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Claas K5D00100, Repair Manual

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Claas K5D00100 Repair Manual Download Page 6

 CONTENTS

SECTION 3 (continued)

Troubleshooting

3.127

Transmission

3.127

Procedures

3.128

Stall Test

3.128

Transmission pressure checks

3.128

Mechanical and electrical checks

3.128

Hydraulic checks

3.129

Troubleshooting guide

3.130

Low clutch pressure

3.130

Low charging pump output

3.130

Overheating

3.130

Noisy converter

3.130

Lack of power

3.130

Check ports - front/rear view (illustration)

3.131

Check ports - left/right view (illustration)

3.132

Check ports - top view (illustration)

3.133

Standard 6-speed transmission (illustration)

3.134

Speed sensor - stand alone check

3.135

SECTION 4

BOOM
Description and Operation

4.1

Description

4.1

Operation

4.2

Maintenance

4.3

Boom

4.3

Removal

4.3

Installation

4.4

Hydraulic cylinders

4.5

Crowd cylinder

4.5

Compensator cylinder

4.5

Lift cylinder

4.5

Extension cylinder

4.5

Boom tray cassette

4.6

Removal

4.6

Installation

4.8

Dismantling

4.8

Assembly

4.8

Inner boom

4.9

Removal

4.9

Installation

4.9

Boom wear pads

4.10

General

4.10

Replacement of outer boom wear pads (front)

4.10

Replacement of outer boom wear pads (side)

4.12

Replacement of inner boom wear pads (rear)

4.13

SECTION 5

CHASSIS
Chassis

5.1

Description

5.1

Operators cab

5.2

Removal

5.2

Installation

5.3

Fuel tank

5.5

Removal

5.5

Installation

5.6

Heater and air conditioning

5.7

Description

5.7

Summary of Contents for K5D00100

Page 1: ... T AS T AS TARGO K50 K60 K70 ARGO K50 K60 K70 ARGO K50 K60 K70 ARGO K50 K60 K70 ARGO K50 K60 K70 REP REP REP REP REPAIR MANUAL AIR MANUAL AIR MANUAL AIR MANUAL AIR MANUAL AXLES AND STEERING ENGINE TRANSMISSION BOOM CHASSIS TECHNICAL DATA ...

Page 2: ...e method of operation and maintenance specified in this handbook should be strictly adhered to For your parts requirements it is essential that only genuine CLAAS parts are fitted Any resultant damage from non genuine parts will invalidate your machine warranty CLAAS operates a policy of continuous improvement to its products and reserve the right to change specifica tions and equipment without no...

Page 3: ...Differential group 1 19 Brake pack and differential housing 1 20 Generic information 1 25 Axle beam trumpet and brake group 1 27 Wheel hub 1 29 Epicyclic reduction gear 1 31 Steering cylinder 1 32 Special tools 1 33 Toe in adjustment 1 39 Steering angle adjustment 1 40 Rear axle pivots 1 41 Removal 1 41 Installation 1 41 Testing after installation 1 42 Troubleshooting 1 43 Operating problems 1 43 ...

Page 4: ...rbox type plate illustration 3 4 Speed sensor 3 5 Speed sensor rotation 3 6 Sensor test 3 6 Speed sensor to module connection 3 7 Arrangement of solenoids 3 8 Solenoids to module wiring 3 9 APC gear selector module 3 10 Display menus 3 11 Display normal 3 12 Gear selection 3 12 Failure codes 3 14 Display 3 14 Display Gearbox speed signal 3 15 Display Machine speed 3 16 Display inputs 3 17 Testing ...

Page 5: ...r damping valves 3 50 Test ports illustration 3 51 Test pressures 3 52 Removal and Installation 3 53 Removal complete with engine 3 53 Removal from engine 3 53 Installation 3 53 Dismantling Transmission 3 54 Dismantling low 1st clutch 3 63 Dismantling 2nd clutch 3 66 Assembly low 1st clutch 3 69 Assembly 2nd clutch 3 73 Dismantling 4th high clutch 3 77 Dismantling 3rd clutch 3 79 Assembly 4th high...

Page 6: ... stand alone check 3 135 SECTION 4 BOOM Description and Operation 4 1 Description 4 1 Operation 4 2 Maintenance 4 3 Boom 4 3 Removal 4 3 Installation 4 4 Hydraulic cylinders 4 5 Crowd cylinder 4 5 Compensator cylinder 4 5 Lift cylinder 4 5 Extension cylinder 4 5 Boom tray cassette 4 6 Removal 4 6 Installation 4 8 Dismantling 4 8 Assembly 4 8 Inner boom 4 9 Removal 4 9 Installation 4 9 Boom wear pa...

Page 7: ...nser coil 5 13 Removal 5 13 Installation 5 13 Axial fan and relay 5 15 Removal 5 15 Installation 5 15 Compressor up to Machine S No 51200471 only 5 17 Removal 5 17 Installation 5 17 Compressor from Machine S No 51200472 only 5 19 Removal 5 19 Installation 5 19 SECTION 6 TECHNICALDATA Dimensions 6 1 Performance 6 2 Machine speed km hr for 106 hp 6 2 Carriage 6 3 Cycle time 6 3 Engine 6 4 Cooling 6 ...

Page 8: ...afety To prevent injury to personnel and damage to equipment and machinery care must be taken to operate in a safe manner Read the Safety Warnings that follow and always work in a safe manner and obey the relevant Warnings Throughout this manual and on the machine there are safety notes Each note starts with a single word The meaning of these single words is as follows Identifies a hazard exists I...

Page 9: ...working on the electrical system to prevent injury caused by electric shock When it is necessary to work on the electrical system with power on for fault diagnosis always have a safety man in attendance Any dust found on the machine or produced during work on the machine should be removed by extraction not by blowing Dust waste should be dampened placed in a sealed container and marked for safe di...

Page 10: ...SECTION 1 AXLES AND STEERING ...

Page 11: ...d support clear of axle 6 Disconnect the inductive magnetic steering sensor electrical lead 7 Slacken front axle wheel nuts 8 Support the chassis at a sufficient height to allow the wheels to be removed 9 Support axle with a fork lift or trolley jacks 10 Remove front wheels 11 Disconnect brake pipes 2 and 3 from left and right brake unit fit blanks to open pipes and brake unit connections Support ...

Page 12: ...0 Nm 221 lbf ft 3 Check axle and wheel hub oil levels are correct 4 When the axle has been dismantled and reassembled refer to the Axle Assembly section and test the differential operation 5 Refer to Page 1 52 and bleed then check brake function 6 Start engine make sure front wheel steering is selected and operate steering through full range several times to bleed air from steering system 7 Test m...

Page 13: ...brake unit connections 15 Disconnect steering pipes 1 from steering cylinder fit blanks to open pipes and steering cylinder connections Support the drive shaft clear of the axle to make sure it is not damaged during axle removal Secure the axle to the fork lift trolley jacks to prevent axle tipping on removal The axle weighs 443 kg take care when removing and transporting 1 Steering pipes 2 Right ...

Page 14: ...ement marked on shim 5 Torque loading Torque load all components to the recommended figure 6 Oil seals To assist with the correct installation of oil seals carry out the following Ensure the shaft is clean and not damaged Assemble with lip side towards the oil side Lubricate seal with oil and fill of seal cavity with grease Use special tools to install seals where available Do not hammer directly ...

Page 15: ...ary use a rubber hammer Cylinder overhaul Refer to Hydraulic Manual for cylinder Dismantling and Assembly 1 Track rod 2 Nut 3 Bolt 4 Hydraulic adapter 5 Steering cylinder Removal 1 Remove the inductive magnetic steering sensor by loosening the locking clamp screws Dismantling Steering cylinder 2 Loosen the track rod end nut until it covers end of threaded pin 3 Use a suitable tool and break the tr...

Page 16: ...n the planetary carrier on a clean workbench and check components for wear and condition 5 Remove O ring 10 and check condition 6 If necessary replace components in planetary carrier as follows 7 Remove the lock rings 5 and washers 6 from pins 7 8 Remove planetary gears 8 from pins 9 Remove the needle roller bearings 9 from the gears NOTE When a new planetary gear is fitted it is recommended that ...

Page 17: ...heel hub on a suitable workbench and remove the bearing seal 20 with a lever 7 Remove the inner and outer bearings cups 21 from the housing using a hammer and drift 8 Remove the bearing cone 22 from the swivel housing side of the hub using a suitable extractor 9 Remove the lock ring 23 securing the hub lock ring gear 17 to the epicyclic ring gear 18 and separate the units 10 Examine the hub lock r...

Page 18: ... the belleville washers 28 13 Remove the swivel housing 29 from the axle beam and position on a suitable workbench 14 Remove the sealing ring 30 from the swivel housing 15 Invert the housing and remove the bush 31 using a hammer and drift 25 Bolt 26 King pin 27 Axle beam 28 Belleville washer 29 Swivel housing 30 Sealing ring 31 Bush 32 Shim The swivel housing is heavy and must be supported with su...

Page 19: ...l procedure will destroy the bush 3 Remove bush 4 if worn or damaged by carefully cutting the bush with a chisel before extraction NOTE The belleville washers 5 and shim 6 may have been removed during the wheel hub removal procedure 4 Remove the belleville washers 5 from the upper and lower beam housing and the shim 6 from the upper housing 5 Using a suitable extractor remove the upper and lower b...

Page 20: ...om the brake housing 11 Differential 12 Brake pack 13 Screw 14 O ring 15 Brake disc 16 Fixed disc 17 Sleeve 18 Bolt 19 Belleville washers 20 Bush 21 Belleville washer 7 Put identification marks on the differential 11 left right brake packs 12 and left right axle beams 2 to aid assembly 8 Position the axle on a suitable workbench and attach lifting gear to the axle beam being removed The axle beams...

Page 21: ...ng cup 13 Attach a suitable hydraulic or air supply to the brake inlet connection 22 on the brake pack 12 Apply the minimum pressure to move the piston 14 Remove piston 23 and O rings 24 15 Remove O rings from piston and inspect for wear Remove the three self adjust split bushings 25 from the piston bores 16 Remove the three parking brake adjuster screws 26 and O rings Hydraulic or air pressure ca...

Page 22: ...e brake pack 12 Apply the minimum pressure to move the piston 25 Remove the piston 39 and remove the O rings 40 41 from piston 26 Remove circlip 42 securing thrust pin 43 to piston and remove thrust pin 27 Remove O rings 44 45 from thrust pin and inspect for wear 28 Remove the other axle beam trumpet and brake group from the differential unit using the above procedure Take care when using a press ...

