Claas TARGO K50 Repair Manual
  1. Manuals
  2. Brands
  3. Claas Manuals
  4. Farm Equipment
  5. TARGO K50
  6. Repair manual
Claas TARGO K50 Repair Manual

Claas TARGO K50 Repair Manual

Hide thumbs Also See for TARGO K50:
Table of Contents

Advertisement

Quick Links

Download this manual
CL CL CL CL CL A A A A A AS T
AS T
AS T
ARGO K50 K60 K70
ARGO K50 K60 K70
AS T ARGO K50 K60 K70
AS T
ARGO K50 K60 K70
ARGO K50 K60 K70
REP
REP
AIR MANUAL
AIR MANUAL
REP AIR MANUAL
REP
REP
AIR MANUAL
AIR MANUAL
AXLES AND STEERING
ENGINE
TRANSMISSION
CHASSIS
TECHNICAL DATA
BOOM

Advertisement

Table of Contents
loading

Related Manuals for Claas TARGO K50

Summary of Contents for Claas TARGO K50

  • Page 1 AIR MANUAL AIR MANUAL REP AIR MANUAL AIR MANUAL AIR MANUAL AXLES AND STEERING ENGINE TRANSMISSION BOOM CHASSIS TECHNICAL DATA CL CL CL CL CL A A A A A AS T AS T AS T ARGO K50 K60 K70 ARGO K50 K60 K70 AS T AS T ARGO K50 K60 K70...
  • Page 2 Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in any way contrary to the intended use or if the machine is not properly driven or maintained then the Company will not accept any liability whatsoever for any damage or injury (whether direct or consequential).

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION General Machine identification Health and Safety SAFETY WARNINGS SECTION 1 AXLES AND STEERING Axles Description Front Axle Removal Installation Rear Axle Removal Installation Servicing Dismantling and assembly (General) Dismantling Steering cylinder Removal Cylinder overhaul Epicyclic reduction gear Wheel hub Axle beam trumpet and brake group Differential group 1.13...
  • Page 4 CONTENTS SECTION 1 (continued) Brakes system - bleeding 1.52 Dissipation (dumping) of hydraulic pressure 1.53 To dump brake system pressure 1.53 To dump a system pressure 1.53 Hydraulic level 1.54 Check 1.54 SECTION 2 ENGINE Description Engine Data Removal and installation General Removal (complete with pod) Installation...
  • Page 5 CONTENTS SECTION 3 (continued) Gearbox power flow 3.27 Gear and clutch layout 3.28 Transmission clutches 3.29 Function 3.30 Powershift gearbox T12000 3.31 Solenoid/gear selection tables 3.32 Table for 6/3 gearbox 3.32 Table for 5/3 gearbox 3.32 Table for 4/2 gearbox 3.33 Gearbox hydraulic selection plans 3.34...
  • 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...
  • Page 7 CONTENTS SECTION 5 (continued) Blower motor Removal Installation Heater coil Removal Installation Air conditioning evaporator coil 5.10 Removal 5.10 Installation 5.11 Receiver-drier assembly 5.12 Removal 5.12 Installation 5.13 Air conditioning condenser coil 5.13 Removal 5.13 Installation 5.13 Axial fan and relay 5.15 Removal 5.15...
  • Page 8 INTRODUCTION General The contents of this Repair Manual, although correct at the time of publication, may be subject to alteration by the manufacturer without notice. This manual assumes that maintenance personnel have a sound knowledge of workshop practices and safety procedures associated with the repairs of this type of machine. This manual is designed to assist with the more specialised information required for removal and strip-down of major components.
  • Page 9 SAFETY WARNINGS Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely dangerous when operating or maintaining a machine. Where possible, only work on or close to engines or machinery when they are stopped. If this is not practical, remember to keep tools, test equipment and all parts of your body well away from moving parts.

  • Page 10: Axles And Steering

    SECTION 1 AXLES AND STEERING...

  • Page 11: Axles

    AXLES & STEERING Axles Description The front and rear axles are both double reduction by 12. Disconnect steering pipes (1) from steering bevel set and planetary hub reduction gears, both have cylinder, fit blanks to open pipes and steering limited slip differentials. The front axle incorporates a cylinder connections.

  • Page 12: Installation

    AXLES & STEERING Installation 1. Installation is the reverse of the removal procedure. 2. Torque load components as follows: Axle to chassis nuts 640 Nm (472 lbf ft.) Drive shaft bolts 70-85 Nm (52-63 lbf ft.) Wheel nuts 300 Nm (221 lbf ft.). 3.

  • Page 13: Rear Axle

    AXLES & STEERING REAR AXLE Removal 1. Park the machine on firm level ground and set the 17. Move axle clear of machine and place on a wheels straight ahead, in line with the chassis. Fit suitable support. chocks to the front and rear of the rear wheels. 2.

  • Page 14: Servicing

    AXLES & STEERING Servicing Dismantling and assembly (General) Dispose of used axle oil in accordance with local regulations. NOTES: (1) Sealing Compound. Ensure both surfaces to be sealed are clean, dry and free from grease. (2) O-ring seals. Lubricate seals before fitting to prevent twisting when inserting the shaft (3) Bearings.

  • Page 15: Dismantling

    AXLES & STEERING Dismantling Steering cylinder Removal 1. Remove the inductive magnetic steering sensor, by loosening the locking clamp screws. 2. Loosen the track rod end nut until it covers end of threaded pin. 3. Use a suitable tool and break the track rod joint. NOTE: This may damage the nut, use a new nut on assembly.

  • Page 16: Epicyclic Reduction Gear

    AXLES & STEERING Epicyclic reduction gear NOTE: This procedure is for the left or right hand epicyclic reduction gear. 1. Position drain plug (1) at highest position and loosen, to dissipate any pressure in axle. 2. Rotate planetary carrier (2) until drain plug is at lowest position, remove drain plug and drain oil into a suitable container.
  • Page 17 AXLES & STEERING Wheel hub NOTE: This procedure is for the left or right hand wheel hub. 1. Remove the circlip (11) and washers (12 & 13) from the U/J shaft (14). 2. Remove the hub lock ring gear attachment bolts (15).
  • Page 18 AXLES & STEERING The swivel housing is heavy and must be supported with suitable equipment before the king pins are removed. 11. Remove the bolts (25) securing the upper king pin (26) to the axle beam (27), remove the king pin, the belleville washers (28) and shim (32).

  • Page 19: Axle Beam Trumpet And Brake Group

    AXLES & STEERING Axle beam trumpet and brake group NOTE: This procedure is for the left or right hand axle beam trumpet and brake group. 1. Remove the drive shaft (1) from the axle beam (2). NOTE: The removal procedure for sealing ring (3) will destroy the sealing ring.
  • Page 20 1.10 AXLES & STEERING 7. Put identification marks on the differential (11), left/right brake packs (12) and left/right axle beams (2) to aid assembly. The axle beams weighs 80 kg. Take care when removing axle beams from differential and use suitable lifting gear.
  • Page 21 1.11 AXLES & STEERING Hydraulic or air pressure can be used to remove the brake piston. Only use the minimum pressure necessary to move piston. 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.
  • Page 22 1.12 AXLES & STEERING Take care when using a press to compress the washers when removing the circlip. Release pressure slowly when circlip removed. 22. Using a suitable press and special tool Part No, CA715056, apply pressure to piston (39) and remove circlip (35).

  • Page 23: Differential Group

    1.13 AXLES & STEERING Differential group When the crown wheel is removed from differential unit the two halves will separate. Make sure component parts are not dropped. NOTE: Mark the two halves of the differential (3) before dismantling to aid assembly. 1.
  • Page 24 1.14 AXLES & STEERING...

