/2001

TRANSMISSION TXL 30/S

1

1

Printed 604.24.113

UK - 26

06/2001

TRANSMISSION TXL 30/S

2. Forcing bearing tool

3. Forcing bearing tool

38 NCD 4 Bon

38 NCD 4 Bon

Induction hardening

4. Forcing bearing tool

5. Forcing bearing tool

38 NCD 4 Bon

38 NCD 4 Bon

Induction hardening

Printed 604.24.113

Induction hardening

UK - 27

06/2001

TRANSMISSION TXL 30/S

6. Forcing bearing tool

7. Installer for alignement of bevel pinion assembly

38 NCD 4 Bon

Aq 35

Induction hardening

8. Locking spanner for slotted nut of hub bearing adjusting 39 Ni Cr Mo 3 Bon

Printed 604.24.113

UK - 28

06/2001

TRANSMISSION TXL 30/S

General Instructions

Shims All adjustments shall be carried out after all adjustment shims have been selected measuring them one by one with a micrometer gauge and, then, summing up all values measured; don't trust incorrect measurement of pack as a unit or sum of nominal value printed on each shim.

Seasl for revolving shafts Proceed as follows for proper fitting of captioned seals: ●

prior assembly, seals should be kept, for at least half an hour, in a bath with the same oil to be sealed;

●

clean thoroughly shaft and make that working surface be not damaged;

●

●

●

●

●

position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be oriented so as that, considering direction of revolving shaft, they lead fluid inside of sealing means; smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space between sealing lip and dust shield lip, if using double sealing lip type seals; press seal in relevant seat or use a proper fitter with flat contact surface; never use hammer or mallet to mount seal; when press fitting seal make sure that it be correctly driven in relevant seat, i.e., perpendicular with respect to its seat, as fitting is completed make sure, if required, that seal itself be in contact with relevant shoulder; to prevent damage of seal lip when inserting shaft, duly protect component during assembly.

"O-Ring" seals Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

Sealing compounds For matching surfaces identified by X use one of following compounds: “RTV SILMATE”, “RHODOR SIL CAF 1” or “LOCTITE PLASTIC GASKET”.

Clean matching surface as follows prior, smearing compound: ● ●

remove old deposits using a metal brush; degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and soda solution.

Bearings When assembling them it is advisable to proceed as follows: ●

heat them at 80 to 90° C before fitting on relevant shafts;

●

cool them before inserting in relevant external seats.

Sring pins When using split pins be sure that Coil pins don't require specific position.

Printed 604.24.113

lengthwise

UK - 29

cleft

be

positioned

toward

stress

on

pin.

06/2001

TRANSMISSION TXL 30/S

Disassembling and assembling transmission WARNING Handle all heavy parts with the appropriate equipment and with the utmost care. Never put your hands and fingers in between parts Oil draining Drain oil thru plug A of axle casing and plugs B of PTO case and transmission case.

1

2 Torque converter removal Remove converter unit by pulling it in axial direction.

3 Removal of torque converter case Remove the screws securing the converter.

4

Printed 604.24.113

UK - 30

06/2001

TRANSMISSION TXL 30/S

Remove the converter case.

5

Converter case overhauling - “A” Version

Remove lock rings shouldering gear on driving shaft and retaining bearing on driven shaft.

6 Lift up gear and chain assembly using proper levers.

7 Lift gears holding them assembled as a set.

8 Printed 604.24.113

UK - 31

06/2001

TRANSMISSION TXL 30/S

Remove lock rings shouldering gear on driving shaft and retaining bearing on driven shaft.

9 Remove screws securing cover retaining driving shaft bearing.

10 Remove driving and driven shafts, complete with bearings.

11

Driving shaft components Note: particular attention should be payed when removing and reinstalling the sealing ring.

12

Printed 604.24.113

UK - 32

06/2001

TRANSMISSION TXL 30/S

Remove bearing retaining rings, respectively on driving and driven shafts. Clean thoroughly all components, check and replace as required.

13 Replace the seal on converter case by using a proper installer.

Note: Lubricate the seal prior installation following specific instructions.

14 Refit bearings on driving and driven shafts and relevand retaining rings.

15 Refit driving and driven shaft assembly in relevant seats on converter case.

16

Printed 604.24.113

UK - 33

06/2001

TRANSMISSION TXL 30/S

Fit lock rings securing bearing on driven shaft and shouldering the gear on driving shaft.

17 Install and secure the bearing retaining cover, smear a medium locking compound on screws and tighten with a torque of 0.3 daNm.

18 Mount drive and driving gear set, complete with chain, on relevant shaft.

19 Fit lock rings securing driving and driven gears.

Note: grease seal ring and relevant seat, on driving shaft, to secure a correct position at assembly on trasmission cover and prevent failure if forced into its seat.

20

Printed 604.24.113

UK - 34

06/2001

TRANSMISSION TXL 30/S

Converter case overhauling - VERSION “B”

Unhook lock ring retaining driven gear.

21 Lift driven gear by proper lever and remove chain.

22 Remove screws securing cover retaining driving gear bearing.

23 Remove driving and driven gears, complete with bearings.

24

Printed 604.24.113

UK - 35

06/2001

TRANSMISSION TXL 30/S

Remove bearing lock rings, respectively on driving and driven gears. Clean thoroughly all components, check and replace as required.

25 Replace the seal on converter case by using a proper installer.

Note: Lubricate the seal prior installation following specific instructions.