Page 23: ... 11 Washer 12 Pinion 13 Taper roller bearing 14 Washer 15 Collapsible spacer 16 Taper roller bearing 17 Shim 18 Outer bearing track 19 Inner bearing track Differential group NOTE Mark the two halves of the differential 3 before dismantling to aid assembly 1 Remove the differential 3 from the housing and secure in a suitable clamp 2 Remove the bolts 1 securing the crown wheel 2 to the differential ...

Page 24: ...AXLES STEERING 1 14 ...

Page 25: ...backlash is eliminated do not over tighten ring nut NOTE Make sure the brake housings are fitted to the correct side of the differential and the reference marks made during disassembly are aligned 4 Fit the left and right brake housings 6 to the differential Use at least two bolts to attach each half space the bolts diametrically opposite to make sure housing is seated correctly 5 Fit the false di...

Page 26: ...to be measured A measured value B known value 100 mm C known value 45 mm A C B X Example A 164 9 mm Therefore X 164 9 45 100 109 9 mm To calculate the shim S necessary between the pinion and bearing subtract the V value stamped on the pinion head 8 V requested conical distance from the X calculated value S X V Example thickness S 109 9 107 00 2 9 mm 8 Pinion ...

Page 27: ...with chamfer of shim next to pinion gear 10 Fit inner bearing race 10 to pinion using special tool 11 Part No CA715179 and a suitable press make sure bearing is fully pressed onto pinion 11 Fit a washer 12 collapsible spacer 13 and washer 14 to the pinion shaft NOTE When seating the outer bearing support the pinion with a suitable reaction weight e g a sledge hammer 12 Fit pinion into differential...

Page 28: ...re loading is achieved If the pre loading is exceeded the collapsible washer must be replaced and the process started again 13 Fit a new ring nut washer 16 and ring nut retainer 14 Fit a new ring nut 17 Hold ring nut retainer with special tool Part No CA715022 tighten ring nut with special tool Part No CA119099 Tighten ring nut in small steps and check the pre loading with special tool Part No CA7...

Page 29: ... pressed onto housing 2 Position each half box on a bench and assemble all inner components sun gears planetary gears thrust washers pins discs and fixed discs as in illustration 3 Fit crown wheel 3 to differential housing 2 4 Apply Loctite 270 to bolt thread 4 and secure crown wheel to differential unit Torque load bolts to 95 Nm 70 lbf ft 1 Taper roller bearing 2 Differential housing 3 Crown whe...

Page 30: ...to brake pack using special tool Part No CA715299 handle Part No CA119033 and a hammer 2 Fit O rings 3 4 to the three thrust pins 5 3 Fit the thrust pins to the negative acting brake piston 6 and secure with circlips 7 4 Fit O rings 8 9 to the inner and outer faces of the negative acting brake piston NOTE Use an eyebolt screwed into the brake pack and a lever to press the piston into the brake pac...

Page 31: ...the adjuster bolts 19 fully in 13 Release hydraulic pressure then push the negative acting brake piston 6 until it contacts the pins 20 14 Apply Loctite 518 to threads of screw 22 fit to brake pack and torque load to 30 Nm 22 lbf ft 15 Fit plug 23 to screw 22 and torque load to 20 Nm 15 lbf ft 16 Fit piston 15 into brake pack 1 and using special tool Part No CA715056 press piston into brake pack u...

Page 32: ...olt 33 to 120 Nm 88 lbf ft 28 O ring 29 O ring 30 Differential assembly 31 Differential housing 32 Bolt 33 Stud bolt 34 Ring nut 19 Fit new O rings 28 29 to the brake pack 1 20 Insert a suitable size bar through the differential assembly 30 and slide assembly into differential housing 31 Make sure the differential is inserted in the correct side of the casing During assembly make sure the brake pa...

Page 33: ...A 119030 29 Adjust the ring nuts 34 remembering that If the measured backlash is less than the given tolerance range move the crown wheel towards the pinion by screwing the ring nut on the crown wheel side in and screwing the opposite ring nut out by the same amount If the measured backlash is more than the given tolerance range move the crown wheel away from the pinion by screwing the ring nut on...

Page 34: ... P 3 85 P 5 8 daN Where P is the pre loading effectively measured on the pinion see Pinion Assembly 33 If the measurement is not within the required range check for correct assembly of components and adjust the differential support ring nuts as follows If the total pre loading is less than the required range tighten the two ring nuts by the same amount keeping the pinion ring gear backlash unchang...

Page 35: ...eth surfaces will be regular Z Excessive contact on the tooth tip Move the pinion towards the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the backlash X Excessive contact on the tooth base Move the pinion away from the ring bevel gear and then move the ring bevel gear towards the pinion in order to adjust the backlash Correction movements 1 move the pi...

Page 36: ...ole if necessary Torque load bolt to 13 Nm 9 6 lbf ft 35 Repeat previous step to other ring nut 36 Fit bearing seal 37 to the pinion drive using special tool Part No CA715156 37 Fit the shim 38 to the pinion 38 Apply a thin film of oil to the lip of the seal 37 and O ring seal 39 and fit to pinion shaft 39 Fit input flange 40 to pinion and secure with circlip 41 35 Retainer 36 Bolt 37 Bearing seal...

Page 37: ...w brake discs are fitted they must be soaked in oil before use 2 Examine the friction discs and fixed discs for signs of burning or damage replace if necessary 3 Position the axle on a suitable workbench and attach lifting gear to the axle beam to be fitted Axle beam trumpet and brake group 4 Fit the inner brake drive plate 1 brake discs 2 and fixed discs 3 to the brake pack 4 5 Fit the sleeve 5 t...

Page 38: ...e beam 7 using special tool Part No CA715157 and a hammer 11 Fit sealing ring 13 to axle beam 7 using special tool Part No CA715402 and a hammer Fill of the seal cavity with grease 12 Lubricate the bush 12 and sealing ring 13 with grease Fit the drive shaft 14 to the axle to engage the differential 6 O ring 7 Axle beam 8 Bolt 9 Nut 10 Bush 11 Bush 12 Bush 13 Sealing ring 14 Drive shaft The axle be...

Page 39: ...ight hand wheel hub 1 Fit the bush 1 in the swivel housing 2 with a hammer or a suitable press and special tool Part No CA715108 2 Fit the seal 3 in the swivel housing 2 with a hammer and special tool Part No CA715321 3 Fit the cone 4 of the spherical joint to the lower king pin 5 with a hammer or a suitable press and special tool Part No CA715321 4 Apply grease to the upper and lower king pin hou...

Page 40: ... to use as location dowels 14 Fit the wheel carrier to the epicyclic ring 18 and secure with locking ring 19 15 Locate the wheel carrier to the swivel housing make sure the two bushes left proud engage in the holes on the carrier Fit bolts 20 to these two positions and tighten bolts to force bushes into swivel housing 10 Wheel hub 11 Bearing track 12 Bearing track 13 Inner taper roller bearing 14 ...

Page 41: ...s 3 to the pins 4 then fit thrust washers 5 and secure with circlip or snapring 6 4 Fit new O ring 7 to the planetary carrier 1 5 Fit the planetary carrier to the wheel hub and secure with retaining screws 8 Torque load retaining screws to 25 Nm 18 lbf ft 6 Fit drain plug 9 and torque load to 80 Nm 59 lbf ft 7 Refer to Service Manual and fill the hubs and differential unit with oil 8 Test differen...

Page 42: ...to 300 Nm 221 lbf ft 2 Fit the steering cylinder 3 to the mounting brackets on the axle and secure with the three cylinder attachment bolts 4 Torque load bolts to 120 Nm 88 lbf ft 3 Fit the hydraulic adapter 5 to the steering cylinder 3 4 Make sure the track rod lock nuts 6 are screwed towards the swivel ends 5 Make sure the cylinder piston is central in the steering cylinder body 6 Fit the track ...

Page 43: ...e used when dismantling and assembling the axle The interchangeable handle Part No CA119033 should always be used when removing and fitting bearings and bushes together with a suitable safety handle Ring nut wrench CA119030 Interchangeable handle CA119033 Pinion lock nut wrench CA119099 ...

Page 44: ...AXLES STEERING 1 34 Oil seal driver CA119143 Driver for bearing CA119230 Pinion shaft lock wrench CA715022 Bearing cone driver CA715026 ...

Page 45: ...AXLES STEERING 1 35 False differential box CA715041 Dummy pinion CA715040 Bush driver CA715039 Bush wrench CA715027 ...

Page 46: ...AXLES STEERING 1 36 Driver for king pin bush CA715042 Driver for oil seal CA715056 Bush driver CA715108 Extension for preload measurement CA715116 ...

Page 47: ...AXLES STEERING 1 37 Kit for backlash measurement CA715146 Oil seal driver CA715156 Bush driver CA715157 Bearing cone driver CA715179 ...

Page 48: ...AXLES STEERING 1 38 Bearing cup driver CA715299 Driver for oil seal CA715321 Bearing races insertion tool CA715401 Driver for oil seal CA715402 ...

Page 49: ...red tolerance range 4 The normal toe in value A is referred to the external diameter of the wheel hub flange therefore the measured value M at the bar ends must be related to the ratio between length of the bar and flange diameter Nominal toe in A Measured toe in M 5 If the toe in is out of adjustment loosen the lock nuts 1 on the track rods 2 and using two wrenches adjust the length of the track ...

Page 50: ...lock nut 1 on all four adjusters of the front and rear axles and screw adjusters 2 inwards 2 Set the adjuster bolt on each of the hubs of the front and rear axles as detailed in the Table then tighten the lock nuts 3 Torque load all lock nuts to 100 Nm 74 lbf ft 1 Lock nut 2 Adjuster AXLE POSITION DIMENSION FRONT A 45 mm FRONT B 45 mm FRONT C 30 mm FRONT D 30 mm REAR A 30 mm REAR B 30 mm REAR C 45...

Page 51: ...ot 5 Remove the front and rear thrust washers 8 from the axle housing 6 Remove the bushes 9 from the front and rear pivots 7 Inspect all components for signs of wear and damage replace as necessary Installation 1 Installation is reverse of the above procedure 2 Fit a new O ring to the front pivot 3 Lubricate the pivots after assembly to the axle housing 1 Pivot 2 Grease nipple 3 Bolt 4 Bolt 5 Inne...

Page 52: ...he wheels turning 3 With the assistance of a second person rotate both wheels in a forward direction as far as possible both the wheels should stop after a while 4 Rotate the left wheel in the forward direction of travel and the right wheel in the rearward direction of travel The wheels should both move freely without difficulty when the axle has been assembled correctly 5 Repeat the above test wh...