  • Page 25: Assembly

    1.15 AXLES & STEERING ASSEMBLY Pinion group 1. Position the differential housing (1) on a workbench. 2. Fit the outer bearing track (2) and inner bearing track (3) for the taper roller bearings in the housing using special tool in kit Part No. CA715401. NOTE: To measure and set up the differential, a false pinion Part No.
  • Page 26 1.16 AXLES & STEERING 5. Using a depth gauge through the central hole in the false pinion, calculate dimension X by using the following formula: X = (conical distance to be measured) A = (measured value) B = (known value) = 100 mm C = (known value) = 45 mm (A + C) –...
  • Page 27 1.17 AXLES & STEERING 6. Remove the false differential (7), Part No. CA 715041, from the centre body of the differential housing. 7. Remove the left and right brake housings (6) from the differential. 8. Remove the ring nut (5) and the false pinion Part No.
  • Page 28 1.18 AXLES & STEERING The torque setting is achieved by the pre-loading measurement on the bearings. Check the pre-loading then gradually increase the torque load on the pinion ring nut until the correct pre-loading is achieved. If the pre-loading is exceeded, the collapsible washer must be replaced and the process started again.

  • Page 29: Differential Group

    1.19 AXLES & STEERING Differential group 1. Fit the taper roller bearing (1) to each half of the differential housing (2). Fit special tool Part No, CA 119230 to bearing and use a hammer to make sure bearing is fully pressed onto housing. 2.

  • Page 30: Brake Pack And Differential Housing

    1.20 AXLES & STEERING Brake pack and differential housing NOTE: The following assembly procedure, for the brake pack, must be carried out on both left and right units. 1. Position flange of brake pack (1) on a flat surface and fit the bearing track (2) to brake pack using special tool Part No.
  • Page 31 1.21 AXLES & STEERING 8. Fit split bushes (14) to piston (15). 9. Fit the O-rings (16 & 17) to the piston and lubricate piston faying surfaces and O-rings with a thin layer of grease. NOTE: Carry out the following steps to all three brake release bolts.
  • Page 32 1.22 AXLES & STEERING Make sure the differential is inserted NOTE: The next stage involves fitting the pinion in the correct side of the casing. adjusting ring nuts, tighten the ring nuts evenly from both sides until backlash has been eliminated. Do not over tighten the ring nuts.
  • Page 33 1.23 AXLES & STEERING 25. Assemble special tool Part No. CA715146 on pinion end. 26. Move the pinion end alternatively and note the pinion-ring gear backlash, measured with the comparator, so that the feeler is in contact with, and at 90° to, the bracket surface of the special tool in correspondence with the reference mark.
  • Page 34 1.24 AXLES & STEERING Pre-loading checks should be measured without the seal ring fitted. 32. With the pinion-ring gear backlash set, measure the total pre-loading (T) of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the 80 mm diameter of special tool Part No, CA715116.

  • Page 35: Generic Information

    1.25 AXLES & STEERING Generic information To test the marks on the bevel gear teeth, paint the ring gear with red lead paint. The marking test should always be carried out on both sides of the ring bevel gear teeth. OK = Correct contact If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular.
  • Page 36 1.26 AXLES & STEERING NOTE: The ring nut may have to be turned slightly to enable the retaining screw to be fitted. 34. Fit the ring nut retainer (35) to secure ring nut (34) to housing and secure with the bolt (36), turn ring nut slightly to align bolt hole, if necessary.

  • Page 37: Axle Beam Trumpet And Brake Group

    1.27 AXLES & STEERING Axle beam trumpet and brake group NOTE: This procedure is for the left or right hand axle beam trumpet and brake group. 1. Examine the brake discs and fixed discs for wear, replace if necessary. NOTE: When new brake discs are fitted, they must be soaked in oil before use.
  • Page 38 1.28 AXLES & STEERING 6. Fit O-ring (6) to axle beam. The axle beams is heavy. Take care when fitting axle beam to differential and use suitable lifting gear. Make sure the axle beam is fitted to the correct side of the differential and the alignment marks made during dismantling are lined Take care, when fitting the axle...

  • Page 39: Wheel Hub

    1.29 AXLES & STEERING Wheel hub NOTE: This procedure is for the left or right 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.
  • Page 40 1.30 AXLES & STEERING 10. Position the wheel hub (10) on a workbench and 16. Press the remaining bushes into the swivel fit the bearing tracks (11 & 12) in the hub with a housing and secure with bolts (20). Torque load all hammer or a suitable press and special tool Part bolts to 120 Nm (88 lbf ft.).

  • Page 41: Epicyclic Reduction Gear

    1.31 AXLES & STEERING Epicyclic reduction gear NOTE: This procedure is for the left or right hand epicyclic reduction gear. When a new planetary gear is fitted, it is recommended that new needle roller bearings are fitted. 1. Position the planetary carrier (1) on a clean workbench.

  • Page 42: Steering Cylinder

    1.32 AXLES & STEERING Steering cylinder 1. Fit the swivel ends (1) to each end of the cylinder piston (2). Torque load 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).

  • Page 43: Special Tools

    1.33 AXLES & STEERING SPECIAL TOOLS It is recommended that the correct special tools are 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.
  • Page 44 1.34 AXLES & STEERING Oil seal driver CA119143 Driver for bearing CA119230 Pinion shaft lock wrench CA715022 Bearing cone driver CA715026...
  • Page 45 1.35 AXLES & STEERING Bush wrench CA715027 Bush driver CA715039 Dummy pinion CA715040 False differential box CA715041...
  • Page 46 1.36 AXLES & STEERING Driver for king pin bush CA715042 Driver for oil seal CA715056 Bush driver CA715108 Extension for preload measurement CA715116...
  • Page 47 1.37 AXLES & STEERING Kit for backlash measurement CA715146 Oil seal driver CA715156 Bush driver CA715157 Bearing cone driver CA715179...
  • Page 48 1.38 AXLES & STEERING Bearing cup driver CA715299 Driver for oil seal CA715321 Bearing races insertion tool CA715401 Driver for oil seal CA715402...

  • Page 49: Toe-In Adjustment

    1.39 AXLES & STEERING Toe-in adjustment NOTE: The two bars must be fixed in the middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft axis. 1. Fit a 1 metre bar on the wheel side of each hub and secure with a wheel nut.

  • Page 50: Steering Angle Adjustment

    1.40 AXLES & STEERING Steering angle adjustment The steering angle on all hubs is set by adjusting the length of the adjuster, between the hub and the head of the adjuster, to the dimensions given in the Table. 1. Loosen lock nut (1) on all four adjusters of the front and rear axles and screw adjusters (2) inwards.

  • Page 51: Rear Axle Pivots

    1.41 AXLES & STEERING Rear axle pivots Removal NOTE: This operation is to be carried out with the axle removed. 1. Remove the front and rear pivots (1) from the axle housing. 2. Remove the grease nipples (2) and bolts (3 & 4) from the front and rear pivots.

  • Page 52: Testing After Installation

    1.42 AXLES & STEERING Testing after installation After the axle has been installed to the machine, test the operation of the differential as follows: 1. Make sure the engine is switched off. 2. Lift the machine so that the wheels on the axle being tested are clear of the ground.

  • Page 53: Troubleshooting

    1.43 AXLES & STEERING Troubleshooting Operating problems The following information is given as a guide to Operating problems and possible causes. s f l c i f ; t l e l i e l i t c i t n i Key to Operating problems table Incorrect installation/defective axle Correct installation or repair or replace the...

  • Page 54: Axle Problems

    1.44 AXLES & STEERING Axle problems The following table gives a description of common axle problems, the cause and repair action to correct the problem. o l l y l l o l l y l l c i f , s t l l i f t n i...

  • Page 55: Axle Noise Problems And Diagnosis

    1.45 AXLES & STEERING Axle noise problems and diagnosis The following table gives a description of axle noises problems, the cause and repair action to correct the problem. e l i . t s . t s . t s .

  • Page 56: Steering

    1.46 AXLES & STEERING Steering Description The steering system is fully hydrostatic. This means that the steering motion is transmitted hydraulically with no mechanical linkage between the steering wheel and the steered wheels. The hydraulic supply is by a dynamic system working with a load-sensing (LS) pump.
  • Page 57 1.47 AXLES & STEERING LS – line...
  • Page 58 1.48 AXLES & STEERING 25. Control valve PVG 32 2. Hydraulic pump, load sensing 36. PVSP, inlet section 3. LS pump compensator 41. Priority valve, brakes and steering 15. Steering cylinder, front 42. Priority valve, steering 19. Steering cylinder, rear 62.