26 Refit bearings on driving and driven gears and relevand lock rings.

Refit driving and driven gear assembly in relevant seats on converter case.

Install and secure the bearing retaining cover, smear a medium locking compound on screws and tighten with a torque of 0.3 daNm.

27 Assemble chain on drive and driven gears.

Insert into its seat the lock ring retaining driven gear.

28

Printed 604.24.113

UK - 36

06/2001

TRANSMISSION TXL 30/S

DISMANTLING AND RE-ASSEMBLING OF DISTRIBUTOR

Distributor dismantling Undo and remove fixing screws of distributor body and remove it.

29 Remove seal.

30

Disassembly of forward-reverse shifting shaft:

undo nut securing electrovalve.

31

Printed 604.24.113

UK - 37

06/2001

TRANSMISSION TXL 30/S

Remove the electrovalves complete with O-Rings.

Check components, clean throughly each component, replace if required (if there are metallic residues, replace the electrovalve complete).

Reassemble components locking solenoid nut with a torque of 1 daNm.

32

Re-assembling of front - back selection valve

Insert electrovalve with relevant seals (righting smeared).

Lock nut with a torque of ~ 7 daNm.

33

Inching Axle dismantling

Undo the four screws securing cover.

34

Printed 604.24.113

UK - 38

06/2001

TRANSMISSION TXL 30/S

Remove Inching control components.

35 Note: To dismantle Inching axle it isn't necessary to dismantle regulating nut: if required, unscrew nut complete and relevant rubber seal.

36

WARNING To not prejudice right working of Inching axle, don't tamper and don't dismantle regulating plug of nut.

36a Remove and replace O-Ring seal.

37

Printed 604.24.113

UK - 39

06/2001

TRANSMISSION TXL 30/S

Clean throughly each component, check them, replace if required.

WARNING Do not alter the position or number of shims inserted under the springs

38

Reassembling Inching Axle

Reassemble regulating nut with relevant rubber seal and lock.

39

WARNING To not prejudice right working of Inching axle, don't tamper and don't dismantle regulating plug of nut.

39a Insert components of Inching Axle.

40 Printed 604.24.113

UK - 40

06/2001

TRANSMISSION TXL 30/S

Smear the four screws with Loctite 242 and lock the cover with a torque of 0.5 daNm.

41

Dismantling of Main Valve - Converter Valve Axle

Unscrew plug and remove small piston of converter pressure regulating valve with relevant spring and possible thicknesses.

42 Undo rear plug, extract small piston from main pressure valve with relevant spring and probable thicknesses.

43

Printed 604.24.113

UK - 41

06/2001

TRANSMISSION TXL 30/S

To remove central bush of axle, undo screw placed under distributor.

44

Reassembling of Main Valve - Converter Valve Axle

Clean throughly each component, check them, replace if required.

- Position the central bushing: - smear locking screw with Loctite 242; - lock bushing; - reassemble thickness;

45

- insert spring and small piston of Main Pressure Valve A; - lock plug with rubber seal.

Follow the same procedure to assemble front part of Converter Valve B.

Printed 604.24.113

UK - 42

06/2001

TRANSMISSION TXL 30/S

Dismantling and re-assembling Modulating Axle

Push bushing and unhook front lock.

46 Extract bushing and remove O-Ring seal.

47 Remove piston and the two springs.

48 Unhook rear lock ring, remove O-Ring seal and Modulating Axle cover.

49

Printed 604.24.113

UK - 43

06/2001

TRANSMISSION TXL 30/S

Components of Modulating Valve Axle

Clean throughly each component, check them, replace if required.

50 Special care has required for bushing complete: unscrew plug, check inside of the same and on the ball that there aren't impurities, clean throughly and reassemble.

51

52 Assemble the O-Ring seal into its seat, insert cover and positionning it, take care not to overtake lock ring seat.

53 Insert lock ring.

54

Printed 604.24.113

UK - 44

06/2001

TRANSMISSION TXL 30/S

Reassemble springs and piston.

55 Assemble into its seat O-Ring seal.

56 Assemble the bushing complete, taking care not to damage the O-Ring seal, push bushing and insert lock ring.

Take care not to overtake lock ring seat.

57

Check conditions of safety valve of lubrication system and relevant seal on distributor adaptor.

58

Printed 604.24.113

UK - 45

06/2001

TRANSMISSION TXL 30/S

DISASSEMBLING TRANSMISSION

Oil drain plug and strainer remove oil drain plug and strainer on suction side.

Clean strainer thoroughly by a proper detergent and blowing with compressed air..

59 Transmission cover remove screws securing the bevel pinion cover.

60 Remove bevel pinion cover.

61 Lift up notches on bevel pinion ring nut collar.

62

Printed 604.24.113

UK - 46

06/2001

TRANSMISSION TXL 30/S

Undo ring nut after both clutches have been packed up with compressed air.

63 Release and remove screws securing transmission cover.

64 Remove the cover, complete with oil pump, form transmission case.

65

Printed 604.24.113

UK - 47

06/2001

TRANSMISSION TXL 30/S

Oil pump and transmission cover overhaul

First of all, remove the oil strainer shield pipe after a mark has been put as a reference at reassembly.

66 Undo screws retaining pump.

67 Remove the pump complete with gasket.

68

Printed 604.24.113

UK - 48

06/2001

TRANSMISSION TXL 30/S

Disassermble the pump. Clean thoroughly all components, check wear of parts and of relevant seats.