Page 53: ...uce the steering angle to minimum and decelerate the machine when the steering begins to kick 7 Incorrect wheel adjustment Check group integrity and wheel side bearings Adjust accordingly 8 Spoiled or worn out axle parts Check the condition of the ring gear pinion gear bearings etc Replace components as necessary 9 Contamination in the axle box or incorrect assembly of parts Look for foreign parti...

Page 54: ... r e p m e t y l t c e r o c n i d e l b m e s s a t e k s a g l i O 2 d e g a m a d p i l l a e S 3 l i o d e t a n i m a t n o C 4 g n i t a m d n a l a e s r o t e k s a g e h t e c a l p e R d e g a m a d f i e c a f r u s l e v e l t c e r r o c e h t o t l l i f s t n a c i r b u l t c e r r o c e s U s l a v r e t n i t c e r r o c t a e c a l p e r d n a e n i l p s e g n a l f t u p n i f...

Page 55: ...s e s i o N 1 d u o l t o n e r a t u b r a e g l a r t u e n n i s e v o m e n i h c a m d n u o s g n i r d n a n o i n i p n e e w t e b h s a l k c a b t c e r r o c n I 2 e l i h w s r a e p p a s i d g n i t a r e l e c e d e l i h w d r a e h g n i t a r e l e c c a t u o n r o w e g n a l f t u p n i r o n o i n i P 3 e v o b a e e s t s u j d a r o e c a l p e R 1 e c a l p e R 2 e c a l ...

Page 56: ...inst each other and proportionally direct oil to the selected steering cylinder Not until the rotary valve is fully open is the LS connection to the tank fully closed A pressure relief valve is fitted in the steering unit If the pressure rises above 175 bar 2537 psi the PRV will open and return excess pressure to tank Shock valves are fitted to in the steering unit to protect the cylinders and hos...

Page 57: ...AXLES STEERING 1 47 LS LS line ...

Page 58: ...ering cylinder rear 22 Steering selector valve 23 Pressure relief valve 175 bar 24 Shock valve 225 245 bar 25 Control valve PVG 32 36 PVSP inlet section 41 Priority valve brakes and steering 42 Priority valve steering 62 Start up valve from Machines S No 51200472 only 65 Test point main system pressure LS ...

Page 59: ... 7 Start engine and bleed the hydraulic lines free of air Steering unit OSPF Start the engine and run until oil is at normal operating temperature and any air is purged from system Set engine at maximum rev min turn the steering wheel until the steering stops make contact If the steering wheel can be turned without significant effort or the wheel turns on it s own the rotor spool or shock valves a...

Page 60: ... hoses from the steering valve assembly and blank open connections on valve and hoses Tie hoses clear of valve 8 From inside the cab remove the nut washer three bolts and washers securing the valve to the steering column Remove the valve from the machine by disconnecting the splined drive Installation 1 Installation is the reverse of the above procedure 2 Make sure all hoses and electrical connect...

Page 61: ...ical connectors If any damage is found the valve must be replaced as a unit 4 Examine the adapter for damage to the block If any damage is found the adapter must be replaced 5 Examine the steering unit for damage to the block If any damage is found the unit must be replaced Assembly 1 Assemble the steering valve assembly in the reverse order to dismantling 2 Use new O rings during assembly 3 Tight...

Page 62: ...e as necessary to maintain accumulator at working pressure throughout the bleeding procedure 4 Attach a bleed tube to the bleed screw 1 on the brake unit nearest to the brake valve front right and put the bleed tube into a suitable container Carefully open bleed screw 1 apply brakes until all air is bled out of line then close bleed screw 1 and remove bleed tube Bleed the other brake units and the...

Page 63: ...ke switch if necessary to the parking brake applied position 5 Press the brake pedal repeatedly until the brake charge warning lamp illuminates 6 Press the brake pedal a further twenty times to ensure that residual pressure in the brake system is fully dissipated 7 Turn the ignition switch to off To dump a system pressure NOTE Thisprocedureappliestoallmachinehydraulic systems except brakes 1 Stop ...

Page 64: ...ulic cylinders are fully closed 3 Stop the engine apply the parking brake 4 Open the engine pod cover 5 Check hydraulic tank sightglass 2 make sure fluid level shows in sightglass and is above the red line NOTE Wait for two minutes after engine is stopped before checking fluid level 6 Replenish fluid if necessary as follows The cap maintains an air pressure of 0 3 bar in the hydraulic tank 7 Clean...

Page 65: ...SECTION 2 ENGINE ...

Page 66: ...xternally mounted and then two filter elements A filter blockage sensor is fitted to the air cleaner body and lights a warning indicator in the cab when the filter requires cleaning The engine must not be operated when the warning indicator is illuminated The engine and gearbox should always be removed as an assembly either by leaving the engine pod in situ and removing the engine and gearbox from...

Page 67: ...fy and label all hoses and electrical connectors before removal Tie back all hoses and electrical cables to make sure they are not damaged during engine removal Do not drain the coolant until the engine is cold 6 Drain the engine cooling system 7 Disconnect the inlet and outlet coolant hoses from the cab heater Tie the hoses clear of the pod 8 Recover the gas from the air conditioning system if fi...

Page 68: ...the chassis 20 Disconnect the air cleaner to engine hose Remove the air cleaner assembly including pre cleaner from the machine Remove the air cleaner support panel 21 Disconnect and remove the flexible exhaust pipe between the engine and silencer Remove the silencer 22 Support the pod using a suitable fork lift under the pod or fit a suitable lifting sling to the engine pod and attach to a suitab...

Page 69: ... gearbox 61 81 Nm 45 60 lbf ft Drive shaft to axle 70 85 Nm 52 63 lbf ft 6 Replenish the cooling system hydraulic system refer to Page 1 55 transmission and engine lubricating oil 6 Charge the air conditioning system if fitted using suitable equipment 8 Start engine and make sure all warning lights operate correctly 9 Make sure all disturbed hoses and pipes do not leak 10 Stop the engine and check...

Page 70: ...7 Drain the transmission system oil 8 Disconnect the inlet and outlet coolant hoses from the radiator Disconnect the expansion tank hose from the radiator 9 Disconnect the oil coolant hoses from the oil cooler 10 Disconnect the hydraulic hoses from the fan hydraulic pump Fit blanks to the pump and hoses 11 Remove the radiator grille then the radiator oil cooler and fan assembly 12 Disconnect the s...

Page 71: ... Unclip the wiring loom from the engine and tie clear of engine 24 Disconnect the accelerator cable from the engine 25 Disconnect the air cleaner to engine hose Remove the air cleaner assembly from the machine 26 Disconnect and remove the flexible exhaust pipe between the engine and silencer Remove the silencer 27 Fit a suitable lifting sling to the engine and attach to a suitable overhead lifting...

Page 72: ...t to gearbox 61 81 Nm 45 60 lbf ft Drive shaft to axle 70 85 Nm 52 63 lbf ft 6 Replenish the cooling system hydraulic system refer to Page 1 54 transmission and engine lubricating oil 7 Charge the air conditioning system if fitted using suitable equipment 8 Start engine and make sure all warning lights operate correctly 9 Make sure all disturbed hoses and pipes do not leak 10 Stop the engine and c...

Page 73: ...SECTION 3 TRANSMISSION ...

Page 74: ...dule APC Automatic Powershift Controller The higher forward gears F4 F5 and F6 are selected automatically by the APC A kickdown function is available by pressing the button on the end of the gear selector lever but is protected by the APC to prevent damage to the transmission Reselect the original gear by pressing the button on the end of the gear selector lever Gear selection without APC option A...

Page 75: ...5Kg 175Kg 175Kg Oil Quantity 16 Litre 16 Litre 16 Litre Torque Convertor Ratio 2 0 1 2 0 1 2 0 1 Gear Ratio in 1st Gear 4 24 1 4 24 1 4 24 1 Gear Ratio in 2st Gear 3 03 1 3 03 1 3 03 1 Gear Ratio in 3rd Gear 2 16 1 2 16 1 2 16 1 Gear Ratio in 4th Gear 1 54 1 1 54 1 1 54 1 Gear Ratio in 5th Gear 0 91 1 0 91 1 0 91 1 Gear Ratio in 6th Gear 0 65 1 0 65 1 0 65 1 Gearbox oil pump 50 C 2000min 50 53 l m...

Page 76: ...TRANSMISSION 3 3 Gearbox layout Typical Shown without Transfer Gearbox A Left view B Front view C Right view 1 From gearbox to oil cooler 2 Oil cooler 3 From oil cooler to gearbox ...

Page 77: ...3 4 TRANSMISSION For the Type Serial No and the Model refer to the plate on the gearbox Gearbox type plate ...

Page 78: ...box controller in Hz relating to gearbox speed This signal is used for Controlling the speed at which gears can be changed Controlling automatic gear change through 5th and 6th Controlling the speed at which a directional change can take place D Speed sensor Speed sensor ...

Page 79: ...sensor must be in the direction of rotation A Sensor test 1 Connect multimeter in series between speed sensor and APC module set multimeter to read mA 2 Start machine 3 The reading should be between 7 mA 14 mA at tickover 4 A reading of 60 mA indicates the wrong wire is being tested 5 A reading of 20 mA indicates a short circuit ...

Page 80: ...TRANSMISSION 3 7 Speed sensor to module connection A Module B Speed sensor Pin 1 Plus Pin 2 Minus 20 Speed sensor Input 21 Module ground 22 Speed sensor earth ...

Page 81: ... are mounted on the left side of the gearbox The reverse solenoid valve controls the reverse clutch The forwards solenoid valve controls the oil flow to the splitter solenoid of the reverse solenoid The splitter solenoid valve controls the oil to 4th high clutch and the forwards clutch The solenoid valve 1 controls clutch 1 The solenoid valve 2 controls oil flow to clutch 2 or clutch 3 ...

Page 82: ...TRANSMISSION 3 9 Solenoids to module wiring ...

Page 83: ...or M is pressed twice and the machine is in motion Machine speed is displayed as Km hr On When mode selector M has been pressed twice but machine is not in motion On When mode selector M has been pressed twice the machine is in motion but there is no output from the speed sensor F Indicator LED type which indicates an APC fault APC gear selector module n o i t i s o p r e v e L d e t c e l e s r a...

Page 84: ...splay the following menus Display normal Display gearbox speed Display forward speed Display Input signal Display normal is the standard display The other display modes are selected by pressing the mode button M on the LED display forward of the steering column ...

Page 85: ...ion the selected gear the failure codes Gear Selection The gear display information is as follows the gear selected with a number the direction selected with a letter F Forwards R Reverse N Neutral Display Display Normal Neutral 5th gear Forwards 1st gear Reverse 3rd gear ...

