NMC-WOLLARD MB-4 200-DF Operation, Maintenance And Parts Manual Download Page 199

Page: 199 / 321

PAGE 10-107

JULY 15, 2001

M200 MB4 Tow Tractor

Manual No. 42975

Item

NMC-
Wollard
Part No.

Vendor
Part No.

Nomenclature

Eff

Units
Per
Assy

T427979-9

Hydraulic Asm-For Hydraulic Brakes

Ref

91938

Fitting, Hydraulic, Ell, 12MJ-12MB90

90413

Fitting, Hydraulic, 08MJ-08MB

91930

Fitting, Hydraulic, Ell, 08MJ-08MB90

90375

Fitting, Hydraulic, Ell, 08MJLL-08MB90

3.1678

Fitting, Hydraulic, Ell, 16MJ-12MP90

3.2965

Fitting, Hydraulic, 08FJ-04MJ

90424

Fitting, Hydraulic, Ell, 04MJ-04MB90

37199

Fitting, Hydraulic, Mod

3.3085

Fitting, Hydraulic, Tee, 4MJ-4MJ-4F JX

F10119

Fitting, Hydraulic, 12MB-12MB

921728

Fitting, Hydraulic, 12B-12MJ45

42713

Fitting, Hydraulic,18MM-08MJ90

NW30236

2023-00

Sender, Temp, Trans, 1/4 NPTF (V00542)

42697

Fitting, Hose, Barb, 20H-20MP

1012226

Fitting, Hydraulic, Ell, 20MJ-20MB90

NW35837

Fitting, Hydraulic, 04MJ-08MB

NW33945

Fitting, Hydraulic, 08MJ-12FJ

1008549

Fitting, Hydraulic, 08MJ-12MB

NW35810

Fitting, Hydraulic, Ell, Swivel, M/F

F101318

Fitting, Hydraulic, Plug, 8MB

F101301

Fitting, Hydraulic,12MB-12FJX

F102080

Fitting, Hydraulic, Ell, 08MJ-12MB90

NW30992

Fitting, Hydraulic, Ell, 16MJ-16MB90

1011270

Fitting, Hydraulic, 04MJ-04MB

1012029

Fitting, Hydraulic, 16MB-16FJX

1008303

Fitting, Hydraulic, Tee, 12MJ-12MJ-12MB

42698

Fitting, Hose Barb, 20H-20FJ

F101258

Fitting, Hydraulic, Ell, 12MJ-16MB90

3.1905

Fitting, Hydraulic, 24MP-20FP

200211

Fitting, Hydraulic, El, 1-1/4, BMI-M/F

42790

Fitting, Hydraulic, El, 14MM-04MJ90

SWXPF589

Fitting, Hydraulic, 20MP-16FP

3.2118

Fitting, Hydraulic, 16MJ-12MP

91925

Fitting, Hydraulic, 04MJ-04MP

3.2966

Fitting, Hydraulic, Tee, 04MJ-04FJX-04MJ

42794

Fitting, Hydraulic, 02FP-04F JX

NW31421

Fitting, Hydraulic, Ell, 16MJ-16MP90

37838

Switch, Press, 60# SPND

37407

Accumulator, 0.5 Gal, Diaphragm

Summary of Contents for MB-4 200-DF

Page 1: ...ANCE AND PARTS MANUAL MODEL 200 DF NSN 1740 01 375 5849 YW PART 2016 NON AIR EQUIPPED AND NSN 1740 01 487 3996YW PART 2016AIR AIR EQUIPPED TO 36A10 3 46 1 NMC WOLLARD Inc 2021 Truax Blvd Eau Claire WI...

Page 2: ...pyright 2000 NMC Wollard Inc This manual is available on CD ROM P N 43532 Keep a copy of your NMC Wollard Inc manuals on your computer or CD ROM You will be able to print pages and adjust page view an...

Page 3: ...rovided in this manual must first make sure that they do not endanger their personal safety or tractor integrity by their choice of methods tools or parts M200 MB4 Tow Tractor Manual No 42975 PAGE 3 J...

Page 4: ...9 5 Change lug nut torque specs from 550 to 420 remove lubed torque 10 3 7 Parts Index updated 10 42 43 Drawing update and added new parts 10 56 57 Drawing update and added new part A TO HOLDERS OF NM...

Page 5: ...hat have been revised are outlined below together with highlights of the revision Please delete the affected pages and enter Revision No 4 dated 10 30 01 Chapter Page No Description of Changes Effecti...

Page 6: ...Exhaust frame fuel sys Updates Trans Sensor added NW35892 was corrected air sys updated Hitch option added All REVISION NO 8 DATED 07 31 03 Pages that have been revised are outlined below together wi...

Page 7: ...ised figure 8 3 added figure 8 4 All Chapt 10 1 2 5 9 34 35 94 95 118 121 142 147 153 157 161 164 TOC Updated Parts index updated updated park brake lever ill parts list added item 9A update schem 438...

Page 8: ...tle hitch bolts updated All 10 42 43 U Joint parts and repair kits updated All REVISION NO 13 DATED January 31 2007 Chapter Page No Description of Changes Effectivity Intro 6 2 7 Revision 13 added All...

Page 9: ...01 10 30 01 NMC Wollard Inc 5 01 15 02 01 15 02 NMC Wollard Inc 6 06 30 02 06 30 02 NMC Wollard Inc 7 01 02 03 01 02 03 NMC Wollard Inc 8 07 31 03 07 31 03 NMC Wollard Inc Rev Issue Date Date Inserted...

Page 10: ...ll 16 000 lbs DBP GVW may vary 15 DBP measured at 14 Turning Radius 4 Wheel 130 Turning Radius 2 Wheel 210 Speed Front 25 mph 1 5 Speed Rear 2 4 mph Fuel Tank Capacity 20 7 Gals 78 3 L Cooling System...

Page 11: ...er of Cylinders 6 Firing Order 1 5 3 6 2 4 Aspiration Turbo Charged Cooling Liquid Coolant Capacity 40 qt Thermostat 181 deg F Oil Capacity 17 3 qt CORROSION PROOFING All frame and body surfaces are s...

Page 12: ...r failure to provide necessary or appropriate maintenance This warranty does not cover deterioration or failure caused by chemicals falling objects dirt and sand or excessive heat or moisture The NMC...

Page 13: ...of your warranty problem Every warranty situation is different and so there are no hard rules We will work with your maintenance personnel and service managers to equitably resolve all claims What sh...

Page 14: ...ual No 42975 Intro TOC INTRODUCTION AND DESCRIPTION OF TRACTOR 1 1 OPERATION 2 1 PREVENTIVE MAINTENANCE AND GUIDELINES FOR REPAIR 3 1 ENGINE 4 1 TRANSMISSION 5 1 FUEL TANK 6 1 STEERING 7 1 BRAKES 8 1...

Page 15: ...when operating on public roads 10 Never allow anyone to ride on the tractor with you except in the passenger seat PAGE 13 JANUARY 31 2004 M200 MB4 Tow Tractor Manual No 42975 IMPORTANT There are nume...

Page 16: ...es lights safety guards etc should be in spected regularly and maintained in a safe operating condition 6 Keep the tractor clean to lessen fire hazards and allow loose or defective parts to be better...

Page 17: ...ates a potentially hazardous situation that if not avoided could result in death or serious injury and indicates hazards that are exposed when guards are re moved Indicates a potentially hazardous sit...

Page 18: ...Form Your Dealer HOW TO INSTALL SAFETY SIGNS Be Sure That The Installation Area Is Clean And Dry Remove The Smallest Portion Of The Split Backing Paper Align The Decal Over The Specified Area And Care...

Page 19: ...HAUST SYSTEM 3 1 3 11 CORROSION PROOFING 3 1 3 12 TIRES 3 1 3 13 ELECTRICAL SYSTEM 3 1 3 13 1 BATTERY 4 1 3 13 2 ALTERNATOR 4 1 3 13 3 CURRENT REGULATOR 4 1 3 13 4 STARTER 4 1 3 13 5 LIGHTS AND ACCESS...

Page 20: ...thick Front and rear bumpers are 1 00 thick 1 3 2 Engine for Tractor w Hydraulic Brakes Cummins 6BT5 9 6 Cylinder 5 9 Liter 152 BPH 2200 rpm Torque 414 ft lbs 1200 rpm 1 3 3 Engine for Tractor w Air B...

Page 21: ...ty to be cooled by coolant which flows through plates inside the oil cooler 1 3 7 Fuel System The lift pump draws fuel from the fuel tank through a pre filter and delivers it to the water separator an...

Page 22: ...t Regulator The current regulator is part of the alterna tor assembly It determines output current according to load such as headlights rear lights etc 1 3 13 4 Starter The starter motor is a gear red...

Page 23: ...h Heater 20a 7 Ignition Switch 8 Fuel Gauge 9 Hourmeter 10 Transmission Temperature Gauge 11 Blank Switch 12 Headlight Switch 13 Worklight Switch 14 Switch Heater 15 High Beam Indicator 16 Brake Warni...

Page 24: ...1 j Drain Heater 15a 11 k Clearance Lights20a 11 l Abs Auxiliary 12 Ignition Switch 13 Trailer Air Supply 14 Parking Brake 15 Headlight Switch 16 Worklight Switch 17 Trailer Clearance Light Switch 18...