69 Check bearing, on pump shell, and replace, if required

70 Reassemble the pump unit, fit driving and driven gears set in pump shell, then, the pump cover stator sleeve, take care to avoid damage on driving gear bushing

71 Remove seal from P.T.O. outlet seat, then, remove needle roller casing.

72

Printed 604.24.113

UK - 49

06/2001

TRANSMISSION TXL 30/S

Remove the outer race, of bevel pinion bearing, by a driff punch.

73 Refit needle roller casing, seal and outer race of bevel pinion bearing.

Note: the press fitting strength exerted to drive needle roller casings, in relevant seats, should be applied evenly and bumpless, on the marked side, by a proper tool resting on the casing and suitably aligned to seat.

74 Reinstall pump on transmission cover, Interpose the seal suitable lubricated, smear medium locking compound on screws.

Tighten with a torque of 2.3 to 2.5 daNm.

75 Replace O-Ring seals on oil delivery ducts. Refit the oil strainer shield pipe, minding to match the references marked at disassembly.

76

Printed 604.24.113

UK - 50

06/2001

TRANSMISSION TXL 30/S

DISASSEMBLY CLUTCHES

Pull out the upper clutch unit complete.

77 Pull out the lower clutch unit complete.

78 Remove the spacer and bearing pre-load adjustment shims of bevel pinion.

79 Pull out the driven gear on bevel pinion.

80

Printed 604.24.113

UK - 51

06/2001

TRANSMISSION TXL 30/S

Clutches overhauling

Unhook and remove, with particular care, rings from clutch shaft.

81 Remove bearing from shaft on constant mesh gear side.

82 Remove bearing inner race and thrust washers of gear.

83

Printed 604.24.113

UK - 52

06/2001

TRANSMISSION TXL 30/S

Remove gear and relevant roller cages along and spacer with inner thrust washers.

84 Remove reaction disc lock ring from its seat and pull out all components.

85 Pull out driving and driven disks from clutch bell housing.

86

Printed 604.24.113

UK - 53

06/2001

TRANSMISSION TXL 30/S

WARNING Use the proper tools.

NEVER USE FINGERS OR HANDS or incorrect tools Compress the reaction spring by a proper tool (no. 1 pag. 25) and pull out the retaining ring.

87 Remove cup and spring.

88 Push out piston from clutch bell housing by injecting compressed air thru inlect ducting.

Clean thorougly all components, check, replace as required and reassamble after O-Rings have been duly lubricated.

89

Printed 604.24.113

UK - 54

06/2001

TRANSMISSION TXL 30/S

Replace the outer and inner seal rings of piston.

Lubricate O-Rings according to instructions.

90 Insert piston, reaction spring and relevant seat cup into clutch bell housing.

91

WARNING Use the proper tools.

NEVER USE FINGERS OR HANDS or incorrect tools Compress the reaction spring and insert the retaining spring into the seat on shaft. (Using the tool no.

1 referenced on page 25 ).

92

Printed 604.24.113

UK - 55

06/2001

TRANSMISSION TXL 30/S

Remount clutch driving and driven disks and reaction ring with relevant retaining ring.

Note: when packing clutch disc bear in mind that a steeldriven disk must face the piston; Complete the assembly by alternating a clutch plate and a steel plate Check clereance as figure 93 a and verify it in three points, every 120°.

93

93a Insert thrust washers of gear roller cages on inner side.

94

Printed 604.24.113

UK - 56

06/2001

TRANSMISSION TXL 30/S

Mount roller cages with relevant spacer and gear positioning the hub true on toothing of clutch disks.

95 Mount thrust washers and bearing inner race on gear side and verify clereance between gear and thrust washer (see fig. 96a).

96

96a

Printed 604.24.113

UK - 57

06/2001

TRANSMISSION TXL 30/S

Mount bearing on shaft, constant mesh gear side.

97 Mount rings in reievant seats.

Note: smear cast rings with grease, after installation, to keep them centered and steady in relevant seat when shafts are inserted, so as to prevent failures or damages.

98

Printed 604.24.113

UK - 58

06/2001

TRANSMISSION TXL 30/S

DEMI AXLE DISASSEMBLY

Undo screws securing shaft to wheel hub on both side.

99 Unlock and remove the half shaft.

100

AXLE CASE DISASSEMBLY

N.B. As shown in the series of photographs below, the axle is equipped with a final drive ring gear on both the right and left side. This does not affect the disassembly operations.

Undo screws fixing cover to axle casing and remover cover

101

Printed 604.24.113

UK - 59

06/2001

TRANSMISSION TXL 30/S

Undo and remove screws securing differential support caps, mind to mark reference for reassembly.

102 Take off caps.

103 Remove differential unit complete with shims.

104 Take off bevel pinion complete with roller cage, of pinion under head bearing, and spacer.

105

Printed 604.24.113

UK - 60

06/2001

TRANSMISSION TXL 30/S

DIFFERENTIAL UNIT DISASSEMBLY AND OVERHAULING

Roller cages of differential bearing can be taken off by a proper puller.

106 Undo and remove screws securing the ring gear and pull it out from casing

107 Mark both half-casings for reference at reassembly.

108

Printed 604.24.113

UK - 61

06/2001

TRANSMISSION TXL 30/S

Separate differential half casings by undoing the fixing screws.