Page 86: ...o high for the downshift selected The left dot indicates that the speed is too high for a direction change D Flash Because the gearbox only has three reverse gears R1 R3 and R5 and the selector has six positions R1 to R6 the actual gear selected in relation to the lever selection is shown in the following illustration ...

Page 87: ...e in the display The following codes are available Display Open circuit in output from APC to solenoids With this failure code the machine will stay in neutral Failure codes The APC controller has received an input from the lever for forwards and reverse at the same time The gearbox will remain in neutral ...

Page 88: ...he following instruction must be followed Speeds up to 99 rpm are displayed using the first number only Speeds from 100 rpm to 999 rpm are displayed using the first two numbers For speeds over 1000 rpm the left LED dot is illuminated and the first two numbers are displayed Display Display for any speed between 70 79 rpm Display Gearbox speed signal Display for a speed between 120 129 rpm Display f...

Page 89: ... mode button M on the LED display forward of the steering column twice The display will now indicate forward speed The speed is in km hr The dot moves to indicate a two digit speed at all times The LED is in the Display Speed mode The machine speed is 12 km hr The machine speed is 6 7 km hr Display Machine speed Display ...

Page 90: ...of the steering column three times The display will now show a segment illuminated to correspond with the input from the forward reverse control lever Example With the gear selection lever in forward gear 1 pin 2 in the connector from the lever and pin 14 in the APC module is live Display S Segment Display inputs e l u d o M C P A n i n i p e v i t c A r e v e l n i n i p e v i t c A 4 1 2 ...

Page 91: ...c s d r a w r o f r e v e L 1 3 2 1 r a e g t s 1 t c e l e s r e v e L 2 2 4 1 r a e g d r 3 t c e l e s r e v e L 6 3 1 5 1 r a e g h t 5 t c e l e s r e v e L 3 9 6 1 n o t t u b n w o d k c i K 4 1 6 2 e s r e v e r r e v e L 5 8 9 1 h c t i w s p m u d e k a r B 8 l a n r e t x e n i P 5 2 e k a r b g n i k r a P 8 l a n r e t x e n i P 5 2 r a e g d n 2 t c e l e s r e v e L 6 2 3 1 2 5 1 4 ...

Page 92: ... e v e L t u p t u o e v i t c A r e v e l m o r f n i p n i p t u p n i e v i t c A e l u d o m C P A n o e h t h t i w y a l p s i D r a e g d e t c e l e s S D R A W R O F e h t h t i w y a l p s i D r a e g d e t c e l e s E S R E V E R 1 2 4 1 1 F 1 r 2 2 3 1 4 1 5 1 2 F 3 r 3 3 1 5 1 3 F 3 r 4 9 3 1 6 1 5 1 4 F 3 r 5 9 6 1 5 F 5 r 6 2 9 4 1 6 1 6 F 5 r s d r a w r o F 3 2 1 _ _ e s r e v e R...

Page 93: ... a n g i S 4 1 5 n i P r e v e L m o r f l a n g i S 5 1 4 n i P r e v e L m o r f l a n g i S 6 1 3 n i P r e v e L m o r f l a n g i S 7 1 h c t i w S g n i d a o R m o r f l a n g i S l a n o i t p O 8 1 d e s U t o N 9 1 6 n i P r e v e L m o r f l a n g i S 0 2 r o s n e S d e e p S t u p n I 1 2 1 3 d n u o r G e l u d o M 2 2 r o s n e S d e e p S r o f h t r a E 3 2 h t r a E 4 2 d e s U t...

Page 94: ...ule will now test all the outputs by sending a test current through the cables The display then uses the following letters to indicate the condition of the circuit as follows G Good S Short to Earth O Open circuit or short to positive Display Output 1 is tested and is GOOD G Output 2 is tested and is SHORTED TO EARTH S Output 3 is tested and is OPEN CIRCUIT OR SHORT TO POSITIVE O Testing output fr...

Page 95: ...the higher gears This system is controlled by the APC It uses the signal from the gearbox speed sensor to control the engagement of 5th and 6th gears when the lever is in the automatic mode A If the lever is in 5th the APC will control the engagement of 5th gear only Kick down When in the test mode the APC automatically scrolls through all the output test 1 through 8 Pins 3 8 and 9 are not active ...

Page 96: ...ctor The gearbox remains the same but with this option the following are not available Speed sensor Gearbox APC module Display menu in cab Kickdown Automatic switching Control lever 1 Control lever 2 Connector to solenoid valves 3 Multi function lever 4 Connector from multi function lever to services ...

Page 97: ... G 1 e v l a v d i o n e l o S 2 w o l l e Y 2 e v l a v d i o n e l o S 4 e t i h W S e v l a v d i o n e l o S 5 d e R h c t i w s n o i t c e r i d l e v a r T 7 w o l l e Y e u l B F e v l a v d i o n e l o S 8 n e e r G e t i h W d i o n e l o s e s r e v e R 1 1 e u l B y l p p u s r e w o P 2 1 0 1 9 6 3 _ d e s u t o N ...

Page 98: ... l o r t n o c e v l a v d i o n e l o s e h T x o b r a e g e h t n i h c t u l c 8 3 1 1 e v l a v d i o n e l o S e v i t a l e r e h t s l o r t n o c e v l a v d i o n e l o s e h T x o b r a e g e h t n i h c t u l c 7 3 1 S e v l a v d i o n e l o S e v i t a l e r e h t s l o r t n o c e v l a v d i o n e l o s e h T x o b r a e g e h t n i h c t u l c 6 4 1 r a e g r e v e l R N V n o i t...

Page 99: ... o t n i s e h c t i w s x o b r a e g e h t 4 F n o i t i s o p l e v a r t n I r a e g 3 R e h t o t n i s e h c t i w s x o b r a e g e h t 4 R n o i t i s o p l e v a r t n I r a e G e v l a v d i o n e l o s e v i t c A h c t u l c d e h c t i w S 4 F 2 d n a S F 2 d n a h g i h h t 4 3 F 2 d n a F 2 h c t u l c s d r a w r o F 2 F 2 d n a 1 S F 1 d n a h g i h h t 4 1 F 2 d n a 1 F 1 d n a s...

Page 100: ...TRANSMISSION 3 27 The gearbox has 6 clutches to select the 6 forward and 3 reverse gears Gearbox power flow ...

Page 101: ...3 28 TRANSMISSION Gear and clutch layout ...

Page 102: ...s e s s e r p m o c d n i h e b n i d e f e r u s s e r p l i o c i l u a r d y h h t i W 6 l e e h w r a e g n e v i r D s k c a p h c t u l c e h t o t e v i r d s t i m s n a r T 7 t f a h s e v i r D t e k s a b r e t u o d n a 6 r a e g o t d e t c e n n o c y l n o s i t f a h s e v i r d e h T A y l p p u s l i o h c t u l C h c t u l c t a h t e g a g n e o t n o t s i p t f e l e h t d n ...

Page 103: ...ve shaft 7 via the clutch pack onto the drive gear 1 Connection B for the non operated clutch has a connection via the related solenoid valve back to tank the spring 2 and ram 5 are in the disengaged position and therefore the clutch is open The connection of the non activated clutch is related to the return motion and the solenoid valve so that the pressure spring 2 moves the piston 5 to the outp...

Page 104: ...orwards clutch assembly Z3 Gear 3 mounted on input shaft Z4 Gear 4 with 4th high clutch assembly Z5 Gear 5 with 3rd clutch assembly Z6 Gear 6 with counter shaft assembly Z7 Gear 7 with 1st clutch assembly Z8 Gear 8 with 2nd clutch assembly E Input shaft V1 Intermediate shaft 1 V2 Intermediate shaft 2 ...

Page 105: ...S 1 F 2 d n a 1 s d r a w r o F t s 1 d n a s d r a w r o F 1 R 2 d n a 1 e s r e v e R t s 1 d n a e s r e v e R 3 R 2 d n a e s r e v e R d n 2 d n a e s r e v e R 5 R e s r e v e R d r 3 d n a e s r e v e R r a e G V M E e v i t c A d e g a g n E s e h c t u l C 5 F s d r a w r o F d r 3 d n a s d r a w r o F 4 F 2 d n a r e t t i l p S s d r a w r o F d n 2 d n a h g i h h t 4 r e t t i l p S ...

Page 106: ... t i l p S s d r a w r o F d n 2 d n a h g i h h t 4 r e t t i l p S 3 F 2 d n a s d r a w r o F d n 2 d n a s d r a w r o F 2 F 2 d n a 1 r e t t i l p S s d r a w r o F t s 1 d n a h g i h h t 4 r e t t i l p S 1 F 2 d n a 1 s d r a w r o F t s 1 d n a s d r a w r o F 1 R 2 d n a 1 e s r e v e R t s 1 d n a e s r e v e R 3 R 2 d n a e s r e v e R d n 2 d n a e s r e v e R ...

Page 107: ...a R d n a h g i H h t 4 n o i t a c i r b u L r a b 0 4 9 2 s i t i u c r i c s i h t n i e r u s e r P e v l a V n o i t a l u d o M y l w o l s p u e r u s s e r p h c t u l c e s r e v e R d n a s d r a w r o F d l i u B d i o n e l o S e s r e v e R h c t u l c e s r e v e R e h t s e s o l C d i o n e l o S r e t t i l p S e h t r o h c t u l c h g i H h t 4 e h t f o e r u s s e r p e h t s ...

Page 108: ...TRANSMISSION 3 35 Neutral ...

Page 109: ...3 36 TRANSMISSION 1st gear ...

Page 110: ...TRANSMISSION 3 37 ...

Page 111: ...3 38 TRANSMISSION 2nd gear ...

Page 112: ...TRANSMISSION 3 39 ...

Page 113: ...3 40 TRANSMISSION 3rd gear ...

Page 114: ...TRANSMISSION 3 41 ...

Page 115: ...3 42 TRANSMISSION 4th gear ...

Page 116: ...TRANSMISSION 3 43 ...

Page 117: ...3 44 TRANSMISSION 5th gear ...

Page 118: ...TRANSMISSION 3 45 ...

Page 119: ...3 46 TRANSMISSION 6th gear ...

Page 120: ...TRANSMISSION 3 47 ...

Page 121: ...3 48 TRANSMISSION Reverse gear ...

Page 122: ...TRANSMISSION 3 49 ...

Page 123: ... Table for gears R3 and R5 Gearbox pump Gear selection Active EMV Active Clutch R3 Reverse and 2nd Reverse and 2nd R5 Reverse Reverse and 3rd P Gearbox pump Accumulator damping valves A Accumulator for clutch modulation ...