Page 25: ...lever pulls a cable which pulls the brake shoes together against the parking brake drum The parking brake is attached to the trans mission output shaft and is completely me chanical 1 3 17 3 Parking...

Page 26: ...point on the bottom edge of frame on which hitches are mounted PAGE 1 8 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 FIGURE 1 3 TRACTOR WEIGHT AND DIMENSIONS APPROXIMATE LIFT LOCATIONS LIFT LOCA...

Page 27: ...2 144 297 223 420 315 0 750 10 172 129 269 201 376 282 1 000 12 704 528 995 746 1 000 8 644 483 909 681 METRIC TIGHTENING TORQUE N m Bolt Size Class 8 8 Dry Class 8 8 Lubed Class 9 8 Dry Class 9 8 Lub...

Page 28: ...4 Transmission See Section 5 Axle SAE 85 W90 API GL5 MIL 2105 B Center Housing 12 qts 11 3L Reduction Housing 1 8 qts 1 75L Each End Hydraulic System Mineral oil only ATF Dextron III PAGE 1 10 JULY 31...

Page 29: ...1 3 21 Schematics And Diagrams PAGE 1 11 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 FIGURE 1 4 HYDRAULIC DIAGRAM CUMMINS W HYDRAULIC BRAKES 42907...

Page 30: ...PAGE 1 12 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 FIGURE 1 5 HYDRAULIC SCHEMATIC CUMMINS W HYDRAULIC BRAKES 42989...

Page 31: ...PAGE 1 13 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 FIGURE 6 HYDRAULIC DIAGRAM CUMMINS W AIR BRAKES 43749...

Page 32: ...PAGE 1 14 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 FIGURE 7 HYDRAULIC SCHEMATIC CUMMINS W AIR BRAKES 43748...

Page 33: ...PAGE 1 15 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 FIGURE 8 AIR DIAGRAM 43840...

Page 34: ...PAGE 1 16 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 This Page Intentionally Blank...

Page 35: ...M200 MB4 Tow Tractor Manual No 42975 PAGE 1 17 JULY 31 2004 FIGURE 9 ELECTRICAL SCHEMATIC CUMMINS DIESEL 6BT5 9 FOR TRACTOR W HYDRAULIC BRAKES 42958...

Page 36: ...PAGE 1 18 JULY 31 2006 M200 MB4 Tow Tractor Manual No 42975 FIGURE 10 ELECTRICAL SCHEMATIC CUMMINS 6BT5 9 W PREHEAT FUNK 2000 200MB4 1 W AIR BRAKES 43886...

Page 37: ...YDRAULIC BRAKES 3 2 2 3 WARNING LIGHTS FOR TRACTORS W AIR BRAKES 3 2 2 4 INSTRUMENTS 3 2 2 5 HEATER OPERATION 4 2 3 STARTING THE ENGINE 4 2 4 HARD STARTING 4 2 4 1 JUMP STARTING THE TRACTOR 5 2 5 DRIV...

Page 38: ...itch con trols the rear work lights 4 The gear shift lever is on the driver s right It permits selection of forward or reverse gears and a neutral position IMPORTANT If the shift lever is moved from t...

Page 39: ...shows the amount of fuel in the fuel tank A sending unit in the tank is connected to the gauge The gauge is marked E and F to indicate the relative quantity of fuel in the tank Keep the needle in the...

Page 40: ...4 If the engine does not start in 15 sec onds turn the start key to the IGN po sition and hold it there for 10 seconds Then engage the starter motor again 5 Observe instruments to be sure each is work...

Page 41: ...ing vehicle should not be run ning Connect the POSITIVE jumper cable clamps to the POSITIVE posts of the two batteries Then connect the NEGATIVE jumper clamp to the good battery Finally place the othe...

Page 42: ...h located to the right of the dash panel he may choose the coordinating mode COOR which will auto matically steer the rear wheels as he oper ates the steering wheel The action of the rear wheels is pr...

Page 43: ...ing brake Place gear shift lever in neutral N Turn off all lights Turn off ignition switch Always set the parking brake when parking NOTE The tractor The automatic trans mission does not have an inter...

Page 44: ...2 11 SHIPPING PAGE 2 8 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 FIGURE 2 6 TRANSPORTATION PLATE...

Page 45: ...2 12 AIR TRANSPORT CERTIFICATION PAGE 2 9 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975...

Page 46: ...PAGE 2 10 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 This Page intentionally Blank...

Page 47: ...NG HOURS 7 3 5 1CHECK HYDRAULIC OIL LEVEL 7 3 6EVERY 250 OPERATING HOURS OR 3 MONTHS 7 3 6 1CHANGE ENGINE OIL AND OIL FILTER 7 3 6 2CHECK AIR CLEANER RESTRICTION 7 3 6 3LUBRICATE GREASE FITTINGS 7 3 6...

Page 48: ...ACCUMULATORS FOR HYDRAULIC BRAKE SYSTEMS 10 3 10 1GENERAL 11 3 10 2OPERATING AND INSTALLATION INSTRUCTION 12 3 11ADJUST POSITION SENSOR 13 3 12GUIDELINES FOR REPAIRING THE TRACTOR 14 3 12 1SPECIAL TOO...

Page 49: ...r vice MORE OFTEN if machine is operating under sandy dusty or wet conditions NEGLECTINGMAINTE NANCECANRESULTINFAILURESORPER MANENTDAMAGETOTRACTOR COMPONENTSANDMAYVOIDTHEWAR RANTY PAGE 3 3 JULY 31 200...

Page 50: ...que 3 6 8 EVERY 500 OPERATING HOURS OR 6 MONTHS Perform 250 hour service 3 6 Pintle Hitch Re torque to 175 ft lbs Initial 500 hrs one time Fuel Filter Change 3 7 1 Coolant Check concentration 3 7 2 Ax...

Page 51: ...PAGE 3 5 JULY 31 2006 M200 MB4 Tow Tractor Manual No 42975 FIGURE 3 1 LUBRICATION LOCATIONS...

Page 52: ...lo cate exact source of the leak If source is a loose hose tighten hose clamp or replace hose if necessary If radiator or water pump is leaking report condition to a su pervisor 3 4 3 Check Engine Oi...

Page 53: ...r cap and observe fluid level mark on filler screen Maintain fluid level within 1 2 on the screen 3 6 EVERY 250 OPERATING HOURS OR 3 MONTHS 3 6 1 Change Engine Oil and Oil Filter See page 4 4 of the C...

Page 54: ...before performing any inspec tion or maintenance to the air system 1 To drain the air pressure it is recom mended to push the trailer park brake air supply button figure 2 3 partially in with out any...

Page 55: ...of shorting burned insulation or terminals and frayed wires 2 Check that retaining clips are secure 3 Remove exterior dirt and grease by wip ing with a cloth dampened with solvent P D 680 4 Allow par...

Page 56: ...Change Axle Oil Refer to 9 2 3 8 4 Adjust Valve Lash Clearances See page 6 9 of the Cummins Operation and Maintenance Manual B Series Engines manual included with this manual 3 8 5 Check Belt Tension...

Page 57: ...ould perform maintenance Read all instructions thoroughly be fore before beginning any type of service or repair Tools Required 1 Gas Valve Core Tool 2 Torque Wrenches 3 Wrench es Intervals Between Ch...

Page 58: ...e gas precharge pressure please refer to previ ous Temperature Effect instructions FPS Unit Turn T handle A clockwise a maximum of 3 full turns from the full counterclockwise position The gauge needle...

Page 59: ...shut off valve on the commercially available nitrogen bottle and slowly fill the accumulator with dry nitrogen gas Precharge very slowly until the pressure in the accumulator reaches 100 psi Once 100...

Page 60: ...es are not described Use the ex ploded views in Section 10 3 12 1 Special Tools There are no special tools required for this tractor Common automotive shop tools are all that is required to service th...

Page 61: ...parts visually for cracks breaks scratches dents bends punctures galling wear scoring stripped threads distortion and deformation Give special attention to bearing surfaces mating surfaces gaskets and...

Page 62: ...PAGE 3 16 JULY 31 2006 M200 MB4 Tow Tractor Manual No 42975 This Page Intentionally Blank...

Page 63: ...4 ENGINE PAGE 4 1 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 4 1 MAJOR REPAIRS 2 4 2 ENGINE REMOVAL 2...

Page 64: ...manifold Tape over opening to prevent debris from entering engine 15 If needed remove screws from hood support and slide back to allow clear ance for removing engine assembly The engine assembly is l...

Page 65: ...WING THE TRACTOR 2 5 5CHECKING FLUID LEVEL AND CONDITION 2 5 5 1CHANGING TRANSMISSION FLUID 3 5 6TRANSMISSION ADJUSTMENTS 3 5 6 1SHIFT LINKAGE 3 5 7NEUTRAL START SWITCH 3 5 8REMOVING ENGINE AND TRANSM...

Page 66: ...hift to neutral and run engine at 1000 1200 RPM Trans mission temperature should drop rapidly to ambient air temperature across heat exchanger If temperature does not drop trouble is indicated The cau...