  • Page 59: Checking The Steering System

    1.49 AXLES & STEERING Checking the steering system Steering cylinder 1. Raise and securely support the front axle. 2. Turn steering fully to left. 3. Disconnect hose from adapter on right hand end of cylinder 4. Start the engine and operate steering wheel fully left to apply maximum hydraulic pressure to cylinder.

  • Page 60: Steering Valve Assembly

    1.50 AXLES & STEERING Steering valve assembly (22) Removal 1. Stop the engine and chock the machine, apply the parking brake. 2. Refer to page 1.53 and dump hydraulic pressure then disconnect the battery. 3. Remove the front cover from outside of the cab. 4.

  • Page 61: Dismantling

    1.51 AXLES & STEERING Dismantling 1. Remove the four cap head screws (1) attaching the steering valve (2) to the adapter (6). Remove and discard the O-ring seals (3). 2. Remove the two cap head screws (7) attaching the adapter (6) to the steering unit (4). Remove and discard the O-ring seals (5).
  • Page 62 1.52 AXLES & STEERING Brake system - bleeding brake system pressure General Bleed the brake system after a brake system component change and when air in the system is suspected. Air in the system will not allow the brakes to release properly and may cause damage. 1.

  • Page 63: Dissipation (Dumping) Of Hydraulic Pressure

    1.53 AXLES & STEERING Dissipation (dumping) of hydraulic pressure Always dump all hydraulic pressure from the system before servicing any hydraulic component. Ensure there is sufficient space and headroom around machine before operating any hydraulic control. To dump brake system pressure 1.

  • Page 64: Hydraulic Level

    1.54 AXLES & STEERING Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid penetrates your skin seek medical help immediately.

  • Page 65: Engine

    SECTION 2 ENGINE...

  • Page 66: Description

    (water separator) then a cartridge filter. The pre-filter has a drain tap fitted. The cartridge filter is a replaceable item, only use genuine Claas parts. Induction air passes through a pre-cleaner (externally mounted) and then two filter elements. A...

  • Page 67: Removal And Installation

    ENGINE REMOVAL AND INSTALLATION General The engine is usually removed complete with gearbox and can be removed as a complete unit with the pod or the pod can be left attached to the machine. Both methods of removal are described. Removal (complete with pod) 1.
  • Page 68 ENGINE 13. Disconnect the fuel supply and fit blanks to the engine and fuel hoses. Tie the hoses clear of the pod. 14. Remove the front drive shaft. 15. Disconnect the rear drive shaft from the transfer gearbox. 16. Remove the hose connections from the rear of the main hydraulic pump.

  • Page 69: Installation

    ENGINE Installation 1. Installation is the reverse of the above procedure, however pay particular attention to the following: 2. Make sure engine and chassis mounted components are not damaged during installation. 3. Make sure all electrical leads are connected to the correct components.

  • Page 70: Removal (Pod Left On Machine)

    ENGINE Removal (pod left on machine) 1. Park the machine on a firm level surface. Apply the parking brake and chock the wheels. 2. Stop the engine 3. Refer to Page 1.53 and dump the hydraulic pressure. 4. Open the engine cover, disconnect the two gas struts and remove the bolts securing the hinges to the engine cover.
  • Page 71 ENGINE 17. Disconnect the rear drive shafts from the drop down box and tie clear of gearbox. 18. Disconnect the inlet and outlet hoses from the gearbox and fit suitable blanks to the gearbox and hoses. 19. Remove the hydraulic pump from the gearbox and support clear of gearbox.

  • Page 72: Installation

    ENGINE Installation 1. Installation is the reverse of the above procedure, however pay particular attention to the following: 2. Make sure engine and chassis mounted components are not damaged during installation. 3. Make sure all electrical leads are connected to the correct components.
  • Page 73 SECTION 3 TRANSMISSION...

  • Page 74: Description

    TRANSMISSION DESCRIPTION The transmission system consists of a torque converter, T12000 transmission and a drop box. The torque convertor connects the engine to the transmission. The drop box connects the transmission to the front and rear drive shafts. The standard transmission has six forward gears and three reverse gears.

  • Page 75: Technical Data

    TRANSMISSION Technical data Gearbox Type DANA T12000 DANA T12000 DANA T12000 Gear Selector APC Powershift APC Powershift APC Powershift STANDARD 40 km/h No of gears (Forward/Reverse) OPTION 25 km/h No of gears (Forward/Reverse) OPTION 20 km/h No of gears (Forward/Reverse) Gear Selector Non APC Non APC...
  • Page 76 TRANSMISSION Gearbox layout (Typical - Shown without Transfer Gearbox) Left view Front view Right view From gearbox to oil cooler Oil cooler From oil cooler to gearbox...

  • Page 77: Gearbox Type Plate (Illustration)

    TRANSMISSION Gearbox type plate For the Type, Serial No and the Model, refer to the plate on the gearbox.

  • Page 78: Speed Sensor

    TRANSMISSION Speed sensor The speed sensor sends an impulse signal to the gearbox 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.

  • Page 79: Speed Sensor Rotation

    TRANSMISSION Speed sensor rotation A Direction of rotation B Mark (indicator) on sensor C O-Ring The mark (B) on the side of the 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.

  • Page 80: Speed Sensor To Module Connection

    TRANSMISSION Speed sensor to module connection Module Speed sensor Pin 1 Plus Pin 2 Minus Speed sensor Input Module ground Speed sensor earth...

  • Page 81: Arrangement Of Solenoids

    TRANSMISSION Arrangement of solenoids Gearbox module Reverse solenoid valve Forwards solenoid valve Splitter solenoid valve Solenoid valve 1 Solenoid valve 2 The solenoids 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.

  • Page 82: Solenoids To Module Wiring

    TRANSMISSION Solenoids to module wiring...

  • Page 83: Apc Gear Selector Module

    3.10 TRANSMISSION APC gear selector module For a given gear selection the APC powershift controller will select the following gears: The speed limit for 6/3 gearbox models is 40 km/hr The speed limit for 5/3 gearbox models is 25 km/hr The speed limit for 4/2 gearbox models is 20 km/hr APC display Display...

  • Page 84: Display Menus

    TRANSMISSION 3.11 Display menus The Gearbox module APC can display 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: Display Normal

    3.12 TRANSMISSION Display Normal The display normal mode gives the following information: - 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...
  • Page 86 TRANSMISSION 3.13 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. Flashing dots in the display have the following meaning: The right dot indicates that the speed is too high for the downshift selected.

  • Page 87: Failure Codes

    3.14 TRANSMISSION Failure codes The display will automatically warn you of any ACTIVE failure codes by flashing the code 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. The APC controller has received an input from the lever for forwards and reverse at the same time.

  • Page 88: Display - Gearbox Speed Signal

    TRANSMISSION 3.15 Display - Gearbox speed signal The display - gearbox speed signal mode gives the gearbox input speed in revs per minute. To enter this mode press the mode button (M) on the LED display forward of the steering column once. To read the correct speed the following instruction must be followed: - Speeds up to 99 rpm are displayed using the...

  • Page 89: Display - Machine Speed

    3.16 TRANSMISSION Display - Machine speed The display machine speed mode gives the indicated forward speed in km/hr. To enter this mode press the 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.

  • Page 90: Display Inputs

    TRANSMISSION 3.17 Display inputs The input display mode allows the inputs to the APC module from the gear selection lever to be tested. To enter this mode press the mode button (M) on the LED display forward of the steering column three times.

  • Page 91: Testing Display Inputs

    3.18 TRANSMISSION Testing display inputs All the signals from the lever to the APC can be tested. Segments in the LED are numbered 1 to 8 (No 7 is not used). t t u i k r...

  • Page 92: Cable Connections From Lever To Apc

    TRANSMISSION 3.19 Cable connections from lever to APC " " " " Pin location from lever...

  • Page 93: Apc Pin Layout

    3.20 TRANSMISSION APC pin layout t i l c t i c t i...

  • Page 94: Testing Output From Apc

    TRANSMISSION 3.21 Testing output from APC The outputs from the APC Module can be tested. To enter this mode press and hold down the mode button (M) on the LED display whilst turning on the ignition to the first position. The APC module will now test all the outputs by sending a test current through the cables.