Page 124: ... ports M12 From oil Cooler M71 Temperature test port M41 1st clutch pressure M43 3rd clutch pressure M42 2nd clutch pressure M11 To cooler M45 Forwards pressure M31 System pressure M46 Reverse pressure M44 4th high pressure ...

Page 125: ... i o o T r a b 4 6 9 2 3 3 M r e l o o c l i o m o r F r a b 0 4 9 2 1 4 M e r u s s e r P h c t u l C t s 1 r a b 5 9 1 5 6 1 2 4 M e r u s s e r P h c t u l C d n 2 r a b 5 9 1 5 6 1 3 4 M e r u s s e r P h c t u l C d r 3 r a b 5 9 1 5 6 1 4 4 M e r u s s e r P h g i H h t 4 r a b 5 9 1 5 6 1 5 4 M e r u s s e r P s d r a w r o F r a b 5 9 1 5 6 1 6 4 M e r u s s e r P e s r e v e R r a b 5 9 1...

Page 126: ...onnectors 9 Remove the flywheel access plate on the engine 10 Turn the engine flywheel and remove the eight bolts securing the flywheel to the converter drive plates REMOVAL INSTALLATION NOTE The rear engine transmission to chassis mounting brackets are attached to the transmission Theenginemustbesupportedbeforetheseareremoved 11 Support the engine using a suitable lifting sling 12 Remove the two ...

Page 127: ... control disc brake not fitted to Targo Figure 3 Remove drive plate attaching cap head screws and washers Remove drive plate and backing ring Figure 5 Remove plug and O ring Figure 4 Remove torque converter plug retainer ring Figure 6 Remove torque converter to turbine shaft retainer ring Dismantling Transmission ...

Page 128: ...ft locating ring Figure 9 Remove filter assembly Figure 10 Remove charging pump permanent hole cover not used when auxiliary pump used Figure 11 Remove pump mounting bolts and washers Remove pump and gasket Figure 12 Remove pressure regulator and regulator sleeve NOTE Use special tool see Figure 427 ...

Page 129: ...nd O ring Figure 14 Remove converter housing to transmission case bolts and washers Figure 15 Remove converter housing and gasket Figure 16 Remove impeller hub gear Figure 17 Remove pump drive idler gear washer Figure 18 Remove pump drive gear and bearing ...

Page 130: ...t and washer Figure 20 Remove solenoid protection cover screws Figure 21 Remove solenoid protection cover Figure 24 Remove valve cartridge and O ring Figure 23 Remove solenoid coil and O ring Figure 22 Remove solenoid valve cartridge retainer nut and O ring ...

Page 131: ...have a bore plug in the centre box Remove bore plug Figure 26 Remove spacer plate bolts and washers Figure 27 Pry spacer plate away from transmission case at dowel pin holes Figure 28 Remove spacer plate and gasket Figure 29 Remove 1st and 2nd clutch assembly Figure 30 Remove forward and reverse clutch assembly ...

Page 132: ...er races Figure 33 Remove brake disc assembly bolts from brake and housing NOTE Brake is not fitted to Targo Figure 34 Remove brake caliper assembly Figure 35 Turn front flange as shown Remove retainer ring from ring groove and output flange from housing Figure 36 Remove output flange oil seal sleeve and front bearing NOTE Brake is not fitted to Targo ...

Page 133: ...g ring Figure 38 Remove output gear to shaft retainer ring Figure 39 Tap output shaft and flange from housing Figure 40 Flange removed NOTE Brake is not fitted to Targo Figure 41 Remove output gear Figure 42 Remove flange oil seal sleeve retainer ring ...

Page 134: ...shaft rear bearing Figure 45 Remove bearing locating ring Figure 46 Remove modulator valve housing Figure 47 Remove inner middle and outer springs Remove valve stop pin and accumulator spool Remove regulator spool and sleeve assembly Figure 48 Remove sensor hole plug and O ring ...

Page 135: ...and dipstick tube Figure 50 Remove air breather Figure 51 Remove supply tube retainer screw Figure 52 Remove tube retainer screw seal washer clip washer and nut Figure 53 Remove supply tube O ring Figure 54 Remove supply tube and screen assembly ...

Page 136: ...lock screw Figure 56 Remove distributor sleeve using a hammer puller Figure 57 Remove sleeve and pilot bearing Figure 58 Removed pilot bearing and sleeve Figure 59 Remove clutch shaft oil sealing rings Figure 60 Remove front bearing using a bearing puller Dismantling low 1st clutch ...

Page 137: ...t washer Figure 62 Remove clutch gear and disc hub Figure 63 Remove clutch gear and pilot bearings Figure 64 Remove outer thrust washer thrust bearing and inner thrust washer Figure 65 Remove clutch disc end plate retainer ring Figure 66 Remove clutch disc end plate retainer ring ...

Page 138: ...move inner and outer clutch discs Figure 68 Compress disc springs and remove retainer ring Figure 69 Remove retainer ring Figure 70 Remove retainer ring retainer Figure 71 Remove disc spring Figure 72 Remove clutch piston wear plate ...

Page 139: ...move clutch piston Figure 74 Remove clutch shaft rear bearing outer race Figure 75 Remove gear and rear bearing inner race using a gear puller Figure 76 Remove inner race from shaft Figure 77 Remove gear from shaft Figure 78 Remove gear locating ring from shaft Dismantling 2nd clutch ...

Page 140: ...re 80 Remove outer thrust washer thrust bearing and inner thrust washer Figure 81 Remove clutch gear and hub and gear bearings Figure 82 Remove outer thrust washer thrust bearing and inner thrust washer Figure 83 Remove clutch disc and end plate retainer ring Figure 84 Remove end plate ...

Page 141: ...ove inner and outer clutch discs Figure 86 Compress disc springs and remove retainer ring Figure 87 Remove retainer ring Figure 88 Remove retainer ring retainer Figure 89 Remove disc springs Figure 90 Remove clutch piston wear plate ...

Page 142: ...move clutch piston Figure 92 The two bleed valves in the clutch drum must be clean and free from foreign material Install clutch piston outer seal ring Figure 93 Install clutch piston inner seal ring NOTE Ring must be sized before installing in clutch drum Sizing is best done by rotating piston while holding a round object against the new seal ring as shown Rotate piston until seal is flush with o...

Page 143: ...against retainer ring Strike the sleeve with a sharp blow using a soft hammer to compress the springs and seat the retainer ring Make sure ring is fully seated in groove Figure 100 Install first steel outer clutch disc Figure 101 Install first friction inner clutch disc Alternate steel and friction discs until ten 10 steel and ten 10 friction discs are in position Figure 102 Install clutch disc en...

Page 144: ...gauge through the slots in the clutch drum and make sure between 0 080 0 135 in 2 03 3 43 mm If the clearance is greater than 0 135 in 3 43 mm add one steel disc under the end plate Figure 105 Position thrust bearing inner washer on clutch shaft Figure 106 Position thrust bearing on clutch shaft against inner thrust bearing washer Figure 106 Install outer thrust bearing washer against bearing Figu...

Page 145: ...ligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is in full position in the clutch assembly Do not force this operation Figure 110 Position inner thrust washer on shaft Figure 111 Position thrust bearing on shaft Figure 112 Position outer thrust washer on shaft Figure 113 Install clutch shaft front bearing NOTE Bearing has a shield which must face up ...

Page 146: ...piston sealing rings are not damaged Figure 117 Install clutch piston wear plate Figure 118 Install piston return disc springs Make sure first spring with large diameter of bevel is towards wear plate Alternate 5 springs See NOTE on Fig 96 Figure 119 Position return spring retainer on clutch shaft Figure 120 Start ring on shaft with snap ring pliers Assembly 2nd clutch ...

Page 147: ...at the retainer ring Make sure ring is fully seated in groove Figure 122 Figure 123 Figure 124 Install clutch disc end plate Figure 125 Install end plate retainer ring Install first friction inner clutch disc Alternate steel and friction discs until five 5 steel and five 5 friction discs are in position Install first steel outer clutch disc Figure 126 Position thrust bearing inner washer on clutch...

Page 148: ...y aligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is in full position in the clutch assembly Do not force this operation Figure 131 Position thrust bearing inner washer on clutch shaft Figure 129 Press needle bearings in clutch gear and disc hub Make sure bearings are pressed level with face of gear on both sides Figure 132 Position thrust bearing on clutch shaft...

Page 149: ...ing washer against bearing Figure 134 Install thrust washer retainer ring Figure 136 Install clutch shaft gear on clutch shaft with long hub of gear downwards Figure 137 Install rear bearing inner race on clutch shaft with bearing race shoulder downwards Figure 135 Install clutch shaft gear locating ring ...

Page 150: ...move first drive gear and front bearing using a gear puller Figure 141 Remove first drive gear locating ring For 3 speed models proceed to Figure 155 Figure 142 Remove outer thrust washer retainer ring Figure 143 Remove outer washer thrust bearing and inner thrust washer Figure 144 Remove clutch gear and disc hub Dismantling 4th high clutch ...

Page 151: ...er from clutch gear Figure 146 Remove outer thrust washer thrust bearing and inner thrust washer Figure 147 Remove end plate retainer ring Figure 148 Remove end plate Figure 149 Remove clutch discs Figure 150 Compress disc springs and remove retainer ring ...

Page 152: ...r Figure 152 Remove disc springs Figure 153 Remove clutch piston wear plate Figure 154 Remove clutch piston Figure 155 Remove clutch shaft rear bearing outer race Figure 156 Remove clutch gear and bearing inner race using a gear puller Dismantling 3rd clutch ...

Page 153: ...gure 158 Remove outer thrust washer thrust bearing and inner thrust washer Figure 159 Remove clutch gear and hub and gear bearings Figure 160 Remove outer thrust washer thrust bearing and inner thrust washer Figure 161 Remove end plate retainer ring Figure 162 Remove end plate ...

Page 154: ...63 Remove clutch discs Figure 164 Compress disc springs and remove retainer ring Figure 165 Remove retainer ring retainer Figure 166 Remove disc springs Figure 167 Remove clutch piston wear plate Figure 168 Remove clutch piston ...

Page 155: ... 93 and size inner ring Install clutch piston in clutch drum Make sure seals are not damaged Figure 171 Install clutch piston wear plate Figure 172 Install piston return disc springs First spring with large diameter of bevel towards wear plate Alternate five 5 springs See NOTE on Fig 96 Figure 173 Install return spring retainer on clutch plate Figure 174 Start ring on shaft with snap ring pliers A...