Page 67: ...ng released This gives automatic compensation for normal wear eliminating the need for adjustment 5 6 1 Shift Linkage The shift linkage is electronically and hy draulically controlled and does not req...

Page 68: ...pport a load None of the weight of the transmission must be allowed to rest on the drive plate during removal or installa tion 14 Secure engine transmission unit to pre vent tipping or falling 15 Matc...

Page 69: ...Calibration With a Known Value PULSE The exact calibration value for the vehicle and type of sensor you are using pulse per mile or pulse per kilometer is 31201 3 However the tenths place is fixed at...

Page 70: ...ed on the LCD read out take your finger off the button and wait After a few seconds the value you have entered will be down loaded into the speedometer s microprocessor and the speedometer will revert...

Page 71: ...00 MB4 Tow Tractor Manual No 42975 PAGE 6 1 JULY 15 2001 Chapter 6 TOC 6 1FUEL TANK 2 6 1 1REMOVAL AND DISASSEMBLY 2 6 1 2CLEANING AND INSPECTION 2 6 1 3REPAIR OR REPLACEMENT 2 6 1 4REASSEMBLY 3 6 1 5...

Page 72: ...ect fuel sending wire and fuel hoses Tank can now be lifted from trac tor for cleaning and inspection IMPORTANT Use care when handling the sending unit to prevent damaging it 6 1 2 Cleaning and Inspec...

Page 73: ...ket cement 2 Secure sending unit with its hardware 3 Temporarily tape or cover tank filler opening to prevent entry of dirt when in stalling tank 4 Apply thread sealer to drain plug threads and instal...

Page 74: ...M200 MB4 Tow Tractor Manual No 42975 PAGE 6 4 JULY 15 2001 This Page Intentionally Blank...

Page 75: ...7 1 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 Chapter 7 TOC 7 1STEERING SYSTEM OVERVIEW 2 7 2STEERING COLUMN 2 7 2 1REMOVAL 2 7 2 2INSTALLATION 2 7 3ORBITROL STEERING GEAR 2 7 3 1REMOVAL 2 7 3...

Page 76: ...umn and push orbitrol toward front of tractor to clear steering column 8 Remove bolts holding steering column in bracket and push steering column out through back of dash panel 7 2 2 Installation 1 Pu...

Page 77: ...ES 3 8 5BRAKE LINES 3 8 5 1SAE 37 FLARE CONNECTION JIC 3 8 5 2SAE STRAIGHT THREAD O RING SEAL 4 8 6BRAKE PEDAL FOR TRACTORS W HYDRAULIC BRAKES 5 8 7BRAKE LIGHT SWITCH ADJUSTMENT FOR TRACTORS W HYDRAUL...

Page 78: ...o two tanks the primary and secondary Both tanks are equipped with check valves so if air pres sure is lost in one the other will still main tain air pressure When the brake pedal foot valve is presse...

Page 79: ...rake linings on both sides of brake disk 3 If brake lining material is worn down to the bottom of the oil grooves brake disks must be replaced 8 4 BLEEDING THE BRAKES 8 5 BRAKE LINES Check brake metal...

Page 80: ...seat impression Replace SAE 45 nuts Use all SAE 37 flare parts IMPORTANT Leaks on this type of con nection won t show until unit has been in service for a few hours 8 5 2 SAE Straight Thread O Ring Se...

Page 81: ...center line and there is not full contact of the cotter pin in the castle nut slots Friction pads that wear down to 060 minimum thick are no longer use able 2 Unhook the parking brake cable clevis fro...

Page 82: ...cted 3 With the park brake lever released check that there is no cable slack at the park brake lever end This is indicated by there being no space between the crimped ferrule on the cable core and the...

Page 83: ...PAGE 8 7 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 FIGURE 8 3 PARKING BRAKE CALIPER...

Page 84: ...rake may not apply enough force or may apply too much force and break caliper In either situation park brake will be non functional with no obvious signs to operator Replace components until assembly...

Page 85: ...EMOVAL 3 9 4AXLE INSTALLATION 3 9 5DRIVE SHAFT AND U JOINT REPAIR 4 9 5 1REMOVAL 4 9 5 2INSTALLATION 4 9 5 3UNIVERSAL JOINT REPAIR 4 9 5 3 1REMOVAL FLANGE YOKE END 4 9 5 3 2REMOVAL SLIP YOKE END 4 9 5...

Page 86: ...n suitable sup ports Make sure tractor is level 3 Remove wheels from axle 4 Using a clean rag and wire brush thor oughly clean dirt and rust from around the three drain plugs axle housing fill plug an...

Page 87: ...around hose ends 5 Relieve pressure in hydraulic system and remove hoses Plug ends of hoses to prevent system contamination 6 Remove axle u bolts Remove the outer u bolts first After the other ones ar...

Page 88: ...ournals 2 Remove retaining ring clips securing bearing caps to flange yoke and separate flange yoke from drive shaft 3 Support drive shaft in a way that will al low bearings to be pressed from yoke wi...

Page 89: ...rease to needle bear ings to retain them in cap 2 Pack grease passage in spider with au tomotive type grease before installation 3 Slide two bearing assemblies onto spi der journals 180 deg apart Use...

Page 90: ...safety equipment tire changing equip ment and safety practices To help get tire on always use an approved rubber lubricant or use a small amount of soapy water for lubricating tire bead Do not attemp...

Page 91: ...te wrench slowly to prevent damage to threads 7 Tighten gradually in an alternating pattern to final torque valve MODEL 200 TRACTORS WHICH WHEEL STUD SIZE TIGHTENING TORQUE DRY Front 22mm 400 ft lbs R...

Page 92: ...M200 MB4 Tow Tractor Manual No 42975 PAGE 9 8 JULY 15 2001 This Page Intentionally Blank...

Page 93: ...1 OF 2 44 AIR COMPRESSOR 48 AIR COMPRESSOR COOLANT PLUMBING 50 AIR COMPRESSOR CONNECTION 52 ENGINE OIL TRANSMISSION FILTERS 54 TRANSMISSION REPAIR PARTS 56 BRAKE PARKING CALIPER 94 EXHAUST 96 FRAME 9...

Page 94: ...HIFTER 136 STEERING 138 TRANSMISSION SPEEDOMETER SENDER 140 WHEELS TIRES 141 INSTRUMENT PANEL FOR HYDRAULIC BRAKES 142 INSTRUMENT PANEL FOR AIR BRAKES 144 ALARMS 144 RELAYS CIRCUIT BREAKERS MODULES 14...

Page 95: ...PAGE 10 3 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 This Page Intentionally Blank...

Page 96: ...ge to the tow tractor caused by the use of non NMC Wollard parts will not be war ranted by NMC Wollard Abbreviations Used in the IPB A R As Required COMM Common item NS Not Shown NSS Not Sold Separate...

Page 97: ...63 121 3 0328 121 3 0716 103 3 0746 103 3 1081 103 139 3 1422 121 3 1604 121 3 1678 107 111 133 3 1820 45 121 3 1905 107 111 3 1920 121 3 1925 121 3 2118 107 111 133 3 2283 121 3 2642 133 3 2965 107 3...

Page 98: ...916 150 42917 152 42918 151 42919 151 42920 151 42921 151 42922 151 42927 55 42939 97 42942 33 42948 133 42960 35 42973 11 42974 11 42976 41 42977 41 42978 41 42979 153 159 42980 45 147 42981 11 43005...

Page 99: ...27 43669 27 43670 27 43671 27 43672 27 43673 27 43674 27 43675 27 43676 27 43677 27 43678 27 43679 27 43680 29 43681 29 43682 29 43683 29 43684 31 43685 31 43686 31 43688 31 43730 111 117 43731 117 11...

Page 100: ...101122 109 111 F101140 103 F101150 101 F101156 103 133 F101161 133 F10119 107 F101258 107 111 F101301 107 111 F101318 107 111 F101514 125 F101518 125 F101519 47 F101526 45 F101529 101 F101550 131 F101...

Page 101: ...3 15 NW35624 15 NW35628 15 NW35688 99 NW35692 139 NW35703 55 NW35714 99 NW35715 99 NW35766 147 NW35773 99 NW35810 107 113 NW35837 107 NW35839 109 115 NW35842 125 NW35843 125 NW35844 125 NW35852 105 10...

Page 102: ...PAGE 10 10 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ACCELERATOR LINKAGE...

Page 103: ...Units Per Assy 0 T446832 16 Linkage System 200MB4 1 Ref 1 41536 Cable Accelerator 1 2 F101865 Clip U bolt 1 3 42973 Bracket Weldment Throttle 1 4 42132 Plate Throttle Lever Ext 1 5 F101863 Ball Joint...

Page 104: ...PAGE 10 12 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ACCELERATOR PEDAL...

Page 105: ...Fork Push Rod Lever Assembly 1 1 D1 D2 D3 NW35401 4 210796 Treadle Conversion Contains Pedal Pivot Spring Clip 1 1 1 E1 E2 E3 E4 E5 NW35401 5 301790 Cable Hanger and Support Bracket Contains Cable Sup...

Page 106: ...PAGE 10 14 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AIR INTAKE ASSEMBLY...