109 Check differential components. Clean thoroughly all parts, check and replace as required.

110 Remount differential positioning components in relevant seats.

111

Printed 604.24.113

UK - 62

06/2001

TRANSMISSION TXL 30/S

Use a suitable equipment heat differential bearing roller cage and install in its seat.

Smear medium locking compound on screws fixing half-casing.

112 Tighten screws with a torque of 7.5 to 8.3 daNm.

113 Heat up, and refit roller cage of bearing on ring gear side.

114

Printed 604.24.113

UK - 63

06/2001

TRANSMISSION TXL 30/S

Should be vel gear set be replaced it is necessary to smear medium locking compound on screws fixing the ring gear and tighten them with torque of 21 to 23 daNm.

115

OIL FILTER CARTRIDGE REPLACEMENT

Unscrew oil filter cartridge with proper wrench.

116 Screw in by hand a brand new cartridge after gasket has been duly oiled.

117 Printed 604.24.113

UK - 64

06/2001

TRANSMISSION TXL 30/S

TRANSMISSION CASE REMOVAL

Undo and remove screws securing transmission case on inner side axle casing.

118 Undo outer screws securing transmission case to axle casing.

119 Remove transmission case from axle casing.

Note: this figure shows bevel pinion still mounted, instead of being removed as reported on sequence Fig. 105, however, this makes no difference to carry out operations descnbed above.

120

Printed 604.24.113

UK - 65

06/2001

TRANSMISSION TXL 30/S

Transmission case overhaul and reassembly

Pull out bearings from relevant seats on case and refit new ones, then, position transmission case on axle casing.

121 Smear medium locking compound on outer screws securing transmission case to axle case and lock with a torque of 10.8 to 12 daNm.

122 Smear medium screw locking compound on inner screws securing transmission cast to axle case and lock. Tightening torque of 10.8 to 12 daNm.

123

Printed 604.24.113

UK - 66

06/2001

TRANSMISSION TXL 30/S

SHOES DISMANTLING

WARNING Handle all heavy parts with the appropriate equipment and with the utmost care.

NEVER PUT YOUR HANDS AND FINGERS IN BETWEEN PARTS

Undo screws securing brake drum to wheel hub.

Remove brake.

Check diameter and wear conditions of shoes lining.

124 Unhook shoe return spring on automatic brake clereance take-up device side.

125 Unhook the two shoe return spring on side of wheel brake cylinder.

126

Printed 604.24.113

UK - 67

06/2001

TRANSMISSION TXL 30/S

Remove brake shoes retaining springs, brake shoes, return fulcrum, hand brake drive and lever cable.

Should hand control cable be replaced, remove fork washer backing cable return spring.

127 Should brake cylinder be replaced; undo the two screws retaining small plate of spring hooking of shoes return.

Unscrew brake oil bleeder, connector and the two screws retaining small cylinder placed behind brake plate, with relevant washers (see fig. 131a).

Position brake cylinder into relevant seat, screw in the two screws with washers with a torque of 2.0 ÷ 2.5 daNm;

128

mount and screw in oil bleeder with a torque of 0.4 ÷ 0.6 daNm, connector with copper seal with a torque of 3.0 ÷ 3.6 daNm. Reassemble small plate hooking springs and screw in the screws with washers with a torque of 2.0 ÷ 2.5 daNm. Should automatic adjusting be replaced, screw in and lock screw with relevant washers with a torque of

129

9 ÷ 10 daNm. Note: Don't dismantle the automatic adjusting to repair it, in case of bad working, replace.

130

Printed 604.24.113

130a

Refit right shoe, hook brake hand control cable on lever and insert retaining spring.

UK - 68

06/2001

TRANSMISSION TXL 30/S

131 1. Plate clamping screws 2. Plate 3. Brake cylinder 4. Bleeding screws 5. Regulator 6. Brake plate 7. Connector 8. Cylinder clamping screws 9. Regulator clamping screws

Refit left shoe and retaining spring fitting in the strut of hand brake control.

132

Printed 604.24.113

UK - 69

06/2001

TRANSMISSION TXL 30/S

Hook on shoe return spring.

During final assembly, make sure that the springs and the brake control cable have been assembled correctly.

133 Note: Enable device D (for automatic brake clearance take-up) and adjust the shoe expansion of 1.4 +/0.3 mm to less than the nominal diameter of the brake by checking that A is equidistant for both pins (fig.

135)

134 After assembling the drum, check that it turns freely and brake a few times in both directions of travel to make sure that the brakes are working correctly.

Disassembling the clamps

Note: Do not loosen the clamping screws on the clearance recovery device.

If the clamps are disassembled without being replaced, do not change the position of the two clamp support pins on the automatic clearance recovery device.

Since the clearance recovery is independent for both directions of travel, it is a good idea to make note of the height A of both pins 1 so that they can be reassembled in the original position.

135

.

During final assembly, check that the opening of the clamps is as specified.

After assembling the drum, check that it turns freely and brake a few times in both directions of travel to make sure that the brakes are working correctly.

Printed 604.24.113

UK - 70

06/2001

TRANSMISSION TXL 30/S

WHEEL HUB DISMANTLY

Undo screws securing brake drum to wheel hub.

Remove brake.

136 Lift up notches on wheel hub locking ring nut.

137 Undo and unscrew completely ring nut securing wheel hub (with special tool no. 8 pag.28).

138 Remove the tab washer, distance washer, bearing and hub.

139

Printed 604.24.113

UK - 71

06/2001

TRANSMISSION TXL 30/S

Pull out the inner race of wheel inner bearing.