  • Page 95: Kick-Down

    3.22 TRANSMISSION 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. When they are tested the display should indicate an open circuit (O). t t i l Kick-down When the KICK-DOWN button is pressed, the machine will change down a gear.

  • Page 96: Option Without Apc

    TRANSMISSION 3.23 Option without APC A gearbox selection option is available. This uses a non APC selector. 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.

  • Page 97: Pin Layout For Control Lever

    3.24 TRANSMISSION Pin layout for control lever o l l c t i o l l...

  • Page 98: Control Lever To Solenoid Circuit

    TRANSMISSION 3.25 Control lever to solenoid circuit t i s t i s c t i e i l c t i...

  • Page 99: Solenoid Switching Pairs

    3.26 TRANSMISSION Solenoid switching pairs 4/3 gearbox t i s c t i 3/3 gearbox t i s c t i t i s c t i...

  • Page 100: Gearbox Power Flow

    TRANSMISSION 3.27 Gearbox power flow The gearbox has 6 clutches to select the 6 forward and 3 reverse gears.

  • Page 101: Gear And Clutch Layout

    3.28 TRANSMISSION Gear and clutch layout...

  • Page 102: Transmission Clutches

    TRANSMISSION 3.29 Transmission clutches t i s s t i c i l s t i l i o...

  • Page 103: Function

    3.30 TRANSMISSION Function With a double clutch in use, only one of the clutches will be closed. The clutch housing will be driven either via the drive gear (6) or by the drive shaft. For example, if pressure is supplied to connector A from the related solenoid valve, it will press against the ram (5), the clutch plate (4) then presses against the lining and therefore the clutch is closed.

  • Page 104: Powershift Gearbox T12000

    TRANSMISSION 3.31 Powershift gearbox T12000 Gear 1 with reverse clutch assembly Gear 2 with forwards clutch assembly Gear 3 mounted on input shaft Gear 4 with 4th high clutch assembly Gear 5 with 3rd clutch assembly Gear 6 with counter shaft assembly Gear 7 with 1st clutch assembly Gear 8 with 2nd clutch assembly Input shaft...

  • Page 105: Solenoid/Gear Selection Tables

    3.32 TRANSMISSION Solenoid/gear selection tables Table for 6/3 Gearbox t t i l t t i l t t i l t t i l t t i l t t i l Table for 5/3 Gearbox t t i l t t i l t t i l t t i l...
  • Page 106 TRANSMISSION 3.33 Table for 4/2 Gearbox t t i l t t i l t t i l t t i l In the 4/2 gearbox, 5th, 6th and Reverse 5th gears are not used.

  • Page 107: Gearbox Hydraulic Selection Plans

    3.34 TRANSMISSION Gearbox hydraulic selection plans NOTE: All schematics shown are typical. Machine NOTE: The description in the following table is circuits may vary. applicable to the gearbox hydraulic selection plans for all gears. t a l n i l t i u n i l t i u...

  • Page 108: Neutral (Schematic)

    TRANSMISSION 3.35 Neutral...

  • Page 109: 1St Gear (Schematic)

    3.36 TRANSMISSION 1st gear...
  • Page 110 TRANSMISSION 3.37...

  • Page 111: 2Nd Gear (Schematic)

    3.38 TRANSMISSION 2nd gear...
  • Page 112 TRANSMISSION 3.39...

  • Page 113: 3Rd Gear (Schematic)

    3.40 TRANSMISSION 3rd gear...
  • Page 114 TRANSMISSION 3.41...

  • Page 115: 4Th Gear (Schematic)

    3.42 TRANSMISSION 4th gear...
  • Page 116 TRANSMISSION 3.43...

  • Page 117: 5Th Gear (Schematic)

    3.44 TRANSMISSION 5th gear...
  • Page 118 TRANSMISSION 3.45...

  • Page 119: 6Th Gear (Schematic)

    3.46 TRANSMISSION 6th gear...
  • Page 120 TRANSMISSION 3.47...

  • Page 121: Reverse Gear (Schematic)

    3.48 TRANSMISSION Reverse gear...
  • Page 122 TRANSMISSION 3.49...

  • Page 123: Gearbox Pump

    3.50 TRANSMISSION Table for gears R3 and R5 Gear selection Active EMV Active Clutch Reverse and 2nd Reverse and 2nd Reverse Reverse and 3rd Gearbox pump Gearbox pump Accumulator damping valves Accumulator for clutch modulation...

  • Page 124: Test Ports (Illustration)

    TRANSMISSION 3.51 Test ports M12 From oil Cooler M71 Temperature test port M41 1st clutch pressure M43 3rd clutch pressure M42 2nd clutch pressure To cooler M45 Forwards pressure M31 System pressure M46 Reverse pressure M44 4th high pressure...

  • Page 125: Test Pressures

    3.52 TRANSMISSION M31 Clutch cooler M32 To oil cooler M33 From oil cooler Test pressures ° 0 NOTE: Use Minimess adapter Part No.2170068.0 (3/8 in. drive)

  • Page 126: Removal And Installation

    TRANSMISSION 3.53 REMOVAL & INSTALLATION Removal complete with engine NOTE: The rear engine/transmission to chassis mounting brackets are attached to the transmission. Refer to the engine removal procedure in the Engine The engine must be supported before these are removed. Section and remove the transmission, complete with engine.

  • Page 127: Dismantling - Transmission

    3.54 TRANSMISSION Dismantling - Transmission Figure 1 Figure 4 Side view of T12000 intermediate drop transmission. Remove torque converter plug retainer ring. Figure 5 Figure 2 Remove plug and O-ring. Rear view showing electric control (disc brake not fitted to Targo). Figure 3 Figure 6 Remove drive plate attaching cap head screws and...
  • Page 128 TRANSMISSION 3.55 Figure 7 Figure 10 Remove torque converter assembly. Remove charging pump permanent hole cover (not used when auxiliary pump used). Figure 8 Figure 11 Remove torque converter to shaft locating ring. Remove pump mounting bolts and washers. Remove pump and gasket. Figure 9 Figure 12 Remove filter assembly.
  • Page 129 3.56 TRANSMISSION Figure 13 Figure 16 Remove sensor port plug and O-ring. Remove impeller hub gear. Figure 14 Figure 17 Remove converter housing to transmission case Remove pump drive idler gear washer. bolts and washers. Figure 18 Figure 15 Remove pump drive gear and bearing. Remove converter housing and gasket.
  • Page 130 TRANSMISSION 3.57 Figure 22 Figure 19 Remove solenoid valve cartridge retainer nut and Remove pump drive idler shaft and washer. O-ring. Figure 20 Figure 23 Remove solenoid protection cover screws. Remove solenoid coil and O-ring. Figure 21 Figure 24 Remove solenoid protection cover. Remove valve cartridge and O-ring.
  • Page 131 3.58 TRANSMISSION Figure 25 Figure 28 Repeat procedures (Fig 22 thru 25) for remaining Remove spacer plate and gasket. solenoid valves. NOTE: A 3-speed will have a bore plug in the centre box. Remove bore plug. Figure 29 Figure 26 Remove spacer plate bolts and washers.
  • Page 132 TRANSMISSION 3.59 Figure 34 Figure 31 Remove brake caliper assembly. Remove high and 3rd clutch assembly. NOTE: Brake is not fitted to Targo. NOTE: A 3-speed will only have 3rd clutch. Figure 32 Figure 35 Remove clutch shaft rear bearing outer races. Turn front flange as shown.
  • Page 133 3.60 TRANSMISSION Figure 37 Figure 40 Remove bearing locating ring. Flange removed. NOTE: Brake is not fitted to Targo. Figure 38 Figure 41 Remove output gear to shaft retainer ring. Remove output gear. Figure 42 Figure 39 Remove flange oil seal sleeve retainer ring. Tap output shaft and flange from housing.
  • Page 134 TRANSMISSION 3.61 Figure 46 Figure 43 Remove modulator valve housing. Remove sleeve and O-ring. Figure 44 Figure 47 Remove output shaft rear bearing. Remove inner, middle and outer springs. Remove valve stop pin and accumulator spool. Remove regulator spool and sleeve assembly. Figure 45 Figure 48 Remove bearing locating ring.
  • Page 135 3.62 TRANSMISSION Figure 52 Figure 49 Remove tube retainer, screw, seal-washer, clip, Remove dipstick and dipstick tube. washer and nut. Figure 53 Figure 50 Remove supply tube O-ring. Remove air breather. Figure 51 Figure 54 Remove supply tube retainer screw. Remove supply tube and screen assembly.