Page 107: ...bow Air Intake 2 200223 Tube Air Cleaner 240 2 3 NW35624 Hose Air Intake 200 14 4 NW33103 Clamp T Bolt 3 00 2 5 NW35623 Clamp T Bolt 2 75 2 6 NW35628 Clamp T Bolt 4 2 7 NW35295 G10 0003 Air Cleaner As...

Page 108: ...PAGE 10 16 JUNE 30 2002 M200 MB4 Tow Tractor Manual No 42975 AXLE FINAL DRIVE...

Page 109: ...ng 1 2 NS 42503 NW30236 Transmission Funk See Pgs 46 56 Sender Trans temp 1 1 3 42312 Axle Rear see separate parts listing 1 4 42651 U Bolt 7 8 14 x 7 x 10 4 5 42720 Guard Rheostat 2 6 42719 Bracket R...

Page 110: ...PAGE 10 18 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AXLE REPAIR PARTS FRONT REAR 1 OF 5...

Page 111: ...176 01 003 13 Intermediate Cover 1 3 43478 276 01 004 01 Housing 1 4 43479 171 01 015 01 Plug 1 5 43480 002 02 0088 Circlip 1 6 43489 819 01 610 01 Magnet Plug 3 7 43490 176 01 002 12 Intermediate Co...

Page 112: ...PAGE 10 20 JULY 15 2001 AXLE REPAIR PARTS FRONT REAR 2 OF 5...

Page 113: ...734 04 009 01 Friction Washer 4 11 43544 734 04 007 02 Differential Pinion 4 12 43545 734 04 008 03 Pin 1 13 43546 014 03 1166 Roll Pin 3 14 43547 176 04 013 01 Shaft Retainer 1 15 43548 734 04 008 0...

Page 114: ...PAGE 10 22 JULY 15 2001 AXLES REPAIR PARTS FRONT REAR 3 OF 5...

Page 115: ...276 06 002 03 Steering Case Left 1 16 43626 276 06 003 03 Steering Case Right 1 17 43627 001 25 1544 Seal 2 18 43628 005 10 1427 Taper Roller Bearing 4 19 43629 005 01 0121 Ball Bearing 2 20 43630 27...

Page 116: ...PAGE 10 24 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AXLE REPAIR PARTS FRONT REAR 4 OF 5...

Page 117: ...2 Planet Gear 6 43 43652 176 06 039 01 Friction Washer 6 44 43653 112 06 022 01 Reduction Bushing 20 45 43654 002 06 0610 Snap Ring 2 46 43476 176 07 029 01 O Ring 2 47 43656 276 06 004 03 Wheel Hub 2...

Page 118: ...PAGE 10 26 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AXLE REPAIR PARTS FRONT REAR 5 OF 5...

Page 119: ...sting Bolt 6 2 43668 176 07 006 01 Spring 6 3 43669 001 05 1353 O Ring 6 4 43670 006 04 1430 Nut 6 5 43671 176 07 002 02 Disc 1 6 43672 176 07 003 02 Disc 1 7 43673 734 07 015 01 Plug 2 8 43674 276 01...

Page 120: ...PAGE 10 28 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AXLE STEERING CYLINDER FRONT REAR...

Page 121: ...2975 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 42311 Axle Front 1 42312 Axle Rear 1 1 43680 276 24 622 01 Articulated Tie Rod 2 2 43681 276 24 620 01 Cylinder 1 3 43682 0...

Page 122: ...PAGE 10 30 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AXLE TRUNNION REAR...

Page 123: ...No Nomenclature Eff Units Per Assy 42312 Axle Rear 1 1 43684 276 25 002 01 Reduction Bushing 4 2 43685 276 25 003 01 Thrust Bushing 2 3 43686 276 25 001 01 Support 2 4 43665 008 01 0213 Grease Fittin...

Page 124: ...PAGE 10 32 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 BATTERY...

Page 125: ...810 Nut Wing 5 16 18 2 4 F9549 Flat Washer 2 5 F100930 Battery Cable Boot Red 1 6 44378 Cable Battery 120 Black 3 8 Stud Starter 1 7 F100311 HHCS 3 8 16 x 1 2 8 F9665 Lock Washer 3 8 2 9 F9666 Hex Nut...

Page 126: ...PAGE 10 34 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 FIRE EXTINGUISHER MIRRORS BRAKE PARKING UNITS WITH OUT AIR BRAKES...

Page 127: ...0569 Nut Jam 3 8 16 1 8 90562 Clevis Cable W1 1203 1 9 NW036860 3 81000108 U Clamp 1 10 NW036860 3 81000246 Spacer 2 11 F100308 Bolt 5 16 18 x 1 5 2 12 NW036860 2 81000131 Link Spacer 1 13 F014476 Nut...

Page 128: ...PAGE 10 36 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 CAB ASSEMBLY GROUP 1 OF 2...

Page 129: ...nch 6271440 2 17 NW035744 13 NS006623 Wiper Arm 16 Inch 6702440 2 18 NW035744 14 NS006624 Wiper Blade 16 Inch 5217040 2 NS NW035744 24 NS006625 Panto Post Kit 48519 2 NS NW035744 25 NS006626 Washer Co...

Page 130: ...PAGE 10 38 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 CAB ASSEMBLY GROUP 2 OF 2 DOORS...

Page 131: ...Door Weldment 1 9 NW035744 35 NS003417 Left Door Hinge 2 10 NW035744 36 NS006063 Left Door Latch EMC 1 400ZN LH 1 11 NW36723 NS001927 Left Door Outside Handle TM1197337 1 12 NW035744 38 NS006632 Left...

Page 132: ...NUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 DECALS 1 WARNING PARKING BRAKE NOT TO BE USED FOR SERVICE BRAKE APPLY PARKING BRAKE BEFORE STARTING ENGINE APPLY PARKING BRAKE BEFORE LEAVING VEHICLE...

Page 133: ...s 1 2 NW017237 Plate Warning 1 3 44377 Plate MB4 Transportation w Air Brakes 1 42978 Plate MB4 Transportation w Hydraulic Brakes 4 153768 Decal Diesel Fuel Only 1 5 42537 Decal NMC 1 75 x 6 38 2 6 SW1...

Page 134: ...M200 MB4 Tow Tractor Manual No 42975 PAGE 10 42 JANUARY 31 2007 DRIVE SHAFT AXLE END TRANS END...

Page 135: ...Driveshaft Dana Funk 14 12 Front 1 42816 Driveshaft Dana Funk 29 69 Rear 1 2 44943 2 Cross Bearing Assy 5 303 1X 1 3 203761 Strap Bolt Kit 3 70 38X 1 4 HHCS 3 8 24 x 1 75 Gr8 4 5 44943 3 Cross Bearing...

Page 136: ...PAGE 10 44 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 ENGINE 1 OF 2...

Page 137: ...Hydraulic Tee 02FP 02FP 1 12 41528 Fitting M10 OR 1 8 NPT 1 12a 41529 O Ring M10 for 41528 Ftg 1 13 43483 3900960 Pan Oil Cummins 6BT5 9 1 43871 3937072 Gasket Oil Pan 1 14 43482 3279228 Dipstick Cum...

Page 138: ...PAGE 10 46 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 ENGINE 2 OF 2...

Page 139: ...Lift Pump 1 NS 43863 3935171 Washer Sealing Lift Pump 2 NS 43866 3901774 Gear Starter Ring 1 NS 43867 3938152 Gasket Intake Manifold 1 NS 43868 3921558 Core Oil Cooler 1 NS 43869 3942914 Gasket Oil Co...

Page 140: ...PAGE 10 48 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AIR COMPRESSOR...

Page 141: ...ctangular Ring 1 6 43441 6 3913370 Stud 2 7 43441 7 3914177 Screw Hex Flange Head Cap 1 8 43441 8 3924867 Hose Flexible 1 9 43441 9 3924869 Connection Oil Drain 1 10 43441 10 3929751 Gasket Acc Drive...

Page 142: ...PAGE 10 50 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AIR COMPRESSOR COOLANT PLUMBING...

Page 143: ...angular Ring 1 4 43441 22 3923369 Clamp Hose 4 5 43441 23 3924146 Bushing Reducing Pipe 2 6 43441 24 3924632 Coupling Plain Hose 1 7 43441 25 3924633 Coupling Elbow Hose 1 8 43441 26 3925226 Connectio...

Page 144: ...PAGE 10 52 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 AIR COMPRESSOR CONNECTION...

Page 145: ...01 M200 MB4 Tow Tractor Manual No 42975 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 Air Compressor Connection Ref 1 43828 A Clamp Hose 2 2 215921 Coupling Plain Hose 1 3...

Page 146: ...PAGE 10 54 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ENGINE OIL TRANSMISSION FILTERS...

Page 147: ...Trans Filter Funk B 1 4 3 0143 Fitting Hydraulic Ell 12MJ 12MBP90 2 5 42927 Bracket Oil Filter Mount 1 6 43107 LF3885 Filter Element Oil 1 6a 43108 HH6981 Filter Head Oil 1 6b NW35703 Filter Element...

Page 148: ...PAGE 10 56 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 149: ...omenclature Eff Units Per Assy 0 43902 40A2357 Group Front Cover 1 1 43902 1 40A2221 Cover Front Assembly 1 2 43902 27 4002855 Tube Front Cover 1 3 43902 40 F7400016D Ball 2 4 43902 41 YZ101113 Plate...