Note: hook up spacer edge with puller to prevent damage on seal.

140

FRAME MOUNT SUPPORT DISASSEMBLY AND REASSEMBLY

Disassembly Disassemble the brakes as described in paragraph “Replacing the Clamps” on page 67 .

Undo screws securing brake back plate to frame mounting support and remove it.

Note: same procedure should be followed for brake on the opposite side.

141 Release frame mount support.

142

Printed 604.24.113

UK - 72

06/2001

TRANSMISSION TXL 30/S

Remove frame mount support.

Note: same procedure should be followed for support on opposite side.

143

Frame mount support reassembly Remove grease seal and replace, if requlred.

144 Lubricate axle sleeve and install frame mount support. Check that support rotation be smooth and free from friction or play.

145 remount brake back plate, smear medium locking compound on screws fixing plate to frame mount support.

146 Printed 604.24.113

UK - 73

06/2001

TRANSMISSION TXL 30/S

Screw in and tighten screws with a torque of 23,5 ÷ 26,5 daNm. Disassemble the brakes as described in paragraph “Replacing the Clamps” on page 67.

147 Check state of seal ring on spindle of axle, if teared, replace fitting it to 7 mm from spindle edge.

Note: Respect assembling quota to evoid possible damages of retaining ring.

Apply oil to the shaft ring before wheel hub assembly.

0,5 mm

7 mm

148

Printed 604.24.113

UK - 74

06/2001

TRANSMISSION TXL 30/S

BEARINGS ADJUSTMENT SPECIFICATIONS

1. Wash the bearings with hot petroleum or a waterfree solvent and dry them by immersing them in melted grease.

b

2. Assemble the bearings with the related hub, after filling with grease (FIAT MR2 or similar) each internal cavity (a).

Attention! Too much grease can cause the overturning of the lip of the seal (b).

Assemble the toothed washer and the screw the ring nut.

a

3. Rotated and hammer the hub to make easier the bedding of the conical rollers on the tracks, and at the same time screw gradually the ring nut to the driving torque of 14.7 daNm.

149 4. Loosen the ring nut and then screw it increasing gradually the driving torque to 1 daNm. 5. Loosen again the ring nut in a way to assure a max. play on the bearings of 0.05 mm, correspondent to about 1/32 of turn of the ring nut.

Lock then the ring nut in the way explained in the point 6.

150

6. Rotate the ring nut in a position in order that the nose of the securig can fit in the slot (see photo 151).

If this is not possible, continue with tightening the nut until it is in the assembled position .

151

Printed 604.24.113

UK - 75

06/2001

TRANSMISSION TXL 30/S

DIFFERENTIAL REASSEMBLY AND BEVEL GEAR SET POSITIONING WITH RELEVANT ADJUSTMENT Reference marking reported on pinion seat P and on differential support seat C.

P=x+y

Dimension C:

true space between differential bearing restlng seat, on ring gear side, and bevel pinion axis.

Dimension P:

true space between bearing shoul der under pinion head and bevel ring gear axis.

P=x+y

152 Determination of SC thickness for ring gear position

C H

H = deviation in tenths of millimeter from nominal dimension of 64 mm; F = dimension from ring gear outer face to bering outer edge; L = 64 mm (nominal dimension) + deviation value as marked on ring gear and reported in tenths of millimeter H; SC

C = value reported ring gear side (opposite to ring nut used to adjust differential bearing preload); SC = thickness of ring gear axial adjustment shim.

153

L

F

In our case: SC = C - (F + L) = 120.1 - (51.6 + 64.1) = mm 4.4 SC = 4,4 mm e.g., thickness of shim to be interposed on ring gear side support (opposite to adjustment ring nut side).

154

Printed 604.24.113

UK - 76

06/2001

TRANSMISSION TXL 30/S

N.B. In the description below, the differential is shown with both the right and left side ring gear. This does not affect the adjustment and assembly operations Insert differential assembly in its seat interposing SC thick shim in space on ring gear side and a shim of any thickness in opposite side space

155 Lock support cap screws with tightening torque of 13.2 to 14.6 daNm, actuate the ring nut to determine the bearing pre-load.

156 Check that revolving torque be included within 0.25 to 0.4 daNm.

157 Mark position of ring nut for final locking.

Note: during this stage of operation be sure that shims are not mixed from one side another..

158 Printed 604.24.113

UK - 77

06/2001

TRANSMISSION TXL 30/S

Determining the thickness (S) to position the pinion

Read dimension P, relevant to bevel pinion (fig. 152).

Read deviation of pinion from nominal dimension of 149.5 mm, e.g., dimension K, to determine dimension A, consequently A = (149.5 ± K).

K = deviation from nominal dimension of 149.5 mm expressed in tenths of millimeter.

159 Measure height B of bearing mounted under pinion head and height D of pinion to determine thickness S by the following formula: S = P - (A + B) if P = 190.48 and deviation on pinion head K = - 1 it results: A = 149.5 - 0.1 = 149.4 bearing height B = 36.6 we will have: S = 190.48 - (149.4 + 36.6) = 4.48 mm

160

S=4,48 mm corresponding to shim S thickness to be interposed on outer race of pinion underhead bearing.