  • Page 136: Dismantling - Low 1St Clutch

    TRANSMISSION 3.63 Dismantling - low 1st clutch Figure 55 Figure 58 Remove oil sleeve distributor lock screw plug. Removed pilot bearing and sleeve. Remove lock screw. Figure 59 Figure 56 Remove clutch shaft oil sealing rings. Remove distributor sleeve using a hammer puller. Figure 57 Figure 60 Remove sleeve and pilot bearing.
  • Page 137 3.64 TRANSMISSION Figure 61 Figure 64 Remove outer thrust washer, bearing and inner Remove outer thrust washer, thrust bearing and thrust washer. inner thrust washer. Figure 65 Figure 62 Remove clutch disc end plate retainer ring. Remove clutch gear and disc hub. Figure 63 Figure 66 Remove clutch gear and pilot bearings.
  • Page 138 TRANSMISSION 3.65 Figure 67 Figure 70 Remove inner and outer clutch discs. Remove retainer ring retainer. Figure 68 Figure 71 Compress disc springs and remove retainer ring. Remove disc spring. Figure 69 Figure 72 Remove retainer ring. Remove clutch piston wear plate.

  • Page 139: Dismantling - 2Nd Clutch

    3.66 TRANSMISSION Figure 73 Figure 76 Turn clutch over and tap shaft on a block of wood to Remove inner race from shaft. remove clutch piston. Dismantling - 2nd clutch Figure 77 Figure 74 Remove gear from shaft. Remove clutch shaft rear bearing outer race. Figure 78 Figure 75 Remove gear and rear bearing inner race using a...
  • Page 140 TRANSMISSION 3.67 Figure 79 Figure 82 Remove thrust bearing and clutch gear retainer ring. Remove outer thrust washer, thrust bearing and inner thrust washer. Figure 80 Figure 83 Remove outer thrust washer, thrust bearing and Remove clutch disc and end plate retainer ring. inner thrust washer.
  • Page 141 3.68 TRANSMISSION Figure 85 Figure 88 Remove inner and outer clutch discs. Remove retainer ring retainer. Figure 86 Figure 89 Compress disc springs and remove retainer ring. Remove disc springs. Figure 87 Figure 90 Remove retainer ring. Remove clutch piston wear plate.

  • Page 142: Assembly - Low 1St Clutch

    TRANSMISSION 3.69 Figure 94 Figure 91 Position piston in low clutch drum. Use caution so as Remove clutch piston. not to damage inner and outer piston sealing rings. Assembly - low 1st clutch Figure 92 Figure 95 The two bleed valves in the clutch drum must be Position clutch piston wear plate on piston.
  • Page 143 3.70 TRANSMISSION Figure 97 Figure 100 Position return spring retainer on clutch shaft. Install first steel outer clutch disc. Figure 98 Figure 101 Start ring on shaft with snap ring pliers. Install first friction (inner) clutch disc. Alternate steel and friction discs until ten (10) steel and ten (10) friction discs are in position.
  • Page 144 TRANSMISSION 3.71 Figure 103 Figure 106 Install end plate retainer ring. Position thrust bearing on clutch shaft against inner thrust bearing washer. Figure 104 Figure 106 NOTE: Check low (1st) clutch pack disc clearance. Install outer thrust bearing washer against bearing. Stand the clutch assembly on end.
  • Page 145 3.72 TRANSMISSION Figure 109 Figure 112 Install clutch gear in the clutch assembly by aligning Position outer thrust washer on shaft. the clutch hub teeth with the clutch inner discs. Make sure the clutch hub is in full position in the clutch assembly.

  • Page 146: Assembly - 2Nd Clutch

    TRANSMISSION 3.73 Assembly - 2nd clutch Figure 115 Figure 118 Install inner and outer clutch piston seal rings. Refer Install piston return disc springs. Make sure first to Figure 93 and size inner ring. spring with large diameter of bevel is towards wear plate.
  • Page 147 3.74 TRANSMISSION Figure 121 Figure 124 Use a sleeve with the correct inner diameter to fit Install clutch disc end plate. 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.
  • Page 148 TRANSMISSION 3.75 Figure 130 Figure 127 Install the clutch gear in the clutch assembly by Position thrust bearing on clutch shaft against inner aligning the clutch hub teeth with the clutch inner thrust bearing washer. discs. Make sure the clutch hub is in full position in the clutch assembly.
  • Page 149 3.76 TRANSMISSION Figure 133 Figure 136 Install outer thrust bearing washer against bearing. Install clutch shaft gear on clutch shaft with long hub of gear downwards. Figure 134 Figure 137 Install thrust washer retainer ring. Install rear bearing inner race on clutch shaft with bearing race shoulder downwards.

  • Page 150: Dismantling - 4Th High Clutch

    TRANSMISSION 3.77 Dismantling - 4th high clutch Figure 139 Figure 142 Remove clutch shaft oil sealing rings. Remove outer thrust washer retainer ring. NOTE: The 4th clutch is only used on the 4 and 6 speed models. Figure 140 Figure 143 Remove first drive gear and front bearing using a Remove outer washer, thrust bearing and inner gear puller.
  • Page 151 3.78 TRANSMISSION Figure 145 Figure 148 Remove bearings and spacer from clutch gear. Remove end plate. Figure 149 Figure 146 Remove clutch discs. Remove outer thrust washer, thrust bearing and inner thrust washer. Figure 147 Figure 150 Remove end plate retainer ring. Compress disc springs and remove retainer ring.

  • Page 152: Dismantling - 3Rd Clutch

    TRANSMISSION 3.79 Figure 151 Figure 154 Remove retainer ring retainer. Remove clutch piston. Dismantling - 3rd clutch Figure 155 Figure 152 Remove clutch shaft rear bearing outer race. Remove disc springs. Figure 156 Figure 153 Remove clutch gear and bearing inner race using a Remove clutch piston wear plate.
  • Page 153 3.80 TRANSMISSION Figure 157 Figure 160 Remove clutch shaft rear bearing inner race. Remove outer thrust washer, thrust bearing and inner thrust washer. Figure 158 Figure 161 Remove outer thrust washer, thrust bearing and Remove end plate retainer ring. inner thrust washer. Figure 162 Figure 159 Remove end plate.
  • Page 154 TRANSMISSION 3.81 Figure 166 Figure 163 Remove disc springs. Remove clutch discs. Figure 164 Figure 167 Compress disc springs and remove retainer ring. Remove clutch piston wear plate. Figure 165 Figure 168 Remove retainer ring retainer. Remove clutch piston.

  • Page 155: Assembly - 4Th High Clutch

    3.82 TRANSMISSION Assembly - 4th high clutch Figure 169 Figure 172 Make sure clutch piston bleed ball is clean and free Install piston return disc springs. First spring with from foreign material. large diameter of bevel towards wear plate. For 3-speed version, proceed to Figure 189. Alternate five (5) springs.
  • Page 156 TRANSMISSION 3.83 Figure 175 Figure 178 Use a sleeve with the correct inner diameter to fit Install clutch disc end plate. 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.
  • Page 157 3.84 TRANSMISSION Figure 184 Figure 181 Press one bearing in clutch gear. Install bearing Position thrust bearing inner washer on clutch shaft. spacer next to bearing. Press second bearing in gear, make sure bearings are flush with face of gear on both sides.
  • Page 158 TRANSMISSION 3.85 Figure 187 Figure 190 Position thrust washer on shaft. Position gear on clutch shaft. Figure 188 Figure 191 Install thrust washer retainer ring. Install clutch shaft front bearing. Make sure bearing NOTE: 3-speed clutch drum is not as shown. shield faces upwards.