Page 150: ...PAGE 10 58 NOVEMBER 30 2005 TRANSMISSION REPAIR PARTS...

Page 151: ...45 Lubrication Assembly Tube Kit 1 8 43902 46 Idler Gear Kit 1 9 43902 9 Sleeve Bore Front 4005295 3 10 43902 47 Impeller Hub Gear Kit 1 11 43902 43 Stator Support Tube Kit 1 12 43902 44 Bearing Kit...

Page 152: ...PAGE 10 60 NOVEMBER 30 2005 TRANSMISSION REPAIR PARTS...

Page 153: ...PAGE 10 61 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 Item Nmc Wollard Part No Description Eff Units Per Assy 1 43903 Group Plate Drive 96105 4046763 1...

Page 154: ...PAGE 10 62 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 155: ...1 5 43904 24 Washer Flat 4003680 60 6 Capscrew F1002014 12 7 43904 26 Washer Thrust 4045901 5 8 Plug Shipping F2310042 1 9 44734 8 Stat Conv 1275A 4145012 1 10 43904 12 Ring Retaining 4003456 2 11 447...

Page 156: ...PAGE 10 64 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 157: ...OVEMBER 30 2005 Item Nmc Wollard Part No DESCRIPTION Eff Units Per Assy 0 43905 Group Shaft Input 96105 40A2222 1 43905 7 Ball Bearing Kit 1 2 43905 4 Capscrew F1003012 3 3 43905 1 Shaft Input 30 Toot...

Page 158: ...LUTCH PLATE FROM THE CLUTCH AS SEMBLY ASSEMBLING AN ADDITIONAL REF 9 SEPERATOR PLATE ON TOP OF THE LAST REF 9 SEPERATOR PLATE ASSEMBLE THE LAST REF 8 CLUTCH PLATE AND FINISH THE CLUTCH ASSEMBLY RECHEC...

Page 159: ...Clutch Separator 22 2E 43906 23 Ring Retaining 2 2F 43906 22 Ring Seal 3 2G 43906 21 Bearing 2 2H 43906 13 Bearing 2 2I 43906 10 Retainer Clutch 2 2J 43906 17 Bearing Ball 1 2K 43906 19 Bearing Ball...

Page 160: ...PAGE 10 68 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 161: ...906 4 O Ring 2 2C Plate Clutch 20 2D Plate Clutch Separator 22 2E Retainer Clutch Plates 2 2F Bearing 2 2G Bearing 1 2H Bearing 1 2I Bearing 2 2J Ring Seal 3 2K Ring Retaining 2 3 43906 3 Ring Back Up...

Page 162: ...PAGE 10 70 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 163: ...20144 2 5 43906 5 Clutch Piston 40A2034 2 6 43906 6 Spring Clutch Return 40A6261 2 7 43906 7 Spring Return 40A2038 2 8 43908 2 Bearing Kit Includes 8A F 1 8A Plate Clutch 20 8B Plate Clutch Separator...

Page 164: ...OSITE ENGINE SIDE BEARING RETAINER ONTO TRANSMISSION WITH TWO CAPSCREWS OMIT O RING 13 PUSH RETAINER INWARD TIGHTEN CAPSCREWS FINGER TIGHT 14 TO SEAT ALL COMPONENTS TIGHTEN EACH CAPSCREW TO 175 IN LB...

Page 165: ...eedle 1 4C Bearing 1 4D Cup 1 4E Bearing Retainer 1 4F Seal Oil 1 4G O Ring 1 4H Bearing Cone 2 4I Bearing Cup 2 4J Cone Bearing 1 4K Cup Bearing 1 5 43902 28 Capscrew F1003014 6 6 43909 10 Bfl Assemb...

Page 166: ...PAGE 10 74 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 167: ...5 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 Item Nmc Wollard Part No DESCRIPTION Eff Units Per Assy 0 43910 Group Yoke Fitting 6C 96105 40A2230 1 43910 1 Yoke 6C YZ4102789 1 2 43910 22 O R...

Page 168: ...NT FACE OF HOUSING USING A SPECIAL LO CATING TOOL MOUNTED IN THE SUC TION SCREEN HOLE IN THE BOTTOM OF THE CASE ALIGN AND POSITION THE BOTTOM END OF THE SUCTION TUBE ATTACH REF 8 SUCTION TUBE CLAMP WI...

Page 169: ...C 2 4 43911 4 Plug Pipe F1900120GVS 3 5 43911 5 Plug Pipe F190034 2 6 43911 7 Tube Suction 40A2035 1 7 43911 8 Clamp Tube 4003307 1 8 43911 9 Capscrew F100108 3 9 43911 11 Suction Screen Kit 40A6020 1...

Page 170: ...PAGE 10 78 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 171: ...0 43912 Group Valve Electric 96105 YZ100597 1 43912 1 Valve Electric Assembly YZ100594 1 2 43912 8 Gasket Kit Valve Body Includes 2A C 1 2A Gasket Valve Body 1 2B Capscrew Socket Head 4 2C Capscrew So...

Page 172: ...F 28 APPLY SLICTITE THREAD COMPOUND TO THREADS OF PLUGS AT ASM REF 29 TO INSTALL SOCKET INTO CONNECTOR PUSH PIN INTO CONNECTOR FROM THE REAR UNTIL LOCKED IN PLACE FIRMLY SEAT SEALS USING PACKARD CABLE...

Page 173: ...0 O Ring F37060916 1 11 43913 11 Plug Dump Valve 4001080 1 12 43913 12 Shim Spring 40A2511 3 13 43913 13 Spool Regulating 40A2512 1 14 43913 14 Plate Orifice 40A1335 1 15 43913 15 Ring Snap F3900056 1...

Page 174: ...PAGE 10 82 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 175: ...ctor Manual No 42975 Item Nmc Wollard Part No DESCRIPTION Eff Units Per Assy 0 44734 43 Group Retainer Bracket 96105 40A2061 1 43914 1 Retainer Bearing 40A2275 1 2 43914 2 Seal Kit Includes 2A C 1 2A...

Page 176: ...PAGE 10 84 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 177: ...actor Manual No 42975 Item Nmc Wollard Part No DESCRIPTION Eff Units Per Assy 0 44734 44 Group Bracket Flange 6c 96105 40A2238 1 44734 47 Flange Kit 1 2 43915 5 Capscrew F1003520H8 6 3 43915 6 Nut Hex...

Page 178: ...PAGE 10 86 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 179: ...44734 45 Group Charge Pump 96105 40A2059 1 43916 1 Pump Charge Assembly See pg 4102062 1 2 43916 11 Gasket Kit Pump 1 3 43916 3 Capscrew F1003052 1 4 43916 4 Capscrew F1003080 1 5 43916 5 Stud 40A2273...

Page 180: ...PAGE 10 88 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 181: ...m NMC Wollard Part No DESCRIPTION Eff Units Per Assy 0 43916 1 Pump Charge Assembly 96105 4102062 1 43917 1 Pump Charge Complete YZ4102523 1 2 43917 7 Bearing Gear Kit 1 3 43917 5 Screw Set F300848V 1...

Page 182: ...PAGE 10 90 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 183: ...y 0 43918 Pump Hardware 96105 40A2158 1 43918 9 O Ring Adapter Kit Includes 1A E 1 1A Spacer Sleeve 1 1B Adapter Sleeve Assembly 1 1C O Ring ARP250 1 1D Capscrew 4 1E O Ring ARP242 1 2 43918 4 Plate A...

Page 184: ...PAGE 10 92 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION REPAIR PARTS...

Page 185: ...PAGE 10 93 NOVEMBER 30 2005 M200 MB4 Tow Tractor Manual No 42975 Item NMC Wollard Part No DESCRIPTION Eff Units Per Assy 1 43919 Group Plate Cover 96105 4001842 1...

Page 186: ...PAGE 10 94 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 BRAKE PARKING CALIPER...

Page 187: ...43918 8 F16204 Washer Lock 4 7 43902 36 F1005032 Capscrew 4 8 43920 7 A01 03658 Bolt 22075 3 9 44734 50 4003779 Lever 22075 1 9A 44819 Lever Reworked Air Brake Units Only 1 10 43920 9 A05 07250 Cotter...

Page 188: ...PAGE 10 96 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 EXHAUST...

Page 189: ...fler 3 4 3 42797 Pipe Exhaust Front 1 4 42939 Pipe Exhaust Middle 1 5 NW34812 24189N Muffler Nelson Division 1 6 NW023112 Hanger Tail Pipe 2 7 42798 Pipe Exhaust Tail w hyd brakes 1 44423 Pipe Exhaust...

Page 190: ...PAGE 10 98 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 FRAME...

Page 191: ...ip 4 14 43469 Support Weldment Hood w Air Brakes 1 42701 Support Weldment Hood w Hydraulic Brakes 1 15 40022 Mount Radiator 1 16 42440 Louver RH 1 17 43448 Louver LH w Air Brakes 1 42439 Louver LH w H...

Page 192: ...PAGE 10 100 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 FUEL SYSTEM...