161

Printed 604.24.113

UK - 78

06/2001

TRANSMISSION TXL 30/S

Prior positioning shim S, mont the seal (suitably greased) and fit outer race of pinion underhead bearing.

162 Fit inner bearing race, under head of pinion, using proper heating equipment of a specific installer.

163 Insert pinion in its seat with housing turned by 90° so that pinion will result mounted vertically, head up.

164 Position suitably a cylinder block (with special tool no.7 pag 28) on supports of differential assembly bearings and probe gap E between pinion head and cylinder block lower side (photo 160).

In this specific case the result is as follows: A = 149.4 as computed on sequence of fig. 170 D = 55 as computed on sequence of fig. 170 E = A - (D + 47.5) e. g.: E = 149.4 - (55 + 47.5) = 46.9 mm.

165

This dimension E should result equal to above value or 0.05 mm lower to compensate backing displacement of bearings when pre-loaded during locking stage.

In case this condition is not met thickness of shim S (place under pinion head) should be changed.

Printed 604.24.113

UK - 79

06/2001

TRANSMISSION TXL 30/S

TRANSMISSION REASSEMBLY

Fit gear on pinion splined shaft.

166 Fit spacer.

167 Refit lower clutch assembly complete.

168 Refit upper clutch assembly complete.

169

Printed 604.24.113

UK - 80

06/2001

TRANSMISSION TXL 30/S

Smear sealing compound on contact surface and reassembly transmission cover complete with oil pump, smear medium screw locking compound and lock with a tightening torque of 6.2 to 6.9 daNm.

170 Measure shim thickness for pre-load of pinion bearings, said value should be suitably increased so as to have no pre-load.

171 Insert spacers, then, fit bearing inner race on pinion shaft and screw in ring nut.

172 Pack up clutches by compressed air. Lock nut with a torque of 66,5 to 73,5 Nm.

173

Printed 604.24.113

UK - 81

06/2001

TRANSMISSION TXL 30/S

Check system passive torque less pinion bearing pre-load.

174 Check end play, remove inner race of bearing fitted on pinion shaft; remove spacer, vary thickness to eliminate the whole play and reach a pre-load of 0.05 mm.

Reassembly all components, lock ring nut at the specified torque, check that increasing of revolving torque be included within 0.15 to 0.4 daNm with respect to the passive torque that was previously checked.

175 Notch ring nut collar.

176 Mount cover, smear medium screw locking compound and tighten with a torque of 0.5 to 0.6 daNm.

177

Printed 604.24.113

UK - 82

06/2001

TRANSMISSION TXL 30/S

DIFFERENTIAL REASSEMBLY

Mount differenhal unit on relevant support, position caps according to reference marked at disassembly.

Smear medium screw locking compound and lock with a torque of 13.2 to 14.6 daNm.

178 Check standard backlash on pinion and ring gear it should be included within 0.18 to 0.23 mm.

Should said value not be met, SC shim thickness should be suitably varied (fig 153).

179 Spread red lead on some tooth of ring gear, mesh gears in both directions many times, so to make evident tooth contact.

Proper and correct tooth contact is visible on ring gear and said marks indicate the optimum contact approached on a tester, therefore, a proper axial position of pinion will emphasize remarking of previous contact.

180

Printed 604.24.113

UK - 83

06/2001

TRANSMISSION TXL 30/S

Bevel pinion-and-ring gear set inspection

Bevel drive tooth contact: Tooth contact should be as shown in the figure.

Correct contact: distance of pinion from ring gear centerlines is correct.

181

Concave side (crown wheel)

183

182

Convex side (crown wheel)

Incorrect tooth contact Distance of pinion from ring gear centerline must be reduced.

184

Concave side (crown wheel)

Printed 604.24.113

185

Convex side (crown wheel)

UK - 84

06/2001

TRANSMISSION TXL 30/S

186

Incorrect tooth contact Distance of pinion from ring gear centerline must be increased.

187

Concave side (crown wheel)

188

Concave side (crown wheel)

Notch adjushng ring nut after it has been tightened up to the reference previously marked (fig. 158).

189 Spread sealing compound on housing edge and mount cover.

190

Printed 604.24.113

UK - 85

06/2001

TRANSMISSION TXL 30/S

Smear medium locking compound on cover screws and lock with a tightening torque of 4.4 to 4.9 daNm.

191 Refit oil drain plug and oil strainer.

192

DISTRIBUTOR REASSEMBLY

Position gasket on gearbox.

Mount distributor, smear medium locking compound on fixing screws, lock with a torque of 1.9 to 2.1 da Nm from center to esternal side.

193

Printed 604.24.113

UK - 86

06/2001

TRANSMISSION TXL 30/S

WHEEL SHAFT REASSEMBLY

Install the half shaft, taking care not to damage the seal ring.

194 Screw in twelve bolts with spring washer and tighten with 13 ÷ 13.6 daNm.

195 Install the brake drum using Loctite 242 for the two fixing bolts and screw in with a torque of 0.8 ÷ 0.9 daNm. Note: Make sure that the brake shoes are not in contact with the drum.

196

Printed 604.24.113

UK - 87

06/2001

TRANSMISSION TXL 30/S

CONVERTER CARTER REASSEMBLY

Spread sealing compound on P.T.0. cover edge.