Page 156: ...ction discs until six 6 steel and six 6 friction discs are in position Figure 178 Install clutch disc end plate Figure 179 Install end plate retainer ring Figure 180 NOTE Check 4th high clutch pack disc clearance Stand the clutch assembly on end The clutch discs on the bottom will fall on to the end plate Measure the distance between the clutch piston and the first steel disc using a feeler gauge ...

Page 157: ...s one bearing in clutch gear Install bearing spacer next to bearing Press second bearing in gear make sure bearings are flush with face of gear on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is in fully engaged in the clutch assembly Do not force this operation Figure 185 Position thrust washer on s...

Page 158: ...speed clutch drum is not as shown Figure 189 Install clutch shaft gear locating ring Figure 190 Position gear on clutch shaft Figure 191 Install clutch shaft front bearing Make sure bearing shield faces upwards Figure 192 Install clutch shaft oil sealing rings Grease rings to facilitate reassembly into front housing ...

Page 159: ...stall clutch piston in clutch drum Make sure sealing rings are not damaged Figure 195 Install clutch piston wear plate Figure 196 Install piston return disc springs First spring with large diameter of bevel towards wear plate Alternate five 5 springs See NOTE on Fig 96 Figure 197 Position return spring ring retainer on clutch shaft Figure 198 Start ring on shaft with snap ring pliers Assembly 3rd ...

Page 160: ...at the retainer ring Make sure ring is fully seated in groove Figure 200 Install first steel outer clutch disc Figure 201 Install first friction inner clutch disc Alternate steel and friction discs until five 5 steel and five 5 friction discs are in position Figure 202 Install clutch disc end plate Figure 203 Install end plate retainer ring Figure 204 Position thrust bearing inner washer on clutch...

Page 161: ...ub Make sure bearings are pressed flush with face of gear on both sides Figure 208 Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is fully engaged in the clutch assembly Do not force this operation Figure 209 Position thrust bearing inner washer on clutch shaft Figure 210 Position thrust bearing on clutch shaft a...

Page 162: ... 213 Install clutch shaft rear bearing outer race Figure 214 Remove outer thrust washer thrust bearing and inner thrust washer NOTE A3 speed transmission will not have external gear teeth on the forward and reverse clutch drum Figure 215 Remove clutch gear and disc hub Figure 216 Remove bearings and spacer from clutch gear Dismantling reverse clutch ...

Page 163: ...st washer thrust bearing and inner thrust washer Figure 218 Remove end plate retainer ring Figure 219 Remove end plate Figure 220 Remove clutch discs Figure 221 Compress disc springs and remove retainer ring Figure 222 Remove retainer ring retainer ...

Page 164: ... Remove clutch piston wear plate Figure 225 Remove clutch piston Figure 226 Remove clutch shaft oil sealing rings Figure 227 Remove outer thrust washer thrust bearing and inner thrust washer Figure 228 Remove clutch gear and disc hub Dismantling forward clutch ...

Page 165: ...er from clutch gear Figure 230 Remove outer thrust washer thrust bearing and inner thrust washer Figure 231 Remove end plate retainer ring Figure 232 Remove end plate Figure 233 Remove clutch discs Figure 215 Compress disc springs and remove retainer ring ...

Page 166: ...plate Figure 238 Remove clutch piston Figure 240 Install inner and outer clutch piston sealing rings Refer to Figure 93 and size inner ring Install clutch piston in clutch drum Make sure sealing rings are not damaged Figure 239 Make sure clutch piston bleed orifice is clean and free from foreign material Assembly forward clutch ...

Page 167: ... Figure 243 Position return spring ring retainer on clutch shaft Figure 244 Start ring on shaft with snap ring pliers Figure 245 Use a sleeve with the correct inner diameter to fit over shaft and against retainer ring Strike the sleeve with a sharp blow using a soft hammer to compress the springs and seat the retainer ring Make sure ring is fully seated in groove Figure 246 Install first steel out...

Page 168: ...utch assembly on end The clutch discs on the bottom will fall on to the end plate Measure the distance between the clutch piston and the first steel disc using a feeler gauge or a taper gauge through the slots in the clutch drum and make sure between 0 048 0 108 in 1 22 2 74 mm If the clearance is greater than 0 108 in 2 74 mm add one steel disc under the end plate Figure 251 Position thrust beari...

Page 169: ... sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is fully engaged in the clutch assembly Do not force this operation Figure 255 Position inner thrust washer on shaft Figure 256 Position thrust bearing on shaft Figure 257 Position outer thrust washer on shaft Figure 258 Install clutch shaft oil sealing rings ...

Page 170: ...nner ring Install clutch piston in clutch drum Make sure sealing rings are not damaged Figure 261 Install clutch piston wear plate Figure 262 Install piston return disc springs First spring with large diameter of bevel towards wear plate Alternate five 5 springs Figure 263 Position return spring retainer on clutch shaft Figure 264 Start ring on shaft with snap ring pliers Assembly reverse clutch ...

Page 171: ...ction discs until six 6 steel and six 6 friction discs are in position Figure 268 Install clutch disc end plate Figure 269 Install end plate retainer ring Figure 270 NOTE Check forward clutch pack disc clearance Stand the clutch assembly on end The clutch discs on the bottom will fall on to the end plate Measure the distance between the clutch piston and the first steel disc using a feeler gauge o...

Page 172: ... one bearing in clutch gear Install bearing spacer next to bearing Press second bearing in gear make sure bearings are flush with face of gear on both sides Install the clutch gear in the clutch assembly by aligning the clutch hub teeth with the clutch inner discs Make sure the clutch hub is fully engaged in the clutch assembly Do not force this operation Figure 275 Position inner thrust washer on...

Page 173: ...Figure 279 Remove regulator valve piston and pressure regulator valve spring Figure 280 Spring and piston removed Figure 281 Position pressure regulator valve spring into regulator valve piston Figure 282 Install pressure regulator valve spring and regulator valve piston as an assembly into regulator valve sleeve Dismantling regulator valve Assembly regulator valve ...

Page 174: ...accumulator spool Refer to Figure 47 Figure 286 Remove cross pin from sleeve NOTE Some units will have two cross pins the same length Some units will have two cross pins of different lengths The longest pin goes in the bottom hole Figure 287 Remove regulator spool spring retainer spring and spacer from housing sleeve Figure 288 Install spring spacer in spring retainer Dismantling dual modulating v...

Page 175: ...ulator valve in sleeve against inner cross pin Figure 292 Compress regulator spool and spring in sleeve far enough to install cross pin Figure 293 Install cross pin into sleeve NOTE Some units will have two cross pins the same length Some units will have two cross pins of different lengths The longest pin goes in the bottom hole Figure 294 From opposite end install accumulator spool in sleeve ...

Page 176: ...dle spring Figure 297 Install inner spring Figure 298 Install stop pin in inner spring Figure 299 If charging pump or pump drive gear are to be replaced remove retainer ring and drive gear Figure 300 Remove reverse idler gear end plate cap head screw and washer Dismantling spacer plate ...

Page 177: ...idler gear Figure 303 Remove reverse idler gear bearing Figure 304 Remove idler gear tanged thrust washer Figure 305 If reverse idler shaft is to be replaced support spacer plate around idler shaft opening and press idler shaft from spacer Figure 306 Idler shaft and locating ring removed ...

Page 178: ...move pump drive idler shaft and thrust washer Figure 310 The stator support is held in place by two retaining rings Remove converter end retainer ring from groove Figure 311 Push support towards transmission side far enough to expose retainer ring Remove retainer ring Figure 312 From converter end remove stator support and thrust washer ...

Page 179: ...aling ring expander ring Figure 315 If support bushing or bearing is to be replaced remove from stator support Figure 316 Compress converter safety valve spring and remove retaining washer Figure 317 Remove safety valve spring Figure 318 Turn spacer plate over and remove safety valve poppet ...

Page 180: ...n bore of spacer Figure 321 Turn spacer over and position safety valve spring on poppet Figure 322 Compress spring and install poppet retaining washer NOTE End of spring must go in recessed side of washer Figure 323 Install plug and seal washer Figure 324 If stator was removed install bushing in support Install needle bearing in stator support Assembly spacer plate ...

Page 181: ...is to be 180 from sealing ring hook joint Figure 327 Position impeller hub gear washer on spacer plate Figure 328 Install stator support through washer and spacer plate Figure 329 Install stator support locating ring Figure 330 Push support back through spacer until locating ring shoulders in support bore Turn spacer plate over and install support retaining ring ...

Page 182: ...lign roll pin in spacer plate Figure 333 Tap shaft into place Figure 334 Install locating ring on reverse idler shaft Figure 335 Support spacer plate and press reverse idler shaft into position and tight against locating ring Figure 336 Turn spacer plate over and position tanged thrust washer on shaft Make sure tang in washer is in notch in spacer plate ...

Page 183: ...sition idler gear end plate and roll pin on idler shaft aligning roll pin with hole in idler shaft Figure 340 Install end plate cap head screw and washer Figure 341 Tighten cap head screw to specified torque Figure 342 Remove flange to bearing retainer ring NOTE Do not remove expansion plug unless it is being replaced Assembly front output flange ...

Page 184: ...using a bearing puller Figure 344 Bearing removed Figure 345 Remove oil sleeve and O ring Figure 346 Remove oil seal from sleeve Figure 347 Remove oil seal retainer ring from output flange Figure 348 Position bearing retainer ring on output flange ...

Page 185: ... in Figure 350 Install new O ring on oil seal sleeve Position oil seal sleeve assembly on output flange NOTE Recessed position of oil seal and sleeve must be up with lip of seal up This leaves a space between oil seal and output bearing Figure 351 Press bearing on output flange Figure 352 Install bearing to flange retainer ring Figure 353 Remove torque converter bearing Figure 354 Remove oil distr...

Page 186: ...ove converter housing plug high and 3rd clutch shaft Figure 357 Remove oil distributor sleeve set screw Figure 358 Remove oil distributor sleeve high and 3rd using a hammer puller Figure 359 Sleeve removed Figure 360 Remove converter housing plug 1st and 2nd clutch shaft ...

Page 187: ...igure 363 Sleeve removed Figure 364 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 365 Install oil distributor in converter housing with long hub towards oil seal Figure 366 Press converter bearing in housing against shoulder Assembly converter housing ...

Page 188: ...e to plug hole Install set screw in converter housing and in oil distributor Figure 370 Install high 3rd clutch shaft oil distributor sleeve in converter housing with inside diameter chamfer up and the notch in the distributor aligned up with the retaining set screw hole in the converter housing Figure 371 Apply Loctite 243 to threads of sleeve set screw NOTE This screw has a hole in it Do not all...