Page 193: ...Flat Washer SAE 3 8 5 4 41433 Cap Fill 2 NPSF Red W Screen 1 7 F101150 Hose Clamp 25 62 6 8 F101015 Hose Fuel Feed 144 9 43481 1 FS9033 In Line Filter 1 10 F101588 Tank Protection Strip 120 11 NW2632...

Page 194: ...PAGE 10 102 JANUARY 31 2004 M200 MB4 Tow Tractor Manual No 42975 HEATER DEFROSTER...

Page 195: ...Defroster 1 12 3 0746 Ftg P N 08MP Close Galv 1 13 3 0716 Ftg P ELL 08FP 08FP90 1 14 NW32352 Ftg P 08MP 10H 2 15 39512 Hose Heater 1 16 42814 Decal Heater Control 1 17 42870 Lower Fixed Vane Defroste...

Page 196: ...PAGE 10 104 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC RESERVOIR...

Page 197: ...MC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 1 NW35852 Plate Cover Hydraulic Reserve 1 2 12763 Cover Tank 1 3 43414 Fill Unit w 8 Basket 7 5 DI 1 4 166572 Gasket Tank 2 5 41388 Re...

Page 198: ...PAGE 10 106 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC DIAGRAM CUMMINS FOR HYDRAULIC BRAKES 1 OF 2 42907...

Page 199: ...16 NW35837 Fitting Hydraulic 04MJ 08MB 2 17 NW33945 Fitting Hydraulic 08MJ 12FJ 4 18 1008549 Fitting Hydraulic 08MJ 12MB 1 19 NW35810 Fitting Hydraulic Ell Swivel M F 1 20 F101318 Fitting Hydraulic P...

Page 200: ...PAGE 10 108 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC DIAGRAM CUMMINS FOR HYDRAULIC BRAKES 2 OF 2 42907...

Page 201: ...L45 1 58 201938 Hose Assembly 8M 84 00 ST EL 1 59 8797 84 Hose Assembly 8M 108 00 ST EL 1 60 203082 Hose Assembly 8L 61 00 ST EL 2 61 14762 21 Hose Assembly 4M 72 00 ST EL 1 62 43043 1 Hose Assembly 1...

Page 202: ...PAGE 10 110 JANUARY 02 2003 HYDRAULIC DIAGRAM CUMMINS FOR AIR BRAKES 1 OF 2 43749...

Page 203: ...nder Trans Temp 04NPTF 1 14 42697 Fitting Hydraulic 20H 20MP 3 15 1012226 Fitting Hydraulic Ell 20MJ 20MB90 1 16 F017687 Fitting Hydraulic 20MP 16FP 1 17 42392 Valve Hydraulic Steering Mode 1 18 10126...

Page 204: ...PAGE 10 112 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC DIAGRAM CUMMINS FOR AIR BRAKES 2 OF 2 43749...

Page 205: ...84 ST 90 1 48 8797 84 Hose Assembly 8M x 108 ST 90 1 49 203082 Hose Assembly 8M x 61 ST 90 1 50 43043 1 Hose Assembly 16M x 34 5 ST ST 1 51 42827 Hose Assembly 8L x 64 ST 90 1 52 200533 Hose 1 25 ID S...

Page 206: ...PAGE 10 114 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC VALVES FOR HYDRAULIC BRAKES...

Page 207: ...5 Relief Valve V00534 1 2 NW35233 06 463 212 Accumulator Charge Valve Mico Inc 1 3 NW35890 606 1094 2500 Priority Valve V00534 1 4 NW36172 2102 155 Hydraulic Brake Valve Carlisle Braking Systems 1 5 3...

Page 208: ...PAGE 10 116 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 HYDRAULIC VALVES FOR AIR BRAKES...

Page 209: ...enclature Eff Units Per Assy 1 NW35892 Relief Valve 1 2 NW35890 Priority Valve 1 3 43743 289808 Valve Air Brake Foot w TRDL 1 4 1012697 Steering Orbit 1 5 NW35066 Low Air Pressure 60PSI 1 6 45545 Air...

Page 210: ...PAGE 10 118 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 43840 AIR SYSTEM AIR CHAMBER AND LINKAGE 1 OF 2 EFF SN 13085 03 EFF SN 13084 03 EARLIER ALSO SEE PG 94...

Page 211: ...ark Brake B 1 15 NW35066 Switch Pressure Low Air 2 16 45545 Actuator Air Hyd Modified See Chapter 11 2 17 43731 Valve Limiting Quick Rel LQ 2 2 18 NW34978 Gauge Dual Air Pressure 1 19 NW35065 Valve Ch...

Page 212: ...PAGE 10 120 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 43840 AIR SYSTEM AIR CHAMBER AND LINKAGE 1 OF 2 EFF SN 13085 03 EFF SN 13084 03 EARLIER ALSO SEE PG 94...

Page 213: ...074 Fitting Hydraulic Ell 06MP 06FP90 2 51 44388 Fitting Air Ell 10T 06MP90 4 52 NW35581 Fitting Air Ell 08T 04MP90 3 53 NW35541 Fitting Air Ell 06T 04MP90 Brass 1 54 44390 Fitting Hydraulic Ell 06MP...

Page 214: ...PAGE 10 122 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 LIGHTS HEADLIGHT...

Page 215: ...M200 MB4 Tow Tractor Manual No 42975 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 1 NW33813 Light Head 1CW22 2 2 43056 78155 Bulb H4 12V 60 55W 78155 Hella 1CW22 1 3 43055...

Page 216: ...PAGE 10 124 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 LIGHTS REAR...

Page 217: ...62271 Back up Work Light Assembly 2 Wire Clear w Hydraulic Brakes 81834 2 3 NW35844 52772 Tail Stop Light Assembly 3 Wire Red w Hydraulic Brakes 81834 2 NW35844 52772 Tail Stop Light Assembly 3 Wire...

Page 218: ...PAGE 10 126 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ROTATING AMBER LIGHT...

Page 219: ...Part No Nomenclature Eff Units Per Assy 1 NW31334 R5700LA Light Amber 62465 1 2 NW34176 511005 Rocker Switch 65439 1 2a NW35384 596628 Switch Insert Beacon Green 65439 1 3 38495 R5012BH Bulb 55 Watt...

Page 220: ...PAGE 10 128 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 1 SPOTLIGHT FOR CAB OPTION...

Page 221: ...rt No Vendor Part No Nomenclature Eff Units Per Assy 26797E Spotlight Option Ref 1 NW32893 7301380 Light Spot V00523 1 NW32893 1 7309530 Replacement Switch For Spot Light 1 Comm Wire 16 Ga Black 14 Co...

Page 222: ...PAGE 10 130 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 TURN SIGNAL OPTION...

Page 223: ...Turn Signal Assembly200MB4 Ref 1 Light Assembly 1 NW30220 Light Amber Turn Signal 2 F101550 Connector 2 Position Female 4 F101552 Terminal Male 4 F101793 Loom 1 350 ID Flex Guard 11 2 F101567 44820 5...

Page 224: ...PAGE 10 132 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 RADIATOR...

Page 225: ...715 12019 Radiator 200 0J567 1 12 305875 206912 Cap Pressure 7 PSI for Rad 42715 0J567 1 14 3 1678 Fitting Ell 16MJ 12MP90 1 15 F101156 Clamp 12 Hose 2 16 40657 Hose 1 17 37322 Pipe Radiator SN13002 0...

Page 226: ...SEATS PAGE 10 134 JANUARY 02 2003 M200 MB4 Tow Tractor Manual No 42975...

Page 227: ...d Part No Vendor Part No Nomenclature Eff Units Per Assy 0 T427979 8 Seat Assembly 200MB4 Ref 1 NW23843 Seat Assembly w Slide 0X0P8 2 2 F9549 Flat Washer 5 16 8 3 F9546 Lock Washer 5 16 8 4 F9547 Hex...

Page 228: ...PAGE 10 136 JULY 31 2003 M200 MB4 Tow Tractor Manual No 42975 SHIFTER...

Page 229: ...5 42480 5 P5631032050Z Screw Flat Head 2 6 42480 6 P144050 Bearing Nylon 3 7 42480 7 RCPA007743 Seal Switch Face 1 8 42480 8 RCPA007601 Pilot Shaft Geneva 1 9 42480 9 RCAA007600 Roller Switch Drive As...

Page 230: ...PAGE 10 138 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 STEERING...

Page 231: ...on Horn 1 4 NW36491 Wheel Steering 1 5 304542 Turn Signal Switch Optional 1 Switch Turn Signal 1 6 NW35692 Clamp Muffler 1 3 8 1 7 NW35603 Bracket Steering Column Support w Hydraulic Brakes 1 43890 Br...

Page 232: ...LY 15 2001 M200 MB4 Tow Tractor Manual No 42975 TRANSMISSION SPEEDOMETER SENDER Item NMC Wollard Part No Vendor Part No Nomenclature Eff Unit s Per Assy 1 43098 YZ4102792 Sender Speedometer Funk Manuf...

Page 233: ...art No Nomenclature Eff Units Per Assy 0 T427979 22 Wheel Tire Assembly 200MB4 Ref 1 41146 Tire 10 00 R20 16 Ply 1 2 38924 Wheel 1 3 204610 Nut Wheel M22 x 1 5 Fitting AR 4 44417 Wheel Tire Ass 4 5 44...