197 Mount converter carter, smear medium locking compound on fixing screws and lock with a torque of 6.2 to 6.9 daNm.

198 Fit converter unit on input shaft.

199

Printed 604.24.113

UK - 88

06/2001

TRANSMISSION TXL 30/S

TYPE AND QUANTITY OF OIL

Transmission Oil OLIO FIAT TUTELA GI/M Special oil for hydraulic transmissions, belonging to the ATF TYPE A-SUFFIX A or ALLISON C3 class.

Quantity:

1st fill-up:

10 liters

Replacement:

9 liters

Axle Oil OLIO FIAT TUTELA W90/M-DA Special oil for standard and self-locking differentials, gears, mechanical steering boxes, transmissions and gear rings.

Meets standard MIL-L2105D or API GL 5 – SAE 80W/90.

Quantity:

Printed 604.24.113

Replacement:

6 liters

UK - 89

06/2001

TRANSMISSION TXL 30/S

DATA FOR COUPLING TO ENGINE

Engine gearbox coupling diagram

FLYWHEEL

1. Converter drive plate 2. Converter reinforcing plate (Toward the flywheel side) 3. Bolts - drive plate to converter Torque wrench settings: 47,5 ÷ 52,5 Nm (4,8 ÷ 5,2 daNm) 4. Spring washer 5. Bolts - drive plate to flywheel Torque wrench settings: 35 Nm +5% –15% (3,5 daNm +5% –15%) 6. Special washer 7. Screws fastening the flywheel cover housing onto the transmission box Torque wrench settings: 35 Nm +5% –15% (3,5 daNm +5% –15%)

Printed 604.24.113

UK - 90

06/2001

TRANSMISSION TXL 30/S

Engine gearbox coupling chek-up

2 MIN DIMENSION

SEATING FACE FOR DRIVE PLAT

Dial gauge mounted on flywheel cover

dial gauge mounted on flywheel

A

Total reading

≤ 0,1 mm

C

Total reading

≤ 0,15 mm

B

Total reading

≤ 0,2 mm

D

Total reading

≤ 0,20 mm

Printed 604.24.113

UK - 91

06/2001

TRANSMISSION TXL 30/S

TECHNICAL DATA

Distributor pressure measurement

1

3

1. Main pressure M10x1 control pression:

4 A

min. 8,5 bar max. 9,5 bar

2. Converter pressure intake M10x1 input pression: min. 4 bar max. 5 bar

B

outlet pression:

min. 2 bar max. 3 bar

3. Reverse pressure intake M10x1 pressure M.I.: min. 8,5 bar max. 9,5 bar

C

5

4. Forward pressure intake M10x1 pressure M.A.: min. 8,5 bar max. 9,5 bar 5. Lubrication pressure M10x1 pressure: 0,8 ÷ 1 bar A. Reverse electrovalve

20 mm corsa

2

max. pressione

B. Forward electrovalve

pressione zero

C. Inching

NOTE: The above data is for the transmission under normal temperature conditions (80-100° C) and with engine speed grater than 2000 r.p.m.

Pressure operating time diagram - Imching travel

Pressure

Stroke mm

Printed 604.24.113

UK - 92

06/2001

TRANSMISSION TXL 30/S

RUNNING-IN

Hydraulic transmission: The running-in time is 60-80 hrs., during which it is necessary to perform the following operations: check the transmission frequently to make sure that there are no oil leaks.

Every 10 hrs: Check the oil level in the transmission and, if required, top up (for oil type pls. refer to the supply list).

Oil level check must be performed at engine idle speed Neutral and operating temperature (minimum 40°C).

At the end of the running-in period: a. change the oil b. remove the oil filter c. wash and blow the suction filter net of the pump.

Above rules must be observed even after an overhaul of the hydraulic transmission.

PERIODIC SERVICING

Every 200 hrs.: Transmission: check oil level with oil dipsticks. If necessary, top up through the inlet plug. The oil level check must be performed with engine at idle speed and operating temperature (minimum 40°C).

Every 800 hrs.: Transmission oil filter: change the filtering cartridge by unscrewing it from support.

Note: As two cartridges have been replaced it is necessary to replace transmission oil. When oil is renewed clean also oil suction filter. Oil replacement should be performed not over a year or 1600 hours.

Axle: check the oil level into the axle body and topping up, if necessary.

Every 1600 hrs.: Axle: change the oil

Irregular operations: Greasing the fixing of the frame mount support.

Printed 604.24.113

UK - 93

06/2001

TRANSMISSION TXL 30/S

TROUBLE SHOOTING PROCEDURE

A. General information Before locating any fault, it is necessary to act as follows: • check oil level and oil condition. For details, pls. see servicing section. pag. 93) • Check transmission, oil cooler and oil cooler pipes to find any damage or leak. Repair if necessary.

• Make sure that the problem is not due to the engine and/or to the axle assy.

Proceed on all pressure checks at normal working temperature. The pressure gauges must have a range of 0-15 bar and must be accurate.

WARNING Never stall converter for more than 10 seconds with high engine r.p.m. Select neutral and let transmission cool. Failure of this precaution can cause serious damage to the transmission.

B. Diagnosis of problems During the diagnosis, switch the selector into all positions and try to find out in which position the problems or noises appear. Determine which parts are in motion. This will be a useful point to determinate the cause. Use the following as a guide in case of problems.

Converter Some transmission problems are related to the converter.

Check and/or replace the converter in the following cases: • weak acceleration with reduced max. speed and overheating (normal stall speed): it can indicate that the one way clutch wheel is sticking.

• A metallic noise from the converter can indicate converter vane damage.