  • Page 159: Assembly - 3Rd Clutch

    3.86 TRANSMISSION Assembly - 3rd clutch Figure 196 Figure 193 Install piston return disc springs. First spring with Make sure clutch piston bleed ball is clean and free large diameter of bevel towards wear plate. from foreign material. Alternate five (5) springs. See NOTE on Fig 96. Figure 194 Figure 197 Install inner and outer clutch piston seal rings.
  • Page 160 TRANSMISSION 3.87 Figure 199 Figure 202 Use a sleeve with the correct inner diameter to fit Install clutch disc end plate. 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.
  • Page 161 3.88 TRANSMISSION Figure 205 Figure 208 Position thrust bearing on clutch shaft against inner Install the clutch gear in the clutch assembly by thrust bearing washer. aligning the clutch hub teeth with the clutch inner discs. Make sure the clutch hub is fully engaged in the clutch assembly.

  • Page 162: Dismantling - Reverse Clutch

    TRANSMISSION 3.89 Dismantling - reverse clutch Figure 214 Figure 211 Remove outer thrust washer, thrust bearing and Install outer thrust bearing washer against thrust inner thrust washer. bearing. NOTE: A 3-speed transmission will not have external gear teeth on the forward and reverse clutch drum. Figure 212 Figure 215 Install clutch shaft rear bearing inner race.
  • Page 163 3.90 TRANSMISSION Figure 217 Figure 220 Remove outer thrust washer, thrust bearing and Remove clutch discs. inner thrust washer. Figure 218 Figure 221 Remove end plate retainer ring. Compress disc springs and remove retainer ring. Figure 219 Figure 222 Remove end plate. Remove retainer ring retainer.

  • Page 164: Dismantling - Forward Clutch

    TRANSMISSION 3.91 Dismantling - forward clutch Figure 223 Figure 226 Remove disc springs. Remove clutch shaft oil sealing rings. Figure 227 Figure 224 Remove outer thrust washer, thrust bearing and Remove clutch piston wear plate. inner thrust washer. Figure 225 Figure 228 Remove clutch piston.
  • Page 165 3.92 TRANSMISSION Figure 232 Figure 229 Remove end plate. Remove bearings and spacer from clutch gear. Figure 230 Figure 233 Remove outer thrust washer, thrust bearing and Remove clutch discs. inner thrust washer. Figure 215 Figure 231 Compress disc springs and remove retainer ring. Remove end plate retainer ring.

  • Page 166: Assembly - Forward Clutch

    TRANSMISSION 3.93 Figure 238 Figure 235 Remove clutch piston. Remove retainer ring retainer. Assembly - forward clutch Figure 236 Figure 239 Remove disc springs. Make sure clutch piston bleed orifice is clean and free from foreign material. Figure 237 Figure 240 Remove clutch piston wear plate.
  • Page 167 3.94 TRANSMISSION Figure 241 Figure 244 Install clutch piston wear plate. Start ring on shaft with snap ring pliers. Figure 245 Figure 242 Use a sleeve with the correct inner diameter to fit Install piston return disc springs. First spring with over shaft and against retainer ring.
  • Page 168 TRANSMISSION 3.95 Figure 247 Figure 250 Install first friction (inner) clutch disc. Alternate steel NOTE: Check forward clutch pack disc clearance. and friction discs until six (6) steel and six (6) friction Stand the clutch assembly on end. The clutch discs discs are in position.
  • Page 169 3.96 TRANSMISSION Figure 253 Figure 256 Install outer thrust bearing washer against thrust Position thrust bearing on shaft. bearing. Figure 257 Figure 254 Position outer thrust washer on shaft. Press 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.

  • Page 170: Assembly - Reverse Clutch

    TRANSMISSION 3.97 Assembly - reverse clutch Figure 259 Figure 262 Make sure clutch piston bleed orifice is clean and Install piston return disc springs. First spring with free from foreign material. large diameter of bevel towards wear plate. Alternate five (5) springs. Figure 263 Figure 260 Position return spring retainer on clutch shaft.
  • Page 171 3.98 TRANSMISSION Figure 265 Figure 268 Use a sleeve with the correct inner diameter to fit Install clutch disc end plate. 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.
  • Page 172 TRANSMISSION 3.99 Figure 274 Figure 271 Press one bearing in clutch gear. Install bearing Position thrust bearing inner washer on clutch shaft. spacer next to bearing. Press second bearing in gear, make sure bearings are flush with face of gear on both sides.

  • Page 173: Dismantling - Regulator Valve

    3.100 TRANSMISSION Figure 277 Figure 280 Position outer thrust washer on shaft. Spring and piston removed. Dismantling - regulator valve Assembly - regulator valve Figure 281 Figure 278 Position pressure regulator valve spring into Tap pin from regulator valve sleeve. Take care as regulator valve piston.

  • Page 174: Dismantling - Dual Modulating Valve

    TRANSMISSION 3.101 Figure 286 Figure 283 Remove cross pin from sleeve. Compress valve spring and valve and install pin into NOTE: Some units will have two cross pins the regulator valve sleeve. same length. Some units will have two cross pins of different lengths.
  • Page 175 3.102 TRANSMISSION Figure 289 Figure 292 Install spring in spring retainer. Compress regulator spool and spring in sleeve far enough to install cross pin. Figure 290 Figure 293 Inspect orifice and make sure clean and clear of any Install cross pin into sleeve. foreign material.

  • Page 176: Dismantling - Spacer Plate

    TRANSMISSION 3.103 Figure 295 Install outer accumulator spring. Figure 298 Install stop pin in inner spring. Figure 299 Figure 296 If charging pump or pump drive gear are to be Install middle spring. replaced, remove retainer ring and drive gear. Dismantling - spacer plate Figure 297 Figure 300...
  • Page 177 3.104 TRANSMISSION Figure 301 Figure 304 Remove end plate and dowel pin. Remove idler gear tanged thrust washer. Figure 302 Figure 305 Remove reverse idler gear. If reverse idler shaft is to be replaced, support spacer plate around idler shaft opening and press idler shaft from spacer.
  • Page 178 TRANSMISSION 3.105 Figure 307 Figure 310 Remove locating ring from idler shaft. The stator support is held in place by two retaining rings. Remove converter end retainer ring from groove. Figure 308 Figure 311 Tap pump drive idler shaft from spacer plate. Push support towards transmission side far enough to expose retainer ring.
  • Page 179 3.106 TRANSMISSION Figure 316 Figure 313 Compress converter safety valve spring and remove Remove stator support oil sealing ring. retaining washer. Figure 317 Figure 314 Remove safety valve spring. Remove sealing ring expander ring. Figure 318 Figure 315 Turn spacer plate over and remove safety valve If support bushing or bearing is to be replaced, poppet.

  • Page 180: Assembly - Spacer Plate

    TRANSMISSION 3.107 Figure 319 Figure 322 Remove plug and seal washer from spacer plate. Compress spring and install poppet retaining washer. NOTE: End of spring must go in recessed side of Assembly - spacer plate washer. Figure 323 Figure 320 Install plug and seal washer.
  • Page 181 3.108 TRANSMISSION Figure 328 Figure 325 Install stator support through washer and spacer Install stator support oil sealing ring expander ring. plate. Figure 326 Figure 329 Install oil sealing ring on expander ring. Install stator support locating ring. NOTE: Expander spring gap is to be 180° from sealing ring hook joint.
  • Page 182 TRANSMISSION 3.109 Figure 334 Figure 331 Install locating ring on reverse idler shaft. Position pump drive idler shaft on spacer plate. Figure 332 Figure 335 Position pump drive shaft through washer and into Support spacer plate and press reverse idler shaft spacer plate.

  • Page 183: Assembly - Front Output Flange

    3.110 TRANSMISSION Figure 340 Figure 337 Install end plate cap head screw and washer. Position idler gear needle bearing on shaft. Lubricate bearing Figure 338 Figure 341 Position idler gear on bearing. Tighten cap head screw to specified torque. Assembly - front output flange Figure 342 Figure 339 Remove flange to bearing retainer ring.
  • Page 184 TRANSMISSION 3.111 Figure 343 Figure 346 Remove bearing using a bearing puller. Remove oil seal from sleeve. Figure 347 Figure 344 Remove oil seal retainer ring from output flange. Bearing removed. Figure 345 Figure 348 Remove oil sleeve and O-ring. Position bearing retainer ring on output flange.