Page 234: ...PAGE 10 142 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 INSTRUMENT PANEL FOR HYDRAULIC BRAKES...

Page 235: ...auge Voltmeter 1 14 NW024702 Gauge Fuel 1 15 NW024701 Gauge Transmission Temp 1 NW030236 Sender Transmission Temp 1 16 41401 Gauge Engine Temperature 1 17 41400 Gauge Oil Pressure 1 18 41434 Gauge Hou...

Page 236: ...PAGE 10 144 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 INSTRUMENT PANEL FOR AIR BRAKES ALARMS...

Page 237: ...Fuel JGPT16 1 15 NW24701 Gauge Transmission Temperature 1 16 41401 Gauge Water Temperature 1 17 41400 Gauge Oil Psi 1 18 41434 Gauge Hour Meter Sol State 1 19 38863 Switch Toggle SPST MS35058 22 2 20...

Page 238: ...PAGE 10 146 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 RELAYS CIRCUIT BREAKERS MODULES...

Page 239: ...ule Assembly 100 1 8 NW23700 Relay Horn 12V 30 Amp 1 9 2 0134 Breaker Circuit 20A Auto Reset 1 10 2 0364 Holder Circuit Breaker 4 Gang 1 11 F101622 Switch Dimmer Hi Lo 1 12 F102160 Relay Starter CC 2...

Page 240: ...PAGE 10 148 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 1 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 1 42914 Harness Dash I 200MB4 1...

Page 241: ...PAGE 10 149 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 2 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 2 42915 Harness Dash II 200 MB4 1...

Page 242: ...PAGE 10 150 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 3 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 3 42916 Harness Engine 200 MB4 1...

Page 243: ...LECTRICAL HARNESS 4 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 4 42918 Harness Light Ground 200MB4 1 5 42919 Harness Positive 200MB4 1 6 42920 Harness Breaker 200MB4...

Page 244: ...PAGE 10 152 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 5 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 9 42917 Harness Steering 200MB4 1...

Page 245: ...PAGE 10 153 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 6 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 10 42979 Harness Rear 1...

Page 246: ...PAGE 10 154 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 7 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43897 Harness Dash I 200MB4 1 1...

Page 247: ...PAGE 10 155 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 8 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43898 Harness Dash II 200MB4 1 1...

Page 248: ...PAGE 10 156 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 9 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43899 Harness Dash III 200MB4 1 1...

Page 249: ...PAGE 10 157 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 10 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43900 Harness Rear I 200MB4 1 1...

Page 250: ...PAGE 10 158 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 11 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43901 Harness Rear II 200MB4 1 1...

Page 251: ...E 10 159 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 12 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43922 Harness Low Air Pressure 200MB4 1...

Page 252: ...PAGE 10 160 JULY 15 2001 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 13 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 43932 Harness Breakers 200MB4 1 1...

Page 253: ...10 161 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 ELECTRICAL HARNESS 14 OF 14 Item NMC Wollard Part No Vendor Part No Nomenclature Eff Units Per Assy 0 44782 Harness Park Brake Shut Down M200M...

Page 254: ...k Ref T464359 21 Hitch Asm Pintle Hook 200MB4 Ref 1 38906 PH 30 Hitch Pintle Hook Holland Option 2 NW22773 PH T60 AOL 8 Hitch Pintle Hook 30 000 2 2 203194 HHCS 1 2 13 x 2 50 GR 8 Front All Units 4 20...

Page 255: ...y 0 44350 Winterization System Opt Ref 1 41855 Heater Block 3 4 NPT 1 2 41856 Cord Block Heater For Cummins 1 3 Bracket Cord 1 4 44625 Heater Immersion 1 5 562A54 Placard 1 6 44627 Cord Extension Wint...

Page 256: ...PAGE 10 164 JULY 31 2004 M200 MB4 Tow Tractor Manual No 42975 This Page Intentionally Blank...

Page 257: ...structions Mico Air Hydraulic Actuators Mico Part No 43730 UEA Shift Quadrant Service Instructions Air Dryer Bendix Part No 43504 Air System MV 3 Control Valve Bendix Part No 43507 Air System TP 5 Pro...

Page 258: ...PAGE 11 2 MANUFACTURERS INFORMATION NOVEMBER 30 2005 200MB4V2 Tow Tractor Manual No 44820 This Page Intentionally Blank...

Page 259: ...Service Manual 2000 Series For complete service information also see 2000 Series Transmission Manual 4003558 FunkManufacturingCompany CTM195 28JUN99 4003557 ENGLISH LITHO IN U S A...

Page 260: ...on the machine or in this manual be alert to the potential for personal injury Information is organized in groups for the various components requiring service instruction At the beginning of each gro...

Page 261: ...information illustrations and specifications in this manual are based on the latest information available at the time of publication The right is re served to make changes at any time without notice C...

Page 262: ...Contents INDX CTM195 28JUL99 ii 2000 Series Transmission 072899 PN 2...

Page 263: ...100 6 Service Information 10 3 Pressure and Flow Checks at The Valve 100 6 2000 Series Powershift Transmission Theory Pressure and Flow Checks at Other Locations 100 7 of Operation 10 4 Setting the Cl...

Page 264: ...00 19 Dimensional CheckRef 1 100 19 Dimensional CheckRef 2 100 19 Dimensional CheckRef 3 100 20 Checking for the Correct Pilot Sleeve Length 100 20 Converter Assembly Installation 100 21 Transmission...

Page 265: ...ep emergency numbers for doctors ambulance service hospital and fire department near your telephone DX WEAR 19 10SEP90 1 1 WEAR PROTECTIVE CLOTHING TS206 UN 23AUG88 Wear close fitting clothing and saf...

Page 266: ...AREA T6642EJ UN 18OCT88 Before starting a job Clean work area and machine Make sure you have all necessary tools to do your job Have the right parts on hand Read all instructions thoroughly do not att...

Page 267: ...mponents incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual DX REPAIR 19 04JUN90 1 1 USE PROPER TOOLS TS779 UN...

Page 268: ...X LOWER 19 04JUN90 1 1 SUPPORT MACHINE PROPERLY TS229 UN 23AUG88 Always lower the attachment or implement to the ground before you work on the machine If you must work on a lifted machine or attachmen...

Page 269: ...lean of trash grease and debris Do not store oily rags they can ignite and burn spontaneously DX SPARKS 19 03MAR93 1 1 PREVENT BATTERY EXPLOSIONS TS204 UN 23AUG88 Keep sparks lighted matches and open...

Page 270: ...da or lime to help neutralize the acid 3 Flush your eyes with water for 15 30 minutes Get medical attention immediately If acid is swallowed 1 Do not induce vomiting 2 Drink large amounts of water or...

Page 271: ...an accident occurs see a doctor immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should ref...

Page 272: ...Safety 05 8 CTM195 28JUL99 05 8 2000 Series Transmission 072899 PN 14...

Page 273: ...by 105 kPa 15 psi Pump out flow at 2000 rpm 40 6 51 7 C 105 125 F is 74 5 Lpm 19 6 gpm Refer to PRESSURE AND FLOW CHECKS AT OTHER LOCATIONS group 100 Converter out flow at 2000 rpm 40 6 51 7 C 105 125...

Page 274: ...General Information 10 2 DPSG YZ07927 124 19 08JUL99 1 1 MODEL INDENTIFICATION YZ1883 UN 20JUL99 2000 Model Indentification CTM195 28JUL99 10 2 2000 Series Transmission 072899 PN 16...

Page 275: ...N COMPONENT IDENTIFICATION this group for location All information on identification plate is needed when contacting FUNK Contact Funk Manufacturing Company Attn Parts Department Industrial Park Highw...

Page 276: ...ere is automatic compensation for normal wear which eliminates the need for adjustment Each clutch uses a composition friction plate and a polished steel reaction plate The power from the engine is tr...

Page 277: ...ntification A Laminated Drive Plate B Front Cover C Serial Tag Location D Charge Pump E Dip Stick F Oil Fill Plug G Parking Brake Disk H Output Yoke I Location for Customer Supplied Dip Stick J Output...

Page 278: ...IFICATION YZ1876 UN 28JUN99 2000 Series Port Identification A Pump Out to Filter B To Control Valve from Filter C Charge Pump with Auxiliary Disconnect D Auxiliary Pump Drive E Converter to Heat Excha...

Page 279: ...0JUN99 1 1 2000 SERIES CLUTCH GEAR IDENTIFICATION YZ1878 UN 30JUN99 2000 Clutch Gears A Reverse Gear B Forward Hi Range C Forward Lo Range D Second Gear E Third Gear F Output G First Gear CTM195 28JUL...

Page 280: ...1 1 2000 SERIES CLUTCH LOCATION LONG DROP YZ1879 UN 30JUN99 Clutch Location Long Drop A First Stage Clutch Assembly B Second Stage Clutch Asembly C Third Stage Clutch Assembly D Output Assembly CTM19...

Page 281: ...3 If the vehicle is to be towed it will be necessary to run the engine at idle speed to lubricate the clutches 4 If the engine cannot be run towing must be limited to 4 82 km h 3 mph Maximum distance...