Page 189: ...ransmission case Figure 376 Install reverse and forward clutch shaft rear bearing in transmission case Figure 374 Apply Loctite 243 and install set screw in transmission case and in oil distributor sleeve Figure 377 Position a new O ring on lower end of modulation valve sleeve and spring assembly Install O ring on other valve sleeve Figure 375 Install set screw plug Figure 378 Install valve or val...

Page 190: ...sembly and tighten to 60 65 lbf ft 81 88 Nm Figure 382 Push supply tube through opening in case and install O ring Figure 383 Install supply tube mounting screw seal washer clip washer and nut Tighten mounting screw securely refer to Figure 384 Figure 381 Position supply tube and screen assembly in transmission case sump Figure 384 ...

Page 191: ... 386 Install air breather Figure 388 Install output shaft inner bearing locating ring in rear of transmission Figure 389 Install rear bearing in case against locating ring Figure 387 Install dipstick tube and dipstick Figure 390 Install a new O ring on rear oil seal sleeve ...

Page 192: ...ring This leaves space between oil seal and bearing Figure 394 Install rear output flange and shaft through output oil seal Align splines on shaft with splines on output gear Install shaft through gear Make sure oil seal is not damaged NOTE Brake disc not fitted to Targo Figure 392 Install oil seal sleeve retainer ring Figure 395 Install output shaft to output gear retainer ring Figure 393 From fr...

Page 193: ...nge assembly into case until snap ring can seat in snap ring groove Figure 400 Install forward and reverse clutch assembly Figure 398 Install high and 3rd clutch shaft rear bearing outer race Figure 401 Install 1st and 2nd clutch shaft rear bearing outer race Figure 399 Install high and 3rd clutch assembly Figure 402 Install 1st and 2nd clutch assembly ...

Page 194: ...r plate Take care not to damage oil sealing rings Figure 406 Position impeller hub gear on stator support Figure 407 Install pump idler gear bearing on idler shaft Figure 405 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 Tighten cap head sc...

Page 195: ...ransmissions only Figure 412 Tighten cartridges to specified torque Figure 413 With cartridge to coil O ring in place position solenoid coil on cartridge Figure 411 With O rings in position install solenoid cartridges Figure 414 With new O rings in position install coil to cartridge nut Tighten nut as per assembly instruction drawing Assembly electric control ...

Page 196: ...s and lockwashers Figure 419 Torque tighten bolts to specified torque Figure 420 Install converter locating ring on turbine shaft Figure 417 Use aligning screws to 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 aga...

Page 197: ...shaft Figure 422 Install converter assembly retainer ring Figure 424 Install bore plug retainer ring Figure 425 Install sensor hole plug end O ring Figure 426 Install regulator sleeve assembly in converter housing Figure 423 With new O ring in place install bore plug in converter assembly ...

Page 198: ...tighten to specified torque Figure 431 If auxiliary pump is used it is not necessary to install the permanent pump hole cover With a new gasket in place install pump hole cover on charging pump Install bolts and washers and tighten to specified torque Figure 429 Install charging pump in converter housing Figure 432 Install oil filter on regulating valve Tighten filter to 20 25 lbf ft 27 34 Nm If b...

Page 199: ...Tighten lock nut Figure 436 Measure the bolt circle diameter and make sure the correct drive plate kit is fitted Align small holes in drive plates Position drive plate and weld nut assembly on torque converter assembly with weld nuts towards converter Align intermediate drive plates and backing plate with holes in torque converter assembly NOTE Two dimples 180 apart in backing ring must be out tow...

Page 200: ...controls including the engine as a complete system By analysing the principles of operation together with the information in this section it should be possible to identify and correct any malfunction that may occur in the system Transmission The T1200 powershift with torque converter transmission troubles fall into three general categories 1 Mechanical problems 2 Hydraulic problems 3 Electrical pr...

Page 201: ...ture 120 C 250 F maximum will cause damage to transmission clutches fluid converter and seals Transmission pressure checks Transmission problems can be isolated by the use of pressure tests 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 Converter charging pressure and tr...

Page 202: ...cuit for pressure and rate of oil flow it is important to make the following transmission fluid check Check oil level in 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 NOTE The transmission must be at operating temperature of 82 93 C 180 200 F to obtain correct fluid level an...

Page 203: ...p m u p n o i t c u s n a e l C p m u p g n i g r a h c e v i t c e f e D p m u p e c a l p e R E S U A C Y D E M E R s g n i r g n i l a e s l i o n r o W d l i u b e r d n a e l b m e s s a s i d e v o m e R y l b m e s s a r e t r e v n o c p m u p g n i g r a h c n r o W p m u p g n i g r a h c e c a l p e R l e v e l l i o w o L l e v e l t c e r r o c o t l l i F r e l o o c l i o y t r i D ...

Page 204: ...TRANSMISSION 3 131 Check Ports ...

Page 205: ...3 132 TRANSMISSION ...

Page 206: ...TRANSMISSION 3 133 ...

Page 207: ...3 134 TRANSMISSION Standard 6 speed transmission ...

Page 208: ...troller but when the sensor is to be tested it must be connected externally Connect the sensor to an external power source and measure the DC voltage across the series resistor The voltage reading should be either 1 2 1 6V for the 7mA current level or 2 6 3 0V for the 14mA 1mA current level If the teeth can be moved slowly distinct toggling between the two levels should be noticed ...

Page 209: ...SECTION 4 BOOM ...

Page 210: ...the machine is fitted with a forward stability indicator located in the cab The forward stability indicator gives a progressive indication of load on the rear axle to warn the operator when the machine is nearing its safe working load To ensure the inner section operates smoothly non metallic wear pads are fitted between the inner and outer sections at the front of the outer boom and the rear of t...

Page 211: ...side the inner boom The forward end is secured to the inner boom and the rear end is secured to the outer boom When the boom is operated the hydraulic hoses for the front auxiliary services and the crowd cylinder are withdrawn from the cassette to allow the boom to extend The front auxiliary services are connected to a manifold on the left side of the inner boom drop down link and are connected by...

Page 212: ...rrectly Disconnect the four hydraulic hoses 1 on the bulkhead connector bracket 2 to the crowd cylinder and auxiliary services Blank the connectors and open hoses 6 Identify the hydraulic hoses to make sure they are reconnected correctly Disconnect the two hydraulic hoses 3 from the extension cylinder 4 blank the cylinder and open hoses NOTE On early models the attachment pins are slotted and reta...

Page 213: ...nd the chassis Make sure the shims take up the play between the chassis and boom Various thickness shims are available 2 When replacing the boom pivot pin 17 insert a 75 mm O D tube through the chassis and into the boom to support the boom as the pin is being fitted Make sure the shims are not damaged or trapped as the pin is fitted 3 Refer to Page 1 54 and replenish the hydraulic tank before engi...

Page 214: ...sator cylinder For the removal installation and maintenance of the compensator cylinder refer to the Hydraulic Manual Lift cylinder For the removal installation and maintenance of the lift cylinder refer to the Hydraulic Manual Extension cylinder For the removal installation and maintenance of the extension cylinder refer to the Hydraulic Manual ...

Page 215: ... 7 Identify the return hydraulic hose 7 at the T connector adjacent to the tap Disconnect the return hydraulic hose 7 from the T connector Blank the connector and open hose 8 Identify the hydraulic hoses 9 and 10 to the auto hitch if fitted Disconnect the two hydraulic hoses 9 and 10 from the autohitch Blank the connectors and open hoses 9 Disconnect the electrical connector plugs to the trailer l...

Page 216: ...move the circlip 23 securing the extension cylinder forward attachment pin 24 to the inner boom 22 and drive out the pin NOTE Make a note of the position of the spigot mounting clamps located on each side of the rear cylinder attachment pin 16 Remove the two bolts and washers 19 on each spigot mounting clamp 18 securing the rear attachment pin to the outer boom 17 17 Remove the cylinder rearwards ...

Page 217: ... Dismantling NOTE The boom tray hoses can only be removed when the boom tray cassette has been removed 1 Remove the two screws securing the hose support brackets to the rear of the boom tray 2 Remove the clamp plate holding the hoses to the bracket 3 Withdraw the steel tubes from the rear of the boom tray cassette 4 Disconnect the hoses from the steel pipes on top of the boom tray 5 Remove the sli...

Page 218: ...5 to the crowd cylinder and auxiliary services Blank the connectors and open hoses The extension cylinder weighs 140 kg 308 lb take care when handling to avoid damage to components and injury to personnel 9 Remove the circlip 6 securing the extension cylinder forward attachment pin 7 to the inner boom and drive out the pin 10 Lift the inner boom out of the outer boom using either a fork lift or ov...

Page 219: ...he front lower wear pads 3 Stop the engine apply the parking brake and chock the wheels 4 Refer to Page 1 53 and dump hydraulic pressure 5 Remove the bolt 1 washer 2 retainer 3 and withdraw the wear pads and shims 4 6 at positions E and F from the bottom of the outer boom 5 6 Clean and inspect the wear pads for wear and damage 7 Fit wear pads E and F to the lower side of the boom with a 2 5 mm 0 1...

Page 220: ... the boom and shim to give a clearance of less than 1 0 mm 0 040 in 14 Remove bolt 1 washer 2 retainer 3 and withdraw the wear pad and shims 4 6 at positions B and C from the upper side of the outer boom 5 15 Clean and inspect the wear pads for wear and damage 16 Fit wear pad B and C to the upper side of the boom and shim to give a clearance of less than 1 0 mm 0 040 in ...

Page 221: ...ported 3 Stop the engine apply the parking brake and chock the wheels 4 Refer to Page 1 53 and dump hydraulic pressure 5 Remove the bolt 4 washer 5 retainer 3 and withdraw the wear pad 2 from both side positions on the outer boom 1 Clean and inspect the wear pads for wear and damage Refit wear pads in reverse order of removal but renew wear pads excessively worn or damaged NOTE Shims are not fitte...

Page 222: ...ottom of the inner boom Fit wear pad B to the left side of the boom with a 2 5 mm 0 10 in shim under the pad Fit wear pads C D and E to the boom without any shims under the pads Refit the inner boom Lever the boom against the outer boom in direction Measure the clearance between the wear pad E and the outer boom and shim to give a clearance of less than 1 0 mm 0 040 in Measure the clearance betwee...

Page 223: ...SECTION 5 CHASSIS ...

Page 224: ...uick and easy engine transmission removal For engine removal refer to the Engine section The cab pod is attached to the left side of the chassis and houses the fuel tank The operators cab is secured to the cab pod The operators cab is easily removed for access to the fuel tank The front and rear axles are attached to mounting points on the chassis The boom is pivoted at the rear of the chassis on ...