  • Page 185: Assembly - Converter Housing Assembly

    3.112 TRANSMISSION Figure 349 Figure 352 Apply a very light coat of Permatex #2 to the outer Install bearing to flange retainer ring. diameter of the output flange oil seal, press oil seal Assembly - converter housing assembly in oil seal sleeve. Oil seal must be flush with one side of face of oil seal sleeve and lip of seal must be in.
  • Page 186 TRANSMISSION 3.113 Figure 358 Figure 355 Remove oil distributor sleeve (high and 3rd) using a Remove converter oil seal. hammer puller. Figure 359 Figure 356 Sleeve removed. Remove converter housing plug (high and 3rd clutch shaft). Figure 357 Figure 360 Remove oil distributor sleeve set screw.

  • Page 187: Assembly - Converter Housing

    3.114 TRANSMISSION Assembly - converter housing Figure 364 Figure 361 Apply a very light coat of Permatex #2 to the outer Remove oil distributor sleeve set screw. diameter of the converter housing oil seal. Press seal in housing with lip of seal in. Figure 362 Figure 365 Remove oil distribution sleeve (1st and 2nd) using a...
  • Page 188 TRANSMISSION 3.115 Figure 367 Figure 370 Install 1st and 2nd clutch shaft oil distributor sleeve Install high-3rd clutch shaft oil distributor sleeve in in converter housing, with inside diameter chamfer converter housing with inside diameter chamfer up up and the notch in the distributor aligned with the and the notch in the distributor aligned up with the retaining set screw hole in the converter housing.

  • Page 189: Assembly - Transmission

    3.116 TRANSMISSION Assembly - transmission Figure 373 Install forward - reverse oil distributor sleeve in Figure 376 transmission case with inside diameter chamfer out Install reverse and forward clutch shaft rear bearing (towards front of transmission) and the notch in the in transmission case.
  • Page 190 TRANSMISSION 3.117 Figure 379 Figure 382 Position a new O-ring on modulator valve housing. Push supply tube through opening in case and install O-ring. Figure 380 Figure 383 Install housing over sleeve and spring assembly and Install supply tube mounting screw, seal washer, clip, tighten to 60 - 65 lbf ft.
  • Page 191 3.118 TRANSMISSION Figure 385 Figure 388 Install sensor hole plug and O-ring. Install output shaft inner bearing locating ring in rear of transmission. Figure 386 Figure 389 Install air breather. Install rear bearing in case against locating ring. Figure 387 Figure 390 Install dipstick tube and dipstick.
  • Page 192 TRANSMISSION 3.119 Figure 394 Figure 391 Install rear output flange and shaft through output oil Apply a very light coat of Permatex #2 to the outer diameter of the output flange oil seal. Press seal in seal. Align splines on shaft with splines on output oil seal sleeve.
  • Page 193 3.120 TRANSMISSION Figure 397 Figure 400 Position front output flange and bearing assembly on Install forward and reverse clutch assembly. output shaft. Using snap ring pliers, squeeze ends together and tap flange assembly into case until snap ring can seat in snap ring groove. Figure 398 Figure 401 Install high and 3rd clutch shaft rear bearing outer...
  • Page 194 TRANSMISSION 3.121 Figure 406 Figure 403 Position impeller hub gear on stator support. Position new transmission case to converter housing gasket on transmission case. A light coat of grease will hold gasket in position. Figure 404 Figure 407 Install spacer plate assembly on transmission, Install pump idler gear bearing on idler shaft.

  • Page 195: Assembly - Electric Control

    3.122 TRANSMISSION Figure 412 Figure 409 Tighten cartridges to specified torque. Install idler gear thrust washer, aligning hole with roll pin. Assembly - electric control Figure 410 Figure 413 Install bore plug and O-rings in centre hole on 3- With cartridge to coil O-ring in place, position speed transmissions only.

  • Page 196: Assembly - Transmission

    TRANSMISSION 3.123 Figure 415 Figure 418 Install solenoid protection cover and mounting Install converter housing to transmission case screws. Torque tighten screws to specified torque. screws and lockwashers. Assembly - transmission Figure 416 Figure 419 Position spacer to converter housing gasket on Torque tighten bolts to specified torque.
  • Page 197 3.124 TRANSMISSION Figure 421 Figure 424 Position converter assembly on stator support and Install bore plug retainer ring. turbine shaft. Figure 425 Figure 422 Install sensor hole plug end O-ring. Install converter assembly retainer ring. Figure 423 Figure 426 With new O-ring in place, install bore plug in Install regulator sleeve assembly in converter converter assembly.
  • Page 198 TRANSMISSION 3.125 Figure 430 Figure 427 Install charging pump to converter housing bolts and Using a special tool, tighten sleeve to 40 - 45 lbf ft. washers and tighten to specified torque. (61.1 - 67.7 Nm). Figure 431 Figure 428 If auxiliary pump is used, it is not necessary to install Position new charging pump to converter housing the permanent pump hole cover.
  • Page 199 3.126 TRANSMISSION Figure 433 Figure 436 Position caliper brake assembly on brake disc. 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.

  • Page 200: Troubleshooting

    TRANSMISSION 3.127 TROUBLESHOOTING The following information is given as a guide to isolating and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a transmission problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components.

  • Page 201: Procedures

    3.128 TRANSMISSION Procedures Stall test A stall test identifies transmission, converter or engine problems. Use the following procedure: 1.Put the machine against a solid barrier, such as a wall and chock the wheels. 2.Put the directional control lever in FORWARD (or REVERSE as applicable).

  • Page 202: Hydraulic Checks

    TRANSMISSION 3.129 Make sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperature for the engine and transmission. Air clean the radiator if necessary. The engine must be operating correctly.

  • Page 203: Troubleshooting Guide

    3.130 TRANSMISSION Troubleshooting guide Refer to the following troubleshooting guide for the diagnosis of typical transmission problems. Low clutch pressure l i o l l i t a l y t l n i l n i l Low charging pump output l i o l l i i t c...
  • 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 TRANSMISSION 3.135 Speed sensor - static standalone test In order to be able to sense the currents, a series resistor of e.g. 200 Ohms must be used. This resistor is integrated in the controller, but when the sensor is to be tested, it must be connected externally.

  • Page 209: Boom

    SECTION 4 BOOM...

  • Page 210: Description And Operation

    BOOM DESCRIPTION AND OPERATION Description The machine has a two section telescopic boom. Each section consists of a box section with the inner section moving inside the outer section. When operating the control valve using the manual controls, take care that you keep clear of any moving components.

  • Page 211: Operation

    BOOM OPERATION The ‘Solo’ handle in the cab operates all boom services. The carriage crowd cylinder is hydraulically connected to the compensator cylinder. Oil is transferred between the crowd and compensator cylinders during the lifting/lowering of the boom to make sure the carriage stays at the same angle to the ground throughout the arc of the lift.

  • Page 212: Maintenance

    BOOM MAINTENANCE Boom Removal NOTE: This procedure details the removal of the boom as a complete assembly. 1. Park the machine on firm and level ground and chock the wheels. Make sure the boom is fully retracted and horizontal. Switch off the engine. 2.

  • Page 213: Installation

    BOOM 9. Remove the bolt (10) and washer (11) retaining the upper attachment pin (12). 10. Drive out the upper attachment pin, lower the cylinder onto the lift cylinder or a suitable support. 11. Disconnect the left and right rear light assembly lighting connectors adjacent to the main control valve.

  • Page 214: Hydraulic Cylinders

    BOOM HYDRAULIC CYLINDERS Crowd cylinder For the removal, installation and maintenance of the crowd cylinder refer to the Hydraulic Manual. Compensator 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.

  • Page 215: Boom Tray Cassette

    BOOM BOOM TRAY CASSETTE Removal 1. Park the machine on firm and level ground and chock the wheels. Make sure the boom is in the horizontal position and extended by 1.5 m (5 ft.). Switch off the engine. 2. Refer to Page 1.53 and dump the hydraulic pressure.1.
  • Page 216 BOOM 11. Identify the hydraulic hoses (13). Disconnect the four hydraulic hoses (13) on the bulkhead connector bracket (15) to the crowd cylinder and auxiliary services. Blank the connectors and open hoses. 12. Identify the hydraulic hoses (20). Disconnect the two hydraulic hoses (20) from the extension cylinder (21), blank the cylinder and open hoses.