Page 282: ...M10 50 37 73 54 M12 87 64 128 94 M14 139 102 204 150 M16 216 160 318 234 M20 435 321 620 457 M24 730 555 1072 790 M30 1450 1103 2129 1570 M36 2533 1927 3721 2744 NOTE Torque tolerance is 20 Do not us...

Page 283: ...3 8 24 46 34 65 48 7 16 14 65 48 92 68 7 16 20 73 54 103 76 1 2 13 99 73 140 103 1 2 20 111 82 159 117 9 16 12 144 106 202 149 9 16 18 160 118 225 166 5 8 11 198 146 280 206 5 8 18 224 165 316 233 3...

Page 284: ...o the groove with plenty of petroleum jelly so O ring is not displaced during assembly 5 Index angle fittings and tighten by hand pressing joint together to insure O ring remains in place 6 Tighten fi...

Page 285: ...r index maximum of one turn 4 Hold fitting head end with a wrench and tighten lock nut and back up washer to proper torque value STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size N m lb ft 3 8...

Page 286: ...1 1 2 UN 95 70 1 1 2 11 1 2 UN 110 80 2 11 1 2 UN 130 95 TAPERED PIPE THREAD WITHOUT SEALANT CHART Thread Size N m lb ft 1 16 27 UNF 20 15 1 8 27 UNF 25 20 1 4 18 UNF 35 25 3 8 18 UNF 45 35 1 2 14 UNF...

Page 287: ...f fitting Remove tape 3 Tighten fitting to torque value shown on chart STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size N m lb ft 3 8 24 UNF 8 6 7 16 20 UNF 12 9 1 2 20 UNF 16 12 9 16 18 UNF 2...

Page 288: ...few hours or gangrene may result Doctors unfamiliar with this type of injury may call the Deere Company Medical Department in Moline Illinois or other knowledgeable medical source Check all oil lines...

Page 289: ...on operating temperature viscosity grades PREHEAT TRANSMISSION FLUID WITH AUXILIARY SOURCE Preheat the transmission fluid to the MINIMUM temperature before operating ALTERNATE WARM UP PROCEDURE Operat...

Page 290: ...ed according to Funk Manufacturing test specifications and have had the oil drained from them prior to shipment The following actions will help protect the unit and component items from internal rust...

Page 291: ...ternal grease with a safety solvent Remove covers or tape from all openings Drain transmission completely Tag transmission to indicate it needs to be filled with oil after installing in vehicle Fill t...

Page 292: ...General Information 10 20 CTM195 28JUL99 10 20 2000 Series Transmission 072899 PN 34...

Page 293: ...ydraulic transmission fluid type C 4 or C 4 grade 30 NOTE The words oil fluid and transmission fluid are used in this manual to mean HYDRAULIC TRANSMISSION FLUID the operating and lubricating oil for...

Page 294: ...ansmission is above the temperature of 71 93 5 C 160 200 F NOTE For checking oil levels the recommended oil temperature is 71 93 5 C 160 200 F Fill transmission to the full mark on dipstick with engin...

Page 295: ...ermittently The filter bypass indicator will be activated Check the converter out oil temperature If the temperature is in the normal working range change the filter IMPORTANT When stalling the conver...

Page 296: ...air temperature across the heat exchanger If the temperature does not lower trouble is indicated Correct overheating problem before the vehicle is operated again DPSG YZ07927 27 19 12MAY99 1 1 OIL ANA...

Page 297: ...ngine start to an indication of pump pressure TEST FOR SUCTION LEAK 1 Fill to normal level with transmission fluid 2 Install a 21 bar 2068 kPa 300 psi pressure gauge in the pump port 3 Start the engin...

Page 298: ...UN99 1 1 SOLENOID CHARGED AND GEAR ENGAGEDLONG DROP YZ1880 UN 30JUN99 2000 Series Solenoid Gear Selection The numbers on the valve shows what solenoid is charged and what clutch gear is activated CTM1...

Page 299: ...CW R2 2 and 4 4 42 E CCW 3 53 OE CW R3 3 and 4 1 77 E CCW 1 41 OE CW E Engine Rotation CCW OE Opposite Engine Rotation CW Looking at the rear of transmission toward the rear of the engine 2000 Series...

Page 300: ...OE CW E Engine Rotation CCW OE Opposite Engine Rotation CW Looking at the rear of transmission toward the rear of the engine 2000 Series 3 Speeds Forward 3 Speeds Reverse 8 2 Gear Set Input Rotation...

Page 301: ...1 or F1 1 and 6 3 68 E CCW 2 94 OE CW R2 or F2 2 and 6 2 50 E CCW 2 00 OE CW R3 or F3 3 and 6 1 00 E CCW 0 80 OE CW E Engine Rotation CCW OE Opposite Engine Rotation CW Looking at the rear of transmis...

Page 302: ...99 1 1 PRESSURE AND FLOW CHECKS AT THE VALVE All pressure and flow tests must be accomplished at 2000 rpm at a converter out temperature of 40 6 51 7 C 105 125 F Port 1 is for clutch pressure which mu...

Page 303: ...T When stalling the converter make sure the transmission is in high gear do not exceed 30 seconds or 121 C 250 F converter out oil temperature NOTE Full throttle stall speeds will vary depending on th...

Page 304: ...the engine speed at idle 750 rpm minimum and the converter out oil temperature at 40 6 51 7 C 105 125 F the clutch pressure must be 1380 kPa 200 psi minimum If the clutch pressure is below 1380 kPa 2...

Page 305: ...lapsed from engine start to an indication of pump pressure NOTE To determine if a suction leak exists fill the transmission completely full of transmission fluid Then start the engine to see if there...

Page 306: ...r valve Clean main regulator valve Oil pressure set too low Add shims 5 maximum O ring on charge pump mount Replace O ring defective Charge pump defective Replace pump Internal disconnect seal damaged...

Page 307: ...e location To determine the defective clutch is simply a matter of elimination For example if the gear selected used solenoids 6 and 3 and low pressure is indicated select another clutch that uses one...

Page 308: ...ds Check wiring and controller Solenoid valve spool stuck Inspect clean and replace if necessary Replace oil and Filter Park brake not released Release park brake DPSG YZ07927 97 19 22JUN99 1 1 NO CON...

Page 309: ...le check that the oil flow is going in the direction indicated by the arrow on top of oil filter base DPSG YZ07927 123 19 08JUL99 1 1 CLUTCH PRESSURE DOES NOT RETURNIN ONE CLUTCH Symptom Problem Solut...

Page 310: ...cumulator spring defective Replace spring Primary pump defective Replace primary pump DPSG YZ07927 100 19 22JUN99 1 1 EXCESSIVE NOISE Symptom Problem Solution Excessive Noise Charge pump defective Rep...

Page 311: ...ansmission and install new seal ring on converter hub DPSG YZ07927 102 19 22JUN99 1 1 TRANSMISSION OVERHEATING Symptom Problem Solution Transmission overheating Converter stalling Shift to lower gear...

Page 312: ...04 19 22JUN99 1 1 OIL LEAKING FROM ENGINE FLYWHEEL Symptom Problem Solution Oil leaking from engine flywheel Converter front cover seal leaking Replace seal and or weep hole in transmission bell housi...

Page 313: ...wo wheel drive if electrical power is lost to the transmission DPSG YZ07927 106 19 22JUN99 1 1 FOUR WHEEL DRIVE WILL NOT DISENGAGEINTERNAL DISCONNECT ONLY Symptom Problem Solution Four wheel drive wil...

Page 314: ...Test and Troubleshooting 100 18 DPSG YZ07927 116 19 28JUN99 1 1 CONVERTER TO ENGINE DIMENSIONS YZ1877 UN 28JUN99 Converter to Engine CTM195 28JUL99 100 18 2000 Series Transmission 072899 PN 56...

Page 315: ...ension K must comply with dimensions S and T as listed for each Funk converter size and dimensions L R and U will have to clear the drive plate and converter assemblies DPSG YZ07927 109 19 23JUN99 1 1...

Page 316: ...b and push back to the front cover Measure from the drive plate face that will be mounted up to the flywheel out to the end of the sleeve or to the positive stop shoulder NOTE This step ties to Dimens...

Page 317: ...g the input shaft centered in the hub bore Push the converter assembly in slowly to feel when the splines and or gear teeth begin to engage If the converter assembly stops at this point rock it back a...

Page 318: ...ne where the problem is and take corrective action before proceeding 3 Push the transmission up to the engine 4 Bolt up the transmission to the engine flywheel housing 5 Attach the drive plate to the...

Page 319: ...15 Identification 10 5 O ring seal fittings Leak test 100 1 Torque Values 10 12 Long drop 100 5 Oil Oil analysis 15 4 Change 15 3 Oil and filter change 15 3 Check Level Oil fill plug 10 5 Recommended...

Page 320: ...00 13 Four wheel drive 100 17 Low pressure 100 10 100 11 No power 100 16 Indx 2 Oil Pressure 100 9 Oil 100 15 Overheating 100 15 Vehicle will not move 100 12 V Valve Pressure and flows 100 6 Voltage R...

Page 321: ...2000 Series Service Manual CTM195 28JUL99...

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