Page 225: ...t and rear windscreen washer pipe at the washer bottle 8 Disconnect the four electrical connector plugs from the cab front bulkhead 9 Disconnect hoses from the steering valve and tie back clear of the cab fit blanks to open pipes and steering valve connections 10 Remove the left headlight and sidelight from the cab Remove the left side worklight if fitted 11 Clamp the heater hoses at the rear of t...

Page 226: ... is connected 3 Make sure the fuel supply and return hoses are routed correctly to avoid trapping and chaffing 4 Installation is the reverse of the above procedure note the following points 5 Torque load the cab attachment bolts to 250 Nm 184 lbf ft 6 Refit cooling system hoses and top up system as required 7 Refer to Page 1 55 and check the hydraulic level and replenish as required 8 Refer to Pag...

Page 227: ... brake Make sure warning light is on Operate foot brakes Operate steering in all modes to bleed air from the system and check indicator lights Operate front and rear wipers and washers Operate the rear side and boom worklights if fitted Test overload indicator Test heater air conditioning Operate rotating beacon Check hydraulic and cooling system fluid levels and fill to correct level as necessary...

Page 228: ...n the tank and the front bulkhead of the pod Fit suitable blanks to the hoses and connectors 7 Remove the bolts washers and nuts 1 2 and 3 securing the fuel tank to the front and rear bulkheads of the pod 8 Remove the tank 7 from the pod Fuel tank Removal 1 Park the machine on firm level ground 2 Stop the engine chock the wheels and disconnect the battery The fuel tank capacity is 200 litres make ...

Page 229: ...ary 2 Inspect the interior of the tank make sure clean and clear of debris 3 Fit drain plug 2 to fuel tank with a new sealing washer 3 4 Installation is the reverse of the above procedure 5 Refuel the fuel tank and check for leaks 6 After tank installation refer to the cab installation procedure and install the cab 7 Fuel tank 8 Support strip 9 Sealing washer 10 Drain plug 11 Hose ...

Page 230: ...emove blower motor Heater and air conditioning Description The heater assembly is fitted in a compartment behind the cab seat and includes the heater coil and blower motor When the air conditioning option is fitted the heater compartment also contains the evaporator coil receiver trinary switch and expansion valve The condenser coil and axial fans are fitted in a housing outside the cab above the ...

Page 231: ...tion is the reverse of the above procedure 2 Test the blower motor before fitting the seat 3 After fitting the seat test the joystick controls 1 Self tapping screw 2 Housing lid 3 Self tapping screw 4 Blower motor 5 Electrical connectors ...

Page 232: ...the hose clips 2 from the hoses and disconnect the two hoses from the heater coil 5 Slide the heater coil out of the housing 5 Installation 1 Installation is the reverse of the above procedure 2 Remove the clamps from the heater hoses 1 and 4 3 Start the engine check the hoses 1 and 4 for leaks 4 Stop the engine and check the coolant level fill to correct level as necessary 5 Test the blower motor...

Page 233: ...2 Stop the engine chock the wheels and disconnect the battery 3 Refer to the blower motor removal procedure and get access to the heater housing 4 Recover the gas from the system using suitable equipment 5 Disconnect the two adapters 2 and 3 connecting the evaporator coil 4 to the expansion valve 1 6 Slide the evaporator coil out of the housing ...

Page 234: ...e procedure 2 Test the blower motor before fitting the seat 3 After fitting the seat test the joystick controls 4 Charge the system using suitable refrigerant charging equipment 5 Test the air conditioning system 1 Expansion valve 2 Adapter 3 Adapter 4 Evaporator coil ...

Page 235: ... Recover the gas from the system using suitable equipment 5 Disconnect the adapter 4 connecting the receiver drier 2 to the expansion valve 1 6 Disconnect the adapter 5 connecting the receiver drier 2 to the external pipe 7 7 Remove the two self tapping screws 6 securing the receiver drier 2 to the housing 3 and remove the receiver drier 1 Expansion valve 2 Receiver drier 3 Housing 4 Adapter 5 Ada...

Page 236: ...system using suitable equipment 5 Disconnect the two pipes 14 and 13 to the condenser coil Remove the pipe support blocks 6 from the coil housing 5 6 Remove the cab roof lining and disconnect the multiplug from the condenser Identify the wiring connectors then disconnect the wiring loom 1 to the axial fans 17 7 Support the unit then remove the four bolts and washers 3 and 4 securing the condenser ...

Page 237: ...HASSIS 1 Wiring loom 2 Machine support 3 Bolt 4 Washer 5 Condenser coil housing 6 Support block 7 Bolt 8 Washer 9 Washer 10 Washer 11 Washer 12 Wingnut 13 Pipe 14 Pipe 15 Grille 16 Condenser coil 17 Axial fan ...

Page 238: ...g connectors then disconnect the wiring loom 2 to the axial fans 21 6 Support the unit then remove the four bolts and washers 5 and 4 securing the condenser coil housing 8 to the machine support 3 and remove the unit 7 Remove the four bolts and washers 9 10 and 11 securing the condenser coil to the housing and remove coil 8 Electrically disconnect the axial fan s from the wiring loom and relay 1 R...

Page 239: ... 2 Wiring loom 3 Machine support 4 Washer 5 Bolt 6 Bolt 7 Washer 8 Condenser coil housing 9 Bolt 10 Washer 11 Washer 12 Washer 13 Washer 14 Wingnut 15 Pipe 16 Pipe 17 Grille 18 Condenser coil 19 Nut 20 Washer 21 Axial fan ...

Page 240: ...ssor 5 8 Remove the adjuster Bolt 9 Washer 10 and Nut 11 Rotate the Compressor 5 and remove the pulley belt 11 from the pulley on the compressor 5 9 Support the compressor 5 and remove the two bolts 4 Washers 3 and Nuts 1 securing the Compressor 5 to the support Bracket 2 and remove the Compressor 5 Installation 1 Installation is the reverse of the above procedure 2 Charge the system using suitabl...

Page 241: ...5 18 CHASSIS 1 Nut 2 Support Bracket 3 Washer 4 Bolt 5 Compressor 6 Electrical lead 7 Hose 8 Hose 9 Bolt 10 Washer 11 Nut 12 Pulley Belt ...

Page 242: ...er 5 8 Move the Tensioner 5 to release the tension on the pulley Belt 10 and remove pulley Belt 10 from the pulley on the Compressor 8 9 Support the Compressor 8 and remove the three Bolts 9 six Washers 2 and three Nuts 3 securing the Compressor 8 to the support Bracket 1 and remove the Compressor 8 Installation 1 Installation is the reverse of the above procedure 2 Charge the system using suitabl...

Page 243: ...5 20 CHASSIS 1 Support Bracket 2 Washer A10 3 Nut M10 4 Nut 5 Pulley Tensioner 6 Bolt 7 Electrical Connector 8 Compressor 9 Bolt M10 x 35 10 Pulley Belt 11 Hose 12 Hose ...

Page 244: ...SECTION 6 TECHNICAL DATA ...

Page 245: ...rall width mm 2300 2300 2300 D Track width mm 1920 1920 1920 E Height over cab on std tyres mm 2380 20 in tyres 2450 2450 F Interior cab width mm 900 900 900 G Wheelbase mm 2800 2800 2800 H Ground clearance mm 410 20 in tyres 446 446 I Turning radius on std tyres mm 3450 3450 3450 J Overall bodywork width mm 2235 2235 2235 Weight unladen kg 6963 7605 7800 ...

Page 246: ... w t h g i e H m m 6 0 0 6 0 7 3 5 2 8 7 5 h c a e r d r a w r o f x a M m m 3 0 0 3 4 4 1 3 7 3 9 3 h c a e r x a m t a y t i c a p a c x a M g k 0 5 2 1 0 0 5 1 0 0 5 1 s n o i t a c i f i c e p s e g a i r r a C B 3 A T I B 3 A T I B 3 A T I e c r o f t u o k a e r B N k 9 4 2 5 2 5 p h 6 0 1 r o f r h m k d e e p s e n i h c a M 1 d r a w r o F 3 6 3 6 3 6 2 d r a w r o F 7 8 7 8 7 8 3 d r a w...

Page 247: ... o z i r o h w o l e b s e e r g e d 7 7 7 d e s i a r y l l u f d r a w k c a b d w o r c x a M l a c i t r e v d n o y e b s e e r g e d 2 8 2 8 2 8 s e e r g e d n o i t a t o r e g a i r r a c l a t o T 3 6 1 3 6 1 3 6 1 m m s k r o f n e e w t e b e c n a t s i d x a M 0 0 2 1 0 0 2 1 0 0 2 1 e m i t e l c y C t f i L c e s 7 7 7 7 7 7 r e w o L c e s 6 5 6 5 6 5 d n e t x E c e s 7 4 8 4 8 6...

Page 248: ... f i h s r e w o P C P A s r a e g f o o N v e R d w F 3 6 h m k 0 4 3 6 h m k 0 4 3 6 h m k 0 4 s r a e g f o o N v e R d w F 3 5 h m k 5 2 3 5 h m k 5 2 3 5 h m k 5 2 s r a e g f o o N v e R d w F 2 4 h m k 0 2 2 4 h m k 0 2 2 4 h m k 0 2 r o t c e l e S r a e G C P A n o N C P A n o N C P A n o N s r a e g f o o N v e R d w F 3 3 h m k 5 2 3 3 h m k 5 2 3 3 h m k 5 2 s r a e g f o o N v e R d w...

Page 249: ...b 0 6 1 0 6 1 0 6 1 w o l f x a m m e t s y s y r a d n o c e S n i m l 0 5 0 5 0 5 s e c i v r e s x u a f o o N n o i t p o r a e r 1 t n o r f 2 r a e r 1 t n o r f 2 r a e r 1 t n o r f 2 s c i r t c e l E y t i c a p a c y r e t t a B r h p m A 8 2 1 8 2 1 8 2 1 t u p t u o r o t a n r e t l A p m A 5 6 5 6 5 6 s e i t i c a p a C m e t s y s c i l u a r d y H e r t i l 8 2 1 8 2 1 8 2 1 k n ...

Page 250: ...THIS PAGE IS INTENTIONALLY BLANK ...

Page 251: ...rily correspond to text and illustrations contained in this publication and without incurring obligation to alter any machines previously delivered Reproduction or translation of this publication in whole or part is not permitted without the written consent of Caterpillar All rights under the provision of the Copyright Act are reserved Paul Dodd Field Service Manager ...

Page 252: ...349865 0 08 2003 ...

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