• Increased stall speed may indicate that the one way clutch is broken.

Clutches Check and/or replace the clutches if the following abnormalties appear.

• High stall speed. This can indicate that the clutch is slipping. A slipping clutch generally squeals.

Note: generally a slipping clutch overheats. This can cause the disks to warp. In case of overheating, the disks can stick together. This can stall the transmission if another clutch is engaged.

• If the truck moves in neutral this can indicate clutch damage. Clutch plates warped.

Printed 604.24.113

UK - 94

06/2001

TRANSMISSION TXL 30/S

C. Inspection

Problems

Causes

Remedies

LEAKS 1. Pump output shaft gasket or PTO shaft leaks

- Faulty gasket - Bad alignement - Damaged shaft

Replace Rectify Replace.

2. Leaks between the outside of the gasket and its seating

- Damaged seal seat in housing

Change seal and apply sealant on the outside diameter.

3. Leaks from the case sealing gasket

- Fixing screws loosened

Tighten the screws.

4. Leaks from the drain plug

- Gasket damaged

Replace.

5. Not easy to locate oil leaks on the transmission

- Oil leaks from the cooler or from the oil cooling circuit

Replace the faulty cooler or the faulty components of the circuit.

6. Oil leaks from the breather

- High oil level

Rectify the oil level.

Printed 604.24.113

UK - 95

06/2001

TRANSMISSION TXL 30/S

Common running faults in all gears

Problems

Causes

Remedies

1. Low oil pressure

- Regulating valve sticking - Internal leakage - Low oil level - Faulty pump - Suction filter clogged - Misadjusted Inching control

Clean and polish the valve Replace the faulty seal rings Add oil Replace the pump Replace Adjust.

2. No oil pressure

- Internal leakage - Damaged pump - Damage in the regulating valve

Replace the faulty parts Replace the pump Clean and polish the valve.

3. Hard clutch engagement

- Sticking high pressure, regulating valve - Engine idling speed too high - Faulty modulating valve - Impurity or foreign particles in the distributor

Clean and polish Rectify Overhaul Disassemble and clean.

4. Slow clutch engagement

- Low clutch pressure - Too low idling speed engine - Faulty modulating valve

See “Low oil pressure” Adjust Overhaul

5. High pressure

- Sticking regulating valve

Clean and polish.

6. High oil temperature

- Faulty cooling circuit - Choke in the cooling circuit - Faulty cooler - Damaged converter - High oil level

Replace the faulty parts Remove Replace Replace Restore the level.

7. Noises in forward and reverse

- Bad alignment of the converter housing or of the converter with the engine - Damaged gears - Damaged converter vane

Align the converter correctly

8. No drive when gears are engaged

- Low pressure - Broken input shaft - Broken converter drive plate - Failure of the electric system

See “Low oil pressure Replace Replace Repair.

9. Bad Inching working

- Sticking valve

Repair or replace.

Printed 604.24.113

UK - 96

Replace the damaged gears Replace the converter.

06/2001

TRANSMISSION TXL 30/S

Running faults with gears engaged Forward and reverse gear

Problems

Causes

Remedies

1. The clutch drags or does not release (the truck moves at idle)

- Warped clutch disks - Mechanical failures - Absence of clearance in the clutch pack - Sticking electrovalve - Sticking selector - Electric failure - Impurity or foreign particles in the distributor

Replace the faulty parts Replace the faulty parts Increase the clearance as per instruction (see fig. 109a) Repair or replace Clean and polish Repair Disassemble and clean.

2. The clutch does not engage (the truck does not move)

- Low pressure - Sticking electrovalve - Sticking selector - Electric failure - Impurity or foreign particles in the distributor

See “Low oil pressure” Repair or replace Clean and polish Repair Disassemble and clean.

3. The truck does not move or it moves weakly

- Low pressure - Broken or worn seal rings

See “Low oil pressure” Replace the faulty parts.

Further problems

Problems

Causes

Remedies

1. Hydraulic noises or valve hums

- Air in the hydraulic circuit or low oil level

Check the oil level and add if failing.

Make the engine run at 1200 r.p.m. to eliminate the air.

2. Noises in forward and reverse gear

- Broken, cracked or worn gear teeth - Worn or damaged bearings

Replace the damaged parts

Printed 604.24.113

UK - 97

Replace.

06/2001

TRANSMISSION TXL 30/S

Fault finding in bad working in idle

Problemes

Causes

Remedies

1. Truck moving forward and reverse gears at idle

- Warped clutch plates or clutch mechanical failure

Replace the faulty parts.

2. The forward and reverse gears remain engaged

- Electric breakdown - Sticking electrovalve - Sticking selector - Impurities or foreign bodies in valve

Repair Repair or replace Clean and polish Dismantle and clean.

Transmission overheating

Problems Overheating

Causes - Too small cooler or oil hoses

- Faulty cooler - Damaged converter - Low oil level - Obstructed suction filter - Improper use of equipment - Low pump pressure, pump worn or damaged - Slipping clutches - Low pressure - Emulsified oil

Printed 604.24.113

UK - 98

Remedies All the external oil lines and the cooler must allow the passage of the oil and have an adequate exchange capacity Replace Replace Restore the level Clean Do not use the engine in extended stall Check the pressures. Inspect the pump if pressures are low. Replace the pump if worn or damaged Check the seal rings and pressures See “Low oil pressure” Check the type of oil or low oil level

06/2001