  • Page 217: Installation

    BOOM Installation 1. Installation is the reverse of the above procedure. 2. Refer to Page 1.54 and replenish the hydraulic tank before engine is started. 3. Purge the hydraulic system by starting the engine and operating the boom services to fully extend and retract cylinders several times.

  • Page 218: Inner Boom

    BOOM INNER BOOM Removal 1. Park the machine on firm and level ground and chock the wheels. Make sure the boom is fully extended and horizontal. Switch off the engine. 2. Refer to Page 1.53 and dump the hydraulic pressure. 3.

  • Page 219: Boom Wear Pads

    4.10 BOOM BOOM WEAR PADS General The front boom wear pads can be removed and installed with the boom assembled. The rear boom wear pads can only be removed and installed with the inner boom removed. The wear pads are self-lubricating. The pads should be fitted in pairs to the front lower positions of the outer boom and the rear upper section of the inner boom.
  • Page 220 BOOM 4.11 12. Fit wear pad D to the side of the boom with a 2.5 mm (0.10 in.) shim the pad. 13. Lever the boom against the inner boom in direction !. Fit wear pad A to the side of the boom and shim to give a clearance of less than 1.0 mm (0.040 in.) 14.
  • Page 221 4.12 BOOM Replacement of outer boom wear pads (side) NOTE: Side boom wear pads are only fitted to models from Serial No. 51200020 to 51200480. 1. Park machine on firm level ground. 2. Extend the boom and roll the carriage face down onto the ground until the weight of the inner boom is supported.

  • Page 222: Replacement Of Inner Boom Wear Pads (Rear)

    BOOM 4.13 Replacement of inner boom wear pads (rear) Remove the inner boom. Remove the bolt (4), washer (5), retainer (6) and remove the wear pads (2) and shims (3) from all positions of the inner boom (1). Clean and inspect the wear pads for wear and damage.

  • Page 223: Chassis

    SECTION 5 CHASSIS...

  • Page 224: Description

    CHASSIS CHASSIS Description The chassis is constructed using a central U-section with an open upper section to allow the boom to sit lower in the frame. Attached to the chassis are the engine pod on the right side and the cab pod on the left side. The engine pod can be removed as a unit from the chassis to provide quick and easy engine/ transmission removal.

  • Page 225: Operators Cab

    CHASSIS Operators cab Removal 1. Park the machine on firm level ground, apply the parking brake and chock the wheels. 2. Raise the boom and fit the boom safety prop. 3. Stop the engine. 4. Refer to Page 1.53 and dump hydraulic pressure, then disconnect the battery.

  • Page 226: Installation

    CHASSIS 14. Support the cab using suitable lifting equipment attached to the lifting eyes installed on the cab roof guard. NOTE: The thread size of the lifting eyes is M16. 15. Remove the front and rear bolts attaching the cab to the pod.
  • Page 227 CHASSIS Operate brake dump selector switch, make sure transmission selects neutral Operate all lights, including rear foglight Operate horn Operate the direction indicators and hazard warning lights Operate parking 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...

  • Page 228: Fuel Tank

    CHASSIS 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 sure the drain tank has sufficient capacity to hold the contents of the fuel tank.

  • Page 229: Installation

    CHASSIS Bolt Fuel tank Washer Support strip Sealing washer Hose Drain plug Cable Hose Sender unit Installation 1. Inspect the pod for damage, make sure the tank support strips (11) are in good condition, replace if necessary. 2. Inspect the interior of the tank, make sure clean and clear of debris.

  • Page 230: Heater And Air Conditioning

    CHASSIS 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.

  • Page 231: Installation

    CHASSIS Installation 1. Installation 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. Self-tapping screw Housing lid Self-tapping screw Blower motor Electrical connectors...

  • Page 232: Heater Coil

    CHASSIS Heater coil Removal 1. Park the machine on firm level ground. 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. Clamp the two hoses (1) and (4) to the heater coil (3), remove the hose clips (2) from the hoses and disconnect the two hoses from the heater coil.

  • Page 233: Air Conditioning Evaporator Coil

    5.10 CHASSIS Hose Hose clip Heater coil Hose Housing Air conditioning evaporator coil Removal 1. Park the machine on firm level ground. 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.

  • Page 234: Installation

    CHASSIS 5.11 Installation 1. Installation 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. 4. Charge the system using suitable refrigerant charging equipment. 5. Test the air conditioning system. Expansion valve Adapter Adapter...

  • Page 235: Receiver-Drier Assembly

    5.12 CHASSIS Receiver-Drier Assembly Removal 1. Park the machine on firm level ground. 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.

  • Page 236: Installation

    CHASSIS 5.13 Installation 1. Installation 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. 4. Charge the system using suitable refrigerant charging equipment. 5. Test the air conditioning system. Air conditioning condenser coil Removal 1.
  • Page 237 5.14 CHASSIS Wiring loom Machine support Bolt Washer Condenser coil housing Support block Bolt Washer Washer Washer Washer Wingnut Pipe Pipe Grille Condenser coil Axial fan...

  • Page 238: Axial Fan And Relay

    CHASSIS 5.15 Axial fan and relay Removal NOTE: Two axial fans (21) are fitted, the removal procedure is the same for both fans. 1. Park the machine on firm level ground. 2. Stop the engine, chock the wheels and disconnect the battery.
  • Page 239 5.16 CHASSIS Relay Washer Wiring loom Washer Machine support Wingnut Washer Pipe Bolt Pipe Bolt Grille Washer Condenser coil Condenser coil housing Bolt Washer Washer Axial fan Washer...

  • Page 240: Compressor (Up To Machine S/No.51200471 Only)

    CHASSIS 5.17 Compressor (Up to Machine S/No. 51200471 only) Removal 1. Park the machine on firm level ground. 2. Stop the engine, chock the wheels and disconnect the battery. 3. Open the engine pod cover. 4. Recover the gas from the system using suitable equipment.
  • Page 241 5.18 CHASSIS Support Bracket Washer Bolt Compressor Electrical lead Hose Hose Bolt Washer Pulley Belt...

  • Page 242: Compressor (From Machine S/No.51200472 Only)

    CHASSIS 5.19 Compressor (From Machine S/No. 51200472 only) Removal 1. Park the machine on firm level ground. 2. Stop the engine, chock the wheels and disconnect the battery. 3. Open the engine pod cover. 4. Recover the gas from the system using suitable equipment.
  • Page 243 5.20 CHASSIS Support Bracket Washer A10 Nut M10 Pulley Tensioner Bolt Electrical Connector Compressor Bolt M10 x 35 Pulley Belt Hose Hose...

  • Page 244: Technical Data

    SECTION 6 TECHNICAL DATA...

  • Page 245: Dimensions

    TECHNICAL DATA Dimensions A Length to front of carriage 4705 4705 4705 B Length front to rear wheels 3876 (20 in .tyres) 4079 4079 C Overall width 2300 2300 2300 D Track width 1920 1920 1920 E Height over cab on std tyres 2380 (20 in.
  • Page 246 TECHNICAL DATA t f i l f i l y t i y t i l u f y t i y t i c i f...
  • Page 247 TECHNICAL DATA y l l l a t y l l c i t y l l l a t y l l c i t t f i...
  • Page 248 TECHNICAL DATA i k r i k r ° y l l ° t f i t f i t f i , y l l a i , y l l a i , y l l a i , y l l a i , y l...
  • Page 249 TECHNICAL DATA o l f o l f , t n , t n , t n y t i e t l c i l t i l c i l t i l t i l l i o t i l t i l t i l...
  • Page 250 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 251 Paul Dodd Field Service Manager Following the policy of Caterpillar to improve their products as technical developments continue, Caterpillar reserve the right to make alterations which may not necessarily 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.
  • Page 252 349865.0 08/2003...

This manual is also suitable for:

Targo k60Targo k70K5d00100K6d00100K7d00100

Table of Contents